Service Manual

ManualsBrandsToro ManualsRiding EquipmentToro 74812

Residential Products

2007 - 2008

Titan™ Z4800 & Z5200

Service Manual

Summary of content (172 pages)

PAGE 1
Residential Products 2007 - 2008 Titan™ Z4800 & Z5200 Service Manual
PAGE 2
ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
PAGE 3
ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.
PAGE 4
TABLE OF CONTENTS SAFETY INFORMATION *HQHUDO ,QIRUPDWLRQ ........................................................................................................................ 7KLQN 6DIHW\ )LUVW............................................................................................................................ SPECIFICATIONS (QJLQH 6SHFL¿FDWLRQV ..................................................................................................................... RPM ....................
PAGE 5
TABLE OF CONTENTS ELECTRICAL cont. ,JQLWLRQ 6ZLWFK ................................................................................................................................ Purpose .................................................................................................................................... /RFDWLRQ ................................................................................................................................... +RZ ,W :RUNV .........................
PAGE 6
TABLE OF CONTENTS MOWER DECK 0RZHU 'HFN 6SLQGOH 5HSODFHPHQW ................................................................................................ 0RZHU 'HFN 6SLQGOH 5HPRYDO ................................................................................................. 0RZHU 'HFN 6SLQGOH ,QVWDOODWLRQ .............................................................................................. ,GOHU $UP $VVHPEO\ 5HSODFHPHQW.............................................................
PAGE 7
TABLE OF CONTENTS HYDROSTATIC DRIVE SYSTEM cont. 1HXWUDO $GMXVWPHQW ....................................................................................................................... Tracking Adjustment ..................................................................................................................... 3XUJLQJ 3URFHGXUHV 7UDQVD[OHV ................................................................................................. +\GUDXOLF 6\VWHP 0DLQWHQDQFH ............
PAGE 8
SAFETY INFORMATION General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION - read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service and repair of the Titan™ Z4800 and Z5200.
PAGE 9
SAFETY INFORMATION 1 THIS PAGE INTENTIONALLY LEFT BLANK.
PAGE 10
SPECIFICATIONS (QJLQH 6SHFL¿FDWLRQV Model Briggs & Stratton 74812 44K777-0123-E1 24 HP 74814 44K777-0123-E1 24 HP Kohler 74816 SV820-0012 23 HP 74818 SV820-0012 23 HP 2 RPM Model Briggs & Stratton Kohler Full Speed 3650 ± 100 (No Load) 3600 ± 75 (No Load) Idle Speed 1650 (min) 1750 (min) Electrical System Charging System Flywheel Alternator Flywheel Alternator 16 amps 15 amps 12 volt 12 volt Negative Ground Negative Ground BCI Group U1 280 CCA BCI Group U1 260 CCA (1) 25 amp
PAGE 11
SPECIFICATIONS Hydrostatic Ground Drive System Hydrostatic Transaxle (2) Hydro-Gear ZT2800 integrated drive system Hydraulic Oil Type Mobil 1 15W-50 synthetic motor oil Speeds 0 – 7.0 mph (11.3 km/hr) Forward 0 – 5.0 mph (8.0 km/hr) Reverse 2 Cutting Deck Cutting Width 48” Deck 52” Deck 48” (122cm) 52” (132cm) Discharge Side Blade Size (3 ea.) 16.25” (41.3cm) Blade Spindles Solid steel spindle shafts with no maintenance bearings. 18.00” (45.
PAGE 12
SPECIFICATIONS Torque Requirements Bolt Location Torque 2007 2008 Spindle Pulley Nut 45 - 55 ft-lbs. (61 - 75 Nm) 95 - 100 ft-lbs. (129 - 135.6 Nm) Blade Mounting Bolt 45 - 55 ft-lbs. (61 - 75 Nm) 45 - 55 ft-lbs. (61 - 75 Nm) Engine Mounting Bolt 27 - 33 ft-lbs. (37 - 45 Nm) 27 - 33 ft-lbs. (37 - 45 Nm) Anti-Scalp Roller Nut 27 - 33 ft-lbs. (37 - 45 Nm) (Nyloc nut) 27 - 33 ft-lbs. (37 - 45 Nm) Wheel Lug Nuts 70 - 90 ft-lbs. (95 - 122 Nm) 70 - 90 ft-lbs.
PAGE 13
SPECIFICATIONS 2 THIS PAGE INTENTIONALLY LEFT BLANK.
PAGE 14
CHASSIS 0RGHO 6HULDO 1XPEHU ,GHQWL¿FDWLRQ The unit model and serial number plate is located on the frame behind the seat on the left side (Fig. 001). 3 Fig. 001 IMG-0162 /XEULFDWLRQ The unit should be greased every 25 hours, or more often when operated in dusty, dirty, or sandy conditions. Note: Grease Type: NGLI grade #2 multi-purpose gun grease. Located under the seat is a diagram showing maintenance points (Fig. 002). *UHDVH WKH IURQW FDVWHU ZKHHOV DQG WKH LGOHU pivots. A.
PAGE 15
CHASSIS 1. Park the machine on a level surface and disengage the blade control switch. 0RZHU GHFN LGOHU JUHDVH ¿WWLQJ GHFN UHPRYHG IRU FODULW\ (Fig. 004): 2. Move the motion control levers outward to the neutral position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
PAGE 16
CHASSIS 3. Remove the hex head bolt and washer securing the caster fork assembly to the front axle (Fig. 007). Front Caster Fork Bearing 5HSODFHPHQW The following procedure is performed on the left hand caster fork assembly. The same procedure should be followed when replacing the right hand caster fork assembly and bearings. Front Caster Fork Bearing Removal 3 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine.
PAGE 17
CHASSIS 5. Using a drift punch and hammer, tap the lower ball bearing out of the front axle frame (Fig. 009). Front Caster Fork Bearing Installation 1. Install the upper and lower ball bearings into the front axle frame (Fig. 011). 3 Fig. 009 IMG-0166 Fig. 011 IMG-0168 6. With a drift punch and hammer, tap the upper ball bearing out of the front axle frame (Fig. 010). 2. Slide the caster fork assembly into the front axle frame, through the upper and lower ball bearings.
PAGE 18
CHASSIS &DVWHU :KHHO $VVHPEO\ 5HSODFHPHQW 4. Remove the wheel spanner from the wheel assembly (Fig. 015). Caster Wheel Assembly Removal 1. Park the machine on a level surface, disengage the blade control (PTO) and turn the ignition key to “OFF” to stop the engine. Remove the ignition key. 2. Raise the front of the machine high enough to permit removing the caster wheel assembly from the caster fork (Fig. 013). 3 Fig.
PAGE 19
CHASSIS Caster Wheel Assembly Installation 7DS D ÀDQJH EHDULQJ LQWR HDFK VLGH RI WKH ZKHHO ULP (Fig. 017). 3. Position the wheel assembly into the caster fork VR WKH YDOYH VWHP DQG JUHDVH ¿WWLQJ DUH IDFLQJ WKH inside (Fig. 019). 3 Fig. 019 Fig. 017 IMG-0175a 2. Slide the wheel spanner into the wheel assembly (Fig. 018). Fig. 018 4. Position a washer on both sides of the wheel beWZHHQ WKH ZKHHO ÀDQJH EHDULQJ DQG WKH IRUN ,QVWDOO the wheel axle bolt through the fork and wheel assembly (Fig.
PAGE 20
CHASSIS 5. Install a nut onto the wheel axle bolt to secure the wheel assembly to the caster fork (Fig. 021). Left Hand Fender & Fuel Tank 5HSODFHPHQW Left Hand Fender & Fuel Tank Removal 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine. Remove the ignition key. 2. Raise the seat and disconnect the negative battery cable from the battery. 3. Remove the two screws securing the bottom edge of the front panel to the frame (Fig.
PAGE 21
CHASSIS 4. Lift up on the front panel and pull the panel out of the slots in the seat box to remove the panel (Fig. 024). 6. Remove the bolt and nut securing the left hand engine guard to the rear engine guard and the screw securing the left hand engine guard to the left hand fender (Fig. 026). B A 3 Fig. 024 IMG-0182 Fig. 026 5. Remove the two screws securing the left side fender to the front of the seat box (Fig. 025). A. Bolt and nut IMG-0185 B. Screw 7.
PAGE 22
CHASSIS 8. Remove the three screws that secure the left hand fender to the top of the seat box (Fig. 028). 10. Turn the fuel shut-off valve to the “OFF” position. Slide the hose clamp off the engine side of the fuel shut-off valve. Slide the fuel line off the shut-off valve (Fig. 030). 3 Fig. 028 IMG-0187 Fig. 030 IMG-0190 9. Lift the left hand fender off of the gas tank (Fig. 029). 11. Remove the hardware securing the fuel tank to the machine (Fig. 031): A A B Fig. 029 IMG-0188 Fig.
PAGE 23
CHASSIS 12. The fuel line coming from the fuel tank is held in place by a clamp located on the side of the seat box assembly. Open the clamp to release the fuel line (Fig. 032). Left Hand Fender & Fuel Tank Installation 1. Position the fuel tank to the left hand side of the machine. Route the fuel line into the clamp located beside the seat box assembly (Fig. 034). Close the clamp to secure the fuel line (Fig. 035). 3 Fig. 032 IMG-0193 Fig. 034 IMG-0193 Fig. 035 IMG-0194 13.
PAGE 24
CHASSIS 2. Position the fuel tank on the side of the seat box assembly. Loosely install a carriage bolt and nut securing the lower front corner of the fuel tank to the frame. (Fig. 036). 4. Install a carriage bolt through the left hand rear tank bracket and the bottom, rear fuel tank mounting hole. Loosely install a washer, spring, and nut onto the carriage bolt (Fig. 038). 3 Fig. 036 IMG-0196 3. Install a carriage bolt through the left hand tank mount bracket and the top front fuel tank mounting hole.
PAGE 25
CHASSIS 6. Tighten the front carriage bolt and nut (Fig. 040). 8. Position the left hand fender assembly over the left hand fuel tank (Fig. 042). 3 Fig. 040 IMG-0191 Fig. 042 7. Install the engine fuel line onto the fuel shut-off valve. Slide the hose clamp in place to secure the fuel line to the shut-off valve (Fig. 041). Fig. 041 3-12 IMG-0190 IMG-0188 9. Install three screws to secure the left hand fender to the seat box assembly (Fig. 043). Fig.
