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Toro titan Z4800 Service Manual

2007-2008
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Residential Products
2007 - 2008
Titan™ Z4800 & Z5200
Service Manual

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Summary of Contents for Toro titan Z4800

  • Page 1 Residential Products 2007 - 2008 Titan™ Z4800 & Z5200 Service Manual...

  • Page 2: About This Manual

    ABOUT THIS MANUAL This service manual was written expressly for Toro 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.
  • Page 3 ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ..................................................SPECIFICATIONS ........................RPM ........................................................................Cutting Deck ........................... Dimensions ..................................................CHASSIS ..............................................Front Caster Fork Bearing Replacement ..................Front Caster Fork Bearing Removal ..................................... Caster Wheel Assembly Replacement ................... Caster Wheel Assembly Removal ....................
  • Page 5 TABLE OF CONTENTS ELECTRICAL cont..........................Purpose ..............................................................................Testing ......................................................Purpose ..............................................................................Testing .................................................... Purpose ..............................................................................Testing ............................Coil Resistance Measurement ....................Measuring Clutch Current Draw ............................................Purpose ..............................................................................Testing ............................
  • Page 6 TABLE OF CONTENTS MOWER DECK ........................................................................................................................................................................................................................................... Mower Deck Replacement ......................Mower Deck Removal ......................................................................................Mower Belt Maintenance ............................................Mower Belt Replacement ......................Mower Belt Removal ............................................
  • Page 7 TABLE OF CONTENTS HYDROSTATIC DRIVE SYSTEM cont........................Tracking Adjustment ................................................................................................... Troubleshooting ..........................

  • Page 8: Safety Information

    - read the instruction because it has to operating practices. Operator’s manuals are available do with your safety. Failure to comply online, through your Toro parts source, or: with the instruction may result in personal injury or even death. The Toro Company...
  • Page 9 SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK. 2007 - 2008 Titan Z Service Manual...

  • Page 10: Specifications

    SPECIFICATIONS Model Briggs & Stratton Kohler 44K777-0123-E1 74812 24 HP 44K777-0123-E1 74814 24 HP SV820-0012 74816 23 HP SV820-0012 74818 23 HP Model Briggs & Stratton Kohler Full Speed 3650 ± 100 (No Load) 3600 ± 75 (No Load) Idle Speed 1650 (min) 1750 (min) Electrical System...

  • Page 11: Hydrostatic Ground Drive System

    SPECIFICATIONS Hydrostatic Ground Drive System Hydrostatic Transaxle (2) Hydro-Gear ZT2800 integrated drive system Hydraulic Oil Type Mobil 1 15W-50 synthetic motor oil 0 – 7.0 mph (11.3 km/hr) Forward Speeds 0 – 5.0 mph (8.0 km/hr) Reverse Cutting Deck 48” Deck 52”...

  • Page 12: Torque Requirements

    SPECIFICATIONS Torque Requirements Torque Bolt Location 2007 2008 Spindle Pulley Nut 45 - 55 ft-lbs. (61 - 75 Nm) 95 - 100 ft-lbs. (129 - 135.6 Nm) Blade Mounting Bolt 45 - 55 ft-lbs. (61 - 75 Nm) 45 - 55 ft-lbs. (61 - 75 Nm) Engine Mounting Bolt 27 - 33 ft-lbs.
  • Page 13 SPECIFICATIONS THIS PAGE INTENTIONALLY LEFT BLANK. 2007 - 2008 Titan Z Service Manual...

  • Page 14: Chassis

    CHASSIS The unit model and serial number plate is located on the frame behind the seat on the left side (Fig. 001). Fig. 001 IMG-0162 The unit should be greased every 25 hours, or more Note: Grease Type: NGLI grade #2 multi-purpose often when operated in dusty, dirty, or sandy conditions.
  • Page 15 CHASSIS 1. Park the machine on a level surface and disengage the blade control switch. (Fig. 004): 2. Move the motion control levers outward to the neutral position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

  • Page 16: Front Caster Fork Bearing Replacement

    CHASSIS Front Caster Fork Bearing 3. Remove the hex head bolt and washer securing the caster fork assembly to the front axle (Fig. 007). The following procedure is performed on the left hand caster fork assembly. The same procedure should be followed when replacing the right hand caster fork assembly and bearings.
  • Page 17 CHASSIS 5. Using a drift punch and hammer, tap the lower ball Front Caster Fork Bearing Installation bearing out of the front axle frame (Fig. 009). 1. Install the upper and lower ball bearings into the front axle frame (Fig. 011). Fig.

