Toro 76601 Service Manual

TITAN®MaxServiceManual

FormNo.3442-428RevA

©2020—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Published:XX2020

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

RevisionHistory

RevisionHistoryPage2

TITAN®MaxServiceManual

3442-428RevA

Preface

ThisservicemanualwaswrittenexpresslyforToroservicetechnicians.TheToroCompanyhasmade
everyefforttomaketheinformationinthismanualcompleteandcorrect.

Basicshopsafetyknowledgeandmechanical/electricalskillsareassumed.TheT ableofContentslists
thesystemsandtherelatedtopicscoveredinthismanual.

Wearehopefulthatyouwillndthismanualavaluableadditiontoyourserviceshop.Ifyouhaveany
questionsorcommentsregardingthismanual,pleasecontactusatthefollowingaddress:

TheT oroCompany

RLC/SWSCustomerCareDepartment

8111LyndaleAvenueSouth

Bloomington,MN55420

TheToroCompanyreservestherighttochangeproductspecicationsormakechangestothismanual
withoutnotice.

TITAN®MaxServiceManual
3442-428RevA

Page3

Preface

ServiceProcedureIcons

ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.

CriticalProcess

Thisiconisusedtohighlight:

•Installingsafetyequipment(shields,guards,seatbelts,brakes,andR.O.P.S.

components)thatmayhavebeenremoved

•Dimensionsorsettingsthatmustbemaintainedforpropermachineoperation

•Aspecicfastenertighteningsequence

•Componentorientationthatmaynotbeobvious

CriticalT orque

Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardT orqueTables.

FluidSpecications

Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine

Operator’sManual.

Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.

Preface

Page4

TITAN®MaxServiceManual

3442-428RevA

TableofContents

Preface................................................................................................................3

Chapter1:Safety............................................................................................1–1

SafetyInstructions.......................................................................................1–2

Chapter2:SpecicationsandMaintenance....................................................2–1

Specications...............................................................................................2–2

TorqueSpecications...................................................................................2–3

Chapter3:Troubleshooting.............................................................................3–1

GeneralTroubleshooting..............................................................................3–3

Chapter4:Engine...........................................................................................4–1

GeneralInformation.....................................................................................4–2

ServiceandRepairs.....................................................................................4–3

Chapter5:Chassis..........................................................................................5–1

GeneralInformation.....................................................................................5–2

ServiceandRepairs.....................................................................................5–3

Chapter6:MowerDeck...................................................................................6–1

GeneralInformation.....................................................................................6–2

ServiceandRepairs.....................................................................................6–3

Chapter7:HydrostaticDriveSystem...............................................................7–1

GeneralInformation.....................................................................................7–2

ServiceandRepairs.....................................................................................7–3

Chapter8:ElectricalSystem...........................................................................8–1

GeneralInformation.....................................................................................8–2

ServiceandRepairs.....................................................................................8–3

AppendixA......................................................................................................A–1

ElectricalDrawingAbbreviations...................................................................A–2

KohlerEngineElectricalSchematic..............................................................A–3

TITAN®MaxServiceManual
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Page5

Preface

Preface

Page6

TITAN®MaxServiceManual

3442-428RevA

Chapter1

Safety

TableofContents

SafetyInstructions................................................................................................................................1–2

ThinkSafetyFirst...............................................................................................................................1–2

TITAN®MaxServiceManual
3442-428RevA

Page1–1

Safety

SafetyInstructions

DANGER

Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldcauseseriouspermanentinjury,disability,or
death.

WARNING

Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.

CAUTION

Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjuryand/ordamage
topropertyorequipment.

ThinkSafetyFirst

Avoidunexpectedstartingofengine…

Alwaysturnofftheengine,removetheignitionkeyanddisconnectthesparkplug
wire(s)beforecleaning,adjusting,orrepair.

Avoidlacerationsandamputations…

Stayclearofallmovingpartswhenevertheengineisrunning.Treatallnormally
movingpartsasiftheyweremovingwhenevertheengineisrunningorhas
thepotentialtostart.

