Toro 74846, 74848, 74851, 74852, 74853 Service Manual
...
Residential Products
2014
TITAN® ZX/MX
Service Manual
ABOUT THIS MANUAL
This service manual was written expressly for authorized Toro dealer service technicians. The Toro Company has
made every effort to make the information in this manual complete and correct.
Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems
and the related topics covered in this manual.
For service information on drive systems, please refer to the Hydro-Gear ZT-2800/ZT-3100/ZT-3400 service manual
(BLN 52441). For information specic to the engines used on this unit, refer to the appropriate engine manufacturer’s
service and repair instructions.
TITAN® model year 2014 is covered in this manual. The manual may also be specied 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 ttings whenever they are exposed. Even a small amount of dirt or other
contamination can severely damage the system.
If you have any questions or comments regarding this manual, please contact us at the following address:
The Toro Company
Residential and Landscape Contractor Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
The Toro Company reserves the right to change product specications or this manual without notice.
Copyright© All Rights Reserved
©2014 The Toro Company
ABOUT THIS MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK.
TABLE OF CONTENTS
1 - Safety Information
General Information ..................................................................................................................................... 1-1
Think Safety First......................................................................................................................................... 1-1
2 - Specications
Torque Specications .................................................................................................................................. 2-1
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) ................................................... 2-2
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) ..................................................... 2-3
Other Torque Specications ........................................................................................................................ 2-4
Equivalents & Conversions.......................................................................................................................... 2-5
Decimal & Millimeter Equivalents .......................................................................................................... 2-5
U.S. to Metric Conversions ................................................................................................................... 2-6
TITAN ZX Specications .............................................................................................................................. 2-7
TITAN MX Specications ............................................................................................................................. 2-8
Engine RPM Information ............................................................................................................................. 2-9
Hydro-Gear ZT-3100 Hydrostatic Transaxles ............................................................................................ 2-10
Checking the Hydraulic Oil Level............................................................................................................... 2-10
3 - Chassis
Model and Serial Number Identication....................................................................................................... 3-1
Grease and Lubrication Point ...................................................................................................................... 3-1
Frame and Chassis Exploded View ............................................................................................................. 3-2
ROPS Exploded View .................................................................................................................................. 3-3
Front Axle / Caster Fork / Bearing Service (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 Bushing Service (ZX) ..................................................................................................... 3-7
Caster Wheel / Bushing Disassembly ................................................................................................... 3-7
Caster Wheel / Bushing Assembly ........................................................................................................ 3-7
Pod / Fender Service ................................................................................................................................... 3-8
Pod / Fender Removal – RH ................................................................................................................. 3-8
Pod / Fender Installation – RH .............................................................................................................. 3-8
Pod / Fender Removal – LH ................................................................................................................. 3-9
Pod / Fender Installation – LH .............................................................................................................. 3-9
Fuel Tank Service ...................................................................................................................................... 3-10
Fuel Tank Removal (MX Shown)......................................................................................................... 3-10
Fuel Tank Installation (MX Shown)...................................................................................................... 3-10
Fuel & Vent Line Routing ............................................................................................................................3-11
Fuel & Vent Line Routing - ZX Models .................................................................................................3-11
Fuel & Vent Line Routing - MX Models ................................................................................................3-11
Fuel & Vent Line Routing - CARB Models .......................................................................................... 3-12
Motion Control Damper Service ................................................................................................................ 3-13
Motion Control Damper Removal (LH side shown) ............................................................................. 3-13
Motion Control Damper Installation ..................................................................................................... 3-13
Toro TITAN 2014 Service Manual
TOC-1
TABLE OF CONTENTS
3 - Chassis cont.
