Toro TITAN HD Service Manual
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Toro TITAN HD Service Manual

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L C E / R e s i d e n t i a l P r o d u c t s
T I T A N ® H D
S e r v i c e Ma n u a l
I s s u e d : J a n u a r y 2 0 1 8

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  • Page 1 L C E / R e s i d e n t i a l P r o d u c t s T I T A N ® H D S e r v i c e Ma n u a l I s s u e d : J a n u a r y 2 0 1 8...
  • Page 2 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 specifications or make changes to this manual without notice. 2018 The Toro Company All Rights Reserved Digital Edition - TITAN®...
  • Page 3 TABLE OF CONTENTS Safety............................Specifications........................Maintenance........................... Troubleshooting........................Chassis..........................Engine............................ Hydrostatic Drive System..................... Mower Deck........................... Electrical..........................Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 4 ICON LEGEND This icon is used to denote Critical Processes or actions that if missed, could greatly impact your safety, lead to mechanical failure, or improper product/ part use. Please pay close attention to these steps as they are distinguished throughout the manual.
  • Page 5 SAFETY Table of Contents General Safety Information....................1-2 Think Safety First.......................1-2 Digital Edition - TITAN® HD Service Manual January 2018 Table of Contents...
  • Page 6 Toro Titan HD Riding Mower. The Titan HD operator’s manual contains safety information and tips for safe operating practices. Operator’s manuals are available online at Toro.com, through your Toro parts source, or:...
  • Page 7 SPECIFICATIONS Table of Contents General Specifications....................... Unit Dimensions........................Torque Specifications......................Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.)........Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric)......Equivalents and Conversions.................... 2-11 2-12 U.S. To Metric Conversions....................Digital Edition - TITAN® HD Service Manual January 2018 Table of Contents...
  • Page 8 SPECIFICATIONS General Specifications Configuration Titan HD 1500 Titan HD 1500 (CA) Titan HD 1500 Model 74450 78450 74451 Engine Toro Kohler Toro Engine Model Toro V-Twin 708CC Kohler 725CC Toro V-Twin 708CC Engine Model LC2P77F ZT720 LC2P77F High Idle 3600 ± 100 RPM 3750 ±...
  • Page 9 SPECIFICATIONS General Specifications (Cont.) Configuration Titan HD 1500 Titan HD 1500 CE Titan HD 1500 CE Model 74452 74447TE 74451TE Engine Toro Engine Model Toro V-Twin 708CC Engine Model LCP77F High Idle 3600 ± 100 RPM 3000 ± 100 RPM Low Idle 1800 ±...
  • Page 10 7 gallon Battery 12 volt - 300 CCA Hydraulic Drive System Transmission ZT3400 Transmission Lubricant 4.45 L (150 oz.) Toro HYPR-OIL™ 500 hydraulic fluid or Mobil 1 15W-50 oil ® Max Ground Speed Up to 9 mph (FWD) Rear Tires 23 x 9.5 - 12...
  • Page 11 Battery 12 volt - 300 CCA Hydraulic Drive System Transmission ZT3400 Transmission Lubricant 4.45 L (150 oz.) Toro HYPR-OIL™ 500 hydraulic fluid or Mobil 1 15W-50 oil ® Max Ground Speed (FWD) Up to 10 mph Rear Tires 24 x 9.5 - 12...
  • Page 12 SPECIFICATIONS Unit Dimensions Model Overall Height Tread Width Overall Width Overall Length ROPS ROPS Caster Drive Wheel Curb Tires Deck Deck ROPS ROPS Down Wheels Wheels Base Weight Chute Chute Down Down 74450 69.7 33.1 37.7 49.7 46.7 63.1 54.1 81.7 80.8 78450...
  • Page 13 The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
  • Page 14 SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (U.S.) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, SAE Grade 5 Bolts, SAE Grade 8 Bolts, 8 Fasteners Screws, Studs & Sems Screws, Studs & Sems Screws, Studs & Sems with Thin with Regular Height with Regular Height...
  • Page 15 SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) Thread Size Class 8.8 Bolts, Screws, Studs with Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Regular Height Nuts (Class 10 or Nuts) stronger Nuts) in-lb.
  • Page 16 SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric) (Cont.) SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Thread Size Recommended Torque** Square Head Hex Socket 7/16 - 20 UNF 65 ± 10 ft-lb. 88 ±...
  • Page 17 SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 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 35/64 0.046875 1.191 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...
  • Page 18 SPECIFICATIONS U.S. to Metric Conversions To Convert Into Multiply By Linear Measurement Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Area Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches...
  • Page 19 Table of Contents Recommended Maintenance Schedule(s)................. Lubrication........................... Lubricating the Caster Wheel Hubs (2500 Series Machines Only)......... Engine Maintenance......................Servicing the Toro V Twin Engine..................Servicing the Air Cleaner....................Servicing the Engine Oil....................3-11 Changing the Engine Oil and Oil Filter.................
  • Page 20 MAINTENANCE Table of Contents Checking the Wheel Lug Nuts................... 3-39 Brake Maintenance......................3-39 Belt Maintenance........................ 3-39 Mower Belt Replacement (Side Discharge Machines)............. 3-39 Mower Belt Replacement (Rear Discharge Machines)............ 3-39 Hydrostatic Drive Belt Replacement................. 3-39 Hydraulic System Maintenance..................3-40 Hydraulic System Safety....................
  • Page 21 • Toro engines - replace the air cleaner foam element* • Toro engines - service the air cleaner paper element* • Toro engines - change the engine oil and oil filter* • Toro engines - check the spark plug(s) Every 200 hours •...
  • Page 22 • Replace the emissions air intake filter • Replace the fuel filter* • Check the parking brake adjustment • (After the initial change) Change the hydraulic system filters and fluid when using Toro 500 oil (more often under severe conditions) ® HYPR-OIL™ Monthly •...
  • Page 23 MAINTENANCE Lubrication Service Interval: Every 50 hours NOTE: Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 lithium or molybdenum-based grease 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key.
  • Page 24 MAINTENANCE Lubricating the Caster Wheel Hubs (2500 Series Machines Only) Service Interval: Yearly 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. Figure 2 A.
  • Page 25 MAINTENANCE Lubricating the Caster Wheel Hubs (2500 Series Machines Only) (Cont.) NOTE: Do not thread the spacer nut all the way onto the end of the axle. Leave approximately 1/8 in. (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. 10.
  • Page 26 Figure 3 A. Kawasaki Engine B. Kohler Engine C. Toro Engine Important: For Kawasaki and Kohler Engines, refer to the Engine Operator’s Manual for additional maintenance procedures. Engine Safety: Shut off the engine before checking the oil or adding oil to the crankcase.
  • Page 27 MAINTENANCE Servicing the Toro V-Twin Engine Servicing the Air Cleaner Service Interval Maintenance Procedure Daily or before starting engine • Check for build-up of dirt and debris around the air cleaner system • Check for loose or damaged components, replace or make appropriate repairs •...