PAGE 26
CHASSIS 10. Install a bolt, washer, and nut to secure the left hand fender to the left hand rear tank mounting bracket (Fig. 044). 12. Install the two screws to secure the left side fender to the front of the seat box (Fig. 046). 3 Fig. 046 Fig. 044 IMG-0183 IMG-0186 ,QVWDOO D EROW DQG ÀDQJH QXW WR VHFXUH WKH OHIW KDQG engine guard to the rear engine guard. Install a screw to secure the left hand engine guard to the left hand fender (Fig. 045). 13.
PAGE 27
CHASSIS 14. Install two screws to secure the bottom of the front panel to the seat box assembly (Fig. 048). 5LJKW +DQG )HQGHU 5HSODFHPHQW Right Hand Fender Removal 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine. Remove the ignition key. 2. Raise the seat and disconnect the negative battery cable from the battery. 3. Remove the two screws securing the bottom of the front panel to the seat box assembly (Fig. 049). 3 Fig.
PAGE 28
CHASSIS 4. Lift up on the front panel and remove the panel from the slots in the seat box assembly (Fig. 050). 6. Remove the bolt and nut securing the right hand engine guard to the rear engine guard and the screw securing the right hand engine guard to the right hand fender (Fig. 052). B A 3 Fig. 050 IMG-0182 Fig. 052 5. Remove the two screws retaining the right side fender to the front of the seat box assembly (Fig. 051). A. Bolt and nut IMG-0205 B. Screw 7.
PAGE 29
CHASSIS 8. Remove the four screws that secure the control panel to the right hand fender (Fig. 054). 10. Remove the wire harness plugs from the back of the ignition switch, the PTO switch and the hour meter (Fig. 056). C 3 Fig. 054 B A IMG-0208 Fig. 056 9. Remove the three screws that secure the right hand fender to the top of the seat box assembly (Fig. 055). A. Ignition switch B. PTO Switch IMG-0211 C. Hour meter 11. Push the choke and throttle levers toward the control plate (Fig. 057). Fig.
PAGE 30
CHASSIS 12. Feed the control panel through the right hand fender (Fig. 058). Right Hand Fender Installation 1. Position the right hand fender onto the right hand side of the seat box assembly (Fig. 060). 3 Fig. 058 IMG-0216 Fig. 060 IMG-0217 13. Remove the right hand fender from the machine (Fig. 059). 2. Feed the control panel up through the opening in the right hand fender (Fig. 061). Fig. 059 IMG-0217 Fig.
PAGE 31
CHASSIS 3. Install three screws to secure the right hand fender to the top of the seat box assembly (Fig. 062). 5. Plug the wire harness plug onto the PTO switch (Fig. 064). 3 Fig. 062 IMG-0209 4. Plug the wire harness plug onto the terminals on the hour meter (Fig. 063). Fig. 063 3-18 IMG-0213 Fig. 064 IMG-0212 6. Connect the two red wire terminal to the outside terminal on the ignition switch (Fig. 065). Fig.
PAGE 32
CHASSIS 7. Plug the wire harness plug onto the ignition switch (Fig. 066). 9. Install a bolt, washer, and nut securing the right hand rear console bracket and right hand fender (Fig. 068). 3 Fig. 066 IMG-0219 Fig. 068 8. Position the control panel onto the right hand fender. Install four screws to secure the control panel to the right hand fender (Fig. 067). IMG-0206 ,QVWDOO D EROW DQG ÀDQJH QXW WR VHFXUH WKH ULJKW KDQG engine guard to the rear engine guard.
PAGE 33
CHASSIS 11. Install two screws to secure the right hand fender to the front of the seat box assembly (Fig. 070). 13. Install two screws to secure the bottom of the front panel to the seat box assembly (Fig. 072). 3 Fig. 070 IMG-0204 12. Install the front panel into the slots in the seat box assembly (Fig. 071). Fig. 071 3-20 Fig. 072 IMG-0180a 14. Connect the negative battery cable to the negative battery terminal.
PAGE 34
CHASSIS 6HDW %R[ 5HSODFHPHQW 4. Unplug the wiring harness connector from the seat switch (Fig. 074). Seat Box Removal 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to “OFF” to stop the engine. Remove the ignition key. 2. Raise the seat and disconnect the negative and positive battery cables from the battery. 3. Remove the two wing nuts securing the battery hold down to the battery. Remove the battery hold down and the battery from the seat box (Fig.
PAGE 35
CHASSIS 6. While supporting the seat, remove the bolt and nut that secure the seat cable stop to the seat box assembly (Fig. 076). 8. Remove the left hand fender and fuel tank. Refer to “Left Hand Fender and Fuel Tank Removal” on page 3-7. 9. Remove the right hand fender. Refer to “Right Hand Fender Removal” on page 3-14. 10. Remove the two screws and washers securing the right hand lever grip to the lever mount post (Fig. 078). 3 Fig. 076 IMG-0224 7. Remove the cotter pin from the seat pivot rod.
PAGE 36
CHASSIS 12. Remove the two screws retaining the hydro fan cover to the seat box assembly (Fig. 079). 14. Remove the two bolts, washers and nuts securing the hydro vent tank and fender support bracket to the seat box (Fig. 081). 3 Fig. 079 IMG-0231 Fig. 081 IMG-0234a 13. Remove the hydro fan cover (Fig. 080). 15. Remove the fender support bracket and lay the hydro vent tank to the side away from the seat box (Fig. 082). Fig. 080 IMG-0233 Fig.
PAGE 37
CHASSIS 16. Push the rubber wire harness grommet through the right side of the seat box assembly (Fig. 083). 18. Push the two wire clamps through the right side of the seat box to free the harness from the seat box (Fig. 085). 3 Fig. 083 IMG-0236 Fig. 085 17. Push the wire harness through the hole (on the right side of the seat box assembly) (Fig. 084). Fig. 084 19. Remove the two bolts, washers and nuts securing the seat delay module to the inside of the seat box.
PAGE 38
CHASSIS 20. Locate the clamp that the throttle and choke cables are routed through on the right side of the seat box. Remove the clamp from the seat box (Fig. 087). 22. Remove the wire harness plug from the left side neutral switch (Fig. 089). 3 Fig. 089 Fig. 087 IMG-0247 IMG-0240 21. Remove the wire harness plug from the right side neutral switch (Fig. 088). 23. Remove the wires from the four solenoid terminals (Fig. 090). A B C D Fig. 090 Fig. 088 IMG-0245 A. B. C. D.
PAGE 39
CHASSIS 24. Remove the two bolts, washers and nuts securing the solenoid to the seat box. Remove the solenoid. (Fig. 091). 26. Unplug the fuel solenoid magneto (yellow/white) wire plug from the grey/black wire plug (Fig. 093). 3 Fig. 093 Fig. 091 25. Remove the nut securing the two ground wires to the engine base. Remove the ground wires (Fig. 092). 27. Remove the alternator (violet) wire from the red wire (Fig. 094). Fig. 094 Fig.
PAGE 40
CHASSIS 28. Remove the oil switch (blue) wire from the oil switch ORFDWHG QH[W WR WKH RLO ¿OWHU )LJ 30. Open the clamp that secures the PTO clutch wire (Fig. 097). Pull the wire harness up through the frame. 3 Fig. 095 IMG-0264a Fig. 097 29. Unplug the PTO clutch wire (brown/green) from the electric PTO clutch (Fig. 096). Fig. 096 31. Push the rubber grommet, located in the rear of the seat box assembly, toward the outside of the seat box.
PAGE 41
CHASSIS 32. Remove two clamps that secure the wire harness to the outside, rear of the seat box (Fig. 099). 34. Remove the screw and nut that secure the relay harness plug to the rear of the seat box assembly (Fig. 101). 3 Fig. 099 IMG-0283a Fig. 101 33. Remove the relay from the wire harness relay plug (Fig. 100). Fig. 100 35. Remove the two screws and nuts that secure the fuse block to the rear of the seat box assembly (Fig. 102). IMG-0276 Fig.
PAGE 42
CHASSIS 36. Remove the clamp for the fuel hose, located on the left rear side of the seat box assembly (Fig. 103). 38. Remove the nut from the brake assembly carriage bolt (Fig. 105). 3 Fig. 103 IMG-0284 37. Remove the clamp retaining the wire harness to the left side of the seat box assembly (Fig. 104). Fig. 105 39. Remove the brake assembly carriage bolt (Fig. 106). Fig. 106 Fig.
PAGE 43
CHASSIS 40. Remove the brake lever assembly (Fig. 107). 42. Pull the brake pivot tube assembly slightly outward (Fig. 109). 3 Fig. 107 IMG-0289a Fig. 109 IMG-0291a 41. Remove the brake assembly spacer (Fig. 108). 43. Remove the washer located on the inside end of the brake pivot tube (Fig. 110). Fig. 108 IMG-0290a Fig.
PAGE 44
CHASSIS 42. Remove the spacer from the inside end of the brake pivot tube (Fig. 111). 5HPRYH WKH ÀDQJHG EXVKLQJ ORFDWHG RQ WKH RXWVLGH of the seat box (Fig. 113). 3 Fig. 111 IMG-0293a IMG-0294a Fig. 114 2007 - 2008 Titan Z Service Manual IMG-0295a 5HPRYH WKH ÀDQJH EXVKLQJ ORFDWHG RQ WKH LQVLGH RI the seat box (Fig. 114). 43. Remove the brake pivot tube (Fig. 112). Fig. 112 Fig.
PAGE 45
CHASSIS 46. Remove the cotter pin from the control pivot pin (Fig. 115). 48. Repeat steps 46 and 47 to remove the cotter pin and control pivot pin on the right hand side. 49. Remove the two screws securing the right side of the seat box to the frame (Fig. 117). 3 Fig. 115 IMG-0298 Fig. 117 IMG-0300 47. Remove the left hand motion control pivot (Fig. 116). 50. Remove the two screws securing the left side of the seat box to the frame (Fig. 118). Fig. 116 IMG-0299 Fig.
PAGE 46
CHASSIS 51. Remove the seat box assembly from the frame (Fig. 119). 53. Remove the three bolts and nuts that secure the three compression springs to the seat box (Fig. 121). 3 Fig. 119 IMG-0302 52. Remove the two carriage bolts and nuts securing the tank mount bracket to the left hand side of the seat box and remove the tank mount bracket (Fig. 120). Fig. 121 54. Remove the two screws and washers that secure the left side motion control stop (Fig. 122). Fig. 122 Fig.
PAGE 47
CHASSIS 55. Remove the left side motion control stop (Fig. 123). Seat Box Installation 1. Position the left side motion control stop on the inside of the seat box (Fig. 124). 3 Fig. 123 IMG-0307 56. Repeat steps 54 and 55 to remove the right side motion control stop. Fig. 124 IMG-0307 2. Install two screws and washers to secure the control stop to the seat box. (Fig. 125). Fig.
