Toro titan zx Service Manual
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Toro titan zx Service Manual

2009-2013
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Residential Products
2009 - 2013
TITAN® ZX/MX
Service Manual
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Summary of Contents for Toro titan zx

  • Page 1 Residential Products 2009 - 2013 TITAN® ZX/MX Service Manual...

  • Page 3: About This Manual

    ABOUT THIS MANUAL This service manual was written expressly for authorized Toro dealer service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
  • Page 4 ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 5: Table Of Contents

    2009 - 2010 TITAN ZX Specifications cont....................2-4 2011 - 2013 TITAN ZX & MX Specifications ....................2-5 2011 - 2013 TITAN ZX & MX Specifications cont..................2-6 2011 - 2013 TITAN ZX & MX Specifications cont..................2-7 2011 - 2013 TITAN ZX &...
  • Page 6 54 Inch Deck .............................6-3 60 Inch Deck .............................6-4 PTO Belt Replacement and Belt Routing ......................6-5 48, 54, 60 Inch Deck Idler / Tensioner Pulley ....................6-5 50 Inch Deck Idler / Tensioner Pulley ......................6-5 Inspecting the Belts ............................6-6 TOC-2 Toro TITAN 2009-2013 Service Manual...
  • Page 7 Location ..............................7-1 How It Works .............................7-1 Testing ...............................7-1 PTO Switch ..............................7-2 Purpose ..............................7-2 Location ..............................7-2 How It Works .............................7-2 Continuity Testing ............................7-3 Seat Switch..............................7-4 Purpose ..............................7-4 Location ..............................7-4 How It Works .............................7-4 Testing ...............................7-4 Toro TITAN 2009-2013 Service Manual TOC-3...
  • Page 8 Location ..............................7-15 How It Works ............................7-15 Testing ..............................7-15 FlyBack Diode ...............................7-16 Purpose ..............................7-16 Location ..............................7-16 Testing ..............................7-17 Wire Harness 1 of 3 ............................7-18 Wire Harness 2 of 3 ............................7-19 Wire Harness 3 of 3 ............................7-20 TOC-4 Toro TITAN 2009-2013 Service Manual...

  • Page 9: Safety Information

    Never operate an engine in a confined area without Always test the safety interlock system after making proper ventilation. adjustments or repairs on the machine. Refer to the Electrical section in this manual for more information. Toro TITAN 2009-2013 Service Manual...
  • Page 10 SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK. Toro TITAN 2009-2013 Service Manual...

  • Page 11: Specifications

    SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications Configurations TITAN ZX5000 TITAN ZX4800 TITAN ZX5450 22 HP Kawasaki V-Twin 50” SD, 3 Blades 23 HP Kohler Courage 48” SD, 3 Blades ‘Pro’ V-Twin 25 HP Kohler Courage 54” SD, 3 Blades ‘Pro’...

  • Page 12: 2009 - 2010 Titan Zx Specifications Cont

    SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications cont. Operator Zone TITAN ZX5000 TITAN ZX4800 TITAN ZX5450 Steering Controls Dual Wrap-Around Levers Dual Wrap-Around Levers Dual Wrap-Around Levers with cushion grips with cushion grips with cushion grips Arm Rests Standard Standard...

  • Page 13: Titan Zx Specifications Cont

    SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications cont. Configurations TITAN ZX6030 TITAN ZX6050 27 HP Kohler Courage 60” SD, 3 Blades ‘Pro’ V-Twin 26 HP Kawasaki V-Twin 60” SD, 3 Blades Power Systems TITAN ZX6030 TITAN ZX6050 Clutch Electric Electric...

  • Page 14: 2009 - 2010 Titan Zx Specifications Cont

    SPECIFICATIONS 2009 - 2010 TITAN ZX Specifications cont. Dimensions TITAN ZX6030 TITAN ZX6050 Weight 724 lbs (estimated) 724 lbs. (estimated) Width Outside Deck 75.1” (190.8cm) Deflector Down 75.1” (190.8cm) Deflector Down Width Outside Tires 46.3” (117.6cm) 46.3” (117.6cm) Wheel Base 49.4”...

  • Page 15: 2011 - 2013 Titan Zx & Mx Specifications

    SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications Configurations TITAN ZX4820 TITAN ZX5420 TITAN ZX6020 21.5 HP Kawasaki V-Twin 48” SD, 3 Blades 23 HP Kawasaki V-Twin 54” SD, 3 Blades 24 HP Kawasaki V-Twin 60” SD, 3 Blades...

  • Page 16: 2011 - 2013 Titan Zx & Mx Specifications Cont

    SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications cont. Configurations TITAN MX4880 TITAN MX5480 TITAN MX6080 21.5 HP Kawasaki V-Twin 48” SD, 3-Blades 23 HP Kawasaki V-Twin 54” SD, 3-Blades 24 HP Kawasaki V-Twin 60” SD, 3-Blades Power Systems...