  • Page 28 MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Removing the Elements (Cont.) 3. Lift the cover and rotate the air cleaner assembly out of the engine (Figure 4). 4. Remove the foam element from the paper element (Figure 5). Figure 4...
  • Page 29 Replace the paper element if it’s damaged or cannot be cleaned thoroughly. Servicing the Engine Oil Recommended Oil: Toro 4-Cycle Premium Engine Oil Oil Type: Detergent Oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 2.4 L (2.5 qts.)
  • Page 30 5. If the level is low, wipe off the area around the oil fill cap/dipstick and add oil to the “FULL” mark on the dipstick. Toro 4-cycle Premium Engine Oil is recommended. Refer to the following information for an appropriate API rating and viscosity.
  • Page 31 MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: After the first 5 hours/after the first month (whichever comes first) Every 100 hours/Yearly (whichever comes first): Change the engine oil and oil filter (more often in dirty or dusty conditions) 1.
  • Page 32 MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) 3. Change the oil filter (Figure 9). NOTE: Ensure that the oil filter gasket touches the engine and then turn the filter an additional 3/4 turn.
  • Page 33 MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Servicing the Spark Plug Service Interval: Every 100 hours/yearly (whichever comes first): Check the spark plugs Every 200 hours/ every 2 years (whichever comes first): Replace the spark plugs Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench to remove and install the spark plug.
  • Page 34 MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Servicing the Spark Plug (Cont.) Installing the Spark Plug 1. Tighten the spark plugs to 22 ± 2 ft-lbs. (25-30 Nm) (Figure 12). Figure 12 Cleaning the Cooling System Service Interval: Before each use 1.
  • Page 35 MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Checking the Spark Arrestor (if equipped) Service Interval: Every 50 hours WARNING! Hot exhaust system components may ignite gasoline vapors even after shutting off the engine. Hot particles exhausted during engine operation may ignite flammable materials.
  • Page 36 MAINTENANCE Servicing the Toro V-Twin Engine (Cont.) Replacing the Emissions - Air Intake Filter Service Interval: Every 500 hours Figure 13 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key.
  • Page 37 MAINTENANCE Servicing the Kohler Engine Servicing the Air Cleaner Service Interval Maintenance Procedure Daily or before starting engine • Check the air cleaner for dirty, loose or damaged parts. Every 25 hours/monthly* • Service or replace the air cleaner pre-cleaner Every 50 hours* •...
  • Page 38 MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Air Cleaner (Cont.) 3. Remove the pre-cleaner and paper element. 4. Remove the element, and gently tap the element to dislodge dirt. NOTE: Do NOT wash the paper element or use pressurized air, as this will damage the element. NOTE: Replace a dirty, bent, or damaged element.
  • Page 39 MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Engine Oil Oil Type: Detergent Oil (API service SJ or higher) Crankcase Capacity: 1.9 L (64 oz.) Viscosity: See Table (Figure 15) SAE 30 Figure 15 Service Interval: Before each use or daily NOTE: Do not overfill the crankcase with oil and run the engine, damage may result.
  • Page 40 MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Engine Oil (Cont.) 4. Check the engine oil level (Figure 16). Figure 16 5. If the level is low, wipe off the area around the oil fill cap, remove cap/dipstick and add oil to the “F” (FULL) mark on the dipstick.
  • Page 41 MAINTENANCE Servicing the Kohler Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: Every 100 hours/Yearly (whichever comes first). Change the engine oil and oil filter more often in dirty or dusty conditions. 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key.
  • Page 42 MAINTENANCE Servicing the Kohler Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) NOTE: Ensure the oil filter gasket touches the engine, then turn the filter an additional extra 3/4 turn (Figure 18). 02:00 Min 2:00 Min Figure 18 4.
  • Page 43 MAINTENANCE Servicing the Kohler Engine (Cont.) Servicing the Spark Plugs Service Interval: Every 200 hours - Check the spark plugs Every 500 hours - Replace the spark plugs NOTE: The spark plug is RFI compliant. Equivalent alternate brand plugs can also be used. Make sure the air gap between the center and side electrodes is correct before installing the spark plug.
  • Page 44 MAINTENANCE Servicing the Kohler Engine (Cont.) Checking the Spark Plug 1. Inspect the spark plug. NOTE: If you see light brown or gray coating on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty. NOTE: Do not clean the spark plug(s).
  • Page 45 MAINTENANCE Servicing the Kohler Engine (Cont.) Cleaning the Blower Housing Service Interval: Every 100 hours/Yearly (whichever comes first) - clean the cooling fins (more often under extremely dusty, dirty conditions). To ensure proper cooling, ensure that the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times.
  • Page 46 MAINTENANCE Servicing the Kawasaki Engine Servicing the Air Cleaner Service Interval Maintenance Procedure Every 250 hours/yearly • Replace the primary air filter (whichever comes first)* • Check the safety air filter Every 500 hours/every 2 years • Replace the safety air filter (whichever comes first)* *More often in dusty/dirty conditions NOTE: Service the air cleaner more often under extremely dusty, dirty conditions.
  • Page 47 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Air Cleaner (Cont.) 3. Clean the inside of the air cleaner cover with compressed air. 4. Gently, slide the primary filter out of the air-cleaner body. NOTE: Avoid knocking the filter into the side of the body. 5.
  • Page 48 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Primary Filter • If the primary filter is dirty, bent, or damaged, replace it • Do not clean the primary filter Servicing the Safety Filter Replace the safety filter, never clean it NOTE: Do not attempt to clean the safety filter.
  • Page 49 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Engine Oil Oil Type: Detergent Oil (API service SF, SG, SH, SJ or SL) Crankcase Capacity: 2.1 L (71 oz.) Viscosity: See Table (Figure 23) Figure 23 NOTE: Although 10W-40 engine oil is recommended for most conditions, you may need to change oil viscosity to accommodate atmospheric conditions.
  • Page 50 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Engine Oil (Cont.) 4. Check the engine oil level (Figure 24). Figure 24 5. If the level is low, wipe off the area around the oil fill cap, remove cap/dipstick and add oil to the “FULL”...
  • Page 51 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Changing the Engine Oil and Oil Filter Service Interval: Every 100 hours- Change the Engine Oil (more often in dirty or dusty conditions) Every 200- hours Change the Oil Filter 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage the parking brake, and remove the key.
  • Page 52 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Changing the Engine Oil and Oil Filter (Cont.) NOTE: Ensure that the oil filter gasket touches the engine and then turn the filter an additional ¾ turn (Figure 26). Figure 26 4. Slowly pour approximately 80% of the specified oil into the filler tube. Check the oil level and slowly add the additional oil needed to bring it to the FULL mark (Figure 27).