Avoidburns…

Donottouchtheengine,mufer,orothercomponents,whichmaybehotduring
operation,whiletheunitisrunningorshortlyafterithasbeenrunning.

Avoidresandexplosions…

Useextremecareinhandlingfuel.Itisammableanditsvaporsareexplosive.
Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.Avoid
spillingfuelandneversmokewhileworkingwithanytypeoffuelorlubricant.
Wipeupanyspilledfueloroilimmediately.Neverremovethefuelcaporadd
fuelwhentheengineisrunning.Alwaysuseapproved,labeledcontainersfor
storingortransportingfuelandlubricants.Donotaddordrainfuelinanenclosed
space.Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.

Safety:SafetyInstructions

Avoidasphyxiation…

Donotoperateanengineinaconnedareawithoutproperventilation.

Avoidinjuryfrombatteries…

Page1–2

TITAN®MaxServiceManual

3442-428RevA

ThinkSafetyFirst(continued)

Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,eyes
andclothing.Batterygasescanexplode.Keepcigarettes,sparksandames
awayfromthebattery.

Avoidinjuryduetoinferiorparts…

Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteriaaremet.

Avoidinjurytobystanders…

Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.

Avoidinjuryduetoprojectiles…

Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbepickedup
andthrownbythepoweredequipment.

Avoidmodications…

Neveralterormodifyanypartunlessitisafactoryapprovedprocedure.

Avoidunsafeoperation…

Alwaystestthesafetyinterlocksystemaftermakingadjustmentsorrepairson
themachine.RefertotheElectricalsectioninthismanualformoreinformation.

Avoidelectricalshock…

Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.They
canbesourcesofshock.De-energizethesystemifyouarehavingtodorepairs.
Iftestingelectricalcomponentsensureyouareworkinginadryenvironment.

HydraulicSystem...

Releaseallpressureinthehydraulicsystembeforeperforminganyworkon
thesystem.Keepyourbodyandhandsawayfrompin-holeleaksornozzles
thatejecthydraulicuidunderhighpressure.Donotuseyourhandstosearch
forleaks.Hydraulicuidescapingunderpressurecanhavesufcientforceto
penetrateundertheskinandcauseseriousinjury.Seekmedicalattentionright
awayifhydraulicuidgetsintheskin.

PersonalProtectiveEquipment…

Tiebacklonghair,anddonotwearlooseclothingorjewelry.Useappropriate
personalprotectiveequipment(PPE)forprotectingyourselffrompotential
hazardsintheenvironmentinwhichyouwillwork.Eachprocessoutlinedinthis
manualmayneeddifferentPPEtoprotecttheserviceperson.Usetheproper
PPEforthetaskathand.

Tools…

Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatarebrokenorin
disrepair.Usethepropertoolfortheproperapplication.

Lifts,Hoists,andJacks…

TITAN®MaxServiceManual
3442-428RevA

Alllifts,hoists,andjacksshouldbeusedinaccordancewiththemanufacturer
information.Inspectlifts,hoists,andjackspriortouse.Donotoverloadlifts,
hoists,andjacks.Donotworkunderasuspendedload.Ensurechockblocks
areusedonequipmentthatcanmove.Useliftsorjacksandjackstandsthat
areratedtosupportthetotalweightofthemachineandanyattachments.Do
notrelyonjackstosupportthemachine.Ifyouareunsureoftheoperationof
anylifts,hoists,andjacksdonotuse.

FireExtinguishers…

Page1–3

Safety:SafetyInstructions

ThinkSafetyFirst(continued)

Theproperclassofreextinguishershouldbeusedincaseofre.

ClassAextinguishersareforordinarycombustiblematerialssuchaspaper,
wood,cardboard,andmostplastics.Thenumericalratingonthesetypesof
extinguishersindicatestheamountofwateritholdsandtheamountofreitcan
extinguish.Geometricsymbol(greentriangle).

ClassBresinvolveammableorcombustibleliquidssuchasgasoline,
kerosene,greaseandoil.ThenumericalratingforclassBextinguishers
indicatestheapproximatenumberofsquarefeetofreitcanextinguish.
Geometricsymbol(redsquare).