  • Page 17: Titan Zx & Mx Specifications Cont

    SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications cont. Configurations TITAN ZX5020 22 HP Kawasaki V-Twin 23 HP Kohler Courage ‘Pro’ V- 50” SD, 3 Blades Twin 24 HP Kawasaki V-Twin Power Systems TITAN ZX5020 Clutch Electric Transaxles Twin Hydro-Gear ZT2800...

  • Page 18: 2011 - 2013 Titan Zx & Mx Specifications Cont

    SPECIFICATIONS 2011 - 2013 TITAN ZX & MX Specifications cont. Operator Zone TITAN ZX5020 Steering Controls Dual Wrap-Around Levers with cushion grips Arm Rests Standard Beverage Holder Standard Hour Meter Standard Dimensions TITAN ZX5020 Weight 605 lbs. (estimated) Width Outside Tires 45.3”...

  • Page 19: Engine Specifications

    Kohler, 23hp, High Idle: 3000 ± 75 RPM 74914 ZX5400 (INTL) Kawasaki, 24hp, High Idle: 3000 ± 100 RPM 74920 ZX4820 (INTL) Kawasaki, 24hp, High Idle: 3000 ± 100 RPM 74924 ZX5420 (INTL) Kawasaki, 24hp, High Idle: 3000 ± 100 RPM Toro TITAN 2009-2013 Service Manual...

  • Page 20: Hydro-Gear Zt-2800 & Zt-3100 Hydrostatic Transaxles

    Every 400 Hours - change the oil and filters for the hydraulic system and bleed the system. Checking the Hydraulic Oil Level Fig. 002 fig. 51 G020323 A. Expansion reservoir C. Engine B. Full cold line 2-10 Toro TITAN 2009-2013 Service Manual...

  • Page 21: Torque Specifications

    Fastener Identification 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 22: Standard Torque For Dry, Zinc Plated & Steel Fasteners (Inch Series)

    Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. 2-12 Toro TITAN 2009-2013 Service Manual...

  • Page 23: Standard Torque For Dry, Zinc & Steel Fasteners (Metric Fasteners)

    Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Toro TITAN 2009-2013 Service Manual 2-13...

  • Page 24: Other Torque Specifications

    All torque values are based on non- lubricated fasteners. Conversion Factors in-lb X 11.2985 = N-cm N-cm X - 0.08851 = in-lb ft-lb X 1.3558 = N-m N-cm X 0.73776 = ft-lb 2-14 Toro TITAN 2009-2013 Service Manual...

  • Page 25: Equivalents & Conversions

    0.9375 23.812 29/64 0.453125 11.509 61/64 0.953125 24.209 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 0.484375 12.303 63/64 0.984375 25.003 0.5000 12.700 1.000 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm Toro TITAN 2009-2013 Service Manual 2-15...

  • Page 26: U.s. To Metric Conversions

    Pressure 1.356 Foot-pounds Newton-Meters Foot-pounds Kilogram-Meters Work 0.1383 Inch-pounds Kilogram-Centimeters 1.152144 Quarts Liters 0.9463 Liquid Volume Gallons Liters 3.785 Gallons/Minute Liters/Minute 3.785 Liquid Flows Fahrenheit Celsius 1. Subtract 32° Temperature 2. Multiply by 5/9 2-16 Toro TITAN 2009-2013 Service Manual...

  • Page 27: Chassis

    RH side of A grease fitting is located on each of the front wheel the unit (Fig. 003). hubs. The front wheel hubs should be greased every 25 hrs. (Fig. 004) Fig. 003 PICT-2057 Fig. 004 PICT-1035 Toro TITAN 2009-2013 Service Manual...

  • Page 28: Front Axle / Caster Fork / Bearing Service

    LOWER bearings from the front axle (C). 5. Using an appropriate punch, tap out and remove the UPPER bearings from the frame hub (C). 6. Properly clean and inspect the frame hub bearing area. Fig. 005 PICT-2058 Toro TITAN 2009-2013 Service Manual...

  • Page 29: Caster Wheel / Bushing Service - Titan Zx Chassis

    6. Lubricate bushings / spanner through grease fitting with No. 2 general-purpose lithium base grease. 5. Properly clean and inspect the front wheel hub area. 7. Safely lower unit and verify proper function. (Fig. 006) Fig. 006 PICT-2058 Toro TITAN 2009-2013 Service Manual...