  • Page 53 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Servicing the Spark Plug Service Interval: Every 100 hours - Replace the spark plugs. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench to remove and install the spark plug.
  • Page 54 MAINTENANCE Servicing the Kawasaki Engine (Cont.) Checking the Spark Plug (Cont.) 2. Check the gap between the center and side electrodes (Figure 28). 3. Set the gap to 0.030 in. (0.76 mm). Figure 28 Installing the Spark Plug 1. Tighten the spark plugs to 16 ft-lbs. (22 Nm). 3-36 Digital Edition - TITAN®...
  • Page 55 MAINTENANCE Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 500 hours/yearly (whichever comes first) - Replace the fuel filter more often in dirty or dusty conditions. NOTE: If any cable ties or clamps are removed, note the position of the tie and replace after servicing the fuel filter.
  • Page 56 MAINTENANCE Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery.
  • Page 57 MAINTENANCE Servicing the Battery Service Interval: Monthly NOTE: The battery should be maintained at 12.6 volts or greater. A battery that has reached a voltage of 12.4 volts or less is considered discharged, and should be recharged. 1. Charge the battery for 30 minutes at 10 A. 2.
  • Page 58 Service Interval: Before each use or daily 1. Allow the hydraulic fluid to cool down. Check the oil level when the oil is cold. 2. Check the expansion tank and if necessary add Toro® HYPR-OIL™ 500 hydraulic fluid to the FULL COLD line (Figure 30).
  • Page 59 MAINTENANCE Hydraulic System Maintenance (Cont.) Changing the Hydraulic System Filters and Fluid Service Interval: After the first 75 hours of use: Change the hydraulic system filters and fluid Every 250 hours (after the initial change): Change the hydraulic-system filters and fluid when using Mobil 1 15W-50 fluid (change the fluid more often under severe conditions).
  • Page 60 MAINTENANCE Hydraulic System Maintenance (Cont.) Removing the Hydraulic System Filters (Cont.) 5. Carefully, clean the area around the filters. NOTE: Do not allow dirt to enter the hydraulic system - contamination may occur. 6. Place a drain pan below the filter to catch the oil that drains when the filter and vent plugs are removed. 7.
  • Page 61 MAINTENANCE Hydraulic System Maintenance (Cont.) Installing the Hydraulic System Filters and Adding Oil (Cont.) 6. Verify that the vent plugs are removed before adding the oil. 7. Slowly pour the specified oil through the expansion reservoir until oil comes out of one of the vent plug holes. 8.
  • Page 62 MAINTENANCE Servicing the Cutting Blades Blade Safety A worn or damaged blade can break and a piece of the blade could be thrown at you or bystanders, resulting in serious injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product.
  • Page 63 MAINTENANCE Servicing the Cutting Blades (Cont.) Checking for Bent Blades 1. Park the machine on a level surface, disengage the PTO, stop the engine, engage parking brake, and remove the key. 2. Disconnect the spark plug wires from the spark plugs. 3.
  • Page 64 Replace the blade if it hits an object, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.
  • Page 65 Replace the blade if it hits an object, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.
  • Page 66 MAINTENANCE Changing the Blades (Rear Discharge Mower Deck) (Cont.) Removal (Cont.) NOTE: Note the type blade and where each blade is installed. See Figure 37 for the correct position. Figure 37 A. Front of Mower Deck D. Counter - Rotating Blade B.
  • Page 67 MAINTENANCE Changing the Blades (Rear Discharge Mower Deck) (Cont.) Installation (Cont.) 2. Install the right blade, curved washer, and blade bolt (left hand threaded bolt) to the spindle shaft (Figure 38) 3. Torque the blade bolts to 95 ± 5 ft-lbs. (122-136 Nm). Figure 38 A.
  • Page 68 MAINTENANCE Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 40). NOTE: Maintain the original angle. NOTE: The blade retains balance if you remove the same amount of material from both cutting edges. Figure 40 A.
  • Page 69 TROUBLESHOOTING Table of Contents Troubleshooting Table......................4-2 Digital Edition - TITAN® HD Service Manual January 2018 Table of Contents...
  • Page 70 TROUBLESHOOTING Troubleshooting Problem Possible Cause Next Step... The starter does not crank The blade control switch (PTO) is Move the blade-control switch (PTO) engaged. to the disengaged position. The parking brake is not engaged. Set the parking brake. The motion-control levers are not in Ensure that the motion-control levers the Neutral-Lock position.
  • Page 71 TROUBLESHOOTING Troubleshooting (Cont.) Problem Possible Cause Next Step... Engine loses power The engine load is excessive. Reduce the ground speed. The air cleaner is dirty. Clean the air cleaner element. The oil level in the crankcase is low. Add oil to the crankcase. The cooling fins and air passages Remove the obstruction and above the engine are plugged.
  • Page 72 TROUBLESHOOTING Troubleshooting (Cont.) Problem Possible Cause Next Step... The machine produces an The blade(s) is/are not sharp. Sharpen the blade(s). uneven cutting height The cutting blade(s) is/are bent. Install new cutting blade(s). The mower deck is not level. Level the mower deck from side-to- side and front-to-rear.
  • Page 73 CHASSIS Table of Contents MyRide Exploded View....................... Caster Assembly and Bearing................... Exploded View....................... Removal......................... Installation........................Caster Wheel........................Service..........................Lubrication Service Interval................... Disassembly........................Assembly........................Left Console........................Removal.......................... 5-10 Installation........................5-12 Right Console........................5-12 Removal.......................... 5-14 Installation........................5-16 Seat............................5-16 Removal........................... 5-16 Installation........................
  • Page 74 CHASSIS Table of Contents Park Brake Handle Assembly.................... 5-27 Removal.......................... 5-27 Installation........................5-28 Adjusting the Park Brake....................5-29 Service Interval....................... 5-29 Motion Control Damper...................... 5-31 Removal.......................... 5-31 Installation........................5-32 Motion Control Assembly....................5-33 Removal.......................... 5-33 Installation........................5-35 Adjusting the Motion Control Handle Position..............
  • Page 75 CHASSIS MyRide Exploded View Figure 1 A. Trailing Arm Tube F. LH Trailing Arm Bracket B. Shoulder Bolt G. Pivot Rod C. Flange Bushing H. RH Trailing Arm Bracket D. Trailing Arm I. Upper Shock Mount Bolt E. Flange Bearing J.
  • Page 76 CHASSIS Caster Assembly and Bearing Figure 2 A. Ball Bearing E. Spring Washer B. Grease Cap F. Bolt C. Frame Assembly G. Flat Washer D. Front Caster Assembly Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 77 CHASSIS Caster Fork Assembly and Bearing Service Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Raise and support the unit so that the front wheels are off the ground. 3.