  • Page 18: Caster Wheel Assembly Removal

    CHASSIS 4. Remove the wheel spanner from the wheel assembly (Fig. 015). Caster Wheel Assembly Removal 1. Park the machine on a level surface, disengage the blade control (PTO) and turn the ignition key to “OFF” to stop the engine. Remove the ignition key. 2.
  • Page 19 CHASSIS Caster Wheel Assembly Installation 3. Position the wheel assembly into the caster fork inside (Fig. 019). (Fig. 017). Fig. 019 IMG-0176 Fig. 017 IMG-0175a 4. Position a washer on both sides of the wheel be- 2. Slide the wheel spanner into the wheel assembly the wheel axle bolt through the fork and wheel (Fig.
  • Page 20 CHASSIS 5. Install a nut onto the wheel axle bolt to secure the Left Hand Fender & Fuel Tank wheel assembly to the caster fork (Fig. 021). Left Hand Fender & Fuel Tank Removal 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to “OFF”...
  • Page 21 CHASSIS 4. Lift up on the front panel and pull the panel out of the 6. Remove the bolt and nut securing the left hand slots in the seat box to remove the panel (Fig. 024). engine guard to the rear engine guard and the screw securing the left hand engine guard to the left hand fender (Fig.
  • Page 22 CHASSIS 8. Remove the three screws that secure the left hand 10. Turn the fuel shut-off valve to the “OFF” position. fender to the top of the seat box (Fig. 028). Slide the hose clamp off the engine side of the fuel shut-off valve.
  • Page 23 CHASSIS 12. The fuel line coming from the fuel tank is held in Left Hand Fender & Fuel Tank Installation place by a clamp located on the side of the seat box assembly. Open the clamp to release the fuel line 1.
  • Page 24 CHASSIS 2. Position the fuel tank on the side of the seat box 4. Install a carriage bolt through the left hand rear tank assembly. Loosely install a carriage bolt and nut bracket and the bottom, rear fuel tank mounting securing the lower front corner of the fuel tank to the hole.
  • Page 25 CHASSIS 6. Tighten the front carriage bolt and nut (Fig. 040). 8. Position the left hand fender assembly over the left hand fuel tank (Fig. 042). Fig. 040 IMG-0191 Fig. 042 IMG-0188 7. Install the engine fuel line onto the fuel shut-off valve.
  • Page 26 CHASSIS 10. Install a bolt, washer, and nut to secure the left hand 12. Install the two screws to secure the left side fender fender to the left hand rear tank mounting bracket to the front of the seat box (Fig. 046). (Fig.
  • Page 27 CHASSIS 14. Install two screws to secure the bottom of the front panel to the seat box assembly (Fig. 048). Right Hand Fender Removal 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to “OFF”...
  • Page 28 CHASSIS 4. Lift up on the front panel and remove the panel from 6. Remove the bolt and nut securing the right hand the slots in the seat box assembly (Fig. 050). engine guard to the rear engine guard and the screw securing the right hand engine guard to the right hand fender (Fig.
  • Page 29 CHASSIS 8. Remove the four screws that secure the control 10. Remove the wire harness plugs from the back of the panel to the right hand fender (Fig. 054). ignition switch, the PTO switch and the hour meter (Fig. 056). Fig.
  • Page 30 CHASSIS 12. Feed the control panel through the right hand fender Right Hand Fender Installation (Fig. 058). 1. Position the right hand fender onto the right hand side of the seat box assembly (Fig. 060). Fig. 058 IMG-0216 Fig. 060 IMG-0217 13.
  • Page 31 CHASSIS 3. Install three screws to secure the right hand fender 5. Plug the wire harness plug onto the PTO switch (Fig. to the top of the seat box assembly (Fig. 062). 064). Fig. 064 IMG-0212 Fig. 062 IMG-0209 6. Connect the two red wire terminal to the outside 4.
  • Page 32 CHASSIS 7. Plug the wire harness plug onto the ignition switch 9. Install a bolt, washer, and nut securing the right hand (Fig. 066). rear console bracket and right hand fender (Fig. 068). Fig. 066 IMG-0219 Fig. 068 IMG-0206 8. Position the control panel onto the right hand fender. Install four screws to secure the control panel to the right hand fender (Fig.
  • Page 33 CHASSIS 11. Install two screws to secure the right hand fender to 13. Install two screws to secure the bottom of the front the front of the seat box assembly (Fig. 070). panel to the seat box assembly (Fig. 072). Fig.
  • Page 34 CHASSIS 4. Unplug the wiring harness connector from the seat switch (Fig. 074). Seat Box Removal 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine. Remove the ignition key. 2.
  • Page 35 CHASSIS 6. While supporting the seat, remove the bolt and 8. Remove the left hand fender and fuel tank. Refer to nut that secure the seat cable stop to the seat box “Left Hand Fender and Fuel Tank Removal” on page assembly (Fig.
  • Page 36 CHASSIS 12. Remove the two screws retaining the hydro fan 14. Remove the two bolts, washers and nuts securing cover to the seat box assembly (Fig. 079). the hydro vent tank and fender support bracket to the seat box (Fig. 081). Fig.
  • Page 37 CHASSIS 16. Push the rubber wire harness grommet through the 18. Push the two wire clamps through the right side of right side of the seat box assembly (Fig. 083). the seat box to free the harness from the seat box (Fig.
  • Page 38 CHASSIS 20. Locate the clamp that the throttle and choke cables 22. Remove the wire harness plug from the left side are routed through on the right side of the seat box. neutral switch (Fig. 089). Remove the clamp from the seat box (Fig. 087). Fig.
  • Page 39 CHASSIS 24. Remove the two bolts, washers and nuts securing 26. Unplug the fuel solenoid magneto (yellow/white) wire the solenoid to the seat box. Remove the solenoid. plug from the grey/black wire plug (Fig. 093). (Fig. 091). Fig. 093 IMG-0258 Fig.
  • Page 40 CHASSIS 28. Remove the oil switch (blue) wire from the oil switch 30. Open the clamp that secures the PTO clutch wire (Fig. 097). Pull the wire harness up through the frame. Fig. 095 IMG-0264a Fig. 097 IMG-0271a 29. Unplug the PTO clutch wire (brown/green) from the electric PTO clutch (Fig.
  • Page 41 CHASSIS 32. Remove two clamps that secure the wire harness to 34. Remove the screw and nut that secure the relay the outside, rear of the seat box (Fig. 099). harness plug to the rear of the seat box assembly (Fig.
  • Page 42 CHASSIS 36. Remove the clamp for the fuel hose, located on the 38. Remove the nut from the brake assembly carriage left rear side of the seat box assembly (Fig. 103). bolt (Fig. 105). Fig. 103 IMG-0284 Fig. 105 IMG-0287a 37.