Motion Control Box / Seat Pivot Service (MX shown) ...................................................................................3-14
Motion Control Box / Seat Pivot Removal ...............................................................................................3-14
Motion Control Box / Seat Pivot Installation ............................................................................................3-16
Motion Control / Actuator Arm Service...........................................................................................................3-17
Motion Control Disassembly (LH Side Shown) .......................................................................................3-17
Motion Control Assembly ........................................................................................................................3-18
Seat Support / Fender Support Service.........................................................................................................3-21
Seat Support Removal (MX Shown) .......................................................................................................3-21
Seat Support Installation (MX Shown) ....................................................................................................3-21
Deck Lift Service............................................................................................................................................3-22
Deck Lift Removal ...................................................................................................................................3-22
Deck Lift Installation ................................................................................................................................3-22
Parking Brake & Linkage Service ..................................................................................................................3-24
Parking Brake & Linkage Removal .........................................................................................................3-24
Parking Brake & Linkage Installation ......................................................................................................3-25
4 - Engine
Engine Replacement .......................................................................................................................................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 ..........................................................................................................................5-5
Purging Procedure...........................................................................................................................................5-6
Hydrostatic Drive Belt Replacement ................................................................................................................5-6
Hydrostatic Drive Belt Removal ................................................................................................................5-6
Hydrostatic Drive Belt Installation .............................................................................................................5-7
Transaxle Replacement ...................................................................................................................................5-9
Transaxle Removal – RH Side Shown ......................................................................................................5-9
Transaxle Installation ..............................................................................................................................5-11
6 - Mower Deck
Mower Deck Exploded Views ..........................................................................................................................6-1
48 Inch Deck .............................................................................................................................................6-1
54 Inch Deck .............................................................................................................................................6-2
60 Inch Deck .............................................................................................................................................6-3
PTO Belt Replacement and Belt Routing ........................................................................................................6-4
48, 54 & 60 Inch Deck ...............................................................................................................................6-4
Inspecting the Belts .........................................................................................................................................6-4
PTO Belt Replacement - 48, 54 & 60 Inch Deck .............................................................................................6-5
TOC-2
Toro TITAN 2014 Service Manual
TABLE OF CONTENTS
6 - Mower Deck cont.
Mower Deck Replacement ..............................................................................................................................6-7
Mower Deck Removal - 48, 54 & 60 Inch Deck ........................................................................................6-7
Mower Deck Installation - 48, 54 & 60 Inch Deck .....................................................................................6-8
Spindle Service................................................................................................................................................6-9
Spindle Removal .......................................................................................................................................6-9
Spindle Installation ....................................................................................................................................6-9
Spindle Exploded Views ................................................................................................................................6-10
Spindle Assembly - 48, 54 & 60 Inch Deck .............................................................................................6-10
Spindle Disassembly ...............................................................................................................................6-10
Spindle Assembly .................................................................................................................................... 6-11
Idler Arm / Deck Belt Tensioner Service ........................................................................................................6-12
Idler Arm / Tensioner Exploded View - 48, 54 & 60 Inch Deck ................................................................ 6-12
Idler Arm 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
Continuity Testing ......................................................................................................................................7-3
Seat Switch......................................................................................................................................................7-4
Purpose .....................................................................................................................................................7-4
Location ....................................................................................................................................................7-4
How It Works .............................................................................................................................................7-4
Testing .......................................................................................................................................................7-5
RH and LH Neutral Switch...............................................................................................................................7-6
Purpose .....................................................................................................................................................7-6
Location ....................................................................................................................................................7-6
How it Works .............................................................................................................................................7-6
Testing .......................................................................................................................................................7-6
Parking Brake Switch ......................................................................................................................................7-7
Purpose .....................................................................................................................................................7-7
Location ....................................................................................................................................................7-7
How it Works .............................................................................................................................................7-7
Testing .......................................................................................................................................................7-8
Parking Brake Circuit ................................................................................................................................7-8
Toro TITAN 2014 Service Manual
TOC-3
TABLE OF CONTENTS
7 - Electrical cont.