  • Page 78 CHASSIS Caster Wheel Service: Titan HD 1500 and Titan HD 2000 Series Figure 3 A. Wheel B. Valve Stem C. Grease Fitting NOTE: The caster wheel is not serviceable and should be replaced as a complete assembly. Caster Wheel Service: Titan HD 2500 Series Figure 4 A.
  • Page 79 CHASSIS Caster Wheel Service (2500 Series) Disassembly 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Raise and support the unit so that the front wheels are off the ground. 3.
  • Page 80 CHASSIS Left Console Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery cables and remove the battery from the tray. 3.
  • Page 81 CHASSIS Left Console Removal (Cont.) 6. Remove the two bolts from the support bracket (Figure 6). Figure 6 7. Remove the fuel cap and disconnect the keeper line (Figure 7). Figure 7 8. Carefully lift the console upward off of the machine. 9.
  • Page 82 CHASSIS Left Console Installation 1. Remove the fuel cap from the gas tank. 2. Lower the console into place, ensuring that it seats properly on the support (Figure 8). Figure 8 3. Install the keeper line into the fuel cap, and reinstall the fuel cap. 4.
  • Page 83 CHASSIS Left Console Installation (Cont.) 5. Install the two screws (T25) through the console bracket (C) (Figure 10). Figure 10 6. Install the two bolts (B) and nuts on the front of the console (Figure 10). 7. Install the shoulder bolt (A) (T30) at the front of the console (Figure 10). 8.
  • Page 84 CHASSIS Right Console Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery terminals. 3. Remove the shoulder bolt (A) (T30) at the front of the console (Figure 11). Figure 11 4.
  • Page 85 CHASSIS Right Console Removal (Cont.) 6. Remove the two bolts from the support bracket. 7. Remove the hex screw securing the control panel assembly to the console. 8. Lift the console upward off of the machine, while feeding the control panel assembly through the opening in the console (Figure 12).
  • Page 86 CHASSIS Right Console Installation 1. Lower the console into place, while moving the control panel assembly through the opening in the console and into position. Ensure that the console seats properly on the supports (Figure 13). Figure 13 NOTE: Before securing the control panel to the console, ensure that all cables and electrical connections are seated firmly in place on the underside of the control panel assembly.
  • Page 87 CHASSIS Right Console Installation (Cont.) 5. Install the two bolts (B) and nuts on the front console (Figure 14). 6. Install the shoulder bolt (A) (T30) at the front of the console (Figure 14). 7. Connect the battery terminals and verify proper function of the unit. 5-15 Digital Edition - TITAN®...
  • Page 88 CHASSIS Seat Figure 15 Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery terminals. 3.
  • Page 89 CHASSIS Fuel Tank Figure 16 A. Vent Hose Assembly C. Fuel Shut-Off Valve B. Fuel Supply Line Removal NOTE: The fuel pick-up system is designed to pull fuel from any part of the tank in low fuel situations as well as reducing the affect of debris in the tank (Figure 17). Figure 17 1.
  • Page 90 CHASSIS Fuel Tank Removal (Cont.) 3. Close the fuel supply valve (Figure 18). Figure 18 4. Remove the right and left side consoles. See “Console Removal,” chapter 5, page 5-8. See “Seat Removal,”chapter 5, page 5-16. 5. Remove the seat assembly. 6.
  • Page 91 CHASSIS Fuel Tank Installation 1. Position the fuel tank assembly onto the frame with the vent ports toward the rear of the machine. 2. Connect the two vent lines to the fuel tank (A) (Figure 20). 3. Connect the fuel supply line to the fuel tank and route the fuel line in the detents molded into the tank (B) (Figure 20).
  • Page 92 CHASSIS Fuel Tank Installation (Cont.) 7. Open the fuel supply valve (Figure 21). Figure 21 8. Connect the battery terminals and verify proper function of the unit. 5-20 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 93 CHASSIS Roll Over Protection System (ROPS) Figure 22 Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Fold the ROPS assembly into the upright position and lock in place (Figure 22). NOTE: For easier access, remove the right and left side consoles.
  • Page 94 CHASSIS Roll Over Protection System (ROPS) Installation 1. Lift the ROPS assembly into position on the rear side of the mounting support. 2. Install the four mounting bolts (Figure 23). Figure 23 NOTE: Orientation of the ROPS hardware is critical. Make sure that the bolts are orientated as shown (Figure 22).
  • Page 95 CHASSIS Throttle Cable Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery. 3. Remove the control panel assembly from the right console. 4.
  • Page 96 CHASSIS Throttle Cable Assembly Installation 1. Route the throttle cable through the right console between the ROPS and the hydraulic fluid reservoir (Figure 26). Figure 26 2. Attach the throttle cable assembly to the control panel assembly using two bolts and nuts. 3.
  • Page 97 CHASSIS Choke Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery. 3. Loosen the clamp securing the choke cable to the choke plate on the engine (A) (Figure 28). Figure 28 4.
  • Page 98 CHASSIS Choke Control Assembly Installation 1. Route the choke cable through the control panel assembly. 2. Thread the jam nut over the choke cable up to the control panel assembly (Figure 29). Figure 29 3. Attach the choke cable assembly to the control panel with the jam nut. 4.
  • Page 99 CHASSIS Park Brake Handle Assembly Figure 30 A. Locking Cotter Pin C. Flange Nut B. Bolt Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. 2.
  • Page 100 CHASSIS Park Brake Handle Assembly Installation 1. Connect the upper brake linkage to the brake shaft. 2. With the park brake handle hardware orientated as shown, install the bolt and flange nut (Figure 31). Figure 31 A. Locking Cotter Pin C.
  • Page 101 CHASSIS Adjusting the Park Brake Figure 33 A. Cotter Pin C. Brake Linkage Shaft B. Park Brake Handle Service Interval: Every 500 hours NOTE: Check to make sure the park brake is adjusted properly. This procedure must be followed after the first 100 hours of operation and every 500 hours thereafter;...
  • Page 102 CHASSIS Adjusting the Park Brake (Cont.) 6. Check both spring lengths, if adjustment is necessary, turn the top nut clockwise to shorten and counterclockwise to lengthen. The spring length should measure 1.75 in. (44 mm) (Figure 35). Figure 35 A. Flange Nut B.
  • Page 103 CHASSIS Motion Control Damper Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. 2. Remove the two bolts securing the motion control damper to the frame (A) and the motion control assembly (B) (Figure 36).
  • Page 104 CHASSIS Motion Control Damper Installation 1. Position the motion control damper on the outside of the frame mounting tab (Figure 37). Figure 37 2. Torque the rear mounting bolt to 200 ± 25 in-lbs. (237-305 Nm). 3. Torque the front mounting bolt to 90 ± 10 in-lbs. (108-135 Nm). 4.
  • Page 105 CHASSIS Motion Control Assembly Figure 38 Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. 2. Raise and support the unit so that the drive wheels are off the ground. NOTE: The console may be removed for easier access.