  • Page 43 CHASSIS 40. Remove the brake lever assembly (Fig. 107). 42. Pull the brake pivot tube assembly slightly outward (Fig. 109). Fig. 107 IMG-0289a Fig. 109 IMG-0291a 41. Remove the brake assembly spacer (Fig. 108). 43. Remove the washer located on the inside end of the brake pivot tube (Fig.
  • Page 44 CHASSIS 42. Remove the spacer from the inside end of the brake pivot tube (Fig. 111). of the seat box (Fig. 113). Fig. 111 IMG-0293a Fig. 113 IMG-0295a 43. Remove the brake pivot tube (Fig. 112). the seat box (Fig. 114). Fig.
  • Page 45 CHASSIS 46. Remove the cotter pin from the control pivot pin (Fig. 48. Repeat steps 46 and 47 to remove the cotter pin and 115). control pivot pin on the right hand side. 49. Remove the two screws securing the right side of the seat box to the frame (Fig.
  • Page 46 CHASSIS 51. Remove the seat box assembly from the frame (Fig. 53. Remove the three bolts and nuts that secure the 119). three compression springs to the seat box (Fig. 121). Fig. 119 IMG-0302 Fig. 121 IMG-0305 52. Remove the two carriage bolts and nuts securing the 54.
  • Page 47 CHASSIS 55. Remove the left side motion control stop (Fig. 123). Seat Box Installation 1. Position the left side motion control stop on the inside of the seat box (Fig. 124). Fig. 123 IMG-0307 56. Repeat steps 54 and 55 to remove the right side Fig.
  • Page 48 CHASSIS 3. Follow the previous 2 steps to install the right side 6. Position the seat box assembly onto the frame (Fig. motion control stop. 128). 4. Position a compression spring to the seat box. Install procedure to install the other 2 compression springs to the seat box (Fig.
  • Page 49 CHASSIS 8. Loosely install two screws to secure the right side of 11. Install a cotter pin on the motion control pivot pin to the seat box assembly to the frame (Fig. 130). secure (Fig. 132). Fig. 130 IMG-0300 Fig. 132 IMG-0311 9.
  • Page 50 CHASSIS 16. Install a spacer on the inside end of the brake shaft of the seat box (Fig. 134). (Fig. 136). Fig. 134 IMG-0313 Fig. 136 IMG-0315a 15. Install the brake shaft (Fig. 135). 17. Install a washer on the inside end of the brake shaft (Fig.
  • Page 51 CHASSIS 18. Install the brake shaft into the slots located on the 20. Install the brake lever assembly onto the outside of bell crank (Fig. 138). the brake shaft (Fig. 140). Fig. 138 IMG-0317 Fig. 140 IMG-0320 19. Install a spacer on the outside end of the brake shaft 21.
  • Page 52 CHASSIS 22. Install a nut onto the carriage bolt (Fig. 142). 24. Install a clamp around the harness and install the clamp barb through the left side of the seat box (Fig. 144). Fig. 142 IMG-0323a Fig. 144 IMG-0327a 23. Install the harness plug onto the left side neutral switch (Fig.
  • Page 53 CHASSIS 26. Install a clamp around the harness and install the 28. Position the fuse block to the inside rear of the seat clamp barb through the right side of the seat box box and install two screws and nuts to secure it (Fig. (Fig.
  • Page 54 CHASSIS 30. Install the relay into the harness plug (Fig. 150). 32. Pull the wire harness from inside the rear of the seat box assembly toward the outside through the thru hole. Install the rubber grommet into the thru hole to protect the wire harness (Fig.
  • Page 55 CHASSIS 34. Plug the PTO clutch wire into the electric PTO clutch 36. Install the blue harness wire to the oil sending (Fig. 154). Fig. 154 IMG-0268a Fig. 156 IMG-0264a 35. Install a clamp securing the PTO clutch wire harness 37.
  • Page 56 CHASSIS 38. Install the yellow/white wire plug into the grey/black 40. Position the solenoid to the back side of the seat wire plug that goes to the fuel solenoid and engine box assembly. Install two bolts, washers, and nuts to magneto (Fig.
  • Page 57 CHASSIS 42. Install a clamp around the throttle and choke cables 44. Install a clamp around the wire harness on the inside and install the clamp through the right, rear side of of the seat box. Install the clamp through the right the seat box assembly (Fig.
  • Page 58 CHASSIS 46. Install the rubber grommet in the wire harness hole 48. Install two bolts, washers, and nuts to secure the (Fig. 166). hydro vent tank and fender support bracket to the seat box (Fig. 168). Fig. 166 IMG-0343a Fig. 168 IMG-0234a 47.
  • Page 59 CHASSIS 51. Position the right hand grip assembly to the lever mount post. Install two screws and washers to secure the hand grip (Fig. 172). Fig. 170 IMG-0344 Fig. 172 IMG-0229a 50. Install two screws to secure the hydro fan cover to 52.
  • Page 60 CHASSIS 55. Position the seat plate on the seat assembly to the 57. Route the seat switch harness wire through the wire inside of the mounting tabs on the seat box. Install clamp located on the bottom of the seat plate (Fig. the seat pivot rod through the mounting holes.
  • Page 61 CHASSIS 59. Install the battery hold down with two hold down bolts and wing nuts (Fig. 177). & Front & Rear Shaft Assembly Assembly Removal 1. Disconnect the battery negative cable. Fig. 177 IMG-0220 60. Install the positive and then the negative battery cable to the battery.
  • Page 62 CHASSIS 3. Place blocks under the mower deck for support. Pull 5. Remove the external retaining ring, washer, and the transport release handle and lower the mower clevis pin securing the front shaft assembly to the deck so that it is resting on the blocks (Fig. 179). height-of-cut assembly (Fig.
  • Page 63 CHASSIS 7. Remove external retaining ring, washer, and clevis 9. Remove the 4 bolts and nuts that secure the front frame (Fig. 183). Fig. 183 IMG-0352 Fig. 185 IMG-0355a 10. Remove the front shaft assembly from the frame (Fig. 186). Fig.
  • Page 64 CHASSIS 11. Remove the 4 bolts and nuts that secure the rear Assembly Installation 1. Position the rear shaft assembly to the frame. Install secure it to the frame (Fig. 189). Fig. 187 IMG-0359a Fig. 189 IMG-0359a 12. Remove the rear shaft assembly from the frame (Fig.
  • Page 65 CHASSIS the frame. Install a clevis pin, washer and external assembly to the rear shaft assembly. Install a clevis retaining ring to secure it to the frame (Fig. 191). pin, washer, and external retaining ring to secure assembly (Fig. 193). Fig.
  • Page 66 CHASSIS Fig. 195 IMG-0345 8. Install the negative battery cable. 2007 - 2008 Titan Z Service Manual 3-53...
  • Page 67 CHASSIS 3-54 2007 - 2008 Titan Z Service Manual...