ClassCresinvolveelectricalequipment,suchasappliances,wiring,circuit
breakersandoutlets.NeverusewatertoextinguishclassCres-theriskof
electricalshockisfartoogreat!ClassCextinguishersdonothaveanumerical
rating.TheCclassicationmeanstheextinguishingagentisnon-conductive.
Geometricsymbol(bluecircle).

ABCreextinguishersareadrychemicaltypeusedformultiplepurposes.See
aboveinformationfordescription.Ensurereextinguishersareserviceableand
replaceanythataredischargedoroutofinspectiondates

Safety:SafetyInstructions

Page1–4

TITAN®MaxServiceManual

3442-428RevA

Chapter2

SpecicationsandMaintenance

TableofContents

Specications.......................................................................................................................................2–2

TorqueSpecications...........................................................................................................................2–3

EquivalentsandConversions.............................................................................................................2–8

U.S.toMetricConversions................................................................................................................2–9

TITAN®MaxServiceManual
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Page2–1

SpecicationsandMaintenance

Specications

TITAN®MaxSpecications

Model76601

Engine

EngineModelKT745-3094

EngineDisplacement747cc

EngineSpeed

EngineOilCapacity1.9L(64oz)withoillter

Frame/AxleWidth

DeckSize152.4cm(60inches)

DeckConguration

DeckConstruction

HOCType

HOCRange3.81–12.7cm(1.5-5.0inches)

FuelTankCapacity26.5L(7gallons)

CARBCompliant

EPAComplaint

ClutchWarner142.36N•m(105ft-lb)

Hydros

HydroOilCapacity(WithFiltersRemoved)4.45L(1.2gallons)

UnitSpeed

RearWheels/Tires58.42x3.48–30.48cm(23x12-12inches)

CastorTires13x6.5-6Smooth

Seat(INCwithArmrests)60.96cm(24inch)SeatsINCwitharmrests

SeatSlideLeverSlide

FloorMatMoldedRubber

Recycler

BaggingSystemOptional

Hourmeter

FootLiftAssistStandard

DeckSpringAssistN/A

HitchKit

Anti-scalpeRollersYes

BatterySize300CCA

GrossWeight(lb)

Length

Width(DeectorDown)191.3cm(75.3inches)

Width(DeectorUp)160.5cm(63.2inches)

Height(ROPSDown)116cm(45.7inches)

Height(ROPSUp)179.6cm(70.7inches)

26HPKohlerwithProAirCleaner

3600±100

FullyWeldedTubularFrame

3-Blade

Fabricated

4Point

No

Yes

Hydro-GearZT-3100

9.0mph

Optional

Standard

Standard

Unit876

208.79cm(82.2inches)

SpecicationsandMaintenance:Specications

Page2–2

TITAN®MaxServiceManual

3442-428RevA

TorqueSpecications

Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For
criticalapplications,asdeterminedbyT oro,eithertherecommendedtorqueora
torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthe
servicemanual.

Thesetorquespecicationsfortheinstallationandtighteningoffastenersshall
applyforallfastenerswhichdonothaveaspecicrequirementidentiedin
theservicemanual.Thefollowingfactorsshallbeconsideredwhenapplying
torque:cleanlinessofthefastener,useofathreadsealant(Loctite),degreeof
lubricationonthefastener,presenceofaprevailingtorquefeature,hardness
ofthesurfaceunderneathofthefastener’shead,orsimilarconditionwhich
affectstheinstallation.

Asnotedinthefollowingtables,torquevaluesshouldbereducedby25%for
lubricatedfastenerstoachievethesimilarstressasadryfastener.Torquevalues
mayalsohavetobereducedwhenthefasteneristhreadedintoaluminumor
brass.Thespecictorquevalueshouldbedeterminedbasedonthealuminum
orbrassmaterialstrength,fastenersize,lengthofthreadengagement,etc.

Thestandardmethodofverifyingtorqueshallbeperformedbymarkingalineon
thefastener(headornut)andmatingpart,thenbackofffastener1/4ofaturn.
Measurethetorquerequiredtotightenthefasteneruntilthelinesmatchup.