  • Page 106 CHASSIS Motion Control Assembly Removal (Cont.) 6. Disconnect the motion control assembly from the frame (Figure 40). Figure 40 7. Lower the motion control assembly through the frame toward the center of the machine, remove the assembly. 5-34 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 107 CHASSIS Motion Control Assembly Installation 1. Position the motion control assembly in place with the linkage extending toward the transmission. 2. Secure the motion control assembly to the frame. 3. Connect the motion control linkage to the transmission (Figure 41). Figure 41 5-35 Digital Edition - TITAN®...
  • Page 108 CHASSIS Motion Control Assembly Installation (Cont.) 4. Adjust the nut on the motion control assembly until the motion control nut (A) is centered in the control plate slots (Figure 42). Figure 42 A. Motion Control Nut 5. Connect the motion control damper to the motion control assembly and torque the bolt to 90 ± 10 in-lbs. (108- 135 Nm).
  • Page 109 CHASSIS Adjusting the Motion Control Handle Position NOTE: Ensure proper adjustment of neutral and tracking settings before adjusting the motion control handles see “Neutral Adjustment,” chapter 7, page 7-4 and/or “Tracking Adjustment,” chapter 7, page 7-7. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key.
  • Page 110 CHASSIS MyRide Replacement Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. 2. Lower the ROPS. 3. Remove the two larger nyloc nuts securing the lower shock mounts to the ROPS. The nyloc nuts can be accessed from the rear of the machine.
  • Page 111 CHASSIS MyRide Replacement (Cont.) Removal (Cont.) 6. Place shoulder bolt back in upper mount and finger tighten with the lock nut (Figure 45). Figure 45 7. Attach the seat and sub-frame assembly to the overhead lift using three lift points (Figure 46). Figure 46 8.
  • Page 112 CHASSIS MyRide Replacement (Cont.) Installation 1. With the seat and sub-frame assembly attached to the overhead lift, lower the seat into the machine, leaving room under the seat. 2. Connect the seat switch. 3. Lower the seat and sub-frame assembly to align the trailing arm with the mount holes in the ROPS tube (Figure 47).
  • Page 113 CHASSIS MyRide Replacement (Cont.) Installation (Cont.) 6. Lower the seat and sub-frame all the way onto the machine. 7. Disconnect the seat and sub-frame from the overhead lift. 8. Secure the front shock with a shoulder bolt. NOTE: Thread should be on the LH side of the machine (from operator’s position) (Figure 49). Figure 49 9.
  • Page 114 ENGINE Table of Contents Engine Mounting - Toro Twin Cylinder Engine Exploded View........Toro Twin Cylinder Engine....................Removal......................... Installation........................Engine Mounting - Kohler Engine Exploded View............6-10 Kohler Engine........................6-11 Removal......................... 6-11 Installation........................6-14 Engine Mounting - Kawasaki Engine Exploded View.............
  • Page 115 ENGINE Engine Mounting - Toro Twin Cylinder Engine Figure 1 A. Muffler Mounting Bolts/Nuts - Torque to 13 ft-lbs. (16-19 Nm) B. PTO Clutch Assembly - Torque clutch mounting bolt to 55 ± 6 ft-lbs. (66-83 Nm) C. Engine/Clutch Stop Mount Bolts (4) - Torque to 30 ± 3 ft-lbs. (36-45 Nm) Digital Edition - TITAN®...
  • Page 116 ENGINE Toro Twin Cylinder Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery.
  • Page 117 ENGINE Toro Twin Cylinder Engine Removal (Cont.) 7. Disconnect the chassis wire harness from the main engine wire harness (Figure 3). Figure 3 8. Disconnect the red (B+) wire from the starter (Figure 4). Figure 4 Digital Edition - TITAN® HD Service Manual...
  • Page 118 ENGINE Toro Twin Cylinder Engine Removal (Cont.) 9. Disconnect the black engine ground wire (Figure 5). Figure 5 10. Disconnect the fuel supply line at the fuel filter (Figure 6). Figure 6 11. Disconnect the throttle cable see “Throttle Cable Removal,” chapter 5, page 5-23.
  • Page 119 ENGINE Toro Twin Cylinder Engine Removal (Cont.) 16. Remove the engine mounting bolts. NOTE: Before removing the engine mounting bolts, note the orientation of the clutch anchor. The clutch wire can remain attached to the clutch anchor. 17. Lift the engine away from the frame.
  • Page 120 ENGINE Toro Twin Cylinder Engine Installation (Cont.) 9. Install the clutch onto the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor (Figure 8). Figure 8 10. Install the two spring washers and the clutch bolt (Figure 9).
  • Page 121 ENGINE Toro Twin Cylinder Engine Installation (Cont.) 17. Connect the black engine ground wire (Figure 10). Figure 10 18. Connect the red (B+) wire from the starter (Figure 11). Figure 11 Digital Edition - TITAN® HD Service Manual Table of Contents...
  • Page 122 ENGINE Toro Twin Cylinder Engine Installation (Cont.) 19. Connect the chassis wire harness to the main engine wire harness (Figure 12). Figure 12 20. Connect the fuel supply line to the fuel filter. 21. Install the engine guard. 22. Open the fuel supply valve.
  • Page 123 ENGINE Engine Mounting - Kohler Engine Figure 13 A. Muffler Mounting Nuts/Bolts - Torque to 20 ± 2 ft-lbs. (25-30 Nm) B. Clutch Mounting Bolt - Torque to 55 ± 6 ft-lbs. (66-83 Nm) C. Engine/Clutch Stop Mounting Bolts (4) - Torque to 30 ± 3 ft-lbs. (36-45 Nm) D.
  • Page 124 ENGINE Kohler Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery. 3. Close the fuel supply valve (Figure 14). Figure 14 4.
  • Page 125 ENGINE Kohler Engine Removal (Cont.) 8. Disconnect the red (B+) wire from the starter (Figure 16). Figure 16 9. Disconnect the black engine ground wire (Figure 17). Figure 17 6-12 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 126 ENGINE Kohler Engine Removal (Cont.) 10. Disconnect the fuel supply line at the fuel filter (Figure 18). Figure 18 11. Disconnect the throttle cable see “Throttle Cable Removal,” chapter 5, page 5-23. 12. Disconnect the choke cable see “Choke Cable Removal,” chapter 5, page 5-25. 13.
  • Page 127 ENGINE Kohler Engine Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Install the oil drain hose assembly (A) (Figure 19). NOTE: Apply pipe sealant to the threads at installation. Torque to 20 ± 3 ft-lbs. (23-31 Nm). Figure 19 3.
  • Page 128 ENGINE Kohler Engine Installation (Cont.) 6. Torque the four engine mounting bolts to 30 ± 3 ft-lbs. (36-45 Nm). 7. Install the key and engine pulley onto the crankshaft. NOTE: Install the engine pulley with the larger diameter hub toward the engine. 8.
  • Page 129 ENGINE Kohler Engine Installation (Cont.) 13. Connect the black engine ground wire (Figure 22). Figure 22 14. Connect the red (B+) wire from the starter (Figure 23). Figure 23 6-16 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 130 ENGINE Kohler Engine Installation (Cont.) 15. Connect the chassis wire harness to the main engine wire harness (Figure 24). Figure 24 16. Connect the fuel supply line to the fuel filter. 17. Install the engine guard. 18. Open the fuel supply valve. 19.
  • Page 131 ENGINE Engine Mounting - Kawasaki Engine Figure 25 A. Muffler Mounting Bolts/Nuts - Torque to 13 ft-lbs. (16-19 Nm) B. Clutch Mounting Bolt - Torque to 55 ± 6 ft-lbs. (66-83 Nm) C. Engine/Clutch Stop Mounting Bolts (4) - Torque to 30 ± 3 ft-lbs. (36-45 Nm) D.
  • Page 132 ENGINE Kawasaki Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery. 3. Close the fuel supply valve (Figure 26). Figure 26 4.
  • Page 133 ENGINE Kawasaki Engine Removal (Cont.) 8. Disconnect the red (B+) wire from the starter (Figure 28). Figure 28 9. Disconnect the black engine ground wire (Figure 29). Figure 29 6-20 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 134 ENGINE Kawasaki Engine Removal (Cont.) 10. Disconnect the fuel supply line at the fuel filter (Figure 30). Figure 30 11. Disconnect the throttle cable see “Throttle Cable Removal,” chapter 5, page 5-23. 12. Disconnect the choke cable see “Choke Cable Removal,” chapter 5, page 5-25. 13.