PAGE 48
CHASSIS 3. Follow the previous 2 steps to install the right side motion control stop. 6. Position the seat box assembly onto the frame (Fig. 128). 4. Position a compression spring to the seat box. Install D VFUHZ DQG D ÀDQJH QXW WR VHFXUH 5HSHDW WKLV procedure to install the other 2 compression springs to the seat box (Fig. 126). 3 Fig. 128 Fig. 126 IMG-0305 IMG-0302 7. Loosely install two screws to secure the left side of the seat box assembly to the frame (Fig. 129). 5.
PAGE 49
CHASSIS 8. Loosely install two screws to secure the right side of the seat box assembly to the frame (Fig. 130). 11. Install a cotter pin on the motion control pivot pin to secure (Fig. 132). 3 Fig. 130 IMG-0300 9. Tighten all 4 screws to secure. Fig. 132 IMG-0311 12. Follow steps 10 and 11 to install the right hand motion control pivot assembly. 10. Install a control pivot pin through the left side of the seat box assembly and left hand motion control pivot assembly (Fig. 131).
PAGE 50
CHASSIS ,QVWDOO WKH EUDNH VKDIW ÀDQJH EXVKLQJ WR WKH RXWVLGH of the seat box (Fig. 134). 16. Install a spacer on the inside end of the brake shaft (Fig. 136). 3 Fig. 134 IMG-0313 15. Install the brake shaft (Fig. 135). Fig. 135 Fig. 136 17. Install a washer on the inside end of the brake shaft (Fig. 137). IMG-0314 Fig.
PAGE 51
CHASSIS 18. Install the brake shaft into the slots located on the bell crank (Fig. 138). 20. Install the brake lever assembly onto the outside of the brake shaft (Fig. 140). 3 Fig. 138 IMG-0317 19. Install a spacer on the outside end of the brake shaft (Fig. 139). Fig. 139 3-38 IMG-0319 Fig. 140 IMG-0320 21. Slide a carriage bolt through the brake shaft (Fig. 141). Fig.
PAGE 52
CHASSIS 22. Install a nut onto the carriage bolt (Fig. 142). 24. Install a clamp around the harness and install the clamp barb through the left side of the seat box (Fig. 144). 3 Fig. 142 IMG-0323a Fig. 144 IMG-0327a 23. Install the harness plug onto the left side neutral switch (Fig. 143). 25. Install the harness plug onto the right side neutral switch (Fig. 145). Fig. 143 IMG-0326a Fig.
PAGE 53
CHASSIS 26. Install a clamp around the harness and install the clamp barb through the right side of the seat box (Fig. 146). 28. Position the fuse block to the inside rear of the seat box and install two screws and nuts to secure it (Fig. 148). 3 Fig. 146 IMG-0329 27. Install the fuel hose clamp barb through the left rear side of the seat box (Fig. 147). Fig. 147 Fig. 148 29.
PAGE 54
CHASSIS 30. Install the relay into the harness plug (Fig. 150). 32. Pull the wire harness from inside the rear of the seat box assembly toward the outside through the thru hole. Install the rubber grommet into the thru hole to protect the wire harness (Fig. 152). 3 Fig. 150 IMG-0331 Fig. 152 IMG-0332a 31. Install two wire harness clamps that secure the wiring harness to the inside, rear of the seat box (Fig. 151). 33. Route the PTO clutch wire through the hole in the frame in front of the engine (Fig.
PAGE 55
CHASSIS 34. Plug the PTO clutch wire into the electric PTO clutch (Fig. 154). 36. Install the blue harness wire to the oil sending VHQVRU QH[W WR WKH RLO ¿OWHU )LJ 3 Fig. 154 IMG-0268a Fig. 156 IMG-0264a 35. Install a clamp securing the PTO clutch wire harness to the clutch anchor bracket (Fig. 155). 37. Install the violet wire connector to the alternator (red) wire (Fig. 157). Fig. 155 Fig.
PAGE 56
CHASSIS 38. Install the yellow/white wire plug into the grey/black wire plug that goes to the fuel solenoid and engine magneto (Fig. 158). 40. Position the solenoid to the back side of the seat box assembly. Install two bolts, washers, and nuts to secure it to the seat box assembly (Fig. 160). 3 Fig. 158 IMG-0258 39. Install the two ground wires to the engine base and install a nut to secure (Fig. 159). Fig. 160 IMG-0254a 41. Install the wires on the four solenoid terminals (Fig. 161): A B C D Fig.
PAGE 57
CHASSIS 42. Install a clamp around the throttle and choke cables and install the clamp through the right, rear side of the seat box assembly (Fig. 162). 44. Install a clamp around the wire harness on the inside of the seat box. Install the clamp through the right side of the seat box assembly (Fig. 164). 3 Fig. 162 IMG-0240 43. Position the seat delay module on the inside of the seat box to the rear, right side. Install two bolts, washers, and nuts to secure (Fig. 163). Fig. 164 45.
PAGE 58
CHASSIS 46. Install the rubber grommet in the wire harness hole (Fig. 166). 48. Install two bolts, washers, and nuts to secure the hydro vent tank and fender support bracket to the seat box (Fig. 168). 3 Fig. 166 IMG-0343a Fig. 168 47. Position the hydro vent tank and fender support bracket to the right rear outside corner of the seat box assembly (Fig. 167). 49. Install the hydro fan cover (Fig. 169). Fig. 169 Fig.
PAGE 59
CHASSIS 1RWH (QVXUH WKH PHWDO WDEV DUH ORFDWHG RXWVLGH RI WKH FURVV IUDPH EUDFNHW )LJ 51. Position the right hand grip assembly to the lever mount post. Install two screws and washers to secure the hand grip (Fig. 172). 3 Fig. 170 IMG-0344 Fig. 172 50. Install two screws to secure the hydro fan cover to the seat box assembly (Fig. 171). IMG-0229a 52. Repeat the previous step to install the left hand grip assembly. 53. Install the right fender.
PAGE 60
CHASSIS 55. Position the seat plate on the seat assembly to the inside of the mounting tabs on the seat box. Install the seat pivot rod through the mounting holes. Install a cotter pin into the end of the seat pivot rod to secure (Fig. 173). 57. Route the seat switch harness wire through the wire clamp located on the bottom of the seat plate (Fig. 175). 3 Fig. 175 Fig. 173 IMG-0223 IMG-0227 58. Plug the wire harness into to the seat switch (Fig. 176). 56.
PAGE 61
CHASSIS 59. Install the battery hold down with two hold down bolts and wing nuts (Fig. 177). +HLJKW RI &XW +2& $VVHPEO\ & Front & Rear Shaft Assembly 5HSODFHPHQW +2& $VVHPEO\ )URQW 5HDU 6KDIW Assembly Removal 1. Disconnect the battery negative cable. 5HPRYH WKH KHLJKW RI FXW DGMXVWHU SLQ IURP WKH KHLJKW RI FXW DGMXVWPHQW )LJ 3 Fig. 177 IMG-0220 60. Install the positive and then the negative battery cable to the battery. Fig.
PAGE 62
CHASSIS 3. Place blocks under the mower deck for support. Pull the transport release handle and lower the mower deck so that it is resting on the blocks (Fig. 179). 5. Remove the external retaining ring, washer, and clevis pin securing the front shaft assembly to the height-of-cut assembly (Fig. 181). 3 Fig. 179 IMG-0347 4. Remove the 4 carriage bolts, strut spacers and nuts that secure the four deck hangers to the front and rear shaft assemblies (Fig. 180). Fig. 181 IMG-0350a 6.
PAGE 63
CHASSIS 7. Remove external retaining ring, washer, and clevis SLQ VHFXULQJ WKH KHLJKW DGMXVWPHQW DVVHPEO\ WR WKH frame (Fig. 183). 9. Remove the 4 bolts and nuts that secure the front VKDIW DVVHPEO\ WR WKH IUDPH RQ WKH ULJKW ÀDQJH RQ WKH OHIW ÀDQJH )LJ 3 Fig. 183 IMG-0352 5HPRYH WKH KHLJKW DGMXVWPHQW DVVHPEO\ )LJ Fig. 184 Fig. 185 10. Remove the front shaft assembly from the frame (Fig. 186). IMG-0353 Fig.
PAGE 64
CHASSIS 11. Remove the 4 bolts and nuts that secure the rear VKDIW DVVHPEO\ WR WKH IUDPH RQ WKH ULJKW ÀDQJH RQ WKH OHIW ÀDQJH )LJ +2& $VVHPEO\ )URQW 5HDU 6KDIW Assembly Installation 1. Position the rear shaft assembly to the frame. Install IRXU EROWV DQG QXWV WKURXJK WKH ÀDQJH EHDULQJV WR secure it to the frame (Fig. 189). 3 Fig. 187 IMG-0359a 12. Remove the rear shaft assembly from the frame (Fig. 188). Fig. 189 IMG-0359a 2. Position the front shaft assembly to the frame.
PAGE 65
CHASSIS 3RVLWLRQ WKH KHLJKW RI FXW DGMXVWPHQW DVVHPEO\ WR the frame. Install a clevis pin, washer and external retaining ring to secure it to the frame (Fig. 191). 3RVLWLRQ WKH UHDU HQG RI WKH KHLJKW RI FXW DGMXVWPHQW assembly to the rear shaft assembly. Install a clevis pin, washer, and external retaining ring to secure WKH KHLJKW DGMXVWPHQW DVVHPEO\ WR WKH UHDU VKDIW assembly (Fig. 193). 3 Fig. 191 IMG-0352 Fig.
PAGE 66
CHASSIS ,QVWDOO WKH KHLJKW DGMXVWHU SLQ LQWR WKH KHLJKW RI FXW DGMXVWPHQW )LJ 3 Fig. 195 IMG-0345 8. Install the negative battery cable.
PAGE 67
CHASSIS 3 7+,6 3$*( ,17(17,21$//< /()7 %/$1.