  • Page 30: Caster Wheel, Bushing & Bearing Service - Titan Mx Chassis

    5. Remove the (2) bearings (D) from the wheel hub. with No. 2 general-purpose lithium base grease. Replace if excessively worn. 7. Safely lower unit and verify proper function. 6. Properly clean and inspect the front wheel hub area. (Fig. 007) Fig. 007 PICT-2060 Toro TITAN 2009-2013 Service Manual...

  • Page 31: Pod / Fender Service

    3. Remove the (3) screws (B) securing the RH fender to frame. 4. Verify choke cable, throttle cable and wiring are properly routed. 4. Maneuver RH fender up and off frame. 5. Connect battery terminals and lower seat. (Fig. 008). Fig. 008 PICT-2061 Toro TITAN 2009-2013 Service Manual...

  • Page 32: Pod / Fender Removal - Lh

    4. Remove fuel cap. 5. Lift LH fender assembly upward and off the frame. Use care while lifting fender upward as the fuel tank neck slips through the rubber grommet. 6. Reinstall fuel cap. Fig. 010 PICT-2064 Toro TITAN 2009-2013 Service Manual...

  • Page 33: Fuel Tank Service

    5. Remove the (2) thread-forming bolts that secure the rear guard tube (C) to the seat support (E). OR Remove the bolts / nuts securing the rear engine guard to the ROPS frame (D). (Fig. 011) Fig. 012 PICT-2066 Fig. 011 PICT-2070 Toro TITAN 2009-2013 Service Manual...

  • Page 34: Fuel Tank Installation

    / loom clams to secure them to the seat support. 7. Install LH pod / fender as outlined in this chapter. 8. Connect the battery cables and lower seat. 9. Verify proper function. Fig. 014 PICT-2066 Toro TITAN 2009-2013 Service Manual...

  • Page 35: Motion Control Damper Service

    4. Remove the nut and bolt (B) that secure the lower motion control damper eyelet to the control box (Fig. 016). Fig. 016 PICT-2071 5. Remove the motion control damper from the unit. Fig. 017 PICT-2072 Toro TITAN 2009-2013 Service Manual...

  • Page 36: Motion Control Box / Seat Pivot Service

    (B), and seat from the unit (Fig. 018). Fig. 019 PICT-2074 5. Remove the RH and LH fenders as shown in this chapter. 6. Safely remove the fuel tank as shown in this chapter. Fig. 018 PICT-2073 3-10 Toro TITAN 2009-2013 Service Manual...
  • Page 37 RH and LH neutral switches and the parking brake switch. Open the loom routing clip and completely remove harness from the Control Box. 9. Remove the motion control rod clips and pins (F) (Fig. 021). Fig. 023 PICT-2084 Fig. 021 PICT-2075 Toro TITAN 2009-2013 Service Manual 3-11...

  • Page 38: Motion Control Box / Seat Pivot Installation

    Fig. 025 PICT-2084 3. Install the (2) bolts/nuts (J) that secure the front motion control bolt to the frame and torque to specification - 17 ft-lbs. (23 Nm) (Fig. 026). Fig. 026 PICT-2088 3-12 Toro TITAN 2009-2013 Service Manual...
  • Page 39 - 30 ft-lbs. (40 Nm). 14. Install the battery and battery cables. Fig. 027 PICT-2075 15. Verify proper function. 6. Install the parking brake linkage, washer and pin and (G) (Fig. 028). Fig. 028 PICT-2076 Toro TITAN 2009-2013 Service Manual 3-13...

  • Page 40: Motion Control / Actuator Arm Service

    6. Remove the activator arm pivot bolt and nut (G) and the activator arm assembly (F) from the control box (Fig. 031). Fig. 029 PICT-2079 Fig. 031 PICT-2081 7. Inspect the pivot bolts, washers, nylon washers and bushings for excessive wear, replace if necessary. 3-14 Toro TITAN 2009-2013 Service Manual...

  • Page 41: Motion Control Assembly

    Be sure the (4) washers are positioned correctly: • Washer 1: Standard Pivot Washer • Washer 2: Standard Pivot Washer • Washer 3: Standard Pivot Washer • Washer 4: Teflon Washer (Fig. 032) Fig. 033 PICT-2082 Fig. 032 PICT-2085 Toro TITAN 2009-2013 Service Manual 3-15...
  • Page 42 8. If needed, install the control box back onto the frame as outlined in this chapter. Fig. 034 PICT-2080 Washer 1 - Standard pivot washer Washer 2 - Standard pivot washer Washer 3 - Standard pivot washer Washer 4 - Teflon washer 3-16 Toro TITAN 2009-2013 Service Manual...

  • Page 43: Seat Support / Fender Support Service

    (C) to the seat support (E). OR Remove the bolts / nuts securing the rear engine guard to the ROPS frame (D) (Fig. 035). Fig. 036 PICT-2066 Fig. 035 PICT-2070 Toro TITAN 2009-2013 Service Manual 3-17...