  • Page 68: Electrical

    ELECTRICAL Electrical System How It Works Start Circuit Two things happen when turning the ignition switch to activates and takes the engine electronic ignition ground Relay (not energized) Interlock Relay (Kill Relay) Fig. 197 xl relay 1 Purpose Coil: The relay used in the Titan Z is used to connect or disconnect the engines electronic ignition and starter Switch: Location...
  • Page 69 ELECTRICAL Testing Solenoid Purpose Location Fig. 200 IMG-0701 Relay (not energized) Fig. 199 xl relay 1 2007 - 2008 Titan Z Service Manual...
  • Page 70 ELECTRICAL How It Works Testing Fig. 201 xl solenoid Fig. 202 2007 - 2008 Titan Z Service Manual...

  • Page 71: Testing

    ELECTRICAL Ignition Switch How It Works Purpose Location Fig. 204 Fig. 203 Testing START 2007 - 2008 Titan Z Service Manual...

  • Page 72: Testing

    ELECTRICAL PTO Switch Testing Purpose Location OFF (IN) ON (OUT) Cont. Cont. Cont. Cont. Fig. 205 Open Open How It Works Continuity? Open Open not used not used contacts inside the switch electrically connect various Fig. 206 2007 - 2008 Titan Z Service Manual...
  • Page 73 ELECTRICAL Electric (PTO) Clutch How It Works Purpose Location so that it is not in contact with the clutch plate and is Testing Fig. 207 IMG-0720 2007 - 2008 Titan Z Service Manual...
  • Page 74 ELECTRICAL Coil Resistance Measurement Measuring Clutch Current Draw Fig. 208 Fig. 209 2007 - 2008 Titan Z Service Manual...
  • Page 75 ELECTRICAL Park Brake Switch How It Works Purpose Location depressed: Fig. 210 Fig. 211 2007 - 2008 Titan Z Service Manual...
  • Page 76 ELECTRICAL Testing Fig. 212 Circuit – No Continuity Circuit - Continuity Circuit – Continuity Circuit – No Continuity 2007 - 2008 Titan Z Service Manual...

  • Page 77: Seat Switch

    ELECTRICAL Seat Switch How It Works Purpose running and the operator vacates the seat with either Note: There is a delay module in the system (Briggs & Stratton Engines only) that causes a slight delay between the moment the operator vacates the seat and the engine shuts down.
  • Page 78 ELECTRICAL Neutral Switch How It Works Purpose Location Fig. 216 Testing Fig. 215 2007 - 2008 Titan Z Service Manual 4-11...
  • Page 79 ELECTRICAL Hour Meter How It Works Purpose Location Fig. 218 Testing Fig. 217 4-12 2007 - 2008 Titan Z Service Manual...
  • Page 80 ELECTRICAL Fuse Block Purpose Location Fig. 219 IMG-0700a How It Works 2007 - 2008 Titan Z Service Manual...
  • Page 81 ELECTRICAL Seat Delay Module (Briggs & Stratton How It Works models only) Purpose the seat switch circuit to keep the engine running in case Location Fig. 221 Fig. 220 4-14 2007 - 2008 Titan Z Service Manual...
  • Page 82 ELECTRICAL Testing Fig. 222 Fig. 223 IMG-0718a 2007 - 2008 Titan Z Service Manual...
  • Page 83 ELECTRICAL Electrical Schematics Briggs & Stratton Engine Fig. 224 2007 - 2008 Titan Z Service Manual...
  • Page 84 ELECTRICAL Briggs & Stratton Engine cont. Fig. 225 2007 - 2008 Titan Z Service Manual 4-17...

  • Page 85: Kohler Engine

    ELECTRICAL Kohler Engine PTO SWITCH SEAT SWITCH POSITION CIRCUIT "MAKE" 1. OFF NONE 2. RUN B + I + A X + Y 3. START B + I + S TERMINAL S TERMINAL I TERMINAL B GRAY BRAKE VIOLET SWITCH VIOLET YELLOW TERMINAL X...
  • Page 86 ELECTRICAL Kohler Engine cont. IGNITION SWITCH FUSE BLOCK Y S X A B ACCESSORIES ORANGE BLACK PINK HOUR METER LIGHT BLUE LIGHT BLUE OIL SWITCH VIOLET ALTERNATOR YELLOW FUEL SOLENOID WHITE MAGNETO BLACK BLACK GROUND START NOID SOLENOID CLUTCH Fig. 227 2007 - 2008 Titan Z Service Manual...
  • Page 87 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 4-20 2007 - 2008 Titan Z Service Manual...

