Toro TITAN Service Manual
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Toro TITAN Service Manual

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Form No. 3438-774 Rev A
®
TITAN Service Manual
Published: September 2020
© 2020—The Toro® Company
Original Instructions (EN)
8111 Lyndale Avenue South
Contact us at www.Toro.com.
Bloomington, MN 55420
All Rights Reserved

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  • Page 1 Form No. 3438-774 Rev A ® TITAN Service Manual Published: September 2020 © 2020—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision History Page 2 Titan Service Manual 3438-774 Rev A...
  • Page 3 The Toro Company RLC/SWS Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or make changes to this manual without notice. Titan Service Manual Page 3 Preface...
  • Page 4 Operator’s Manual. Note: Refer to the service decal on the machine and the machine Operator’s Manual for commonly used fluid specifications and capacities. Preface Page 4 Titan Service Manual 3438-774 Rev A...

  • Page 5: Table Of Contents

    General Information ..................7–2 Service and Repairs ..................7–3 Chapter 8: Electrical ..................8–1 General Information ..................8–2 Service and Repairs ..................8–3 Appendix A ......................A–1 Electrical Drawing Abbreviations..............A–2 Electrical Schematic ..................A–3 Titan Service Manual Page 5 Preface 3438-774 Rev A...
  • Page 6 Preface Page 6 Titan Service Manual 3438-774 Rev A...
  • Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 Titan Service Manual Page 1–1 Safety 3438-774 Rev A...

  • Page 8: Safety Instructions

    Avoid asphyxiation… Do not operate an engine in a confined area without proper ventilation. Avoid injury from batteries… Safety: Safety Instructions Page 1–2 Titan Service Manual 3438-774 Rev A...
  • Page 9 Do not rely on jacks to support the machine. If you are unsure of the operation of any lifts, hoists, and jacks do not use. Fire Extinguishers… Titan Service Manual Page 1–3 Safety: Safety Instructions 3438-774 Rev A...
  • Page 10 ABC fire extinguishers are a dry chemical type used for multiple purposes. See above information for description. Ensure fire extinguishers are serviceable and replace any that are discharged or out of inspection dates Safety: Safety Instructions Page 1–4 Titan Service Manual 3438-774 Rev A...
  • Page 11 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–4 Equivalents and Conversions......................2–9 U.S. to Metric Conversions ......................2–10 Titan Service Manual Page 2–1 Specifications and Maintenance 3438-774 Rev A...

  • Page 12: Specifications

    Clutch Non-adjustable Adjustment Hydraulic Drive System Transmission ZT-2800 Transmission 4.45 L (150 oz) Toro HYPR-OIL® 500 hydraulic fluid or Mobil 1 20W-50 oil Lubricant Max Ground Up to 8.5 mph Speed (FWD) Max Ground Up to 5 mph Speed (REV)
  • Page 13 Warner — 105 ft-lb Clutch Adjustment Non-adjustable Hydraulic Drive System Transmission ZT-2800 Transmission 4.45 L (150 oz) Toro HYPR-OIL® 500 hydraulic fluid or Mobil 1 20W-50 oil Lubricant Max Ground Speed Up to 8.5 mph (FWD) Max Ground Speed Up to 5 mph...

  • Page 14: Torque Specifications

    Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
  • Page 15 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 Titan Service Manual Page 2–5 Specifications and Maintenance: Torque Specifications 3438-774 Rev A...
  • Page 16 The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. Thin nuts include jam nuts. Specifications and Maintenance: Torque Specifications Page 2–6 Titan Service Manual 3438-774 Rev A...
  • Page 17 The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts. Titan Service Manual Page 2–7 Specifications and Maintenance: Torque Specifications...
  • Page 18 85 ± 15 in-lb *Hole size, material strength, material thickness and finish must be considered when determining specific torque values. All torque values are based on non-lubricated fasteners. Specifications and Maintenance: Torque Specifications Page 2–8 Titan Service Manual 3438-774 Rev A...
  • Page 19 24.209 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 0.484375 12.303 63/64 0.984375 25.003 0.5000 12.700 1.000 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm Titan Service Manual Page 2–9 Specifications and Maintenance: Torque Specifications 3438-774 Rev A...
  • Page 20 Inch-Pounds Kilogram-Centimeters 1.152144 Quarts Liters 0.9463 Liquid Volume Gallons Liters 3.785 Liquid Flows Gallons/Minute Liters/Minute 3.785 1. Subtract by 32° Temperature Fahrenheit Celsius 2. Multiply by 5/9 Specifications and Maintenance: Torque Specifications Page 2–10 Titan Service Manual 3438-774 Rev A...
  • Page 21 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 Titan Service Manual Page 3–1 Troubleshooting 3438-774 Rev A...
  • Page 22 • Return the unit to service by repairing, rebuilding or replacing Solution Confirmation • Did the issue go away • Was the root cause of the issue correctly repaired • Are there any other new symptoms Troubleshooting: General Troubleshooting Page 3–2 Titan Service Manual 3438-774 Rev A...