PAGE 68
ELECTRICAL Electrical System How It Works Start Circuit $ UHOD\ LV DQ HOHFWULFDOO\ DFWXDWHG VZLWFK )LJ Two things happen when turning the ignition switch to WKH ³67$57´ SRVLWLRQ &XUUHQW ÀRZV IURP WKH LJQLWLRQ VZLWFK WR WKH VWDUWHU VROHQRLG FRLO WHUPLQDO $W WKH VDPH WLPH FXUUHQW ZLOO ÀRZ WKURXJK WKH 372 3RZHU 7DNH 2II VZLWFK 2)) SRVLWLRQ WKURXJK WKH EUDNH VZLWFK LQ WKH 2)) RU 3DUN SRVLWLRQ WR WKH FRLO WHUPLQDO RI WKH LQWHUORFN UHOD\ NLOO UHOD\ 7KH LQWHUORFN UHOD\ NLOO UHO
PAGE 69
ELECTRICAL Testing Solenoid 'LVFRQQHFW WKH UHOD\ IURP WKH ZLUH KDUQHVV Purpose 9HULI\ WKH FRLO UHVLVWDQFH EHWZHHQ WHUPLQDOV DQG ZLWK D PXOWLPHWHU RKPV VHWWLQJ 5HVLVWDQFH VKRXOG EH IURP WR RKPV 7KHUH VKRXOG EH FRQWLQXLW\ EHWZHHQ WHUPLQDOV D DQG 7KH SXUSRVH RI WKH VROHQRLG LV WR FRQQHFW WKH EDWWHU\ WR WKH VWDUWHU PRWRU RQ WKH HQJLQH ZKHQ WKH LJQLWLRQ VZLWFK LV WXUQHG WR ³67$57´ 7KH VROHQRLG LV XVHG WR SURWHFW WKH LJQLWLRQ VZLWFK IURP KLJK FXUUHQW GUDZQ E\ WKH VWDUWHU
PAGE 70
ELECTRICAL How It Works Testing 7KH VROHQRLG KDV WZR SULPDU\ SDUWV 2QH D FRLO ZLUH LV ZUDSSHG DURXQG DQ LURQ FRUH :KHQHYHU YROWV LV DSSOLHG WR WKH FRLO LW EHFRPHV D PDJQHW 7KH RWKHU SDUW LV D EDU W\SH VZLWFK %HFDXVH LW KDV D ODUJH FRQWDFW DUHD ZLWK FRQWDFW WHUPLQDOV LW FDQ HDVLO\ KDQGOH WKH KLJK FXUUHQW ORDGV UHTXLUHG E\ WKH VWDUWHU PRWRU RI WKH HQJLQH 'LVFRQQHFW WKH VROHQRLG IURP WKH ZLUH KDUQHVV :KHQ YROWV LV DSSOLHG WR WKH FRLO LW EHFRPHV DQ HOHFWURPDJQHW 7KLV TXLFNO\ SXOOV
PAGE 71
ELECTRICAL Ignition Switch How It Works Purpose 'HWHQWV LQVLGH WKH VZLWFK JLYH LW SRVLWLRQV 2)) 581 DQG 67$57 7KH 67$57 SRVLWLRQ LV VSULQJ ORDGHG VR WKH F\OLQGHU DXWRPDWLFDOO\ UHWXUQV WR 581 RQFH WKH NH\ LV UHOHDVHG )LJ 7KH LJQLWLRQ VZLWFK SURYLGHV WKH SURSHU VZLWFKLQJ IRU WKH VWDUWHU LJQLWLRQ DFFHVVRULHV DQG VDIHW\ FLUFXLWV Location B 7KH LJQLWLRQ VZLWFK LV ORFDWHG RQ WKH FRQWURO SDQHO WR WKH ULJKW VLGH RI WKH RSHUDWRU )LJ A Y S 4 X I Fig.
PAGE 72
ELECTRICAL PTO Switch Testing Purpose 'LVHQJDJH WKH 372 VHW WKH SDUNLQJ EUDNH WXUQ WKH LJQLWLRQ WR 2)) DQG UHPRYH WKH NH\ 7KH 372 3RZHU 7DNH 2II VZLWFK LV XVHG WR WXUQ RQ WKH (OHFWULF 372 &OXWFK DQG IXQFWLRQV DV SDUW RI WKH VDIHW\ LQWHUORFN V\VWHP Location 7KH 372 VZLWFK LV ORFDWHG RQ WKH FRQWURO SDQHO WR WKH ULJKW VLGH RI WKH RSHUDWRU )LJ 'LVFRQQHFW WKH ZLUH KDUQHVV IURP WKH 372 VZLWFK 3UHVV LQ RQ WKH ORFNLQJ WDEV RQ HDFK VLGH RI WKH VZLWFK DQG SXOO WKH VZLWFK RXW RI
PAGE 73
ELECTRICAL Electric (PTO) Clutch How It Works Purpose 7KH 372 FOXWFK LV FRPSRVHG RI WKUHH PDMRU FRPSRQ HQWV WKH ¿HOG WKH FOXWFK SODWH DQG WKH IULFWLRQ SODWH 7KH FOXWFK SODWH DOZD\V WXUQV ZLWK WKH HQJLQH 7KH ¿HOG LV D FRLO RI ZLUH RQ DQ LURQ FRUH ZKLFK EHFRPHV DQ HOHFWURPDJQHW ZKHQ SRZHU LV DSSOLHG 7KLV FOXWFK HOHFWULFDOO\ FRQWUROV WKH HQJDJHPHQW DQG GLVHQJDJHPHQW RI WKH 3RZHU 7DNH 2II 372 SXOOH\ Location 7KH HOHFWULF FOXWFK LV ORFDWHG RQ WKH 372 HQG RI WKH HQJLQH FUDQNVKDIW )LJ
PAGE 74
ELECTRICAL Coil Resistance Measurement Measuring Clutch Current Draw 'LVHQJDJH WKH 372 VHW WKH SDUNLQJ EUDNH WXUQ WKH LJQLWLRQ 2)) DQG UHPRYH WKH NH\ 'LVHQJDJH WKH 372 VHW WKH SDUNLQJ EUDNH WXUQ WKH LJQLWLRQ 2)) DQG UHPRYH WKH NH\ 'LVFRQQHFW FOXWFK ZLUH FRQQHFWRU IURP WKH ZLUH KDUQHVV 'LVFRQQHFW WKH FOXWFK ZLUH FRQQHFWRU IURP WKH ZLUH KDUQHVV 6HW WKH PXOWLPHWHU RU YROW RKP PHWHU WR FKHFN UHVLVWDQFH RKPV 6HW WKH PXOWLPHWHU WR FKHFN DPSV DPS VFDOH &R
PAGE 75
ELECTRICAL Park Brake Switch How It Works Purpose 7KLV GRXEOH SROH SOXQJHU W\SH VZLWFK KDV IRXU WHUPLQDOV ,Q WKH 67$57 SRVLWLRQ LW LV XVHG WR HQVXUH WKH SDUN EUDNH LV LQ WKH 21 SRVLWLRQ $W WKH VDPH WLPH LW DOORZV FXUUHQW WR ÀRZ WKURXJK WKH VDIHW\ FLUFXLW :KHQ WKH SDUN EUDNH LV UHOHDVHG LW E\SDVVHV ERWK WKH QHXWUDO VZLWFKHV DV ORQJ DV WKH RSHUDWRU LV VLWWLQJ LQ WKH VHDW WR PDLQWDLQ FXUUHQW IRU WKH VDIHW\ FLUFXLW )LJ 7KH SDUN EUDNH VZLWFK LV XVHG WR HQVXUH WKH WUDQVD[OHV DUH LQ QHXWUDO
PAGE 76
ELECTRICAL Testing 'LVFRQQHFW WKH VZLWFK IURP WKH ZLUH KDUQHVV 5HPRYH WKH VZLWFK IURP WKH EUDFNHW 8VLQJ D PXOWLPHWHU RKPV VHWWLQJ IROORZ WKH SURFHGXUHV OLVWHG EHORZ )LJ A B C D Fig.
PAGE 77
ELECTRICAL Seat Switch How It Works Purpose :KHQ WKH VHDW LV YDFDWHG WKH VZLWFK LV RSHQ DQG WKHUH LV 12 FRQWLQXLW\ EHWZHHQ WKH WZR WHUPLQDOV :KHQ WKH VHDW LV RFFXSLHG WKH VZLWFK FORVHV DQG WKHUH LV FRQWLQXLW\ EHWZHHQ WKH WZR WHUPLQDOV )LJ 7KH VZLWFK LV SDUW RI WKH VDIHW\ FLUFXLW ,I WKH HQJLQH LV running and the operator vacates the seat with either WKH 372 HQJDJHG RU WKH SDUNLQJ EUDNH GLVHQJDJHG WKH HQJLQH ZLOO VKXW GRZQ Note: There is a delay module in the system (Briggs & Stratton E
PAGE 78
ELECTRICAL Neutral Switch How It Works Purpose 7KLV VLQJOH SROH SOXQJHU QRUPDOO\ RSHQ W\SH VZLWFK KDV WZR WHUPLQDOV :KHQ WKH PRWLRQ FRQWURO SLYRW KDQGOH LV LQ WKH QHXWUDO SRVLWLRQ KDQGOH RXWZDUG LW SXVKHV RQ WKH VZLWFK SOXQJHU FORVLQJ WKH FRQWDFW DQG FRQQHFWLQJ WKH WHUPLQDOV )LJ 7KH QHXWUDO VZLWFKHV DUH XVHG WR HQVXUH WKH PRWLRQ FRQ WURO KDQGOHV DUH LQ WKH QHXWUDO SRVLWLRQ WR VWDUW WKH XQLW 7KH VZLWFKHV DUH DFWLYDWHG E\ PRYLQJ WKH PRWLRQ FRQWURO KDQGOHV WR WKH QHXWUDO SRVLWLRQ KD
PAGE 79
ELECTRICAL Hour Meter How It Works Purpose 6LQFH D QRUPDO FORFN PLJKW EH DIIHFWHG E\ YDULDWLRQV LQ YROWDJH DQG FXUUHQW WKH KRXU PHWHU LV PDGH XS RI DQ HOHFWULF ³ZLQGHU´ DQG D PHFKDQLFDO FORFN PRYHPHQW :KHQ SRZHU LV DSSOLHG D FRLO LV HQHUJL]HG WR ZLQG WKH PRYHPHQW 7KH PRYHPHQW XQZLQGV LQ DERXW VHFRQGV $V LW ¿QLVKHV LWV URWDWLRQ LW UH HQHUJL]HV WKH FRLO VR WKDW WKH F\FOH FDQ VWDUW RYHU )LJ 7KH KRXU PHWHU NHHSV WUDFN RI WKH DFWXDO UXQQLQJ KRXUV RI WKH PDFKLQH RU WKH WLPH WKDW WKH LJ
PAGE 80
ELECTRICAL Fuse Block Purpose 7KH IXVH EORFN KRXVHV WKH HOHFWULFDO V\VWHP IXVHV Location 5DLVH WKH VHDW DQG UHPRYH WKH K\GUR IDQ FRYHU WR DFFHVV WKH IXVH EORFN ORFDWHG RQ WKH LQVLGH UHDU RI WKH VHDW ER[ DVVHPEO\ )LJ 4 A B C Fig.