  • Page 135 ENGINE Kawasaki Engine Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Install the muffler and new exhaust gaskets. NOTE: Torque the muffler mounting bolts or nuts to 13 ft-lbs. (16-19 Nm). 3. Install the oil drain hose assembly (A) (Figure 31). NOTE: Torque oil drain hose (at engine block) to 26 ±...
  • Page 136 ENGINE Kawasaki Engine Installation (Cont.) 7. Torque the four engine mounting bolts to 30 ± 3 ft-lbs. (36-45 Nm). 8. Install the key and engine pulley onto the crankshaft. NOTE: Install the engine pulley with smaller diameter hub toward the engine. 9.
  • Page 137 ENGINE Kawasaki Engine Installation (Cont.) 17. Connect the black engine wire (Figure 34). Figure 34 18. Connect the red (B+) wire from starter (Figure 35). Figure 35 NOTE: Torque nut on starter relay to 32 ± 3 in-lbs. (3-4 Nm). 6-24 Digital Edition - TITAN®...
  • Page 138 ENGINE Kawasaki Engine Installation (Cont.) 19. Connect the chassis wire harness to the main engine wire harness (Figure 36). Figure 36 20. Connect the fuel supply line to the fuel filter. 21. Install the engine guard. 22. Open the fuel supply valve. 23.
  • Page 139 HYDROSTATIC DRIVE SYSTEM Table of Contents Hydrostatic Drive Exploded View..................Using the Drive Wheel Release Valves (Bypass Valves)..........Adjusting the Motion Control Linkage (Neutral Setting)..........Tracking Adjustment......................Purging Procedure......................Hydrostatic Drive Belt......................Removal........................... Installation........................7-11 Hydrostatic Drive Transmission..................7-13 Removal........................... 7-13 Installation........................
  • Page 140 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Exploded View (2000 Series Shown) Figure 1 A. Right Hydrostatic Drive Transmission D. Bypass Lever B. Bypass Lever E. Left Hydrostatic Drive Transmission C. Hydraulic Fluid Reservoir F. Cross Shaft NOTE: Torque sequence of transmission mounting bolts is critical, see Chapter 7, page 7-16.
  • Page 141 HYDROSTATIC DRIVE SYSTEM Using the Drive Wheel Release Valves (Bypass Valves) The drive wheel release valves are located on the left and right sides underneath the engine block. 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key.
  • Page 142 HYDROSTATIC DRIVE SYSTEM Adjusting the Motion Control Linkage (Neutral Setting) Located on either side of the machine, below the seat are the pump control linkages. Rotating the end nut (A) (Figure 3) with 1/2 in. deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral.
  • Page 143 HYDROSTATIC DRIVE SYSTEM Adjusting the Motion Control Linkage (Neutral Setting) (Cont.) NOTE: Ensure that the parking brake is engaged and that the motion control levers are in neutral (out) to start the engine, the operator does not have to be present in the seat. 6.
  • Page 144 HYDROSTATIC DRIVE SYSTEM Adjusting the Motion Control Linkage (Neutral Setting) (Cont.) 11. Shut off the machine. 12. Remove the jumper wire from the wire harness and plug the connector into the seat switch. 13. Lower the unit. 14. Raise the mower deck and install the height-of-cut pin. 15.
  • Page 145 HYDROSTATIC DRIVE SYSTEM Tracking Adjustment 1. Disengage the PTO switch. 2. Drive to an open, flat area and move the motion control levers to the neutral-lock position. 3. Move the throttle midway between the FAST and SLOW positions. 4. Move both motion control levers fully forward until they both hit the stops in the t-slot. 5.
  • Page 146 HYDROSTATIC DRIVE SYSTEM Purging Procedure Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system. This purge procedure should be implemented any time a hydrostatic system has been opened to facilitate maintenance, any additional oil has been added to the system, or a replacement transaxle has been installed.
  • Page 147 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Removal 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Raise and support the unit so that the drive wheels are off the ground. 3.
  • Page 148 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt (Cont.) Removal (Cont.) NOTE: If the drive idler spring is removed, ensure proper spring orientation on re-installation (Figure 7) Figure 7 5. Slip the drive belt off of the idler pulleys. 6. Carefully, remove the drive belt from the hydrostatic drive pulleys. NOTE: Inspect the belt for excessive wear, damage, or cracking, replace if necessary.
  • Page 149 HYDROSTATIC DRIVE SYSTEM Idler Spring and Hydrostatic Drive Belt Figure 8 A. Engine Pulley B. Hydrostatic Transmission Pulleys Installation 1. Route the hydrostatic drive belt around the engine pulley. 2. Carefully route the drive belt around the two hydrostatic transmission pulleys. 3.
  • Page 150 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Installation (Cont.) 4. Place the idler spring through the frame slot and onto the idler pulley stud (if previously removed). NOTE: Ensure proper orientation with the hook openings facing away from the idler pivot. 5.
  • Page 151 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Figure 10 A. Cross Shaft B. Front and Rear Mounting Bolts C. Axle Horn Bolts Removal 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2.
  • Page 152 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Removal (Cont.) 8. Disconnect the motion control linkage from the transmission (Figure 11). Figure 11 9. Disconnect the bypass arm (Figure 12). Figure 12 7-14 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 153 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Removal (Cont.) 10. Disconnect the lower brake linkage from the transmission (Figure 13). Figure 13 11. Disconnect the hydraulic fluid hose from the top of the transmission. 12. Remove the bolt that connects the transmission to the cross shaft (A) (Figure 14). 13.
  • Page 154 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Figure 15 A. Cross Shaft B. Front and Rear Mounting Bolts C. Axle Horn Bolts Installation 1. Lift and support the transmission, and install the two axle horn bolts, washers, and nuts as shown. Do not fully tighten the nuts at this time (Figure 15).
  • Page 155 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Installation (Cont.) 3. Install the front and rear hydro mounting bolts, washers, and nuts (B) (Figure 15). Do not tighten at this time. NOTE: The proper torque sequence, as outlined below, is critical in avoiding damage to the hydrostatic transmission and the frame.
  • Page 156 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Installation (Cont.) 10. Connect the bypass arm (Figure 18). Figure 18 11. Connect the motion control linkage (Figure 19). Figure 19 NOTE: Attach the motion control linkage as shown with the offset toward the outside of the machine. 7-18 Digital Edition - TITAN®...
  • Page 157 HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Transmission Installation (Cont.) 12. Carefully install the drive belt see “Drive Belt Installation,” chapter 7, page 7-11. 13. Install the mower belt, see “Mower Belt Replacement,” chapter 8, page 8-5. 14. Verify that the hub nut is properly torqued, torque to 250 ± 10 ft-lbs. (325-353 Nm). 15.