  • Page 23: General Troubleshooting

    Clean or replace the fuel cap. There is dirt in the fuel filter. Replace the fuel cap. There is dirt, water, or stale fuel in the Clean and flush the fuel system. fuel system. Titan Service Manual Page 3–3 Troubleshooting: General Troubleshooting 3438-774 Rev A...
  • Page 24 The pump drive belt is worn, loose or Check the belt tension or install a new broken. belt. The idler spring is broken or missing. Replace the spring. Troubleshooting: General Troubleshooting Page 3–4 Titan Service Manual 3438-774 Rev A...
  • Page 25 There is inadequate current supply. Repair or replace the clutch lead wire or electrical system. Clean the connector contacts. The rotor/armature air gap is too large. Remove the shim or replace the clutch. Titan Service Manual Page 3–5 Troubleshooting: General Troubleshooting 3438-774 Rev A...
  • Page 26 Troubleshooting: General Troubleshooting Page 3–6 Titan Service Manual 3438-774 Rev A...
  • Page 27 Chapter 4 Engine Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 Toro Twin Cylinder Engine Replacement.................... 4–4 Kawasaki Engine Replacement ....................... 4–10 Titan Service Manual Page 4–1 Engine 3438-774 Rev A...

  • Page 28: General Information

    General Information The TITAN® series of mowers use 2 different engine combinations; 708cc Toro twin cylinder OHV 4 cycle engine (LC2P77F) and 726cc Kawasaki twin cylinder OHV 4 cycle engine (FR651V). Engine: General Information Page 4–2 Titan Service Manual 3438-774 Rev A...

  • Page 29: Service And Repairs

    Service and Repairs Engine Assembly g322220 Figure 3 Engine Taptite Screw Flat Washer Muffler Titan Service Manual Page 4–3 Engine: Service and Repairs 3438-774 Rev A...

  • Page 30: Toro Twin Cylinder Engine Replacement

    Toro Twin Cylinder Engine Replacement Toro Twin Cylinder Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.
  • Page 31 Toro Twin Cylinder Engine Removal (continued) g321702 Figure 6 10. Disconnect the fuel supply line at the fuel filter. g321705 Figure 7 11. Remove vent line at splice with Toro supplied hose. Titan Service Manual Page 4–5 Engine: Service and Repairs 3438-774 Rev A...
  • Page 32 Toro Twin Cylinder Engine Removal (continued) g321706 Figure 8 12. Disconnect the throttle cable. 13. Disconnect the choke cable. 14. Remove the clutch mounting bolt and washer. Slide the clutch off of the crankshaft. 15. Remove the engine pulley. 16. Remove the engine mounting bolts.
  • Page 33 Toro Twin Cylinder Engine Installation (continued) g321707 Figure 9 5. Install the 3 remaining engine bolts. 6. Torque the 4 engine mounting bolts to 52 ± 5.8 N • m (450 ± 50 in-lb). 7. Apply anti-seize to the clutch end of the crankshaft.
  • Page 34 Toro Twin Cylinder Engine Installation (continued) 11. Torque the clutch bolt to 69-83 N • m (50-60 ft-lb). 12. Connect the choke cable. 13. Connect the throttle cable. 14. Connect the black engine ground wire. Note: Apply Loctite to ground bolt.
  • Page 35 Toro Twin Cylinder Engine Installation (continued) g321703 Figure 13 17. Connect the fuel supply line to the fuel pump. 18. Connect the vent line to barb/splice. g321706 Figure 14 19. Install the hydrostatic drive belt. 20. Install the mower belt.