  • Page 44: Seat Support Installation

    / loom clams to secure them to the seat support. 6. Install RH and LH pod / fender as outlined in this chapter. 7. Connect the battery cables and lower seat. 8. Verify proper function. Fig. 038 PICT-2066 3-18 Toro TITAN 2009-2013 Service Manual...

  • Page 45: Deck Lift Service

    7. Torque fasteners A, B and C to specification - 30 ft- lbs. (40 Nm). 8. Install and level the deck as shown in Chapter 6. 9. Install and properly route the PTO belt, then install the PTO belt tensioner spring. (Fig. 041, next page) Toro TITAN 2009-2013 Service Manual 3-19...
  • Page 46 CHASSIS Fig. 041 PICT-2068 3-20 Toro TITAN 2009-2013 Service Manual...

  • Page 47: Parking Brake & Linkage Service

    PICT-2083 8. Slide the brake bell crank (H) to one side and remove the bell crank from the frame. 9. Inspect all linkage rods, pivot points and bushings for excessive wear, replace if necessary. Toro TITAN 2009-2013 Service Manual 3-21...

  • Page 48: Parking Brake & Linkage Installation

    10. Inspect for proper brake function. 11. Verify proper parking brake function. (Fig. 046) Fig. 045 PICT-2046 1” Apply Thin Coating of Engine Assembly Lube Apply Thin Coating of Engine Assembly Lube Fig. 046 PICT-2078 3-22 Toro TITAN 2009-2013 Service Manual...

  • Page 49: Rops Exploded View & Torque Values

    4. Torque the (2) bolts (C) to specification – 75 ft-lbs. (101 Nm) Torque values: D. Seat Belt Mounting Fasteners – 75 ft-lbs. (101 Nm) E. Rubber Bumper Mounting Fastener - 17 ft-lbs. (23 Nm) Toro TITAN 2009-2013 Service Manual 3-23...
  • Page 50 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK. 3-24 Toro TITAN 2009-2013 Service Manual...

  • Page 51: Engine

    ENGINE Engine Replacement PTO Clutch & Clutch Stop Mounting (All Models) (Fig. 048) Kawasaki Clutch / Clutch Stop Location Kohler / Briggs and Stratton Clutch / Clutch Stop Location Fig. 048 PICT-2027 Toro TITAN 2009-2013 Service Manual...

  • Page 52: Engine Mounting Exploded Views

    A. PTO clutch bolt - apply Loctite 242 - 55 ft-lbs. (76 Nm) ® B. Engine/clutch stop mounting bolts - Loctite 242 - 33 ft-lbs. (44 Nm) C. Muffler to engine fastener - 13 ft-lbs. (17.5 Nm) Toro TITAN 2009-2013 Service Manual...

  • Page 53: Engine Mounting - Kohler Engine

    A. PTO clutch bolt - apply Loctite 242 - 55 ft-lbs. (76 Nm) ® B. Engine/clutch stop mounting bolts - Loctite 242 - 33 ft-lbs. (44 Nm) C. Muffler to engine fastener - 13 ft-lbs. (17.5 Nm) Toro TITAN 2009-2013 Service Manual...

  • Page 54: Engine Mounting - Briggs & Stratton Engine

    A. PTO clutch bolt - apply Loctite 242 - 55 ft-lbs. (76 Nm) ® B. Engine/clutch stop mounting bolts - Loctite 242 - 33 ft-lbs. (44 Nm) C. Muffler to engine fastener - 13 ft-lbs. (17.5 Nm) Toro TITAN 2009-2013 Service Manual...

  • Page 55: Engine Removal

    10. Remove the fasteners that secure the heat shield to the muffler and frame and remove the heat shield. If necessary, remove the muffler from the engine. Fig. 054 PICT-2056 17. The engine can now be lifted vertically from the frame. Toro TITAN 2009-2013 Service Manual...

  • Page 56: Engine Installation

    - 13 ft-lbs. (17.5 Nm). 10. Install heat shield to the muffler mounting screws Fig. 057 PICT-2041 and torque to specification - 5 ft-lbs. (7 Nm). Toro TITAN 2009-2013 Service Manual...
  • Page 57 PTO Belt Replacement and Belt Routing” on page 6-5. Install the PTO belt tensioner spring to the deck. 20. Connect battery cables and verify engine oil level. 21. Safely start engine and verify proper operation. Toro TITAN 2009-2013 Service Manual...
  • Page 58 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. Toro TITAN 2009-2013 Service Manual...

  • Page 59: Hydrostatic Drive System

    HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Exploded Views (Fig. 058) Fig. 058 PICT-2038 Toro TITAN 2009-2013 Service Manual...