FastenerIdentication

InchSeriesBoltsandScrews

g272208

Figure1

1.Grade13.Grade8

2.Grade5

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Page2–3

SpecicationsandMaintenance:TorqueSpecications

MetricBoltsandScrews

g272209

Figure2

1.Class8.82.Class10.9

SpecicationsandMaintenance:TorqueSpecications

Page2–4

TITAN®MaxServiceManual

3442-428RevA

StandardTorqueforDry,ZincPlated,andSteelFasteners(InchSeries)

ThreadSizeGrade1,

#6-32UNC

#6-40UNF

#8-32UNC

#8-36UNF

#10-24UNC

#10-32UNF

1/4-20UNC

1/4-28UNF

5/16-18UNC

5/16-24UNF

3/8-16UNC

3/8-24UNF

7/16-14UNC

7/16-20UNF

1/2-13UNC

1/2-20UNF

5/8-11UNC

5/8-18UNF

3/4-10UNC

3/4-16UNF

7/8-9UNC

7/8-14UNF

5,&8

Fasteners

withThin

HeightNuts

in-lbin-lbN•cmin-lbN•cmin-lbN•cm

10±213±2147±23

13±225±5282±30

18±230±5339±56

48±753±7599±79100±101130±113140±151582±169

53±765±10734±113115±121299±136160±171808±192

115±15105±151186±169200±252260±282300±303390±339

138±17128±171446±192225±252542±282325±333672±373

ft-lbft-lb

16±216±222±330±341±443±558±7

17±218±224±335±447±550±668±8

27±327±337±450±568±770±795±9

29±329±339±455±675±877±8104±11

30±348±765±975±8102±11105±11142±15

32±453±772±985±9115±12120±12163±16

65±1088±12119±16150±15203±20210±21285±28

75±1095±15129±20170±18230±24240±24325±33

93±12140±20190±27265±27359±37375±38508±52

115±15165±25224±34300±30407±41420±43569±58

140±20225±25305±34430±45583±61600±60813±81

155±25260±30353±41475±48644±65667±66904±89

SAEGrade1Bolts,Screws,

Studes&Semswith

RegularHeightNuts(SAE

Grade2orBetterNut)

N•m

SAEGrade5Bolts,Screws,
Studs&SemswithRegular

HeightNuts(SAEGrade

5orBetterNut)

15±2169±2323±3260±34

17±2192±2325±3282±34

29±3328±3441±5463±56

31±4350±4543±5486±56

42±5475±5660±6678±68

48±5542±5668±7768±79

ft-lb

N•m

SAEGrade8Bolts,Screws,
Studs&SemswithRegular

HeightNuts(SAEGrade

8orBetterNut)

ft-lb

N•m

Note:Reducetorquevalueslistedinthetableaboveby25%forlubricatedfasteners.Lubricated

fastenersaredenedasthreadscoatedwithalubricantsuchasoil,graphite,orthreadsealantsuch
asLoctite.

Torquevaluesmyhavetobereducedwheninstallingfastenersintothreadedaluminumorbrass.The
specictorquevalueshouldbedeterminedbasedonthefastenersize,thealuminumorbasematerial
strength,lengthofthreadengagement,etc.

ThenominaltorquevalueslistedaboveforGrade5and8fastenersarebasedon75%oftheminimum
proofloadspeciedinSAEJ429.Thetoleranceisapproximately±10%ofthenominaltorquevalue.
Thinnutsincludejamnuts.

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Page2–5

SpecicationsandMaintenance:TorqueSpecications

StandardTorqueforDry,ZincPlated,andSteelFasteners(MetricSeries)

ThreadSize

M5X0.857±6644±6878±8881±90

M6X1.096±101085±113133±141503±158

M8X1.2519±226±328±338±4

M10X1.538±452±554±673±8

M12X1.7566±790±1093±10126±14

M16X2.0166±17255±23229±23310±31

M20X2.5325±33440±45450±46610±62

Class8.8Bolts,Screws,StudswithRegular

HeightNuts(Class8orStrongerNuts)

in-lbN•cmin-lbN•cm

ft-lb

N•m

Class10.9Bolts,Screws,StudswithRegular

HeightNuts(Class10orstrongerNuts)

ft-lb

N•m

Note:Reducetorquevalueslistedinthetableaboveby25%forlubricatedfasteners.Lubricated

fastenersaredenedasthreadscoatedwithalubricantsuchasoil,graphite,orthreadsealantsuch
asLoctite.