  • Page 36: Kawasaki Engine Replacement

    Figure 15 9. Disconnect the black engine ground wire. 10. Disconnect the fuel supply line at the fuel filter. 11. Remove vent line at splice with Toro supplied hose. 12. Disconnect the throttle cable. 13. Disconnect the choke cable. 14. Remove the clutch mounting bolt and washer. Slide the clutch off of the crankshaft.
  • Page 37 19. Install the hydrostatic drive belt. 20. Install the mower belt. 21. Install the muffler and new exhaust. Note: Torque muffler mounting bolts or nuts to 17-20 N • m (150-170 in-lb). Titan Service Manual Page 4–11 Engine: Service and Repairs 3438-774 Rev A...
  • Page 38 24. Connect the battery by installing the positive cable first, then the negative cable to the battery. 25. Lower the unit and verify proper function. Note: Verify engine speed is set to proper RPM specification for the applicable model. Engine: Service and Repairs Page 4–12 Titan Service Manual 3438-774 Rev A...
  • Page 39 Seat and MyRIDE™ Platform Replacement (MR Models Only)............5–13 Fuel Tank Replacement ........................5–18 Throttle Control Assembly Replacement..................5–20 Choke Control Assembly Replacement.................... 5–22 Park Brake Handle Assembly Replacement..................5–24 Motion Control Assembly Replacement ................... 5–26 Titan Service Manual Page 5–1 Chassis 3438-774 Rev A...

  • Page 40: General Information

    General Information The TITAN® series uses a common frame with 2 different configurations, a MYRIDE® suspension platform and a conventional solid platform. The frame is constructed from 10 gauge steel. Chassis: General Information Page 5–2 Titan Service Manual 3438-774 Rev A...

  • Page 41: Service And Repairs

    Service and Repairs Caster Tires Assembly g322218 Figure 17 Screw Tire and Wheel Asm Caster Fork Titan Service Manual Page 5–3 Chassis: Service and Repairs 3438-774 Rev A...
  • Page 42 Upper Shock Mount Bracket Seat Latch Bracket Shock/Spring Asm Cam Lock Asm Upper Shock Mount Bracket Shock/Spring Asm Trailing Arm Tube Trailing Arm Floormat Backer Plate Front Subframe Chassis: Service and Repairs Page 5–4 Titan Service Manual 3438-774 Rev A...

  • Page 43: Caster Assembly And Bearing Replacement

    5. Lower the caster wheel away from the caster fork. 6. Remove the dust caps, felt washers, and wheel spanner. 7. Remove the bearings (bearings may have a slight press fit). Titan Service Manual Page 5–5 Chassis: Service and Repairs...

  • Page 44: Left Console Replacement

    3. Remove the 3 (T30) shoulder screws from the left console. g321205 Figure 19 4. Remove the fuel cap and disconnect the keeper line. Chassis: Service and Repairs Page 5–6 Titan Service Manual 3438-774 Rev A...
  • Page 45 2. Lower the console into place, ensuring that it seats properly on the supports. g321204 Figure 21 3. Install the left side control lever. 4. Install the keeper line into the fuel cap, and reinstall the fuel cap. Titan Service Manual Page 5–7 Chassis: Service and Repairs 3438-774 Rev A...

  • Page 46: Right Console Replacement

    2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Remove the 3 (T30) shoulder screws from the right console. Chassis: Service and Repairs Page 5–8 Titan Service Manual 3438-774 Rev A...
  • Page 47 Note: The control panel assembly should be supported while servicing the machine, to avoid damage to the cables or wire harness. Titan Service Manual Page 5–9 Chassis: Service and Repairs 3438-774 Rev A...
  • Page 48 2. Secure the control panel assembly to the console. 3. Install the 3 (T30) shoulder screws securing the right console to the machine. Torque screws 11 N • m (100 in-lb). g321208 Figure 26 Chassis: Service and Repairs Page 5–10 Titan Service Manual 3438-774 Rev A...

  • Page 49: Seat Replacement (Zx Models Only)

    4. Connect the battery by installing the positive cable first, then the negative cable to the battery. 5. Install the right side control lever. Seat Replacement (zx Models Only) g321210 Figure 27 Stop Rod Cotter Pin Seat Pan Titan Service Manual Page 5–11 Chassis: Service and Repairs 3438-774 Rev A...
  • Page 50 7. Lift and lower the seat to verify proper function of the seat pivots and the seat latch. 8. Connect the battery by installing the positive cable first, then the negative cable to the battery. 9. Verify proper function of the unit. Chassis: Service and Repairs Page 5–12 Titan Service Manual 3438-774 Rev A...