  • Page 88: Mower Deck

    MOWER DECK Mower Deck Spindle Replacement 4. Using a rag or a thickly-padded glove for protection, hold the end of the blade and remove the nut on the spindle pulley (Fig. 230). Mower Deck Spindle Removal 1. Remove the mower deck from the machine. Refer to “Mower Deck Removal”...
  • Page 89 MOWER DECK 6. Raise and support the rear of the mower deck with a 9. Using a rag or a thickly-padded glove for protection, jack stand or lift. hold the end of the blade and loosen the blade bolt (Fig. 234). 7.
  • Page 90 MOWER DECK 11. Remove the spacer on the bottom of the spindle 13. Remove the spacer from the spindle housing (Fig. shaft (Fig. 236). 238). Fig. 236 IMG-0623a Fig. 238 IMG-0626a 12. Remove the spindle shaft and bearing shield (Fig. 14.
  • Page 91 MOWER DECK 15. Remove the spacer from the housing (Fig. 240). Housing spacer, and bearings (Fig. 242) Fig. 240 IMG-0634a Fig. 242 IMG-0633 A. Housing C. Bearing (2) B. Spacer 16. Turn the housing over and drive the other bearing out of the other side with a punch (Fig.
  • Page 92 MOWER DECK Mower Deck Spindle Installation 3. Tap the second bearing into the pulley side of the spindle housing until it seats (Fig. 245). 1. Tap a bearing into the blade end of the housing until it seats (Fig. 243). Fig.
  • Page 93 MOWER DECK 5. Place a spacer onto the spindle shaft (Fig. 247). 7. With two washers on the blade bolt, install the blade bolt and two washers into the spindle shaft (Fig. 249). Fig. 247 IMG-0650a Fig. 249 IMG-0648 6. Position the mower blade onto the spindle shaft and spacer (Fig.
  • Page 94 MOWER DECK 10. Install 6 screws to secure the spindle assembly to 12. Install the spindle pulley nut. Torque the spindle the mower deck. Torque the 6 screws to 200 – 250 pulley nut to 50 ft-lbs (67.8 Nm) (Fig. 253). in-lbs.
  • Page 95 1. Remove the mower deck from the machine. Refer to “Mower Deck Removal” on page 5-18. 2. With a spring tool (Toro part number 92-5771) remove the extension spring from the spring post located at the rear of the mower deck (Fig. 257).
  • Page 96 MOWER DECK 4. Remove the nut and washer securing the idler arm 6. Remove the carriage bolt and washer from the deck to the mower deck (Fig. 259). (Fig. 261). Fig. 259 IMG-0657 Fig. 261 IMG-0659 5. Remove the idler arm from the mower deck (Fig. 7.
  • Page 97 MOWER DECK 8. Tap out the two sleeve bearings (Fig. 263). 10. Remove the idler pulley and idler bushing from the idler arm assembly (Fig. 265). Fig. 263 IMG-0663a Fig. 265 IMG-0666a 9. Remove the nut and carriage bolt securing the idler pulley to the idler arm assembly (Fig.
  • Page 98 MOWER DECK Idler Arm Assembly Installation 3. Install a sleeve bearing into the top and bottom of the idler arm assembly pivot (Fig. 268). 1. Install the carriage bolt and idler bushing to the idler arm assembly (Fig. 266). Fig. 268 IMG-0670a Fig.
  • Page 99 MOWER DECK 5. Position the pivot bushing onto the carriage bolt (Fig. 7. Install a washer and nut onto the carriage bolt to 270). secure (Fig. 272). Fig. 270 IMG-0672a Fig. 272 IMG-0674a 6. Install the idler arm assembly onto the pivot bushing (Fig.
  • Page 100 They are both replaced the same way (Fig. 276). Fig. 274 IMG-0656a 10. Using a spring tool (Toro part number 92-5771), install the other end of the extension spring onto the Fig. 276 IMG-0683 spring post located at the rear of the mower deck (Fig.
  • Page 101 MOWER DECK 2. Remove the idler pulley (Fig. 278). Fixed Idler Pulley Installation 1. Install a carriage bolt through the mower deck and position the idler bushing onto the carriage bolt (Fig. 280). Fig. 278 IMG-0677 3. Remove the idler bushing and carriage bolt from the Fig.
  • Page 102 MOWER DECK Electric PTO Clutch Replacement 4. Unplug the harness connector from the electric PTO clutch plug (Fig. 284). Electric PTO Clutch Removal 1. Remove the negative battery cable from the battery. 2. Locate the idler arm assembly on the mower deck. Rotate the idler arm toward the rear of the mower deck and slip the mower deck belt off the idler pulley (Fig.
  • Page 103 MOWER DECK 6. Remove the electric PTO clutch from the engine Electric PTO Clutch Installation crankshaft (Fig. 286). 1. Apply anti-sieze compound to the engine crankshaft. Slide the electric PTO clutch onto the engine crank- shaft (Fig. 287). Fig. 286 IMG-0379 7.
  • Page 104 MOWER DECK 3. With 3 washers installed on the electric PTO clutch 6. Install the mower deck belt around the electric PTO bolt, apply thread locking compound to the threads clutch pulley (Fig. 291). of the clutch bolt (Fig. 289). Fig.
  • Page 105 MOWER DECK Mower Deck Replacement 5. Remove the nut, bolt and pivot bushing from the four deck struts (B). Remove the blocking to lower the mower deck to the ground (Fig. 294). Mower Deck Removal 1. Park the machine on a level surface and disengage the blade control switch.
  • Page 106 MOWER DECK Mower Deck Installation 6. Attach the hardware from the deck hanger and deck lift arm on both sides of the deck (Fig. 296). 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to the neutral position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operation position.

  • Page 107: Leveling The Mower Deck

    MOWER DECK Leveling the Mower Deck 6. Check the front-to-rear blade level any time you install the mower. If the front blade tip is not 1/16 – 5/16” (1.6 – 7.9mm) lower than the rear blade tip, The mower blades must be level from side-to-side, and adjust the blade level.

  • Page 108: Adjusting The Blade Slope

    MOWER DECK 10. Loosen the leveling adjust locking nuts on all four Adjusting the Blade Slope corners so that the mower deck is sitting securely on all four blocks. Make sure that the deck hangers are 1. Check the front-to-rear blade slope any time you all the way down (at the top of the slot) and the deck install the mower.
  • Page 109 MOWER DECK 7. Loosen the leveling adjust locking nuts on all four 8. Carefully rotate the blades front-to-rear (Fig. 302). corners so that the deck is sitting securely on all four blocks. Make sure that the deck hangers are all the way down (at the top of the slot) and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts (Fig.