Starter Solenoid & Starting System .................................................................................................................7-9
Purpose .....................................................................................................................................................7-9
Location ....................................................................................................................................................7-9
How It Works (solenoid only) ....................................................................................................................7-9
Starter Solenoid Testing (solenoid only)....................................................................................................7-9
Starting System Schematic ...........................................................................................................................7-10
Starter Solenoid Circuit & Operation .......................................................................................................7-10
Electric PTO Clutch ....................................................................................................................................... 7-11
Purpose ..................................................................................................................................................7-11
Location ..................................................................................................................................................7-11
How It works ...........................................................................................................................................7-11
Testing .....................................................................................................................................................7-11
Coil Resistance Measurement ................................................................................................................ 7-11
PTO Clutch Electrical Specications .......................................................................................................7-11
PTO Clutch Continuity to Ground Check ................................................................................................7-12
Measuring Clutch Current Draw ..............................................................................................................7-12
PTO Clutch Electrical Specications .......................................................................................................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
Location ..................................................................................................................................................7-16
How It Works ...........................................................................................................................................7-16
Testing .....................................................................................................................................................7-16
FlyBack Diode ...............................................................................................................................................7-17
Purpose ...................................................................................................................................................7-17
Location ..................................................................................................................................................7-17
Testing .....................................................................................................................................................7-18
Wire Harness View 1 of 3 ..............................................................................................................................7-19
Wire Harness View 2 of 3 ..............................................................................................................................7-20
Wire Harness View 3 of 3 ..............................................................................................................................7-21
TOC-4
Toro TITAN 2014 Service Manual
General Information
SAFETY INFORMATION
This symbol means WARNING or PER SONAL SAFETY INSTRUCTION – read
the instruction because it has to do with
your safety. Failure to comply with the
instruction may result in personal injury
!
This manual is intended as a service and repair manual
only. The safety instructions provided herein are for
troubleshooting, service, and repair of the TITAN® zero
turn mowers.
or even death.
Think Safety First
Avoid unexpected starting of engine…
Always turn off the engine and disconnect the spark plug
wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations…
Stay clear of all moving parts whenever the engine is
running. Treat all normally moving parts as if they were
moving whenever the engine is running or has the
potential to start.
The TITAN operator’s manuals contain safety information and operating tips for safe operating practices.
Operator’s manuals are available online through your
Toro parts source or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
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, sparks and ames away from
the battery.
Avoid injury due to inferior parts…
Use only original equipment parts to ensure that
important safety criteria are met.
1
Avoid burns…
Do not touch the engine, mufer, or other components,
which may increase in temperature during operation,
while the unit is running or shortly after it has been
running.
Avoid res and explosions…
Avoid spilling fuel and never smoke while working with
any type of fuel or lubricant. Wipe up any spilled fuel
or oil immediately. Never 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 conned area without
proper ventilation.
Avoid injury to bystanders…
Always clear the area of bystanders before starting or
testing powered equipment.
Avoid injury due to projectiles…
Always clear the area of sticks, rocks or any other debris
that could be picked up and thrown by the powered
equipment.
Avoid modications…
Never alter or modify any part unless it is a factory
approved procedure.
Avoid unsafe operation…
Always test the safety interlock system after making
adjustments or repairs on the machine. Refer to the
Electrical section in this manual for more information.
Toro TITAN 2014 Service Manual
1-1
1
SAFETY INFORMATION
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1-2
Toro TITAN 2014 Service Manual
SPECIFICATIONS
Torque Specications
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 identied and
specied in the service manual.
These torque specications for the installation and
tightening of fasteners shall apply to all fasteners
which do not have a specic requirement identied
in the service manual. The following factors shall be
consid ered when applying torque: cleanliness of the
fastener, use of a thread sealant (e.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 fastener is threaded
into aluminum or brass. The specic torque value should
be determined based on the aluminum or brass material
strength, fastener size, length of thread engagement,
etc.