  • Page 51: Seat And Myride™ Platform Replacement (Mr Models Only)

    Figure 29 Seat Asm Pivot Rod Seat Pan Trailing Arm Shock Mounting Bracket Upper Shock Mount Bracket Shock/Spring Asm Trailing Arm Tube Lower Mount Bracket Front Subframe Rear Subframe Titan Service Manual Page 5–13 Chassis: Service and Repairs 3438-774 Rev A...
  • Page 52 Figure 30 7. Disconnect the vent line at the splice fitting. g321202 Figure 31 8. Remove the bolt and nut securing the front shock/spring assembly to the MyRIDE® platform. Chassis: Service and Repairs Page 5–14 Titan Service Manual 3438-774 Rev A...
  • Page 53 Release the vent hose keepers. g321448 Figure 33 10. Remove the 2 bolts and nuts securing the frame brackets to the main frame on each side of the machine. Titan Service Manual Page 5–15 Chassis: Service and Repairs 3438-774 Rev A...
  • Page 54 2. Lower the MyRIDE® assembly onto the main frame, aligning the frame brackets on each side with the mating holes in the main frame. Reconnect the fuel line keeper under the seat. Chassis: Service and Repairs Page 5–16 Titan Service Manual 3438-774 Rev A...
  • Page 55 4. Install the self-tapping screw on the frame bracket on each side of the machine. g321446 Figure 37 5. Install the bolt and nut securing the front shock/spring assembly to the MyRIDE™ Platform. Titan Service Manual Page 5–17 Chassis: Service and Repairs 3438-774 Rev A...

  • Page 56: Fuel Tank Replacement

    12. Connect the battery by installing the positive cable first, then the negative cable to the battery. 13. Verify proper function. Fuel Tank Replacement Fuel Tank Removal g321450 Figure 39 Fuel Tank Hold-Down Rod Vent Line Fuel Supply Line Chassis: Service and Repairs Page 5–18 Titan Service Manual 3438-774 Rev A...
  • Page 57 7. Install the fuel cap by sliding the d-ring into the neck of the fuel tank. Secure the fuel cap to the tank. 8. Connect the battery by installing the positive cable first, then the negative cable to the battery. Titan Service Manual Page 5–19 Chassis: Service and Repairs 3438-774 Rev A...

  • Page 58: Throttle Control Assembly Replacement

    6. Remove the throttle cable from the throttle plate, noting the position of the cable in the plate. 7. Pull the throttle cable assembly through the console and out of the machine. Chassis: Service and Repairs Page 5–20 Titan Service Manual 3438-774 Rev A...
  • Page 59 7. Ensure that the throttle control lever is in the fast idle position. Note: Pull on the cable and verify the engine is at full throttle, then tighten the clamp. g321453 Figure 45 Titan Service Manual Page 5–21 Chassis: Service and Repairs 3438-774 Rev A...

  • Page 60: Choke Control Assembly Replacement

    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. Chassis: Service and Repairs Page 5–22 Titan Service Manual 3438-774 Rev A...
  • Page 61 8. Ensure that the choke control lever is pressed down fully and tighten the cable clamp . g323084 Figure 48 9. Connect the battery by installing the positive cable first, then the negative cable to the battery. Titan Service Manual Page 5–23 Chassis: Service and Repairs 3438-774 Rev A...

  • Page 62: Park Brake Handle Assembly Replacement

    1. Assemble the bushings and wave spring over the bolt and through the park brake. Note: Assemble the bushings and wave spring over the bolt and through the park brake Chassis: Service and Repairs Page 5–24 Titan Service Manual 3438-774 Rev A...
  • Page 63 4. Cycle the park brake lever to ensure that it locks in the engaged position. 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. Titan Service Manual Page 5–25 Chassis: Service and Repairs...