PAGE 81
ELECTRICAL Seat Delay Module (Briggs & Stratton models only) How It Works Purpose 7KH VHDW GHOD\ PRGXOH FLUFXLW ERDUG LV PDGH XS RI VHY HUDO GLIIHUHQW HOHFWULFDO FRPSRQHQWV D WUDQVLHQW YROWDJH VXSSUHVVRU FDSDFLWRU WUDQVLVWRUV GLRGHV DQG D UHOD\ 7KHVH FRPSRQHQWV ZRUN WRJHWKHU WR PDLQWDLQ YROWDJH LQ the seat switch circuit to keep the engine running in case RI VKRUW WHUP YROWDJH LQWHUUXSWLRQ )LJ :KHQ RSHUDWLQJ WKH PDFKLQH RQ URXJK WHUUDLQ WKH RSHUDWRU FDQ PRPHQWDULO\ FRPH RII WKH VHDW
PAGE 82
ELECTRICAL Testing 5DLVH WKH VHDW DQG GLVFRQQHFW WKH VHDW VZLWFK ,Q VWDOO D MXPSHU ZLUH LQ SODFH RI WKH VHDW VZLWFK )LJ Fig.
PAGE 83
ELECTRICAL Electrical Schematics Briggs & Stratton Engine 4 Fig.
PAGE 84
ELECTRICAL Briggs & Stratton Engine cont. 4 Fig.
PAGE 85
ELECTRICAL Kohler Engine PTO SWITCH 2 SEAT SWITCH 1 4 3. START B+I+S 4 3 2 1 2 1 PINK X +Y 5 VILOET ORANGE B+I+A 6 PINK NONE 2. RUN 7 GRAY 1.
PAGE 86
ELECTRICAL Kohler Engine cont.
PAGE 87
ELECTRICAL 4 THIS PAGE INTENTIONALLY LEFT BLANK.
PAGE 88
MOWER DECK Mower Deck Spindle Replacement Mower Deck Spindle Removal 4. Using a rag or a thickly-padded glove for protection, hold the end of the blade and remove the nut on the spindle pulley (Fig. 230). 1. Remove the mower deck from the machine. Refer to “Mower Deck Removal” on page 5-18. 2. Remove the 2 nuts securing the spindle cover to the deck (Fig. 228). And remove the spindle cover. Fig. 230 IMG-0613 5. Remove the spindle pulley (Fig. 231). Fig. 228 5 IMG-0611 3.
PAGE 89
MOWER DECK 6. Raise and support the rear of the mower deck with a jack stand or lift. 9. Using a rag or a thickly-padded glove for protection, hold the end of the blade and loosen the blade bolt (Fig. 234). 7. Remove the 6 screws securing the spindle housing to the mower deck (Fig. 232). Fig. 234 Fig. 232 IMG-0618a IMG-0616 10. Remove the blade bolt and two washers from the spindle shaft (Fig. 235). 5 8. Remove the spindle assembly from the mower deck (Fig. 233). Fig. 235 Fig.
PAGE 90
MOWER DECK 11. Remove the spacer on the bottom of the spindle shaft (Fig. 236). Fig. 236 IMG-0623a 12. Remove the spindle shaft and bearing shield (Fig. 237). 13. Remove the spacer from the spindle housing (Fig. 238). Fig. 238 IMG-0626a 14. With a punch, drive one of the bearings out of the housing (Fig. 239). 5 Fig. 237 2007 - 2008 Titan Z Service Manual IMG-0625a Fig.
PAGE 91
MOWER DECK 15. Remove the spacer from the housing (Fig. 240). Housing spacer, and bearings (Fig. 242) A C B C Fig. 240 IMG-0634a Fig. 242 A. Housing B. Spacer IMG-0633 C. Bearing (2) 16. Turn the housing over and drive the other bearing out of the other side with a punch (Fig. 241). 5 Fig.
PAGE 92
MOWER DECK 3. Tap the second bearing into the pulley side of the spindle housing until it seats (Fig. 245). Mower Deck Spindle Installation 1. Tap a bearing into the blade end of the housing until it seats (Fig. 243). Fig. 245 Fig. 243 IMG-0636a 2. Turn the spindle housing over and install the spacer into the housing (Fig. 244). 4. With the bearing shield and spacer installed on the spindle shaft, install the spindle shaft into the spindle housing (Fig. 246). 5 Fig. 246 Fig.
PAGE 93
MOWER DECK 5. Place a spacer onto the spindle shaft (Fig. 247). Fig. 247 7. With two washers on the blade bolt, install the blade bolt and two washers into the spindle shaft (Fig. 249). IMG-0650a Fig. 249 IMG-0648 6. Position the mower blade onto the spindle shaft and spacer (Fig. 248). 8. Torque the blade bolt to 37 ± 5 ft-lbs. (50 + 6.8 Nm) to secure the blade. 5 9. Position the spindle assembly to the inside of the mower deck (Fig. 250). Fig. 248 IMG-0647a Fig.
PAGE 94
MOWER DECK 10. Install 6 screws to secure the spindle assembly to the mower deck. Torque the 6 screws to 200 – 250 in-lbs. (16.7 – 20.8 Nm) (Fig. 251). 12. Install the spindle pulley nut. Torque the spindle pulley nut to 50 ft-lbs (67.8 Nm) (Fig. 253). Fig. 253 Fig. 251 11. Install the spindle pulley onto the spindle shaft. The side of the pulley with the large hub should face toward the spindle housing (Fig. 252). 13. Route the mower deck belt around the spindle pulley (Fig. 254). 5 Fig. 254 Fig.
PAGE 95
MOWER DECK 14. Check that the mower deck belt is routed properly. Refer to the belt routing decal (Fig. 255): Idler Arm Assembly Replacement Idler Arm Assembly Removal 1. Remove the mower deck from the machine. Refer to “Mower Deck Removal” on page 5-18. 2. With a spring tool (Toro part number 92-5771) remove the extension spring from the spring post located at the rear of the mower deck (Fig. 257). Fig. 255 109-6035 15. Position the belt cover onto the mower deck. Install two nuts to secure (Fig. 256).
PAGE 96
MOWER DECK 4. Remove the nut and washer securing the idler arm to the mower deck (Fig. 259). Fig. 259 IMG-0657 5. Remove the idler arm from the mower deck (Fig. 260). 6. Remove the carriage bolt and washer from the deck (Fig. 261). Fig. 261 IMG-0659 7. Remove the pivot bushing from the idler arm assembly (Fig. 262). 5 Fig. 260 2007 - 2008 Titan Z Service Manual IMG-0658 Fig.
PAGE 97
MOWER DECK 8. Tap out the two sleeve bearings (Fig. 263). Fig. 263 10. Remove the idler pulley and idler bushing from the idler arm assembly (Fig. 265). IMG-0663a Fig. 265 IMG-0666a 9. Remove the nut and carriage bolt securing the idler pulley to the idler arm assembly (Fig. 264). 5 Fig.
PAGE 98
MOWER DECK 3. Install a sleeve bearing into the top and bottom of the idler arm assembly pivot (Fig. 268). Idler Arm Assembly Installation 1. Install the carriage bolt and idler bushing to the idler arm assembly (Fig. 266). Fig. 268 Fig. 266 IMG-0670a IMG-0667a 4. Install a carriage bolt and washer through the mower deck (Fig. 269). 2. Position the idler pulley onto the carriage bolt and install a nut to secure the pulley (Fig. 267). 5 Fig. 269 Fig.
PAGE 99
MOWER DECK 5. Position the pivot bushing onto the carriage bolt (Fig. 270). Fig. 270 IMG-0672a 6. Install the idler arm assembly onto the pivot bushing (Fig. 271). 7. Install a washer and nut onto the carriage bolt to secure (Fig. 272). Fig. 272 IMG-0674a *UHDVH WKH ¿WWLQJ RQ WKH LGOHU DUP DVVHPEO\ )LJ 273). 5 Fig. 271 5-12 IMG-0673a Fig.
PAGE 100
MOWER DECK 9. Install the extension spring on the idler arm assembly post (Fig. 274). Fixed Idler Pulley Replacement Fixed Idler Pulley Removal 1RWH 7KHUH DUH WZR ÀDW LGOHU SXOOH\V ORFDWHG RQ WRS of the mower deck. They are both replaced the same way (Fig. 276). Fig. 274 IMG-0656a 10. Using a spring tool (Toro part number 92-5771), install the other end of the extension spring onto the spring post located at the rear of the mower deck (Fig. 275). Fig.
PAGE 101
MOWER DECK 2. Remove the idler pulley (Fig. 278). Fixed Idler Pulley Installation 1. Install a carriage bolt through the mower deck and position the idler bushing onto the carriage bolt (Fig. 280). Fig. 278 IMG-0677 3. Remove the idler bushing and carriage bolt from the mower deck (Fig. 279). 5 Fig. 280 IMG-0680 2. Position the idler pulley onto the idler bushing. Install a nut to secure the pulley (Fig. 281). Fig. 279 IMG-0679a Fig.
PAGE 102
MOWER DECK Electric PTO Clutch Replacement 4. Unplug the harness connector from the electric PTO clutch plug (Fig. 284). Electric PTO Clutch Removal 1. Remove the negative battery cable from the battery. 2. Locate the idler arm assembly on the mower deck. Rotate the idler arm toward the rear of the mower deck and slip the mower deck belt off the idler pulley (Fig. 282). Fig. 284 IMG-0377a 5. Remove the bolt securing the electric PTO clutch to the engine crankshaft (Fig. 285). Fig.
PAGE 103
MOWER DECK 6. Remove the electric PTO clutch from the engine crankshaft (Fig. 286). Electric PTO Clutch Installation 1. Apply anti-sieze compound to the engine crankshaft. Slide the electric PTO clutch onto the engine crankshaft (Fig. 287). Fig. 286 IMG-0379 7. To test the electric PTO clutch, refer to the Electric (PTO) Clutch testing procedures in the Electrical section on page 4-6 and 4-7. 5 Fig. 287 IMG-0424 0DNH VXUH WKH VORW RQ WKH HOHFWULF FOXWFK ¿WV RQ WKH clutch anchor (Fig. 288).
PAGE 104
MOWER DECK 3. With 3 washers installed on the electric PTO clutch bolt, apply thread locking compound to the threads of the clutch bolt (Fig. 289). 6. Install the mower deck belt around the electric PTO clutch pulley (Fig. 291). Fig. 291 Fig. 289 IMG-0372 IMG-0429a 4. Install the clutch bolt, 2 spring washers, and washer to the crankshaft. Torque the clutch bolt to 55 ft-lbs. (74.6 Nm). 7.