Torquevaluesmayhavetobereducedwheninstallingfastenersintothreadedaluminumorbrass.The
specictorquevalueshouldbedeterminedbasedonthefastenersize,thealuminumorbasematerial
strength,lengthofthreadengagement,etc.

Thenominaltorquevalueslistedabovearebasedon75%oftheminimumproofloadspeciedinSAE
J1199.Thetoleranceisapproximately±10%ofthenominaltorquevalue.Thinheightnutsincludejam
nuts.

SpecicationsandMaintenance:TorqueSpecications

Page2–6

TITAN®MaxServiceManual

3442-428RevA

SAEGrade8SteelSetScrews

ThreadSize

SquareHeadHexSocket

1/4-20UNC

5/16-18UNC

1/2-13UNC75±15ft-lb50±10ft-lb

3/8-16UNC35±10ft-lb18±3ft-lb

140±20in-lb73±12in-lb

215±35in-lb145±20in-lb

RecommendedTorque

WheelBoltsandLugNuts

ThreadSizeRecommendedTorque**

7/16-20UNFGrade565±10ft-lb

1/2-20UNFGrade580±10ft-lb

M12X1.25Class8.880±10ft-lb

M12X1.5Class8.880±10ft-lb

88±14N•m

108±14N•m

108±14N•m

108±14N•m

**Forsteelwheelsandnon-lubricatedfasteners.

ThreadCuttingScrews(ZincPlatedSteel)

Type1,Type23,orTypeF

ThreadSizeBaselineTorque*

No.6-32UNC

No.8-32UNC

No.10-24UNC

1/4-20UNC

5/16-18UNC

3/8-16UNC

20±5in-lb

30±5in-lb

38±7in-lb

85±15in-lb

110±20in-lb

200±100in-lb

*Holesize,materialstrength,materialthicknessandnishmustbeconsideredwhendetermining
specictorquevalues.Alltorquevaluesarebasedonnon-lubricatedfasteners.

ConversionFactors

in-lbX11.2985=N•cm

ft-lbX1.3558=N•m

N•cmX0.08851=in-lb

N•cmX0.73776=ft-lb

ThreadCuttingScrews(ZincPlatedSteel)

ThreadsSize

TypeATypeB

No.6182020±5in-lb

No.8151830±5in-lb

No.10121638±7in-lb

No.12111485±15in-lb

ThreadsperInch

BaselineTorque*

*Holesize,materialstrength,materialthicknessandnishmustbeconsideredwhendetermining
specictorquevalues.Alltorquevaluesarebasedonnon-lubricatedfasteners.

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SpecicationsandMaintenance:TorqueSpecications