  • Page 64: Motion Control Assembly Replacement

    Disconnect the motion control damper from the motion control assembly. 6. Disconnect the motion control linkage from the motion control assembly. 7. Disconnect the motion control assembly from the frame. Chassis: Service and Repairs Page 5–26 Titan Service Manual 3438-774 Rev A...
  • Page 65 3. Move the levers into the operating position. 4. Loosen the 2 bolts that secure the motion control handles to the motion control assembly. 5. Align the levers front to back and secure the bolts. Titan Service Manual Page 5–27 Chassis: Service and Repairs 3438-774 Rev A...
  • Page 66 The motion control levers should always be mounted on the inside of the motion control assembly. Chassis: Service and Repairs Page 5–28 Titan Service Manual 3438-774 Rev A...
  • Page 67 Using the Drive Wheel Release Valves (Bypass Valves) ..............6–4 Neutral Adjustment ..........................6–4 Tracking Adjustment .......................... 6–5 Hydro Change Procedure ........................6–5 Purging Procedure ..........................6–6 Hydrostatic Drive Belt Replacement....................6–7 Hydrostatic Drive Transmission Replacement..................6–9 Titan Service Manual Page 6–1 Hydrostatic Drive System 3438-774 Rev A...

  • Page 68: General Information

    General Information The TITAN® series of mowers use Hydro-Gear hydrostatic transaxles model ZT-2800. All drives use the same type of fluid. The oil must have a minimum rating of 9.0 cSt (55 SUS) at 230° F (110° C) with an API classification of SL is recommended.

  • Page 69: Service And Repairs

    Hydrostatic Drive Belt Idler Arm Pulley Idler RH Hydro Asm Pulley Idler Hydro Hose Idler Spring Rear Hydro Support Hydro Hose Hydro Cross Plate LH Bypass Lever Titan Service Manual Page 6–3 Hydrostatic Drive System: Service and Repairs 3438-774 Rev A...

  • Page 70: Using The Drive Wheel Release Valves (Bypass Valves)

    Repeat for both drive wheels if necessary. Note: When the unit is in neutral, the stud should be roughly centered in the slot of the control plate. Hydrostatic Drive System: Service and Repairs Page 6–4 Titan Service Manual 3438-774 Rev A...

  • Page 71: Tracking Adjustment

    1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake Titan Service Manual Page 6–5 Hydrostatic Drive System: Service and Repairs...

  • Page 72: Purging Procedure

    Breather Hole 7. Remove the breather hose and fill vent located on the top of the hydro. 8. Fill approximately 2 quarts of Toro HYPR-OIL® or 20W-50 engine oil to the level of the top port plug hole. 9. Re-install the top port plug.Figure 58...

  • Page 73: Hydrostatic Drive Belt Replacement

    Remove the spring from the drive idler arm and inspect for damage or wear g321832 Figure 59 6. Remove the clutch stop. 7. Remove the rear pulley. 8. Remove the idler arm and pulley. Titan Service Manual Page 6–7 Hydrostatic Drive System: Service and Repairs 3438-774 Rev A...
  • Page 74 6. Place the idler spring onto the idler arm loop and use a spring removal tool to secure the spring (A) into the slot on the right rear of the frame. Hydrostatic Drive System: Service and Repairs Page 6–8 Titan Service Manual 3438-774 Rev A...