PAGE 105
MOWER DECK 5. Remove the nut, bolt and pivot bushing from the four deck struts (B). Remove the blocking to lower the mower deck to the ground (Fig. 294). Mower Deck Replacement Mower Deck Removal 1. Park the machine on a level surface and disengage the blade control switch. A A 2. Move the motion control levers outward to the neutral position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. B 3.
PAGE 106
MOWER DECK 6. Attach the hardware from the deck hanger and deck lift arm on both sides of the deck (Fig. 296). Mower Deck Installation 1. Park the machine on a level surface and disengage the blade control switch. A 2. Move the motion control levers outward to the neutral position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operation position. 3. Slide the mower deck under the machine. 4.
PAGE 107
MOWER DECK Leveling the Mower Deck The mower blades must be level from side-to-side, and slightly sloped from front-to-back. Check the side-to-side level and the front-to-back slope any time you install the mower deck or when you see an uneven cut on your lawn. 1. Park the machine on a level surface and disengage the blade control switch. 2.
PAGE 108
MOWER DECK 10. Loosen the leveling adjust locking nuts on all four corners so that the mower deck is sitting securely on all four blocks. Make sure that the deck hangers are all the way down (at the top of the slot) and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts. Adjusting the Blade Slope 5HFKHFN WKDW WKH EORFNV ¿W MXVW VQXJO\ XQGHU WKH deck skirt. Make sure all attachment bolts are tight. 2.
PAGE 109
MOWER DECK 7. Loosen the leveling adjust locking nuts on all four corners so that the deck is sitting securely on all four blocks. Make sure that the deck hangers are all the way down (at the top of the slot) and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts (Fig. 301). 8. Carefully rotate the blades front-to-rear (Fig. 302). B C A B C D C A B Fig. 301 5 C C A B C Fig. 302 A. Blades front to rear B.
PAGE 110
MOWER DECK Mower Belt Maintenance 5. Pull the idler pulley in the direction shown and remove the belt from the pulleys (Fig. 303). Service interval: Every 25 hours ! WARNING ! Mower Belt Inspection The spring is under tension when installed and can cause personal injury. Check the belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. Be careful when removing the belt.
PAGE 111
MOWER DECK Mower Belt Installation 1. Route the new belt around the engine pulley and mower pulleys (Fig. 304). Fig. 304 5 109-6035 2. Pull the idler pulley in the direction shown (Fig. 305) and route the belt onto the idler pulley. A BC D E F Fig. 305 A. Outside pulley B. Spring C. Idler pulley ¿J * D. Mower belt E. Engine pulley F. Pull idler in this direction 3. Install the belt covers over the outside spindles.
PAGE 112
ENGINE 3. Remove the mower deck belt from around the electric PTO clutch pulley (Fig. 307). Engine Replacement Engine Removal Note: This procedure was performed with a Briggs & Stratton engine. Kohler engine replacement is similar except for cable connections. 1. Remove the positive and negative battery cables from the battery. 2. Locate the idler arm assembly on the mower deck and pull the arm toward the rear of the machine. Remove the mower deck belt from around the idler pulley (Fig. 306). Fig.
PAGE 113
ENGINE 5. Remove the clutch bolt securing the electric PTO clutch to the engine crankshaft (Fig. 309). Fig. 309 7. Using a spring tool (Toro part number 92-5771), rotate the transmission drive belt idler arm to release tension from the transmission drive belt. Remove the transmission drive belt from the idler pulley (Fig. 311). IMG-0378 Fig. 311 IMG-0423a 6. Remove the electric PTO clutch from the engine crankshaft (Fig. 310). 8. Remove the transmission drive belt from the engine pulley (Fig. 312).
PAGE 114
ENGINE 9. Slide the engine pulley off the crankshaft (Fig. 313). Fig. 313 11. Turn the fuel shut-off valve to the “OFF” position. Slide the fuel line clamp away from the engine side of the fuel line and disconnect the fuel line. Drain any fuel that may be left in the line (Fig. 315). IMG-0385 Fig. 315 IMG-0413a 10. Remove the key from the engine crankshaft keyway (Fig. 314). 12. Loosen the throttle clamp located on the rear of the engine and remove the throttle cable from the clamp (Fig. 316). 6 Fig.
PAGE 115
ENGINE 13. Remove the throttle cable from the engine throttle linkage (Fig. 317). Fig. 317 IMG-0390a 14. Loosen the choke cable clamp located on the rear of the engine and remove the choke cable from the clamp (Fig. 318). 15. Remove the choke cable from the engine choke linkage (Fig. 319). Fig. 319 IMG-0392a 16. Remove the violet wire from the red alternator wire (Fig. 320). 6 Fig. 320 Fig.
PAGE 116
ENGINE 17. Remove the blue wire from the oil sending sensor ORFDWHG QH[W WR WKH RLO ¿OWHU )LJ Fig. 321 19. Remove the nut securing the heavy red wire to the starter and remove the heavy read wire from the starter (Fig. 323). IMG-0264a Fig. 323 18. Remove the yellow/white wire plug from the grey/ black wire (fuel solenoid and engine magneto) plug (Fig. 322). IMG-0394a 20. Remove the nut securing the 2 ground wires to the engine base. Remove the 2 ground wires (Fig. 324). 6 Fig.
PAGE 117
ENGINE 21. Remove the 4 bolts, washers, and nuts securing the engine to the frame (Fig. 325). Engine Installation 1. Position the engine onto the frame (Fig. 327). Fig. 325 IMG-0397 Fig. 327 IMG-0405a 22. Raise the engine off the frame (Fig. 326). Note: For photo purposes the rear engine guards and rear casting was removed. 2. Install 4 engine mounting bolts, washers, and nuts to secure the engine to the frame (Fig. 328). 6 Fig. 328 Fig. 326 23.
PAGE 118
ENGINE 4. Position the 2 ground wires onto the engine ground base. Install a nut to secure the 2 ground wires (Fig. 329). Fig. 329 IMG-0395a 5. Position the heavy red wire onto the starter terminal. Install a nut to secure the heavy red wire to the starter terminal (Fig. 330). 6. Plug the yellow/white wire plug to the grey/black (fuel solenoid and the engine magneto) wire plug (Fig. 331). Fig. 331 IMG-0258 7.
PAGE 119
ENGINE 8. Install the violet wire plug into the red alternator wire plug (Fig. 333). Fig. 333 10. Move the choke control lever in the full open position (the choke linkage is moved all the way to the left). Install the choke cable into the bottom portion of the clamp and tighten the clamp to secure (Fig. 335). IMG-0260 Fig. 335 IMG-0408 9. Install the choke cable into the choke linkage located on the rear of the engine (Fig. 334). 11.
PAGE 120
ENGINE 12. Move the throttle control lever on the control panel to the low throttle position. Position the throttle cable into the top of the throttle cable clamp, push the throttle cable until the throttle linkage on the engine stops. Tighten the throttle cable clamp (Fig. 337). 14. Install a key into the crankshaft keyway (Fig. 339). Fig. 339 Fig. 337 IMG-0412 IMG-0415 15. Apply anti-seize compound to the crankshaft (Fig. 340). 13.
PAGE 121
ENGINE 16. Slide the engine pulley onto the crankshaft so that the inside chamfer on the pulley ID is installed toward the engine and the pulley keyway aligns with the key in the crankshaft (Fig. 341). 18. With a spring tool (Toro part number 92-5771), rotate the transmission drive belt spring idler arm to release tension on idler arm. Route the transmission drive belt around the idler arm pulley (Fig. 343). Fig. 341 Fig. 343 IMG-0417a 17.
PAGE 122
ENGINE 19. Slide the electric PTO clutch onto the engine crankshaft (Fig. 345). Fig. 345 21. With the washer installed on the clutch bolt, apply thread locking compound onto the threads of the electric clutch bolt (Fig. 347). IMG-0424 Fig. 347 0DNH VXUH WKH VORW RQ WKH HOHFWULF 372 FOXWFK ¿WV RQ the clutch anchor (Fig. 346). IMG-0429a 22. Torque the clutch bolt to 50 to 55 ft-lbs (67.8 – 74.6 Nm) (Fig. 348). 6 Fig. 346 IMG-0430a Fig.
PAGE 123
ENGINE 23. Plug the wire harness connector to the electric PTO clutch connector (Fig. 349). Fig. 349 25. Pull the mower deck idler arm assembly toward the rear of the machine and route the mower belt around the idler pulley (Fig. 351). IMG-0377a Fig. 351 24. Route the mower deck belt around the electric PTO clutch (Fig. 350). IMG-0432a 26. Check the mower deck belt routing (Fig. 352). 6 Fig. 350 IMG-0372 Fig. 352 109-6035 27.
PAGE 124
ENGINE 0XIÀHU 5HSODFHPHQW 3. Remove the two engine mount bolts, washers and QXWV UHWDLQLQJ WKH PXIÀHU JXDUG WR WKH IUDPH DQG WKH engine (Fig. 355). 0XIÀHU 5HPRYDO Note: This procedure was performed with Briggs 6WUDWWRQ HQJLQH .RKOHU HQJLQH PXIÀHU replacement is similar. 1. Remove the left screw retaining the front of the PXIÀHU JXDUG WR WKH IUDPH )LJ Fig. 355 IMG-0709a 4. Loosen the two bolts and nuts retaining the rear of WKH PXIÀHU JXDUG WR WKH UHDU FDVWLQJ )LJ Fig.
PAGE 125
ENGINE 5HPRYH WKH PXIÀHU JXDUG IURP WKH XQLW )LJ Fig. 357 6. Remove the 4 screws, washers and 2 gaskets UHWDLQLQJ WKH PXIÀHU WR WKH HQJLQH )LJ ± /+ DQG )LJ ± 5+ IMG-0710 Fig. 358 IMG-0714 Fig.
PAGE 126
ENGINE 5HPRYH WKH PXIÀHU IURP WKH HQJLQH )LJ Fig.
PAGE 127
ENGINE THIS PAGE INTENTIONALLY LEFT BLANK.
PAGE 128
HYDROSTATIC DRIVE SYSTEM 4. Remove the mower deck belt from around the electric PTO clutch. Push the excess deck belt forward towards the mower deck (Fig. 362). Hydro Drive Belt Replacement Hydro Drive Belt Removal 1. Disconnect the negative battery cable from the battery. 2. Raise and support the rear end of the machine with a lift or jack stands. 3. Locate the idler arm assembly on the mower deck. Pull the arm toward the rear of the machine and remove the mower deck belt from the idler pulley (Fig. 361).