  • Page 110: Mower Belt Maintenance

    MOWER DECK Mower Belt Maintenance 5. Pull the idler pulley in the direction shown and remove the belt from the pulleys (Fig. 303). Service interval: Every 25 hours WARNING The spring is under tension when installed and can Mower Belt Inspection cause personal injury.
  • Page 111 MOWER DECK Mower Belt Installation 1. Route the new belt around the engine pulley and mower pulleys (Fig. 304). Fig. 304 109-6035 2. Pull the idler pulley in the direction shown (Fig. 305) and route the belt onto the idler pulley. A BC D E Fig.
  • Page 112 ENGINE Engine Replacement 3. Remove the mower deck belt from around the electric PTO clutch pulley (Fig. 307). Engine Removal Note: This procedure was performed with a Briggs & Stratton engine. Kohler engine replacement is similar except for cable connections. 1.
  • Page 113 ENGINE 5. Remove the clutch bolt securing the electric PTO 7. Using a spring tool (Toro part number 92-5771), clutch to the engine crankshaft (Fig. 309). rotate the transmission drive belt idler arm to release tension from the transmission drive belt. Remove the transmission drive belt from the idler pulley (Fig.
  • Page 114 ENGINE 9. Slide the engine pulley off the crankshaft (Fig. 313). 11. Turn the fuel shut-off valve to the “OFF” position. Slide the fuel line clamp away from the engine side of the fuel line and disconnect the fuel line. Drain any fuel that may be left in the line (Fig.
  • Page 115 ENGINE 13. Remove the throttle cable from the engine throttle 15. Remove the choke cable from the engine choke linkage (Fig. 317). linkage (Fig. 319). Fig. 317 IMG-0390a Fig. 319 IMG-0392a 14. Loosen the choke cable clamp located on the rear 16.
  • Page 116 ENGINE 17. Remove the blue wire from the oil sending sensor 19. Remove the nut securing the heavy red wire to the starter and remove the heavy read wire from the starter (Fig. 323). Fig. 321 IMG-0264a Fig. 323 IMG-0394a 18.
  • Page 117 ENGINE 21. Remove the 4 bolts, washers, and nuts securing the Engine Installation engine to the frame (Fig. 325). 1. Position the engine onto the frame (Fig. 327). Fig. 325 IMG-0397 Fig. 327 IMG-0405a 22. Raise the engine off the frame (Fig. 326). 2.
  • Page 118 ENGINE 4. Position the 2 ground wires onto the engine ground 6. Plug the yellow/white wire plug to the grey/black base. Install a nut to secure the 2 ground wires (Fig. (fuel solenoid and the engine magneto) wire plug 329). (Fig.
  • Page 119 ENGINE 8. Install the violet wire plug into the red alternator wire 10. Move the choke control lever in the full open position plug (Fig. 333). (the choke linkage is moved all the way to the left). Install the choke cable into the bottom portion of the clamp and tighten the clamp to secure (Fig.
  • Page 120 ENGINE 12. Move the throttle control lever on the control panel 14. Install a key into the crankshaft keyway (Fig. 339). to the low throttle position. Position the throttle cable into the top of the throttle cable clamp, push the throttle cable until the throttle linkage on the engine stops.
  • Page 121 ENGINE 16. Slide the engine pulley onto the crankshaft so that 18. With a spring tool (Toro part number 92-5771), the inside chamfer on the pulley ID is installed rotate the transmission drive belt spring idler arm to toward the engine and the pulley keyway aligns with release tension on idler arm.
  • Page 122 ENGINE 19. Slide the electric PTO clutch onto the engine crank- 21. With the washer installed on the clutch bolt, apply shaft (Fig. 345). thread locking compound onto the threads of the electric clutch bolt (Fig. 347). Fig. 345 IMG-0424 Fig.
  • Page 123 ENGINE 23. Plug the wire harness connector to the electric PTO 25. Pull the mower deck idler arm assembly toward the clutch connector (Fig. 349). rear of the machine and route the mower belt around the idler pulley (Fig. 351). Fig.
  • Page 124 ENGINE 3. Remove the two engine mount bolts, washers and engine (Fig. 355). Note: This procedure was performed with Briggs replacement is similar. 1. Remove the left screw retaining the front of the Fig. 355 IMG-0709a 4. Loosen the two bolts and nuts retaining the rear of Fig.
  • Page 125 ENGINE 6. Remove the 4 screws, washers and 2 gaskets Fig. 357 IMG-0710 Fig. 358 IMG-0714 Fig. 359 IMG-0715 6-14 2007 - 2008 Titan Z Service Manual...
  • Page 126 ENGINE Fig. 360 IMG-0717 Torque the engine mounting bolts to 200 ± 2007 - 2008 Titan Z Service Manual 6-15...
  • Page 127 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. 6-16 2007 - 2008 Titan Z Service Manual...