EquivalentsandConversions

DecimalandMillimeterEquivalents

FractionsDecimals

1/64

1/32

3/64

1/16

5/64

3/32

1/8

9/64

5/32

11/64

3/16

13/64

7/32

15/64

1/4

17/64

9/32

19/64

5/16

21/64

11/32

23/64

3/8

25/64

13/32

27/64

7/16

29/64

15/32

31/64

1/2

mm

0.0156250.397

0.031250.794

0.0468751.191

0.06251.588

0.0781251.984

0.93752.381

0.12503.175

0.1406253.572

0.156253.969

0.1718754.366

0.18754.762

0.2031255.159

0.218755.556

0.2343755.953

0.25006.350

0.2656256.747

0.281257.144

0.2968757.541

0.31257.541

0.3281258.334

0.343758.731

0.3593759.128

0.37509.525

0.3906259.922

0.4062510.319

0.42187510.716

0.437511.112

0.45312511.509

0.4687511.906

0.48437512.303

0.500012.70011.00025.400

1mm=0.03937in.0.001in.=0.0254mm

FractionsDecimals

33/64

16/32

35/64

9/16

37/64

19/32

5/8

41/64

21/32

43/64

11/64

45/64

23/32

47/64

3/4

49/64

25/32

51/64

13/16

53/64

27/32

55/64

7/8

57/64

29/32

59/64

15/16

61/64

31/32

63/64

0.51562513.097

0.5312513.484

0.54687513.891

0.562514.288

0.57812514.684

0.5937515.081

0.625015.875

0.64062516.272

0.6562516.669

0.67187517.066

0.687517.462

0.70312517.859

0.7187518.256

0.73437518.653

0.750019.050

0.76562519.447

0.7812519.844

0.79687520.241

0.812520.638

0.82812521.034

0.8437521.431

0.85937521.828

0.875022.225

0.89062522.622

0.9062523.019

0.92187523.416

0.937523.812

0.95312524.209

0.9687524.606

0.98437525.003

mm

SpecicationsandMaintenance:TorqueSpecications

Page2–8

TITAN®MaxServiceManual

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U.S.toMetricConversions

LinearMeasurement

Area

Volume

Pressure

Work

LiquidVolume

LiquidFlows

TemperatureFahrenheit

ToConvert

MilesKilometers1.609

YardsMeters0.9144

FeetMeters0.3048

Feet

InchesMeters0.0254

Inches

InchesMillimeters25.4

SquareMilesSquareKilometers

SquareFeetSquareMeters

SquareInchesSquareCentimeters

AcreHectare0.4047

CubicY ardsCubicMeters

CubicFeetCubicMeters

CubicInchesCubicCentimeters

Tons(Short)

PoundsKilograms0.4536 Weight

OuncesGrams

Pounds/SquareInch

Foot-PoundsNewton-Meters1.356

Foot-PoundsKilogram-Meters0.1383

Inch-Pounds

Quarts

Gallons

Gallons/MinuteLiters/Minute

Kilogram-Centimeters

IntoMultiplyBy

Centimeters

Centimeters

MetricT ons0.9078

Kilopascal6.895

Liters0.9463

Liters3.785

Celsius

30.48

2.54

2.59

0.0929

6.452

0.7646

0.02832

16.39

28.3495

1.152144

3.785

1.Subtractby32°

2.Multiplyby5/9

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SpecicationsandMaintenance:TorqueSpecications

SpecicationsandMaintenance:TorqueSpecications

Page2–10

TITAN®MaxServiceManual

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Chapter3

Troubleshooting

TableofContents

GeneralTroubleshooting.......................................................................................................................3–3

TITAN®MaxServiceManual
3442-428RevA

Page3–1Troubleshooting

GEARS

TheSystematicapproachtodening,diagnosingandsolvingproblems.

G

E

A

GatherInformation

•Informationreportedbythecustomer

•Informationobservedbyyou

•Establishthewhat,whereandwhenoftheissue

EvaluatePotentialCauses

•Considerpossiblecausesoftheproblemtodevelopahypothesis

•Narrowdownthefocusoftheproblem

AssessPerformance

•Ensureyouhaveallthenecessarytoolsfortesting

•T estallpotentialcausesofthefailure

•Reevaluateandcreatenewhypothesesifnecessary

Repair

R

•Returntheunittoservicebyrepairing,rebuildingorreplacing

SolutionConrmation

•Didtheissuegoaway

S

•Wastherootcauseoftheissuecorrectlyrepaired

•Arethereanyothernewsymptoms

Troubleshooting:GeneralTroubleshooting

Page3–2

TITAN®MaxServiceManual

3442-428RevA

GeneralTroubleshooting

Problem

Thestarterdoesnotcrank

Theenginedoesnotstart,starts
hard,orfailstokeeprunning

PossibleCauseCorrectiveAction

Thebladecontrolswitch(PTO)is
engaged.

Theparkingbrakeisnotengaged.