  • Page 158: Table Of Contents

    MOWER DECK Table of Contents Mower Deck System Exploded View................Mower Belt (Side Discharge Mower Decks)..............Mower Belt (Rear Discharge Mower Decks)..............Mower Belt Replacement (Rear Discharge Mower Decks)..........Mower Deck......................... 8-11 Removal........................... 8-11 Installation........................8-13 Mower Spindle........................8-15 Removal.......................... 8-15 Installation........................
  • Page 159 MOWER DECK 1500 and 2000 Series, Side Discharge (48 in. Deck Shown) Figure 1 A. Discharge Baffle E. Idler Pulley B. Anti-Scalp Roller F. Mower Belt C. Belt Cover G. Flat Idler Pulley D. Deflector Assembly Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...
  • Page 160 MOWER DECK 2500 Series, Side Discharge (60 in. Deck Shown) Figure 2 A. Idler Arm Assembly H. Discharge Baffle B. Spindle Assembly I. Anti-Scalp Roller C. Spindle Shaft J. RH Belt Cover D. Bearing Shield K. LH Belt Cover E. Pulley L.
  • Page 161 MOWER DECK Rear Discharge Mower Deck Figure 3 A. Idler Assembly (Counter Rotating Belt) I. Idler Pulley B. Double Cord Sheave J. Mower Belt C. Reverse Drive Sheave (Left Hand Thread) K. Belt Cover D. Spindle Shaft L. Flat Idler Pulley E.

  • Page 162: Mower Belt (Side Discharge Mower Decks)

    4. Remove the mower belt covers. 5. Remove the spring tension from the idler pulley. NOTE: For 1500 and 2000 series mower decks, use the spring removal tool (Toro part number 92-5771) to remove the spring from the mower deck post (Figures 4 and 5).
  • Page 163 MOWER DECK Mower Belt (Side Discharge Mower Decks) Replacement (Cont.) Figure 5 A. Spring Removal Tool D. Idler Arm B. Idler Spring E. Mower Belt C. Mower Deck Post NOTE: For 2500 series mower decks, use a 3/8 in. breaker bar in the square hole in the idler arm. Turn the breaker bar counter clockwise to remove the tension from the mower belt.
  • Page 164 MOWER DECK Mower Deck (Side Discharge Mower Decks) Replacement (Cont.) 6. Remove the belt from the deck pulleys and the clutch pulley. 7. Route the new belt around the clutch pulley and deck pulleys (Figures 5 and 6). 8. Install the idler spring (if previously removed). NOTE: Make sure to seat the spring ends in the anchor grooves.

  • Page 165: Mower Belt (Rear Discharge Mower Decks)

    MOWER DECK Mower Belt (Rear Discharge Mower Decks) Replacing the Counter Rotating Belt 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2.

  • Page 166: Mower Belt Replacement (Rear Discharge Mower Decks)

    MOWER DECK Mower Belt Replacement (Rear Discharge Mower Deck) 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery terminals. 3.
  • Page 167 MOWER DECK Mower Belt Replacement (Rear Discharge Mower Deck) (Cont.) Figure 9 9. Install the idler spring if previously removed. see “Replacing the Counter Rotating Belt,” chapter 8, page 8-8. 10. Install the counter rotating belt, 11. Install the belt covers. 12.

  • Page 168: Removal

    MOWER DECK Mower Deck Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery terminals. 3.
  • Page 169 MOWER DECK Mower Deck Removal (Cont.) 8. Remove the two bolts and nuts on each side of the machine (Figure 11). Figure 11 A. Remove the Nuts and Bolts here B. Remove the Nuts and Bolts here 9. Slide the deck out toward the right side of the machine. 8-12 Digital Edition - TITAN®...

  • Page 170: Installation

    MOWER DECK Mower Deck Installation 1. Place the deck on the ground on the right side of the machine. 2. Carefully slide the deck into position under the machine. 3. Connect the two bolts and nuts on each side of the machine (A) (Figure 12). 4.
  • Page 171 MOWER DECK Mower Deck Installation (Cont.) 5. Install the mower belt see “Mower Belt Replacement,” chapter 8, page 8-5. 6. Install the mower belt covers. see “Leveling the Mower 7. Raise the deck to the 3 in. (76 mm) height-of-cut position and check for deck level Deck,”...

  • Page 172: Mower Spindle

    MOWER DECK Mower Spindle Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2. Disconnect the battery terminals. 3.

  • Page 173: Installation

    MOWER DECK Mower Spindle Installation NOTE: Ensure that the underside of the deck is clean before proceeding with the spindle installation. 1. Carefully position the spindle against the deck and align the mounting holes. 2. Install six spindle mounting screws. Torque to 12 ± 2 ft-lbs. (14-19 Nm). NOTE: Spindle mounting screws are thread forming.
  • Page 174 MOWER DECK Mower Spindle Figure 14 A. Bearing and Spacer Assembly F. Rotary Blade B. Taptite Screw G. Belleville Washer C. Bearing Shield H. Blade Bolt D. Spindle Shaft I. Washer E. Pulley J. Lock Nut Disassembly (Refer to Figure 14) 1.

  • Page 175: Assembly

    MOWER DECK Mower Spindle Assembly 1. Inspect the inside of the spindle housing for wear or damage. 2. Press the top bearing into the spindle housing by pressing equally on the inner and outer race. NOTE: Ensure that the bearing seats against the shoulder in the spindle housing. 3.

  • Page 176: Leveling The Mower Deck

    MOWER DECK Leveling the Mower Deck 1. Park the machine on a flat level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. 2. Disconnect the battery terminals. 3. Check to ensure that all tires are properly inflated and adjust as necessary. 4.
  • Page 177 MOWER DECK Leveling the Mower Deck 6. Measure between the outside cutting edges (blade tips) and the flat surface. If all measurements are not within 3/16 in. (5 mm), an adjustment is required and this procedure should be continued. 7. Carefully rotate the blades so that they are perpendicular to the rear of the deck (Figure 16). Ensure the front blade tip is lower than the rear blade tip as indicated in the Block Height and Rake Table.
  • Page 178 MOWER DECK Leveling the Mower Deck (Cont.) 10. Place two blocks (see Block Height and Rake table) under the rear edge of the cutting deck skirt, one on each side of the cutting deck. 11. Set the height-of-cut lever to the 3 in. (76 mm) position. 12.

  • Page 179: Servicing The Cutting Blades

    MOWER DECK Leveling the Mower Deck (Cont.) 12. Carefully rotate the blades side-to-side so that they are parallel to the rear of the deck. 13. Loosen the leveling adjustment lock nuts (Figure 18) on all four corners so that the deck is sitting squarely on all four blocks.