PAGE 129
HYDROSTATIC DRIVE SYSTEM 5HPRYH WKH K\GUR GULYH EHOW IURP DURXQG WKH ¿[HG idler pulley (Fig. 364). Fig. 364 8. Lift the seat assembly. Loosen the two screws that secure the hydro fan cover to the seat box (Fig. 366). IMG-0438a Fig. 366 7. Remove the hydro drive belt from around the engine pulley (Fig. 365). IMG-0440a 9. Remove the hydro fan cover (Fig. 367). 7 Fig. 365 7-2 IMG-0439a Fig.
PAGE 130
HYDROSTATIC DRIVE SYSTEM 10. Remove the hydro drive belt from around the right and left hydro pulleys and out the bottom of the machine (Fig. 368). Hydro Drive Belt Installation Fig. 369 Fig. 368 109-6014 IMG-0443 1. Route the hydro drive belt around the left and right hydro pulleys (Fig. 370). Fig.
PAGE 131
HYDROSTATIC DRIVE SYSTEM 2. Route the hydro drive belt around the inside of the ULJKW ¿[HG LGOHU SXOOH\ )LJ Fig. 371 4. Using a spring tool (Toro part number 92-5771) release tension from the hyrdo drive idler arm and route the hydro drive belt around the idler pulley (Fig. 373). IMG-0445a Fig. 373 IMG-0435 3. Route the hydro drive belt around the engine sheave (Fig. 372). 5. Check the routing of the hydro drive belt, refer to the drive belt routing diagram (Fig. 374). 7 Fig.
PAGE 132
HYDROSTATIC DRIVE SYSTEM 6. Pull the mower deck idler arm assembly toward the rear of the machine and route the mower deck belt around the idler pulley and the electric PTO clutch pulley (Fig. 375 and Fig. 376). 7. Release the mower deck idler arm. 8. Check the mower deck belt routing (Fig. 377). Fig. 377 Fig. 375 109-6035 IMG-0432a 9. Position the hydro fan cover (Fig. 378). Fig. 376 7 IMG-0372 Fig.
PAGE 133
HYDROSTATIC DRIVE SYSTEM 10. Install the two screws securing the hydro fan cover to the seat box (Fig. 379). Fig. 379 IMG-0440a 11. Lower the seat. /RZHU WKH UHDU HQG RI WKH PDFKLQH WR WKH ÀRRU 13. Connect the negative battery cable to the battery.
PAGE 134
HYDROSTATIC DRIVE SYSTEM Motion Control Damper Replacement Motion Control Damper Removal 4. Remove the two nuts securing the motion control damper to the frame and the motion control pivot (Fig. 381). 1. Raise the seat. 2. Remove the negative and then the positive battery cable from the battery. 3. Loosen the two wing nuts on the battery hold down bolts. Remove the battery from the machine (Fig. 380). Fig. 381 IMG-0457 5. Remove the motion control damper from the machine (Fig. 382). Fig.
PAGE 135
HYDROSTATIC DRIVE SYSTEM 3. Install a nut on each end of the damper to secure (Fig. 385). Motion Control Damper Installation 1. Install two nuts on each screw of the motion control damper (Fig. 383). Fig. 385 Fig. 383 IMG-0477 IMG-0468a 4. Position the battery into the machine. Install the battery hold down to secure (Fig. 386). ,QVWDOO WKH ¿[HG HQG RI WKH GDPSHU WR WKH IUDPH Install the rod end of the damper to the motion control pivot (Fig. 384). 7 Fig. 386 Fig. 384 IMG-0476 IMG-0456 5.
PAGE 136
HYDROSTATIC DRIVE SYSTEM 5. Remove the two screws and washers retaining the left hand lever grip assembly from the lever mount post (Fig. 388). Motion Control Pivot Assembly Replacement The following procedures show replacing and servicing the left hand motion control pivot assembly. The same procedures can be followed to replace and service the right hand motion control pivot assembly. Exceptions are noted within the procedures. Motion Control Pivot Removal 1. Raise the seat. 2.
PAGE 137
HYDROSTATIC DRIVE SYSTEM 7. Remove the nut from the top of the left hand motion control damper and move the damper out of the motion control pivot (Fig. 390). 9. Remove the cotter pin located on the control pivot pin (Fig. 392). Fig. 392 Fig. 390 IMG-0483a IMG-0480 8. Remove the bolt and nut securing the steering rod to the left hand motion control pivot assembly (Fig. 391). 10. Remove the control pivot pin from the motion control pivot assembly (Fig. 393). 7 Fig. 393 Fig.
PAGE 138
HYDROSTATIC DRIVE SYSTEM 11. Remove the motion control pivot assembly from the seat box assembly (Fig. 394). Fig.
PAGE 139
HYDROSTATIC DRIVE SYSTEM 3. With a long punch and hammer, remove the two bearings in the motion control pivot (Fig. 397). Motion Control Pivot Disassembly 1. Remove the neutral switch from the motion control pivot assembly (Fig. 395). Fig. 397 Fig. 395 IMG-0494a IMG-0516a 2. Remove the two bolts, metal washers, (2) plastic washers, and nuts retaining the lever mount post to the motion control pivot (Fig. 396). 7 Fig.
PAGE 140
HYDROSTATIC DRIVE SYSTEM Motion Control Pivot Assembly 1. Tap two new bearings into the motion control pivot assembly (Fig. 398). 3. Tighten the bolts and nuts until you feel resistance on the lever mount post - Do Not over-tighten (Fig. 400). Fig. 400 Fig. 398 IMG-0489a IMG-0502a 2. Install the bolts, metal washers, plastic washers, lever mount post, and nuts to the motion control pivot (Fig. 399). 4. Install the neutral switch into the motion control pivot assembly (Fig. 401).
PAGE 141
HYDROSTATIC DRIVE SYSTEM Motion Control Pivot Assembly Installation 3. Install a cotter pin on the end of the control pivot pin (Fig. 404). 1. Install the left hand motion control pivot assembly between the seat box assembly and the motion control bracket (Fig. 402). Fig. 404 Fig. 402 IMG-0519 IMG-0521 4. Install a bolt and nut securing the steering rod to the left hand motion control pivot assembly (Fig. 405). 2.
PAGE 142
HYDROSTATIC DRIVE SYSTEM 5. Install the motion control damper screw through the left hand motion control pivot assembly. Install a nut to secure (Fig. 406). Fig. 406 IMG-0480a 6. Plug the wire harness plug onto the left neutral switch (Fig. 407). 7. Install two screws and washers retaining the left hand lever grip assembly to the lever mount post (Fig. 408). Fig. 408 IMG-0523a 8. Left Hand Motion Control Pivot: Install the left hand fender and fuel tank.
PAGE 143
HYDROSTATIC DRIVE SYSTEM 9. Position the battery into the machine. Install the battery hold down bracket to secure (Fig. 409). Brake Linkage & Brake Handle Assembly Replacement Brake Linkage & Brake Handle Assembly Removal 1. Raise the seat. 2. Remove the negative and then the positive battery cable from the battery. 3. Loosen the two wing nuts on the battery hold down bolts and remove the battery from the machine (Fig. 410). Fig. 409 IMG-0456 10.
PAGE 144
HYDROSTATIC DRIVE SYSTEM 4. Remove the left hand fender and fuel tank. Refer to Left Hand Fender and Fuel Tank Removal on page 3-7. 7. Remove the brake lever (Fig. 413). 5. Remove the nut securing the brake arm assembly pivot (Fig. 411). Fig. 413 IMG-0289a 8. Remove the spacer from the pivot (Fig. 414). Fig. 411 IMG-0287a 6. Remove the brake arm assembly pivot carriage bolt (Fig. 412). Fig. 414 Fig.
PAGE 145
HYDROSTATIC DRIVE SYSTEM 9. Pull the brake pivot tube assembly out slightly from the frame (Fig. 415). Fig. 415 IMG-0291a 10. Remove the washer located on the inside end of the brake pivot tube (Fig. 416). 7 11. Remove the spacer from the inside end of the brake pivot tube (Fig. 417). Fig. 417 12. Remove the brake pivot tube (Fig. 418). Fig. 418 Fig.
PAGE 146
HYDROSTATIC DRIVE SYSTEM 5HPRYH WKH ÀDQJHG EXVKLQJ ORFDWHG RQ WKH RXWVLGH of the seat box assembly (Fig. 419). Fig. 419 15. With a spring tool (Toro part number 92-5771), remove the right extension spring located between the spring anchor plate and the brake shaft assembly (Fig. 421). IMG-0295a Fig. 421 IMG-0524 5HPRYH WKH ÀDQJH EXVKLQJ ORFDWHG RQ WKH LQVLGH RI the seat box assembly (Fig. 420). 16.
PAGE 147
HYDROSTATIC DRIVE SYSTEM 17. Rotate the brake shaft assembly forward and down. Remove the e-clip retaining the brake arm to the brake shaft assembly (Fig. 423). Fig. 423 IMG-0528a 19. Remove the cotter pin from the clevis pin that secures the right side spring anchor plate to the brake handle on the transmission (Fig. 425). Fig. 425 IMG-0530 18. Remove the brake arm from the machine (Fig. 424). 20. Remove the right side spring anchor plate (Fig. 426). Fig. 424 Fig.
PAGE 148
HYDROSTATIC DRIVE SYSTEM 21. Repeat steps 19 and 20 to remove the left side spring anchor plate. 24. Remove the brake shaft from the transmission and frame (Fig. 429). 22. Remove the nut securing the right side of the brake shaft to the transmission and frame (Fig. 427). Fig. 429 Fig. 427 IMG-0535a IMG-0532 23. Remove the nut securing the left side of the brake shaft to the transmission and frame (Fig. 428). 7 Fig.
PAGE 149
HYDROSTATIC DRIVE SYSTEM Brake Linkage & Brake Handle Assembly Installation 3. Install a nut securing the left hand end of the brake shaft to the transmission and frame (Fig. 432). 1. Position the brake shaft to the transmission and frame (Fig. 430). Fig. 432 Fig. 430 IMG-0535a IMG-0533 4. Install the left side spring anchor plate onto the left brake handle clevis pin. Install a cotter pin to secure (Fig. 433). 2.
PAGE 150
HYDROSTATIC DRIVE SYSTEM 5. Install the right side spring anchor plate onto the right brake handle clevis pin. Install a cotter pin to secure (Fig. 434). 7. Install an e-clip to retain the brake arm to the brake shaft assembly (Fig. 436). Fig. 436 Fig. 434 IMG-0528a IMG-0539a 6. Install the brake arm from the brake shaft assembly to the seat box assembly (Fig. 435). 8.