Fastener Identication
Inch Series bolts and Screws
(A) Grade 1 & 2
(B) Grade 5
2
(C) Grade 8
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
Toro TITAN 2014 Service Manual
2-1
SPECIFICATIONS
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
2
Grade
1, 5, & 8
Thread Size
# 6-32 UNC 10 ± 2 13 ± 2 147 ± 23 15 ± 2 169 ± 23 23 ± 2 260 ± 34
# 6-40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8-32 UNC 13 ± 2 25 ± 5 282 ± 30 29 ± 3 330 ± 30 41 ± 4 460 ± 45
# 8-36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10-24 UNC 18 ± 2 30 ± 5 339 ± 56 42 ± 4 475 ± 45 60 ± 6 674 ± 70
# 10-32 UNF 48 ± 4 = 540 ± 45 68 ± 6 765 ± 70
1/4-20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4-28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16-18 UNC 115 ± 15 105 ± 15 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16-24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8-16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8-24 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 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4-16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8-9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8-14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
with Thin
Height
Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts,
Screws, Studs, & Sems
with Regular Height Nuts
(SAE J995 Grade 2 or
Stronger Nuts)
SAE Grade 5 Bolts,
Screws, Studs, & Sems
with Regular Height Nuts
(SAE J995 Grade 2 or
Stronger Nuts)
SAE Grade 8 Bolts,
Screws, Studs, & Sems
with Regular Height Nuts
(SAE J995 Grade 2 or
Stronger Nuts)
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated
fasteners are dened 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 threaded aluminum
or brass. The specic torque value should be
determined based on the fastener size, the
aluminum or base material strength, length of
thread engagement, etc.
2-2
®
.
Toro TITAN 2014 Service Manual
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75%
of the minimum proof load specied in SAE
J429. The tolerance is approximately ± 10%
of the nominal torque value. Thin height nuts
include jam nuts.
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm
M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 28 ± 3 ft-lb 38 ± 4 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 54 ± 6 ft-lb 73 ± 8 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 93 ± 10 ft-lb 126 ± 14 N-m
M16 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 dened 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 threaded aluminum
or brass. The specic torque value should be
determined based on the fastener size, the
aluminum or base material strength, length of
thread engagement, etc.
Regular Height Nuts
(Class 8 or Strong Nuts)
®
.
Note: The nominal torque values listed above are
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 10 or Strong Nuts)
based on 75% of the minimum proof load
specied in SAE J1199. The tolerance is
approximately ± 10% of the nominal torque
value. Thin height nuts include jam nuts.
2
Toro TITAN 2014 Service Manual
2-3
SPECIFICATIONS
Other Torque Specications
2
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb
5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb
3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb
1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non-lubricated fasteners.
Thread
Size
No. 6 18 20 20 ± 5 in-lb
Threads per Inch
Type A Type B
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
Thread Cutting Screws
(Zinc Plated Steel)
Baseline Torque*
No. 8 - 32 UNC 30 ± 5 in-lb
No. 10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors Conversion Factors
in-lb X 11.2985 = N-cm N-cm X - 0.08851 = in-lb
ft-lb X 1.3558 = N-m N-cm X 0.73776 = ft-lb
No. 8 15 18 30 ± 5 in-lb
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and
nish must be considered when determining specic
torque values. All torque values are based on
nonlubricated fasteners.