  • Page 60: Hydrostatic Drive Belt Routing

    HYDROSTATIC DRIVE SYSTEM Hydrostatic Drive Belt Routing (Fig. 059) Bottom View Rear View Fig. 059 PICT-2039 Toro TITAN 2009-2013 Service Manual...

  • Page 61: Hydro-Gear Zt-2800 & Zt-3100 Hydrostatic Transaxles

    Every 400 Hours - change the oil and filters for the hydraulic system and bleed the system. Checking the Hydraulic Oil Level A. Expansion tank C. Engine B. Full cold line Fig. 061 fig. 51 G020323 Toro TITAN 2009-2013 Service Manual...

  • Page 62: Neutral Adjustment

    3. (Fig. 064) Fig. 062 PICT-6459a 3. Start the engine and run at full RPM. 4. Verify the motion control handles are in the outward neutral position. Fig. 064 PICT-6483 Toro TITAN 2009-2013 Service Manual...
  • Page 63 Fig. 066 PICT-6474a assembly as shown in chapter 3. 17. Remove the seat switch bypass jumper wire and reconnect the seat switch harness connection. 18. Safely lower the unit and verify proper drive system function. Toro TITAN 2009-2013 Service Manual...

  • Page 64: Tracking Adjustment

    (A) to specification – 8 ft-lbs. (11 Nm). 5. Install the control panel cover, then torque the retaining bolt to specification – 4.5 ft-lbs. (6 Nm). 6. Verify proper drive system function. Toro TITAN 2009-2013 Service Manual...

  • Page 65: Purging Procedure

    When the transaxles move forward at normal speed, purging is complete. • Noisy operation • Lack of power or drive after short term operation. • High operation temperature and excessive expansion of “oil”; in the latter case, oil may overflow. Toro TITAN 2009-2013 Service Manual...

  • Page 66: Hydrostatic Drive Belt Replacement

    9. Remove the belt from around both hydro input pulleys. Do not bend or damage the hydro cooling fans while walking the belt upward off the input pulleys. 10. Remove the belt from the unit and inspect. Replace if necessary. Toro TITAN 2009-2013 Service Manual...

  • Page 67: Hydrostatic Drive Belt Installation

    Note: The drive pulley is marked “CLUTCH SIDE” 076). for proper installation (Fig. 074). Kawasaki Clutch / Clutch Stop Location Kohler / Briggs and Stratton Clutch / Clutch Stop Location Fig. 074 PICT-2044 Fig. 076 PICT-2045 Toro TITAN 2009-2013 Service Manual...

  • Page 68: Transaxle Replacement

    6. Remove the hydro bypass rod (C), retaining clip, and washer then remove the rod from the unit. 7. Remove the hydro control rod nut and bolt (D) (Fig. 077). Fig. 077 PICT-2046 5-10 Toro TITAN 2009-2013 Service Manual...
  • Page 69 10. Disconnect and plug the hydro reservoir hoses at the hydro mounting fasteners (Fig. 081). hydro fitting. Be sure to capture and dispose of fluid and shop towels properly (Fig. 079). Fig. 081 PICT-2049 Fig. 079 PICT-2047 Toro TITAN 2009-2013 Service Manual 5-11...

  • Page 70: Transaxle Installation

    Torque bolts to specification – 17 ft-lbs. (23 Nm) (Fig. 084). Fig. 082 PICT-2050 14. Remove the (1) rear hydro mounting fastener (Fig. 083). Fig. 084 PICT-2048 Fig. 083 PICT-2051 15. Lower the hydro assembly then remove it from the frame. 5-12 Toro TITAN 2009-2013 Service Manual...
  • Page 71 3rd – Torque the (1) rear hydro mount fastener to 5. Connect the hydro reservoir hoses at the hydro specification – 17 ft-lbs. (23 Nm) (Fig. 086). fitting (Fig. 088). Fig. 086 PICT-2051 Fig. 088 PICT-2047 Toro TITAN 2009-2013 Service Manual 5-13...
  • Page 72 12. Install the rear wheels and torque lug nuts to specification – 80 ft-lbs. (108 Nm). 13. Connect battery terminals. 14. Safely lower unit. 15. Add 20w50 engine oil or Toro HYPR-OIL 500 to the ® hydro reservoir FULL COLD mark.

  • Page 73: Mower Deck

    A. Blade bolt - 105 ft-lbs. (143 Nm) D. 30 ft-lbs. (40 Nm) B. Washer - concave side towards blade E. Spindle housing-to-deck bolts - 14 ft-lbs. (19 Nm) C. Pulley Nut - 105 ft-lbs. (143 Nm) Toro TITAN 2009-2013 Service Manual...