  • Page 128: Hydrostatic Drive System

    (Fig. 361). Fig. 362 IMG-0372 5. Using a spring tool (Toro part number 92-5771), release the tension from the hydro drive belt idler arm and remove the hydro drive belt from the idler arm pulley (Fig. 363).
  • Page 129 HYDROSTATIC DRIVE SYSTEM 8. Lift the seat assembly. Loosen the two screws that idler pulley (Fig. 364). secure the hydro fan cover to the seat box (Fig. 366). Fig. 364 IMG-0438a Fig. 366 IMG-0440a 7. Remove the hydro drive belt from around the engine pulley (Fig.
  • Page 130 HYDROSTATIC DRIVE SYSTEM 10. Remove the hydro drive belt from around the right Hydro Drive Belt Installation and left hydro pulleys and out the bottom of the machine (Fig. 368). Fig. 369 109-6014 Fig. 368 IMG-0443 1. Route the hydro drive belt around the left and right hydro pulleys (Fig.
  • Page 131 HYDROSTATIC DRIVE SYSTEM 2. Route the hydro drive belt around the inside of the 4. Using a spring tool (Toro part number 92-5771) release tension from the hyrdo drive idler arm and route the hydro drive belt around the idler pulley (Fig.
  • Page 132 HYDROSTATIC DRIVE SYSTEM 6. Pull the mower deck idler arm assembly toward the 7. Release the mower deck idler arm. rear of the machine and route the mower deck belt around the idler pulley and the electric PTO clutch 8. Check the mower deck belt routing (Fig. 377). pulley (Fig.
  • Page 133 HYDROSTATIC DRIVE SYSTEM 10. Install the two screws securing the hydro fan cover to the seat box (Fig. 379). Fig. 379 IMG-0440a 11. Lower the seat. 13. Connect the negative battery cable to the battery. 2007 - 2008 Titan Z Service Manual...
  • Page 134 HYDROSTATIC DRIVE SYSTEM Motion Control Damper Replacement 4. Remove the two nuts securing the motion control damper to the frame and the motion control pivot (Fig. 381). Motion Control Damper Removal 1. Raise the seat. 2. Remove the negative and then the positive battery cable from the battery.
  • Page 135 HYDROSTATIC DRIVE SYSTEM Motion Control Damper Installation 3. Install a nut on each end of the damper to secure (Fig. 385). 1. Install two nuts on each screw of the motion control damper (Fig. 383). Fig. 385 IMG-0477 Fig. 383 IMG-0468a 4.
  • Page 136 HYDROSTATIC DRIVE SYSTEM Motion Control Pivot Assembly 5. Remove the two screws and washers retaining the left hand lever grip assembly from the lever mount Replacement post (Fig. 388). The following procedures show replacing and servicing the left hand motion control pivot assembly. The same procedures can be followed to replace and service the right hand motion control pivot assembly.
  • Page 137 HYDROSTATIC DRIVE SYSTEM 7. Remove the nut from the top of the left hand motion 9. Remove the cotter pin located on the control pivot control damper and move the damper out of the pin (Fig. 392). motion control pivot (Fig. 390). Fig.
  • Page 138 HYDROSTATIC DRIVE SYSTEM 11. Remove the motion control pivot assembly from the seat box assembly (Fig. 394). Fig. 394 IMG-0485 2007 - 2008 Titan Z Service Manual 7-11...
  • Page 139 HYDROSTATIC DRIVE SYSTEM Motion Control Pivot Disassembly 3. With a long punch and hammer, remove the two bearings in the motion control pivot (Fig. 397). 1. Remove the neutral switch from the motion control pivot assembly (Fig. 395). Fig. 397 IMG-0494a Fig.
  • Page 140 HYDROSTATIC DRIVE SYSTEM Motion Control Pivot Assembly 3. Tighten the bolts and nuts until you feel resistance on the lever mount post - Do Not over-tighten (Fig. 400). 1. Tap two new bearings into the motion control pivot assembly (Fig. 398). Fig.
  • Page 141 HYDROSTATIC DRIVE SYSTEM Motion Control Pivot Assembly Installation 3. Install a cotter pin on the end of the control pivot pin (Fig. 404). 1. Install the left hand motion control pivot assembly between the seat box assembly and the motion control bracket (Fig.
  • Page 142 HYDROSTATIC DRIVE SYSTEM 5. Install the motion control damper screw through the 7. Install two screws and washers retaining the left left hand motion control pivot assembly. Install a nut hand lever grip assembly to the lever mount post to secure (Fig. 406). (Fig.
  • Page 143 HYDROSTATIC DRIVE SYSTEM 9. Position the battery into the machine. Install the Brake Linkage & Brake Handle battery hold down bracket to secure (Fig. 409). Assembly Replacement Brake Linkage & Brake Handle Assembly Removal 1. Raise the seat. 2. Remove the negative and then the positive battery cable from the battery.
  • Page 144 HYDROSTATIC DRIVE SYSTEM 4. Remove the left hand fender and fuel tank. Refer to 7. Remove the brake lever (Fig. 413). Left Hand Fender and Fuel Tank Removal on page 3-7. 5. Remove the nut securing the brake arm assembly pivot (Fig.
  • Page 145 HYDROSTATIC DRIVE SYSTEM 9. Pull the brake pivot tube assembly out slightly from 11. Remove the spacer from the inside end of the brake the frame (Fig. 415). pivot tube (Fig. 417). Fig. 415 IMG-0291a Fig. 417 IMG-0293a 10. Remove the washer located on the inside end of the 12.
  • Page 146 HYDROSTATIC DRIVE SYSTEM 15. With a spring tool (Toro part number 92-5771), re- of the seat box assembly (Fig. 419). move the right extension spring located between the spring anchor plate and the brake shaft assembly (Fig. 421). Fig. 419 IMG-0295a Fig.
  • Page 147 HYDROSTATIC DRIVE SYSTEM 17. Rotate the brake shaft assembly forward and down. 19. Remove the cotter pin from the clevis pin that Remove the e-clip retaining the brake arm to the secures the right side spring anchor plate to the brake shaft assembly (Fig.
  • Page 148 HYDROSTATIC DRIVE SYSTEM 21. Repeat steps 19 and 20 to remove the left side 24. Remove the brake shaft from the transmission and spring anchor plate. frame (Fig. 429). 22. Remove the nut securing the right side of the brake shaft to the transmission and frame (Fig.
  • Page 149 HYDROSTATIC DRIVE SYSTEM Brake Linkage & Brake Handle Assembly 3. Install a nut securing the left hand end of the brake shaft to the transmission and frame (Fig. 432). Installation 1. Position the brake shaft to the transmission and frame (Fig. 430). Fig.
  • Page 150 HYDROSTATIC DRIVE SYSTEM 5. Install the right side spring anchor plate onto the 7. Install an e-clip to retain the brake arm to the brake right brake handle clevis pin. Install a cotter pin to shaft assembly (Fig. 436). secure (Fig. 434). Fig.
  • Page 151 HYDROSTATIC DRIVE SYSTEM 9. Using a spring tool (Toro part number 92-5771), install the left extension spring onto the spring box assembly for the brake shaft pivot assembly anchor plate and the brake shaft assembly (Fig. (Fig. 440). 438). Fig. 440 IMG-0312 Fig.
  • Page 152 HYDROSTATIC DRIVE SYSTEM 13. Slide the brake pivot tube about half way through the 15. Install a washer on the inside end of the brake pivot tube (Fig. 444). Fig. 444 IMG-0316a Fig. 442 IMG-0314 14. Install a spacer on the inside end of the brake pivot bushings, spacer and washer and into the slots tube (Fig.
  • Page 153 HYDROSTATIC DRIVE SYSTEM 17. Install a spacer on the outside end of the brake pivot 19. Slide a carriage bolt through the brake pivot tube tube (Fig. 446). (Fig. 448). Fig. 446 IMG-0319 Fig. 448 IMG-0288 18. Install the brake lever assembly on the outside end 20.
  • Page 154 HYDROSTATIC DRIVE SYSTEM 21. Install the left hand fender and fuel tank. Refer to Transaxle Replacement Left Hand Fender and Fuel Tank Installation on page 3-10. Note: These instructions show the removal and Installation of the left side transaxle. The 22.
  • Page 155 HYDROSTATIC DRIVE SYSTEM 5. Locate the mower deck idler arm assembly. Pull the 7. Loosen the two screws securing the hydro fan cover mower deck idler arm toward the rear of the machine to the seat box (Fig. 454). and remove the mower deck belt from the idler pulley (Fig.
  • Page 156 HYDROSTATIC DRIVE SYSTEM 9. Using a spring tool (Toro part number 92-5771) 11. Remove the carriage screw and knob handle secur- release the tension from the hydro drive belt idler ing the hydro bypass arm to the frame (Fig. 458).
  • Page 157 HYDROSTATIC DRIVE SYSTEM 15. Remove the nut, bolt, and washer securing the ing rod to the hydro control arm (Fig. 460). brake pivot and brake shaft assembly to the trans- axle and the frame (Fig. 462). Fig. 460 IMG-0557 Fig. 462 IMG-0558a 14.
  • Page 158 HYDROSTATIC DRIVE SYSTEM (Fig. 464). tension rod and tube between the left and right transaxles. Remove the tension rod and tube (Fig. 466). Fig. 464 IMG-0563 Fig. 466 IMG-0571 18. Remove the nut, carriage bolt, and spacer securing the back of the transaxle to the frame (Fig. 465). 20.
  • Page 159 HYDROSTATIC DRIVE SYSTEM 21. Slowly lower the transaxle away from the frame (Fig. 23. Remove the cotter pin retaining the spring anchor 468). plate to the brake arm and remove the spring anchor plate (Fig. 470). Fig. 468 IMG-0572 Fig. 470 IMG-0575 22.
  • Page 160 HYDROSTATIC DRIVE SYSTEM Transaxle Installation 3. Loosely install two carriage bolts and nuts to secure the transaxle to the frame (Fig. 473). 1. Position the hydro bypass arm onto the bypass arm linkage located on the transaxle. Secure with a hair- pin cotter (Fig.
  • Page 161 HYDROSTATIC DRIVE SYSTEM 5. Loosely nstall the carriage bolt, spacer, and nut to secure the rear of the transaxle to the frame (Fig. 475). 8. Tighten the two carriage bolts and nuts securing the transaxle to the frame (Fig. 477). Fig.
  • Page 162 HYDROSTATIC DRIVE SYSTEM 10. Tighten the bolt and nut securing the brake pivot to the transaxle and frame (Fig. 479). to the hydro control arm (Fig. 481). Fig. 481 IMG-0557 Fig. 479 IMG-0558a rod between the right and left transaxles. 482).
  • Page 163 HYDROSTATIC DRIVE SYSTEM 15. Install the spring anchor plate in the slot located on 17. Using a spring tool (Toro part number 92-5771), the brake shaft assembly (Fig. 483). install the left extension spring between the spring anchor plate and the brake shaft assembly (Fig.
  • Page 164 Fig. 487 IMG-0439a 22. Route the mower deck drive belt around the electric 20. Using a spring tool (Toro part number 92-5771), PTO clutch pulley (Fig. 490). release the tension on the hydro drive belt idler arm. Route the belt around the idler pulley (Fig. 488).
  • Page 165 HYDROSTATIC DRIVE SYSTEM 23. Pull the mower deck idler arm toward the rear of the 25. Install the left rear tire and wheel assembly. machine. Route the mower deck belt around the inside of the spring idler arm pulley and release the 26.