2-4
Toro TITAN 2014 Service Manual
SPECIFICATIONS
Equivalents & Conversions
Decimal & Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 16/32 0.53125 13.484
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.9375 2.381 19/32 0.59375 15.081
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 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 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 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
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254mm
2
Toro TITAN 2014 Service Manual
2-5
SPECIFICATIONS
U.S. to Metric Conversions
To Convert Into Multiply By
2
Miles
Yards
Feet
Linear Measurement
Area
Volume
Weight
Pressure Pounds/Sq. In. Kilopascal 6.895
Work
Liquid Volume
Liquid Flows Gallons/Minute Liters/Minute 3.785
Temperature Fahrenheit Celsius
Feet
Inches
Inches
Inches
Square Miles
Square Feet
Square Inches
Acre
Cubic Yards
Cubic Feet
Cubic Inches
Tons (Short)
Pounds
Ounces
Foot-pounds
Foot-pounds
Inch-pounds
Quarts
Gallons
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
Square Kilometers
Square Meters
Square Centimeters
Hectare
Cubic Meters
Cubic Meters
Cubic Centimeters
Metric Tons
Kilograms
Grams
Newton-Meters
Kilogram-Meters
Kilogram-Centimeters
Liters
Liters
1. Subtract 32°
2. Multiply by 5/9
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
1.356
0.1383
1.152144
0.9463
3.785
2-6
Toro TITAN 2014 Service Manual
SPECIFICATIONS
TITAN ZX Specications
Congurations ZX4800 ZX5400 ZX6000
21.5 HP Kawasaki V-Twin 48” SD, 3-blades
23 HP Kawasaki V-Twin 54” SD, 3-blades
24 HP Kawasaki V-Twin 60” SD, 3-blades
Power Systems
Clutch Electric Electric Electric
Transaxles
Drive
Maximum Ground Speed 8.5 mph/4.0 mph 8.5 mph/4.0 mph 8.5 mph/4.0 mph
Rear Drive Tires 22” x 10”-10 22” x 10”-10 22” x 10”-10
Front Caster Tires 13 x 5 smooth 13 x 5 smooth 13 x 5 smooth
Fuel/Capacity 5 gallons (18.9 L) 5 gallons (18.9 L) 5 gallons (18.9L)
Mowing Deck
Type Side Discharge Side Discharge Side Discharge
Deck Construction 10 gauge fabricated steel 10 gauge fabricated steel 10 gauge fabricated steel
Spindle Housings Die cast aluminum Die cast aluminum Die cast aluminum
Spindle Shaft/Bearings
Blade Tip Speed
Cutting Height 1.5” to 4.5” 13 positions 1.5” to 4.5” 13 positions 1.5” to 4.5” 13 positions
Anti-Scalp Rollers 3 Adjustable 3 Adjustable 3 Adjustable
Frame Construction
Twin Hydro-Gear ZT-3100
w/charge pumps
Belt Drive with selftensioning system
Three 25mm diameter
spindles in permanently
lubed ball bearings
18,800 ft/min @
3700 RPM
1.5” X 3” (.109” wall)
Mechanical Steel Tubing
Twin Hydro-Gear ZT-3100
w/charge pumps
Belt Drive with selftensioning system
Three 25mm diameter
spindles in permanently
lubed ball bearings
18,644 ft/min @
3700 RPM
1.5” X 3” (.109” wall)
Mechanical Steel Tubing
Twin Hydro-Gear ZT-3100
w/charge pumps
Belt Drive with selftensioning system
Three 25mm diameter
spindles in permanently
lubed ball bearings
18,908 ft/min @
3700 RPM
1.5” X 3” (.109” wall)
Mechanical Steel Tubing
2
Dimensions
Weight 735 lbs. (estimated) 750 lbs. (estimated) 773 lbs. (estimated)
Width Outside Tires 44.3” (117.6cm) 46.4” (117.9cm) 46.4” (117.9cm)
Overall Width
Wheel Base 49.4” (125.5cm) 49.4” (125.5cm) 49.4” (125.5cm)