  • Page 74: 50 Inch Deck

    A. Blade bolt - 55 ft-lbs. (76 Nm) D. 30 ft-lbs. (40 Nm) B. Washer - concave side towards blade E. Spindle housing-to-deck bolts - 17 ft-lbs. (23 Nm) C. Pulley Nut - 55 ft-lbs. (76 Nm) Toro TITAN 2009-2013 Service Manual...
  • Page 75 A. Blade bolt - 105 ft-lbs. (143 Nm) D. 30 ft-lbs. (40 Nm) B. Washer - concave side towards blade E. Spindle housing-to-deck bolts - 14 ft-lbs. (19 Nm) C. Pulley Nut - 105 ft-lbs. (143 Nm) Toro TITAN 2009-2013 Service Manual...
  • Page 76 A. Blade bolt - 105 ft-lbs. (143 Nm) D. 30 ft-lbs. (40 Nm) B. Washer - concave side towards blade E. Spindle housing-to-deck bolts - 14 ft-lbs. (19 Nm) C. Pulley Nut - 105 ft-lbs. (143 Nm) Toro TITAN 2009-2013 Service Manual...

  • Page 77: Pto Belt Replacement And Belt Routing

    A. PTO Belt D. PTO Clutch Pulley B. Spindle Pulley E. Idler Fig. 096 PICT-2030 C. PTO Belt Tensioner A. PTO Belt D. PTO Clutch Pulley B. Spindle Pulley E. Idler C. PTO Belt Tensioner Toro TITAN 2009-2013 Service Manual...

  • Page 78: Inspecting The Belts

    3. Lower the mower to the 3 inch (76mm) height-of-cut position. 4. Remove the belt covers (Fig. 098). Fig. 098 fig. 67 G015789 A. Loosen the screws C. Remove belt cover B. Pivot the belt cover up Toro TITAN 2009-2013 Service Manual...
  • Page 79 MOWER DECK 5. Using a spring tool, (Toro part no. 92-5771), remove 9. Using a spring tool, (Toro part no. 92-5771), install the idler spring from the deck post to remove tension the idler spring over the deck post and placing ten- on the idler pulley (Fig.

  • Page 80: Pto Belt Replacement - 50 Inch Deck

    5. If necessary, remove the floor pan to access the idler pulley. 6. Using a spring tool, (Toro part no. 92-5771), remove the idler spring from the deck hook to remove tension on the idler pulley and roll the belt off of the Fig.

  • Page 81: Mower Deck Replacement

    9. Carefully lift the deck off the rear hanger bolts and lower the front of the mower deck to the ground. 10. Raise the height-of-cut to the transport position. 11. Slide the mower out from underneath the machine. Fig. 102 fig. 70 G010311 Toro TITAN 2009-2013 Service Manual...

  • Page 82: Mower Deck Installation - 48 And 54 Inch Deck

    Fig. 105 fig. 72 G010309 C. Washer G. Rear deck hanger D. Welded post on deck bracket A. Hairpin C. Washer B. Link bar 5. Properly route and install the PTO belt and tensioner spring. 6-10 Toro TITAN 2009-2013 Service Manual...

  • Page 83: Mower Deck Installation - 60 Inch Deck

    8. Raise the height-of-cut to the transport position. 9. Slide the mower out from underneath the machine. Fig. 107 fig. 72 G010309 A. Hairpin C. Washer B. Link bar 6. Properly route and install the PTO belt, then install tensioner spring. Toro TITAN 2009-2013 Service Manual 6-11...

  • Page 84: Mower Deck Removal - 50 Inch Deck

    (Fig. 109). 9. Raise the height-of-cut to the transport position 10. Slide the mower out from underneath the machine. Fig. 108 fig. 70 G010311 6-12 Toro TITAN 2009-2013 Service Manual...

  • Page 85: Mower Deck Installation - 50 Inch Deck

    E. Rear hanger bolts B. Hairpin F. J-hook C. Washer G. Rear deck hanger D. Welded post on deck bracket 5. Properly route PTO belt around deck pulleys and PTO clutch, then install the idler/tensioner spring. Toro TITAN 2009-2013 Service Manual 6-13...

  • Page 86: Spindle Service

    8. Remove blade. 7. Install belt cover(s) onto deck and sufficiently tighten mounting bolts. 8. Safely verify proper function. (Fig. 111) 50 Inch Decks 48, 54 and 60 Inch Decks Fig. 111 PICT-2034 6-14 Toro TITAN 2009-2013 Service Manual...

  • Page 87: Spindle Exploded Views

    Spindle Exploded Views Spindle Assembly - 48, 54 and 60 Inch Deck (Fig. 112) Fig. 112 PICT-2033 Spindle Assembly - 50 Inch Deck (Fig. 113) Fig. 113 PICT-2032a A. Bearing C. Spindle housing B. Bearing spacer Toro TITAN 2009-2013 Service Manual 6-15...