  • Page 166: Neutral Adjustment

    HYDROSTATIC DRIVE SYSTEM Neutral Adjustment 4. Remove the bolt and nut retaining the seat stop cable to the seat plate (Fig. 496). 1. Raise the rear end of the machine and support it on jack stands (Fig. 494). Fig. 496 IMG-0591 Fig.
  • Page 167 HYDROSTATIC DRIVE SYSTEM 6. Observe the rear tires to see if there is any move- 9. Loosen the two jam nuts and turn the adjustment rod ment. If the tire is creeping in either direction, a nut (Fig. 500): neutral adjustment is needed (Fig. 498). A.

  • Page 168: Tracking Adjustment

    HYDROSTATIC DRIVE SYSTEM 12. If adjustment is completed, tighten the two jam nuts Tracking Adjustment against the adjustment rod nut. If the machine turns right or left when the handles are 13. Install the bolt and nut securing the seat stop cable evenly pushed forward, adjust on the side opposite the to the seat plate (Fig.

  • Page 169: Hydraulic System Maintenance

    HYDROSTATIC DRIVE SYSTEM Purging Procedures - Transaxles Hydraulic System Maintenance Checking the Hydraulic Oil Level drive applications, it is critical that it be purged from the system. Service Interval: Before each use or daily These purge procedures should be implemented any Check expansion tank and if necessary add MOBIL 1 time a hydrostatic system has been opened to facilitate 15W-50 synthetic motor oil to the FULL COLD line (Fig.
  • Page 170 HYDROSTATIC DRIVE SYSTEM Change the Hydraulic System Filter 6. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. Service Interval: 400 hours thereafter. 7. Start engine and move throttle control ahead to 1/2 throttle position.

  • Page 171: Troubleshooting

    HYDROSTATIC DRIVE SYSTEM Troubleshooting In many cases, problems with the ZT-2800™ are not related WARNING to a defective transaxle, but are caused by slipping drive belts, partially engaged bypass valves, and loose or damaged control linkages. Be sure to perform all applicable corrective actions Do not attempt any servicing or adjustments with the engine running.

  • Page 172: Service Manual

    2007 - 2008 Titan™ Z4800 & Z5200 Service Manual Form No. 492-9207...

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