  • Page 180: Electric Pto

    MOWER DECK Electric PTO Clutch Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. 2. Disconnect the battery terminals. 3. Raise and support the unit so that the drive wheels are off the ground. 4.

  • Page 181: Installation

    MOWER DECK Electric PTO Clutch Installation 1. Install the clutch onto the crankshaft ensuring that the slot in the clutch aligns with the tab on the clutch anchor (Figure 20). Figure 20 2. Install the two spring washers and clutch bolt (Figure 21). Figure 21 A.
  • Page 182 MOWER DECK Electric PTO Clutch Installation (Cont.) NOTE: Ensure wire harness is properly routed to avoid contact with the mower belt or drive belt (Figure 22). Figure 22 5. Connect the battery terminals. 6. Lower the unit and verify proper function. 8-25 Digital Edition - TITAN®...
  • Page 183 PTO Clutch Continuity to Ground Check..............Measuring Clutch Current Draw..................9-17 9-18 Diode..........................9-19 Wire Diagram - Toro Engines (1500 Series)................ 9-20 Wire Diagram - Kohler Engine (2000 Series)..............9-21 Wire Diagram - Kawasaki Engines (2500 Series)............... Digital Edition - TITAN® HD Service Manual...

  • Page 184: Electrical System Exploded View

    ELECTRICAL Electrical System Exploded View Figure 1 A. Ignition Key G. Solenoid B. Ignition Switch H. Neutral Switches C. PTO Switch I. Park Brake Switch D. Hourmeter J. Clutch Connector E. 12V Power Port K. Fuse Block F. Wire Harness L.

  • Page 185: General Information

    ELECTRICAL General Information 1. Always use a digital multi-meter for electrical testing procedures and record voltage reading results. 2. Before performing any electrical troubleshooting, always: -Verify proper battery voltage (above 12.4 volts) : Batteries reading 12.4 volts or less are considered discharged -Check that all engine and chassis ground wires are securely connected and not damaged.

  • Page 186: Fuse Block And Fuses

    Figure 2 The fuse block houses the fuses that protect the electrical system from electrical surges. NOTE: Always use Toro fuses when replacing a damaged or blown fuse. Testing 1. Visual Inspection: The fuses used in this application may be visually inspected. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade (Figure 3).

  • Page 187: Key/Ignition Switch

    ELECTRICAL Key/Ignition Switch Figure 4 The ignition switch makes the proper connections for the starter, safety circuits, and accessories. Detents inside the switch control the three switch positions: OFF, RUN, and START. The START position is spring loaded so that it automatically returns to the RUN position when released.

  • Page 188: Testing

    ELECTRICAL Key/Ignition Switch (Cont.) Testing 1. Remove the control panel from the right console. 2. Disconnect the ignition switch from the wire harness. 3. Using a digital multi-meter set to the OHM or Continuity setting, verify that continuity exists between the terminals listed for each switch position.

  • Page 189: Hourmeter

    ELECTRICAL Hourmeter Figure 6 The hourmeter records hours of operation when the ignition key is ON and the PTO switch is ON. Testing 1. With the ignition switch in the RUN position and the PTO switch closed (ON), verify battery voltage and ground to the hourmeter.

  • Page 190: Operator Presence Switch (Seat Switch)

    ELECTRICAL Operator Presence Switch (Seat Switch) Figure 8 With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the neutral switches. NOTE: The operator presence switch is part of the seat assembly. Testing 1.

  • Page 191: Neutral Switch - Left And Right

    ELECTRICAL Neutral Switch - Left and Right Figure 9 Figure 10 The neutral switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed, the circuit closes and there is continuity between the terminals. Motion Control Levers in neutral position (OUT), the switch will have continuity (closed).

  • Page 192: Parking Brake Switch

    ELECTRICAL Parking Brake Switch Figure 11 Figure 12 The parking brake switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed (parking brake ON), the circuit closes and there is continuity between the terminals. This allows battery voltage to flow to the rest of the safety interlock system.

  • Page 193: Starter Solenoid

    ELECTRICAL Starter Solenoid Figure 13 The solenoid is a remote switch that connects the battery to the starter motor when the ignition switch is turned to START. The solenoid protects the ignition switch from the high current drawn by the starter motor. Testing 1.

  • Page 194: Pto Switch

    ELECTRICAL PTO Switch Figure 15 The PTO switch provides battery voltage from the ignition switch to the PTO clutch. As part of the safety interlock system, the PTO switch will prevent the engine from cranking/starting when in the ON position by preventing the starter solenoid from grounding through the kill relay. NOTE: The engine will not crank over when the PTO switch is in the ON position.

  • Page 195: Testing

    ELECTRICAL PTO Switch (Cont.) Testing 1. Remove the control panel from the right console. 2. Disconnect the PTO switch from the wire harness. 3. With the switch in the ON position (button pulled OUT). Figure 16 4. Using a digital multi-meter set to the OHM or Continuity setting, verify the following: -Pin 2 and 5 should have continuity (closed) -Pin 1 and 4 should have continuity (closed) -Pin 1 and 7 should NOT have continuity (open)

  • Page 196: Electric Pto Clutch

    ELECTRICAL Electric PTO Clutch The PTO clutch electronically controls the engagement and disengagement of the PTO pulley (deck belt). The PTO clutch is composed of three major components: -field -clutch plate -friction plate The clutch plate always turns with the engine (crankshaft). The field is a coil of wire on an iron core which becomes an electromagnet when power is applied.

  • Page 197: Coil Resistance Measurement

    ELECTRICAL Electric PTO Clutch (Cont.) Coil Resistance Measurement Figure 17 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2.

  • Page 198: Pto Clutch Continuity To Ground Check

    ELECTRICAL Electric PTO Clutch (Cont.) PTO Clutch Continuity to Ground Check 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2.

  • Page 199: Measuring Clutch Current Draw

    ELECTRICAL Electric PTO Clutch (Cont.) Measuring Clutch Current Draw NOTE: Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. Figure 19 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key.

  • Page 200: Tvs Diode

    ELECTRICAL TVS Diode Figure 20 The TVS Diode protects the electrical system from current surges caused by PTO engagement and disengagement. Testing No testing procedure available. If the diode is suspected to be faulty, replace the diode. 9-18 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...

  • Page 201: Wire Diagram - Toro Engines (1500 Series)

    ELECTRICAL Wire Diagram - Toro Engines (1500 Series) Figure 21 9-19 Digital Edition - TITAN® HD Service Manual January 2018 Table of Contents...
  • Page 202 ELECTRICAL Wire Diagram - Kohler Engines (2000 Series) Figure 22 9-20 Digital Edition - TITAN® HD Service Manual Table of Contents January 2018...

  • Page 203: Wire Diagram - Kawasaki Engines (2500 Series)

    ELECTRICAL Wire Diagram - Kawasaki Engines (2500 Series) Figure 23 9-21 Digital Edition - TITAN® HD Service Manual January 2018 Table of Contents...
  • Page 204 L C E / R e s i d e n t i a l P r o d u c t s...

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