  • Page 88: Spindle Disassembly

    5. Install spindle shaft (D) into spindle housing. 6. Install spindle assembly to the deck as outlined in this chapter. 7. If necessary, install the deck onto the frame. (Fig. 115) Fig. 114 PICT-2035 Fig. 115 PICT-2063 6-16 Toro TITAN 2009-2013 Service Manual...

  • Page 89: Idler Arm / Deck Belt Tensioner Service

    Idler Arm / Tensioner Exploded Views Idler Arm / Tensioner - 48, 54, 60 Inch Deck (Fig. 116) Fig. 116 PICT-2037 A. Washer C. Spacer B. Friction washer - D. 30 ft-lbs. (40 Nm) (composite) Toro TITAN 2009-2013 Service Manual 6-17...

  • Page 90: Idler Arm / Tensioner - 50 Inch Deck

    MOWER DECK Idler Arm / Tensioner - 50 Inch Deck (Fig. 117) Fig. 117 PICT-2036 A. Washer C. Spacer B. Friction washer - D. 30 ft-lbs. (40 Nm) (composite) 6-18 Toro TITAN 2009-2013 Service Manual...

  • Page 91: Idler Arm Inspection

    5. Inspect pivot bolt, friction washers, standard washers, spacers and replace if necessary. 6. Remove the fastener that secures idler pulley to the idler bracket. Inspect pulley bearing and replace if necessary. Toro TITAN 2009-2013 Service Manual 6-19...

  • Page 92: Checking For Bent Blades

    39 G009679 A. Deck C. Blade B. Spindle housing Fig. 120 fig. 41 G009681 A. Blade, side previously measured B. Measurement position used previously C. Opposing side of blade being moved into measure- ment position 6-20 Toro TITAN 2009-2013 Service Manual...

  • Page 93: Leveling Mower Deck - 48, 54, 60 Inch Deck

    Note: If a bent blade is replaced with a new one and the dimension obtained continues to exceed 1/8” (3mm), the blade spindle shaft could be bent. b. If the variance is within constraints, move to the next blade. Repeat this procedure on each blade. Toro TITAN 2009-2013 Service Manual 6-21...

  • Page 94: Checking The Front-To-Rear Blade Slope

    B. Outside cutting edges the blade to the flat surface here Fig. 123 fig. 63 G007199 A. Blades front-to-rear C. Measure from the tip of B. Outside cutting edges the blade to the flat surface here 6-22 Toro TITAN 2009-2013 Service Manual...

  • Page 95: Leveling The Mower Deck

    Fig. 126 fig. 66 G010321 60 inch mower decks A. Deck lift arm C. Leveling adjust locking nut B. Deck hanger D. Slot in deck hanger Toro TITAN 2009-2013 Service Manual 6-23...

  • Page 96: Leveling Mower Deck - 50 Inch Deck

    3. Carefully rotate the blades side to side. 6-24 Toro TITAN 2009-2013 Service Manual...

  • Page 97: Checking The Front-To-Rear Blade Slope

    C. Sail area of blade surface here Fig. 128 fig. 62 G009659 A. Blades front-to-rear C. Measure from the tip of B. Outside cutting edges the blade to the flat surface here Toro TITAN 2009-2013 Service Manual 6-25...

  • Page 98: Leveling The Mower Deck

    5. Recheck that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight. 6. Verify the deck is level by checking the side-to-side level and front-to-rear blade slope; repeat deck leveling procedure if necessary. 6-26 Toro TITAN 2009-2013 Service Manual...

  • Page 99: Electrical

    3. Verify there is NO continuity between terminals not listed for the position. Key Switch Continuity Table No continuity between any terminals Continuity – B R I A only START Continuity – B R I S only Toro TITAN 2009-2013 Service Manual...

  • Page 100: Pto Switch

    The PTO Switch provides battery voltage from the key switch to the parking brake switch and neutral switches as a part of the Safety Interlock System to allow the unit to crank / start (Fig. 134). Fig. 133 PICT-2001 Fig. 134 PICT-2002 Toro TITAN 2009-2013 Service Manual...

  • Page 101: Continuity Testing

    - Pin 2 and 5 should not have continuity (open) - Pin 1 and 4 should not have continuity (open) (Fig. 137 and Fig. 138) Fig. 137 PICT-1006 Fig. 138 PICT-2003 Note: Switch pins 3 and 9 are not used. Toro TITAN 2009-2013 Service Manual...

  • Page 102: Seat Switch

    (Fig. 139). - When the seat is occupied, the switch CLOSES and there should be continuity between the two switch terminals. (Fig. 140) Fig. 139 PICT-1009 Fig. 140 PICT-2005 Toro TITAN 2009-2013 Service Manual...