Overall Length 77.3” (196.3cm) 77.3” (196.3cm) 77.3” (196.3cm)
Height
Toro TITAN 2014 Service Manual
61.5” Deector Down
52.4” Deector Up
72.4” ROPS Up
45.6” ROPS Down
67.9” Deector Down
57.7” Deector Up
72.4” ROPS Up
45.6” ROPS Down
75.0” Deector Down
63.0” Deector Up
72.4” ROPS Up
45.6” ROPS Down
2-7
2
SPECIFICATIONS
TITAN MX Specications
Congurations MX5400 MX6000
23 HP Kawasaki V-Twin 54” SD, 3-Blades
24 HP Kawasaki V-Twin 60” SD, 3-Blades
Power Systems
Clutch Electric Electric
Transaxles Twin Hydro-Gear ZT-3100
with Charge Pump,
Shock Valves and
Heavy Duty Gears
Drive Belt Drive self-tensioning
system
Maximum Ground Speed 8.5 mph/4.0 mph 8.5 mph/4.0 mph
Rear Drive Tires 22” x 10”-12 22” x 10”-12
Front Caster Tires 13” x 6” Smooth 13” x 6” Smooth
Fuel / Capacity 5 gallons (18.9L) 5 gallons (18.9L)
Twin Hydro-Gear ZT-3100
with Charge Pump,
Shock Valves and
Heavy Duty Gears
Belt Drive self-tensioning
system
Mower Decks
Type Side Discharge Side Discharge
Deck Construction
Material
Spindle Housing Die cast aluminum Die cast aluminum
Spindle Shaft/Bearings Three 25mm diameter
Blade Tip Speed 18,644 ft/min @
Cutting Height 1.5” to 4.5” 13 Positions 1.5” to 4.5” 13 Positions
Anti-Scalp Rollers 3 Adjustable 3 Adjustable
Frame Construction 1.5” X 3” (.109” wall)
Dimensions
Weight 813 lbs. (estimated)
Width Outside Tires 47.2” (119.9cm) 47.2” (119.9cm)
Width Outside Deck 67.9” Deector Down
Wheel Base 49.2” (125.0cm) 49.2” (125.0cm)
Overall Length 77.4” (196.6cm) 77.4” (196.6cm)
Overall Height 73.4” ROPS Up
10 gauge fabricated steel 10 gauge fabricated steel
Three 25mm diameter
spindles in permanently
lubed ball bearings
3700 RPM
Mechanical Steel Tubing
57.7” Deector Up
46.9” ROPS Down
spindles in permanently
lubed ball bearings
18,908 ft/min @
3700 RPM
1.5” X 3” (.109” wall)
Mechanical Steel Tubing
75.0” Deector Down
63.0” Deector Up
73.4” ROPS Up
46.9” ROPS Down
2-8
Toro TITAN 2014 Service Manual
Engine RPM Information
Model # Model Engine Information
74846 ZX 4800 (INTL) Kawasaki, 21.5hp, High Idle: 3000 ± 100 RPM
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
SPECIFICATIONS
2
Toro TITAN 2014 Service Manual
2-9
2
SPECIFICATIONS
Hydro-Gear ZT-3100 Hydrostatic Transaxles
Fig. 001 PICT-1002
Lubrication Toro HYPR-OIL® 500 or 20w50 Engine Oil
Oil Capacity ZT-3100 77.23 . oz. (2284ml) each (not including reservoir or hose volume)
Oil Level Check Check expansion reservoir and if necessary add the specied 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 lters for the hydraulic system and bleed
the system.
Every 400 Hours - change the oil and lters for the hydraulic system and bleed the
system.
Checking the Hydraulic Oil Level
C
A
B
Fig. 002 g. 51 G020323
A. Expansion reservoir C. Engine
B. Full cold line
2-10
Toro TITAN 2014 Service Manual
CHASSIS
Model and Serial Number
Identication
The model and serial number identication plate is
located on the frame, near the engine, on the RH side of
the unit (Fig. 003).
Fig. 003 PICT-2057
Grease and Lubrication Point
Grease Type – No. 2 general-purpose lithium base
grease
A grease tting is located on each of the front wheel
hubs.
The front wheel hubs should be greased every 25 hrs.
(Fig. 004).