Themotion-controlleversarenotinthe
Neutral-Lockposition.

Thebatteryisdead.

Theelectricalconnectionsarecorroded
orloose.

Thefuseisblown.Replacethefuse.

Therelayorswitchiswornordamaged.

Thefueltankisempty.Fillthefueltank.

Thefuelshut-offvalveisclosed.Openthefuelshut-offvalve.

Theoillevelinthecrankcaseislow .Addoiltothecrankcase.

Thethrottleisnotinthecorrectposition.Besurethatthethrottlecontrolis

Thereisdirtinthefuellter .Replacethefuellter .

Thereisdirt,water,orstalefuelinthe
fuelsystem.

Movetheblade-controlswitch(PTO)to
thedisengagedposition.

Settheparkingbrake.

Ensurethatthemotion-controllevers
areintheNeutral-Lockposition.

Chargethebattery.

Checktheelectricalconnectsforgood
contact.

Testandreplacefaultyrelayorswitch.

midwaybetweentheslowandfast
positions.

Cleanandushthefuelsystem.

Enginelosespower

Theaircleanerisdirty.

Theseatswitchisnotfunctioning
properly.

Theelectricalconnectionsare
corroded,loose,ordamaged.

Therelayorswitchiswornordamaged.

Thesparkplugisfouledorimproperly
gapped.

Thesparkplugwireisnotconnected.

Theengineloadisexcessive.Reducethegroundspeed.

Theaircleanerisdirty.

Theoillevelinthecrankcaseislow .Addoiltothecrankcase.

Thecoolingnsandairpassages
abovetheengineareplugged.

Theventholeinthefuelcapisplugged.Cleanorreplacethefuelcap.

Thereisdirtinthefuellter .Replacethefuellter .

Cleanorreplacetheaircleaner
element.

Checktheseat-switchindicator.
Replacetheseatifnecessary.

Checktheelectricalconnectionsfor
goodcontact.Cleantheconnector
terminalsthoroughlywithelectrical­contactcleaner,applydielectricgrease,
andmaketheappropriateconnections.

Testandreplacefaultyrelayorswitch.

Adjustorreplacethesparkplug.

Checkthesparkplugwireconnection.

Cleantheaircleanerelement.

Removetheobstructionandthoroughly
cleancoolingnsandtheairpassages.

TITAN®MaxServiceManual
3442-428RevA

Thereisdirt,water,orstalefuelinthe
fuelsystem.

Page3–3

Cleanandushthefuelsystem.

Troubleshooting:GeneralTroubleshooting

GeneralTroubleshooting(continued)

Problem

Theengineoverheats

Themowerpullstotheleftorright
(withleversfullyforward)

Themachinedoesnotdrive

Themachinevibratesabnormally

PossibleCauseCorrectiveAction

Theengineloadisexcessive.Reducethegroundspeed.

Theoillevelinthecrankcaseislow .Addoiltothecrankcase.

Thecoolingnsandtheairpassages
abovetheengineareplugged.

Thetrackingneedsadjustment.Adjustthetracking.

Thetirepressureinthedrivetiresis
notcorrect.

Thebypassvalvesarenotclosedtight.Tightenthebypassvalves.

Thepumpbeltisworn,looseorbroken.

Thepumpbeltisoffapulley.Changethebelt.

Theidlerspringisbrokenormissing.Replacethespring.

Thehydraulicoillevelislowortoohot.Addhydraulicoiltothereservoirsorlet

Thecuttingblade(s)is/arebentor
unbalanced.

Theblademountingboltisloose.Tightentheblademountingbolt.

Theenginemountingboltsareloose.Tightentheenginemountingbolts.

Removetheobstructionandthoroughly
cleancoolingnsandtheairpassages.

Adjustthetirepressureinthedrive
tires.

Changethebelt.

itcooldown.

Installnewcuttingblade(s).

Themachineproducesanuneven
cuttingheight

Thebladesdonotrotate

Theenginepulley,idlerpulley,orblade
pulleyisloose.

Theenginepulleyisdamaged.Replacetheenginepulley.

Thebladespindleisbent.Replacethespindle.