  • Page 75: Hydrostatic Drive Transmission Replacement

    3. Raise and support the unit so that the drive wheels are off the ground. 4. Remove the drive wheel(s). 5. Remove the drive belt. 6. Disconnect the motion control linkage from the transmission. Titan Service Manual Page 6–9 Hydrostatic Drive System: Service and Repairs 3438-774 Rev A...
  • Page 76 Hydrostatic Drive Transmission Removal (continued) g321830 Figure 63 7. Disconnect the bypass arm. g321835 Figure 64 8. Disconnect the lower brake linkage from the transmission. Hydrostatic Drive System: Service and Repairs Page 6–10 Titan Service Manual 3438-774 Rev A...
  • Page 77 12. Loosen the 2 bolts connecting the transmission to the rear cross member. 13. Remove the front mounting bolt. 14. Support the transmission and remove the mounting hardware. Lower the transmission. Titan Service Manual Page 6–11 Hydrostatic Drive System: Service and Repairs 3438-774 Rev A...
  • Page 78 • Tighten the 2 outer mounting bolts. 4. Remove the protective cap from the hydraulic oil nipple, install the overflow tube, and move the hose clamps into place. Hydrostatic Drive System: Service and Repairs Page 6–12 Titan Service Manual 3438-774 Rev A...
  • Page 79 Hydrostatic Drive Transmission Installation (continued) g321831 Figure 68 5. Connect the lower brake linkage to the transmission. g321834 Figure 69 6. Connect the bypass arm. Titan Service Manual Page 6–13 Hydrostatic Drive System: Service and Repairs 3438-774 Rev A...
  • Page 80 9. Install the drive wheel and torque the lug nuts to 110 ± 14 N•m (80 ± 10 ft-lbs). 10. Add hydraulic oil to the proper level using the vent plugs. Hydrostatic Drive System: Service and Repairs Page 6–14 Titan Service Manual 3438-774 Rev A...
  • Page 81 12. Adjust the neutral setting, if necessary. 13. Lower the unit and verify proper function. 14. Connect the battery by installing the positive cable first, then the negative cable to the battery. Titan Service Manual Page 6–15 Hydrostatic Drive System: Service and Repairs 3438-774 Rev A...
  • Page 82 Hydrostatic Drive System: Service and Repairs Page 6–16 Titan Service Manual 3438-774 Rev A...
  • Page 83 Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Mower Belt Replacement ........................7–6 Mower Deck Replacement ......................... 7–7 Mower Spindle ........................... 7–8 Electric PTO Clutch Replacement....................7–11 Titan Service Manual Page 7–1 Mower Deck 3438-774 Rev A...

  • Page 84: General Information

    General Information The TITAN® series of mowers uses 3 different deck sizes a 48 inch fabricated, 54 inch fabricated, and a 60 inch fabricated. All the decks use a 4-point lift system. All units have a 1.5-4.5 inch height-of-cut range.

  • Page 85: Service And Repairs

    Idler Belt Guide Washout Fitting V-Belt Hose Connector Bearing Shield Cutoff Baffle Flat Idler Pulley Spindle Asm Idler Bushing Spindle Shaft Idler Arm Asm Blade Washout Fitting Titan Service Manual Page 7–3 Mower Deck: Service and Repairs 3438-774 Rev A...
  • Page 86 Spanner Tube Flat Idler Pulley Deck Asm Idler Bushing Cut-off Baffle Idler Arm Asm Deck Asm Washout Fitting Spindle Asm Discharge Deflector Spindle Shaft Spacer Fender Mulch Blade Mower Deck: Service and Repairs Page 7–4 Titan Service Manual 3438-774 Rev A...
  • Page 87 V-Belt Washout Fitting Flat Idler Pulley Connector Hose Bearing Shield Deck Asm Idler Bushing Spindle Asm Idler Arm Asm Spindle Shaft Discharge Deflector Mulch Blade Spacer Fender Titan Service Manual Page 7–5 Mower Deck: Service and Repairs 3438-774 Rev A...

  • Page 88: Mower Belt Replacement

    1. Route the new belt around the clutch pulley and deck pulleys. g322062 Figure 77 2. Install the idler spring using the spring removal tool. 3. Ensure that the belt is properly seated in all pulleys. Mower Deck: Service and Repairs Page 7–6 Titan Service Manual 3438-774 Rev A...

  • Page 89: Mower Deck Replacement

    3. Lift the rear of the mower deck and attach the chains to the rear lift arms. 4. Attach the front chains to the front deck lift arms. Titan Service Manual Page 7–7 Mower Deck: Service and Repairs...

  • Page 90: Chapter 7: Mower Deck

    4. Install the mower belt. 5. Install the mower belt covers. 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. Mower Deck: Service and Repairs Page 7–8 Titan Service Manual 3438-774 Rev A...
  • Page 91 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. Titan Service Manual Page 7–9 Mower Deck: Service and Repairs 3438-774 Rev A...
  • Page 92 5. Apply anti-seize to the spindle shaft and install the spindle shaft. 6. Flip the spindle over while supporting the shaft through the spindle housing. 7. Install the bearing shield. 8. Install the pulley. Mower Deck: Service and Repairs Page 7–10 Titan Service Manual 3438-774 Rev A...