3
Fig. 004 PICT-3006
Toro TITAN 2014 Service Manual
3-1
CHASSIS
Frame and Chassis Exploded View
(Fig. 005)
B
B
3
B
D
B
B
B
D
3-2
A
C
Fig. 005 PICT-3027
A. 35 ft-lbs. (47 Nm) C. 5 ft-lbs. (7 Nm)
B. 17 ft-lbs. (23 Nm) D. 50 in-lbs. (4 Nm)
Toro TITAN 2014 Service Manual
ROPS Exploded View
(Fig. 006)
CHASSIS
3
E
Fig. 006 PICT-3005
ROPS Mounting Torque Sequence:
1. Install, but do not tighten all ROPS mounting fasteners.
2. Torque the (4) fasteners (A) to specication – 35 ft-lbs. (47 Nm)
3. Torque the (4) fasteners (B) to specication – 25 ft-lbs. (34 Nm)
4. Torque the (2) fasteners (C) to specication – 75 ft-lbs. (101 Nm)
5. Torque the (4) fasteners (D) to specication – 35 ft-lbs. (47 Nm)
C
B
B
A
A
D
D
Other Torque Values:
E. Seat Belt Mounting Fasteners – 75 ft-lbs. (101 Nm)
Toro TITAN 2014 Service Manual
3-3
CHASSIS
3
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
wear, replace if necessary.
5. Using an appropriate punch, tap out and remove the
LOWER bearings from the frame hub.
6. Using an appropriate punch, tap out and remove the
UPPER bearings from the frame hub.
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 thrust washer (D) onto the caster fork shaft.
3. Install the caster assembly up through the bearings
and hold in position.
4. Install washer (E).
5. Install fastener (B) and torque to specication - 17
ft-lbs. (23 Nm).
6. Install the dust cap (A) until fully seated.
7. Safely lower unit and verify proper function
(Fig. 007).
7. Properly clean and inspect the frame hub bearing
area.
A
E
D
B
C
3-4
Fig. 007 PICT-3002
Toro TITAN 2014 Service Manual
CHASSIS
Front Axle / Caster Fork / Bearing
Service (ZX)
Front Axle / Caster Fork / Bearing Disassembly
1. Safely raise and support unit so front wheels are off
the ground.
2. Remove the dust cap (A).
3. Support under caster wheel and remove the fastener
(B).
4. Remove caster fork (C) from front frame hub.
Inspect the caster fork shaft, thrust washer (D) and
spacer (E) for excessive wear, replace if necessary.
5. Using an appropriate punch, tap out and remove the
LOWER bearings from the frame hub.
6. Using an appropriate punch, tap out and remove the
UPPER bearings from the frame hub.
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. Install the caster assembly up through the bearings
and hold in position.
4. Install washer (F).
5. Install fastener (B) and torque to specication -17
ft-lbs. (23 Nm).
6. Install the dust cap (A) until fully seated.
7. Safely lower unit and verify proper function
(Fig. 008).
3
7. Properly clean and inspect the front axle bearing
area.
A
F
D
B
E
C
Toro TITAN 2014 Service Manual
Fig. 008 PICT-3001
3-5
CHASSIS
3
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. Remove and inspect wheel spanner (B). Replace if
excessively worn.
4. Use an appropriate punch to remove the (2)
bushings (C) from the wheel hub. Inspect bushings
and replace if excessively worn.
5. Remove the (2) bearings (D) from the wheel hub.
Replace if excessively worn.
6. Properly clean and inspect the front wheel hub area.
Caster Wheel, Bushing and Bearing Assembly
1. Lightly lubricate bearings (D), 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) bearings (D) and (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. Install the nut / bolt (A) and torque nut to
specication - 35 ft-lbs. (47 Nm).
6. Lubricate bushings / bearings through grease tting
with No. 2 general-purpose lithium base grease.
7. Safely lower unit and verify proper function
(Fig. 009).