Themotormountislooseorworn.

Theblade(s)is/arenotsharp.Sharpentheblade(s).

Thecuttingblade(s)is/arebent.Installnewcuttingblade(s).

Themowerdeckisnotlevel.

Theundersideofmowerisdirty .Cleantheundersideofthemower.

Thetirepressureisnotcorrect.Adjustthetirepressure.

Thebladespindleisbent.Replacethespindle.

Themowerdeckbeltisdamaged,
worn,loose,orbroken.

Themowerdeckbeltisoffthepulley.

Tightentheappropriatepulley,check
tomakesureidlerspringsarenotover
stretched.

Checkthemountingbolts.

Levelthemowerdeckfromside-to­sideandfront-to-rear.

Installanewdeckbelt.

Installthemowerbeltonthedeck
pulleyandchecktheidlerpulley,idler
arm,andspringforcorrectpositionand
function.

Troubleshooting:GeneralTroubleshooting

Thepumpdrivebeltisworn,looseor
broken.

Theidlerspringisbrokenormissing.Replacethespring.

Page3–4

Checkthebelttensionorinstallanew
belt.

TITAN®MaxServiceManual

3442-428RevA

GeneralTroubleshooting(continued)

Theclutchdoesnotengage

Problem

Thefuseisblown.Replacethefuse.Checkthecoil

Thereisalowvoltagesupplyatthe
clutch.

Thecoilisdamaged.Replacetheclutch.

Thereisinadequatecurrentsupply .Repairorreplacetheclutchleadwireor

Therotor/armatureairgapistoolarge.

PossibleCauseCorrectiveAction

resistance,batterycharge,charging
system,andwiringconnections,and
replacecomponentsifnecessary.

Checkthecoilresistance,battery
charge,chargingsystem,andwiring
connectionsandreplacepartsif
necessary.

electricalsystem.Cleantheconnector
contacts.

Removetheshimorreplacetheclutch.

TITAN®MaxServiceManual
3442-428RevA

Page3–5

Troubleshooting:GeneralTroubleshooting

Troubleshooting:GeneralTroubleshooting

Page3–6

TITAN®MaxServiceManual

3442-428RevA

Chapter4

Engine

TableofContents

GeneralInformation..............................................................................................................................4–2

ServiceandRepairs.............................................................................................................................4–3

EngineReplacement..........................................................................................................................4–4

TITAN®MaxServiceManual
3442-428RevA

Page4–1Engine

GeneralInformation

TheTitanMaxusesA26HP747ccKohlertwincylinderOHV4cycleengine
withaproaircleaner(KT745-3094).

Engine:GeneralInformation

Page4–2

TITAN®MaxServiceManual

3442-428RevA

ServiceandRepairs

EngineAssembly

g341898

1.Engine

2.OilDrainHoseAssembly

3.Mufer

4.EngineSheave

5.ClutchAnchor

TITAN®MaxServiceManual
3442-428RevA

Figure3

Page4–3

6.PTOClutch

7.FlatIdlerPulley

8.IdlerArmAssembly

9.V-belt

Engine:ServiceandRepairs

EngineReplacement

EngineRemoval

1.ParkthemachineonalevelsurfaceanddisengagethePTO.Stoptheengine,
waitforallmovingpartstostop,andremovekey.Engagetheparkingbrake.

2.Disconnectthebatterybyremovingthenegativecablerst,thenthepositive
cablefromthebattery.

3.Draintheoilintoasuitablecontainer.

4.Closethefuelsupply .

g344221

Figure4

5.Removetheengineguard.

6.Removethedeckdrivebeltfromthemowerdeck.DeckDriveBeltRemoval

(page6–10)

7.Removethehydrostaticdrivebeltfromthemachine.HydrostaticDriveBelt

Removal(page7–8)

8.Disconnectthechassiswireharnessfromthemainenginewireharness.

Engine:ServiceandRepairs

g335893

Figure5

9.Disconnectthered(B+)wirefromthestarter.

Page4–4

TITAN®MaxServiceManual

3442-428RevA