  • Page 103: Rh And Lh Neutral Switch

    3. With the plunger pushed in, there should be Fig. 142 PICT-2010 continuity between the terminals. With the plunger pulled out, there should not be continuity between the terminals. Toro TITAN 2009-2013 Service Manual...

  • Page 104: Parking Brake Switch

    • Operator must be in seat. Park Brake OFF (engine running): • Normally closed contacts are closed – Battery voltage directly to kill relay coil and fuel solenoid, neutral switches NOT in circuit. • Operator must be in seat. Toro TITAN 2009-2013 Service Manual...

  • Page 105: Parking Brake Circuit

    Pin 4 and 5 – OPEN, NO continuity between the pins Switch Plunger Depressed: Pin 2 and 3 – OPEN, NO continuity between the pins Pin 4 and 5 – CLOSED, continuity between the pins Toro TITAN 2009-2013 Service Manual...

  • Page 106: Starter Solenoid & Starting System

    “normally open” position. The solenoid closes and opens the switch very quickly. This minimizes the “arcing” that can damage other types of switches. The ignition switch is protected because only a small amount of current is needed to activate the coil. Toro TITAN 2009-2013 Service Manual...

  • Page 107: Starter Solenoid Circuit & Operation

    CLOSED, supplying battery voltage to the control side of the kill relay. Note: The engine will not crank over to start when the PTO switch is ON. (Fig. 151) Starting System Schematic Fig. 151 PICT-2014 Toro TITAN 2009-2013 Service Manual...

  • Page 108: Electric Pto Clutch

    Fig. 152 coil resist msmt_v2 5. See the PTO Clutch Electrical Specifications chart. PTO Clutch Electrical Specifications Ohms Amp Draw Continuity Specification Specification to Ground 2.84 + 15% 4.23A + 15% OPEN 7-10 Toro TITAN 2009-2013 Service Manual...

  • Page 109: Pto Clutch Continuity To Ground Check

    - The parking brake is OFF and the handles in any position. Note: The engine will not crank over to start when the PTO switch is ON. (Fig. 154, next page) Toro TITAN 2009-2013 Service Manual 7-11...

  • Page 110: Pto Circuit Schematic

    ELECTRICAL PTO Circuit Schematic Fig. 154 PICT-2015 7-12 Toro TITAN 2009-2013 Service Manual...

  • Page 111: Pto Clutch Replacement

    7. Install PTO belt, then tensioner spring. 8. Safely lower unit. 9. Verify proper function. (Fig. 155) Kawasaki Clutch / Clutch Stop Location Kohler / Briggs and Stratton Clutch / Clutch Stop Location Fig. 155 PICT-2062 Toro TITAN 2009-2013 Service Manual 7-13...

  • Page 112: Hour Meter

    With the key ON and PTO switch CLOSED, verify battery voltage and ground are present at the hour The hour meter is located on the RH control panel (Fig. meter (Fig. 157). 156). Fig. 156 PICT-2001 Fig. 157 PICT-2016 7-14 Toro TITAN 2009-2013 Service Manual...

  • Page 113: Fuse Block & Fuses

    A failed fuse can be identified by the broken/melted element inside the fuse cover or a damaged spade (Fig. 159 and Fig. 160). Fig. 158 PICT-2013 Fig. 159 IMG-1214a Fig. 160 PICT-2017 Toro TITAN 2009-2013 Service Manual 7-15...

  • Page 114: Flyback Diode

    (Fig. 162 and Fig 163). The flyback diode protects the electrical system from current surges caused by PTO engagement and disen- gage ment (Fig. 161). Fig. 162 PICT-2021 Fig. 161 DSCN-0149a Fig. 163 PICT-2024 7-16 Toro TITAN 2009-2013 Service Manual...

  • Page 115: Testing

    - A properly functioning diode will be open in one direction and have an ohms resistance value when the meter leads are reversed as shown: (Fig. 164 and Fig. 165) Fig. 165 PICT-2023 Toro TITAN 2009-2013 Service Manual 7-17...

  • Page 116: Wire Harness 1 Of 3

    ELECTRICAL Wire Harness 1 of 3 Fig. 166 PICT-2018 7-18 Toro TITAN 2009-2013 Service Manual...

  • Page 117: Wire Harness 2 Of 3

    ELECTRICAL Wire Harness 2 of 3 Fig. 167 PICT-2019 Toro TITAN 2009-2013 Service Manual 7-19...

  • Page 118: Wire Harness 3 Of 3

    ELECTRICAL Wire Harness 3 of 3 Fig. 168 PICT-2020 7-20 Toro TITAN 2009-2013 Service Manual...
  • Page 120 2009 - 2013 TITAN® ZX/MX Service Manual Form Number 492-9336...

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