  • Page 93: Electric Pto Clutch Replacement

    4. Remove the mower belt. 5. Disconnect the clutch wire connector from the clutch. 6. Remove the clutch mounting bolt and washers. Slip the clutch off of the crankshaft. Titan Service Manual Page 7–11 Mower Deck: Service and Repairs 3438-774 Rev A...
  • Page 94 7 N • m (55 ± 5 ft-lb). 4. Connect the clutch power wire to the clutch. Note: Ensure wire harness is properly routed to avoid contact with the mower. g322060 Figure 83 Mower Deck: Service and Repairs Page 7–12 Titan Service Manual 3438-774 Rev A...
  • Page 95 Electric PTO Clutch Installation (continued) 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. 6. Lower the unit and verify proper function. Titan Service Manual Page 7–13 Mower Deck: Service and Repairs 3438-774 Rev A...
  • Page 96 Mower Deck: Service and Repairs Page 7–14 Titan Service Manual 3438-774 Rev A...
  • Page 97 Neutral Switch — Left and Right ......................8–6 Parking Brake Switch ......................... 8–6 Starter Solenoid ..........................8–7 PTO Switch ............................8–8 Electric PTO Clutch..........................8–9 TVS Diode............................8–11 Magneto Stop Relay ........................8–11 Titan Service Manual Page 8–1 Electrical 3438-774 Rev A...

  • Page 98: General Information

    Note: Jumper wires should be used for troubleshooting only, NEVER leave a jumper wire in place to bypass a safety circuit. Electrical: General Information Page 8–2 Titan Service Manual 3438-774 Rev A...

  • Page 99: Service And Repairs

    Neutral Switch Ignition Switch Solenoid Battery Negative Cable PTO Switch Engine Ground Hourmeter Clutch Diode 15A Fuse Neutral Switch Wire Harness Magneto Stop Relay 25A Fuse Park Brake Switch Titan Service Manual Page 8–3 Electrical: Service and Repairs 3438-774 Rev A...

  • Page 100: Fuse Block And Fuses

    Fuse Block and Fuses The fuse block houses the fuses that protect the electrical system from electrical surges. Note: Always use Toro fuses when replacing a damaged or blown fuse. g322165 Figure 85 Fuse Block and Fuses Testing 1. Visual Inspection: The fuses used in this application may be visually inspected.

  • Page 101: Hourmeter

    1. Without starting the engine, with the ignition switch in the “RUN” position and the PTO switch closed (ON) verify the battery voltage and ground to the hourmeter. Titan Service Manual Page 8–5 Electrical: Service and Repairs 3438-774 Rev A...

  • Page 102: Operator Presence Switch (Seat Switch)

    This allows proper voltage and ground signal path for the safety interlock and PTO operations. • Parking Brake ON, the switch should have continuity (closed). • Parking Brake OFF, the switch should NOT have continuity (open). Electrical: Service and Repairs Page 8–6 Titan Service Manual 3438-774 Rev A...

  • Page 103: Service And Repairs

    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. Titan Service Manual Page 8–7 Electrical: Service and Repairs...

  • Page 104: Pto Switch

    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. Electrical: Service and Repairs Page 8–8 Titan Service Manual 3438-774 Rev A...

  • Page 105: Electric Pto Clutch

    The friction plate is the only piece that moves vertically on the crankshaft. It is normally spring loaded so that it is not in contact with the clutch plate and is Titan Service Manual Page 8–9 Electrical: Service and Repairs...
  • Page 106 5. The 2 clutch connector terminals should never have continuity to ground and should OPEN at all times. 6. If continuity is found between the PTO connector and ground, the PTO clutch and the PTO switch must be replaced. Electrical: Service and Repairs Page 8–10 Titan Service Manual 3438-774 Rev A...

  • Page 107: Tvs Diode

    Magneto Stop Relay The magnento stop relay grounds the magneto when the key is turned to the “OFF” position. When the key is turned to the “RUN” position, the solenoid is Titan Service Manual Page 8–11 Electrical: Service and Repairs...
  • Page 108 Magneto Stop Relay (continued) grounded through the stop relay and the magneto is no longer grounded. The magneto stop relay prevents starting in an unsafe position. Electrical: Service and Repairs Page 8–12 Titan Service Manual 3438-774 Rev A...
  • Page 109 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 Electrical Schematic...........................A–3 Titan Service Manual Page A–1 Foldout Drawings 3438-774 Rev A...

  • Page 110: Electrical Drawing Abbreviations

    Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Foldout Drawings Page A–2 Titan Service Manual 3438-774 Rev A...

  • Page 111: Electrical Schematic

    Electrical Schematic g322167 , Drawing Rev A, Sheet 1 3438-774 Rev A Page A–3...

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