3-6
A
D
C
B
Fig. 009 PICT-3003
Toro TITAN 2014 Service Manual
CHASSIS
Caster Wheel and Bushing Service (ZX)
Caster Wheel / Bushing Disassembly
1. Safely raise and support unit so front wheels are off
the ground.
2. Support under caster wheel and remove the nut /
bolt (A).
3. Remove and inspect wheel spanner (B). Replace if
excessively worn.
4. Using an appropriate punch, remove the (2)
bushings (C) from the wheel hub. Inspect bushings
and replace if excessively worn.
5. Properly clean 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. Install the nut / bolt (A) and torque nut to
specication - 35 ft-lbs. (47 Nm).
6. Lubricate bushings / spanner through grease tting
with No. 2 general-purpose lithium base grease.
7. Safely lower unit and verify proper function
(Fig. 010).
3
A
C
Toro TITAN 2014 Service Manual
B
Fig. 010 PICT-3004
3-7
CHASSIS
3
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. Remove the (3) screws (B) securing the RH fender
to frame.
4. Maneuver RH fender up and off frame.
A
Pod / Fender Installation – RH
1. Maneuver RH fender into position.
2. Install the (3) screws (B) that secure the RH fender
to frame and torque to specication – 7 ft-lbs. (9
Nm).
3. Position control panel (A) back onto RH fender.
Install and sufciently tighten the (4) 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).
B
B
B
3-8
Fig. 011 PICT-2061
Toro TITAN 2014 Service Manual
CHASSIS
Pod / Fender Removal – LH
1. Raise seat and disconnect battery terminals
2. Remove the (3) screws (A) securing the LH fender to
the unit frame.
3. Lubricate rubber fuel tank neck grommet with soapy
water (Fig. 012).
Pod / Fender Installation – LH
1. Lubricate rubber fuel tank neck grommet with soapy
water.
2. Remove fuel cap 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 specication 7 ft-lbs. (9
Nm).
6. Connect battery terminals and lower seat (Fig. 013).
3
Fig. 012 PICT-2065
4. Remove fuel cap from fuel tank.
5. Lift LH fender assembly upward and off the frame.
Use care while lifting fender upward as the fuel tank
neck slips through the grommet.
6. Reinstall fuel cap.
Toro TITAN 2014 Service Manual
A
Fig. 013 PICT-2064
3-9
CHASSIS
3
Fuel Tank Service
Fuel Tank Removal (MX Shown)
1. Raise seat and disconnect battery terminals
2. Remove the RH and LH pod / fender as shown in
this chapter.
3. Remove the (2) bolts that secure the hydro
expansion tank (A) to the seat support. Move the
tank rearward for fuel tank removal clearance.
4. Remove the (1) fastener securing the fuel tank
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
Fuel Tank Installation (MX Shown)
1. Position the fuel tank 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
specication – 17 ft-lbs. (23 Nm).
3. Install the fuel tank retaining rod (B) and torque
retaining bolt to specication – 8 ft-lbs. (11 Nm). Be
sure the front rod end is engaged into the control
box assembly (Fig. 015).
B
8. Remove the seat support bar from the frame.
9. The fuel tank is now loose and can be removed from
the unit frame.
(Fig. 014)
B
CC A A
Fig. 014 PICT-3016
Fig. 015 PICT-2069
4. Install the (2) bolts (A) that secure the hydro
expansion tank to the seat support and torque to
specication – 5 ft-lbs. (7 Nm).
5. Properly route cables / wiring and reinstall cable ties
/ loom clams to secure them to the seat support.
6. Properly route and reconnect the fuel / vent line(s).
Note: The fuel tank is labeled “FUEL” for the fuel
hose tting connection and “VENT” for the
fuel tank vent tting connection.
7. Install the RH and LH pod / fender as outlined in this
chapter.
8. Connect the battery cables and lower seat.
9. Verify proper function.
3-10
Toro TITAN 2014 Service Manual
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