PAGE 151
HYDROSTATIC DRIVE SYSTEM 9. Using a spring tool (Toro part number 92-5771), install the left extension spring onto the spring anchor plate and the brake shaft assembly (Fig. 438). ,QVWDOO WKH ÀDQJH EXVKLQJ WR WKH LQVLGH RI WKH VHDW box assembly for the brake shaft pivot assembly (Fig. 440). Fig. 440 Fig. 438 IMG-0312 IMG-0527 10. Using a spring tool (Toro part number 92-5771), install the right extension spring onto the spring anchor plate and the brake shaft assembly (Fig. 439).
PAGE 152
HYDROSTATIC DRIVE SYSTEM 13. Slide the brake pivot tube about half way through the ÀDQJH EXVKLQJV )LJ Fig. 442 IMG-0314 14. Install a spacer on the inside end of the brake pivot tube (Fig. 443). 15. Install a washer on the inside end of the brake pivot tube (Fig. 444). Fig. 444 IMG-0316a 6OLGH WKH EUDNH SLYRW WXEH IDUWKHU WKURXJK WKH ÀDQJH bushings, spacer and washer and into the slots located on the bell crank (Fig. 445). 7 Fig. 443 IMG-0315a Fig.
PAGE 153
HYDROSTATIC DRIVE SYSTEM 17. Install a spacer on the outside end of the brake pivot tube (Fig. 446). Fig. 446 IMG-0319 18. Install the brake lever assembly on the outside end of the brake pivot tube (Fig. 447). 19. Slide a carriage bolt through the brake pivot tube (Fig. 448). Fig. 448 IMG-0288 20. Install a nut on the end of the carriage bolt to secure (Fig. 449). 7 Fig. 447 7-26 IMG-0289a Fig.
PAGE 154
HYDROSTATIC DRIVE SYSTEM 21. Install the left hand fender and fuel tank. Refer to Left Hand Fender and Fuel Tank Installation on page 3-10. 22. Position the battery in the machine. Install the battery hold down to secure (Fig. 450). Transaxle Replacement Note: These instructions show the removal and Installation of the left side transaxle. The same procedure is used to remove and install the right side transaxle. Transaxle Removal 1. Raise the seat. 2.
PAGE 155
HYDROSTATIC DRIVE SYSTEM 5. Locate the mower deck idler arm assembly. Pull the mower deck idler arm toward the rear of the machine and remove the mower deck belt from the idler pulley (Fig. 452). 7. Loosen the two screws securing the hydro fan cover to the seat box (Fig. 454). Fig. 454 Fig. 452 IMG-0546 IMG-0364a 8. Remove the hydro fan cover from the machine (Fig. 455). 6. Remove the mower deck belt from around the electric PTO clutch and push the excess belt forward toward the mower deck (Fig. 453).
PAGE 156
HYDROSTATIC DRIVE SYSTEM 9. Using a spring tool (Toro part number 92-5771) release the tension from the hydro drive belt idler arm and remove the hydro drive belt from the hydro drive idler pulley (Fig. 456). 11. Remove the carriage screw and knob handle securing the hydro bypass arm to the frame (Fig. 458). Fig. 458 Fig. 456 IMG-0554a IMG-0435 10. Remove the hydro drive belt from around the transaxle pulley and hydro fan (Fig. 457). 12. Locate the hydro tank vent hose on top of the transaxle.
PAGE 157
HYDROSTATIC DRIVE SYSTEM 5HPRYH WKH EROW DQG ÀDQJH QXW VHFXULQJ WKH VWHHU ing rod to the hydro control arm (Fig. 460). Fig. 460 15. Remove the nut, bolt, and washer securing the brake pivot and brake shaft assembly to the transaxle and the frame (Fig. 462). IMG-0557 Fig. 462 14. Remove the left extension spring located between the spring anchor plate and the brake shaft assembly (Fig. 461). IMG-0558a 16. Remove the brake pivot from the end of the brake shaft assembly (Fig. 463). 7 Fig.
PAGE 158
HYDROSTATIC DRIVE SYSTEM 3RVLWLRQ D ÀRRU MDFN XQGHU WKH WUDQVD[OH IRU VXSSRUW (Fig. 464). Fig. 464 5HPRYH WKH ÀDQJH QXW DQG ZKL] QXW VHFXULQJ WKH tension rod and tube between the left and right transaxles. Remove the tension rod and tube (Fig. 466). IMG-0563 Fig. 466 IMG-0571 18. Remove the nut, carriage bolt, and spacer securing the back of the transaxle to the frame (Fig. 465). 20. Remove the two carriage bolts and nuts retaining the transaxle to the frame bracket (Fig. 467). 7 Fig.
PAGE 159
HYDROSTATIC DRIVE SYSTEM 21. Slowly lower the transaxle away from the frame (Fig. 468). Fig. 468 23. Remove the cotter pin retaining the spring anchor plate to the brake arm and remove the spring anchor plate (Fig. 470). IMG-0572 Fig. 470 22. Remove the hairpin cotter retaining the hydro bypass arm to the transaxle and remove the bypass arm (Fig. 469). IMG-0575 24. To service the transaxle refer to Hydro-Gear ZT2800 Service and Repair Manual (BLN 52441). 7 Fig.
PAGE 160
HYDROSTATIC DRIVE SYSTEM 3. Loosely install two carriage bolts and nuts to secure the transaxle to the frame (Fig. 473). Transaxle Installation 1. Position the hydro bypass arm onto the bypass arm linkage located on the transaxle. Secure with a hairpin cotter (Fig. 471). Fig. 473 Fig. 471 IMG-0579 IMG-0580 4. Loosely install the tube spacer and tension rod EHWZHHQ WKH WZR WUDQVD[OHV ZLWK D ÀDQJH QXW DQG ZKL] QXW )LJ 5DLVH WKH WUDQVD[OH WR WKH IUDPH ZLWK D ÀRRU MDFN (Fig. 472). 7 Fig.
PAGE 161
HYDROSTATIC DRIVE SYSTEM 5. Loosely nstall the carriage bolt, spacer, and nut to secure the rear of the transaxle to the frame (Fig. 475). Fig. 475 5HPRYH WKH ÀRRU MDFN IURP XQGHU WKH WUDQVD[OH 8. Tighten the two carriage bolts and nuts securing the transaxle to the frame (Fig. 477). IMG-0583a Fig. 477 6. Position the brake pivot onto the end of the brake shaft assembly. Install a bolt and washer through WKH IUDPH WUDQVD[OH DQG EUDNH SLYRW ÀDQJH /RRVHO\ install a nut onto the bolt (Fig. 476).
PAGE 162
HYDROSTATIC DRIVE SYSTEM 10. Tighten the bolt and nut securing the brake pivot to the transaxle and frame (Fig. 479). Fig. 479 IMG-0558a 7LJKWHQ WKH ZKL] QXW DQG ÀDQJH QXW RQ WKH WHQVLRQ rod between the right and left transaxles. 12. Install the carriage bolt and knob handle securing the hydro bypass arm to the frame (Fig. 480). ,QVWDOO D EROW DQG ÀDQJH QXW VHFXULQJ WKH VWHHULQJ URG to the hydro control arm (Fig. 481). Fig.
PAGE 163
HYDROSTATIC DRIVE SYSTEM 15. Install the spring anchor plate in the slot located on the brake shaft assembly (Fig. 483). Fig. 483 17. Using a spring tool (Toro part number 92-5771), install the left extension spring between the spring anchor plate and the brake shaft assembly (Fig. 485). IMG-0588a Fig. 485 16. Install the other end of the spring anchor plate onto the transaxle brake arm. Secure with a cotter pin (Fig. 484). IMG-0527 18.
PAGE 164
HYDROSTATIC DRIVE SYSTEM 19. Route the hydro drive belt around the engine drive pulley (Fig. 487). Fig. 487 IMG-0439a 20. Using a spring tool (Toro part number 92-5771), release the tension on the hydro drive belt idler arm. Route the belt around the idler pulley (Fig. 488). 21. Check the routing of the hydro drive belt. Refer to the hydro drive belt routing decal (Fig. 489). Fig. 489 109-6014 22. Route the mower deck drive belt around the electric PTO clutch pulley (Fig. 490). 7 Fig. 490 Fig.
PAGE 165
HYDROSTATIC DRIVE SYSTEM 23. Pull the mower deck idler arm toward the rear of the machine. Route the mower deck belt around the inside of the spring idler arm pulley and release the idler arm (Fig. 491). 25. Install the left rear tire and wheel assembly. 26. Position the hydro fan cover. Tighten the two screws to secure the hydro fan cover to the seat box (Fig. 493).
PAGE 166
HYDROSTATIC DRIVE SYSTEM 4. Remove the bolt and nut retaining the seat stop cable to the seat plate (Fig. 496). Neutral Adjustment 1. Raise the rear end of the machine and support it on jack stands (Fig. 494). Fig. 496 Fig. 494 IMG-0591 IMG-0589 2. Run the engine and operate the drive system for 10 minutes to warm up the transaxles. Shut the engine off. 5. Engage the park brake and start the machine. Release the park brake once the engine starts to run.
PAGE 167
HYDROSTATIC DRIVE SYSTEM 6. Observe the rear tires to see if there is any movement. If the tire is creeping in either direction, a neutral adjustment is needed (Fig. 498). 9. Loosen the two jam nuts and turn the adjustment rod nut (Fig. 500): A. Counterclockwise rotation shortens the rod and adjusts for reverse tire movement. Note: A small amount of creep in reverse is OK. B. Clockwise rotation lengthens the rod for forward tire movement. Fig. 498 IMG-0600 Fig. 500 IMG-0606a 7.
PAGE 168
HYDROSTATIC DRIVE SYSTEM 12. If adjustment is completed, tighten the two jam nuts against the adjustment rod nut. Tracking Adjustment 13. Install the bolt and nut securing the seat stop cable to the seat plate (Fig. 502). If the machine turns right or left when the handles are evenly pushed forward, adjust on the side opposite the direction of turn (Fig. 504). A C B C Fig. 502 IMG-0591 Fig. 504 A. Control Arm Shaft B. Adjust Stop 14.
PAGE 169
HYDROSTATIC DRIVE SYSTEM Purging Procedures - Transaxles Hydraulic System Maintenance 'XH WR WKH HIIHFWV DLU KDV RQ HI¿FLHQF\ LQ K\GURVWDWLF drive applications, it is critical that it be purged from the system. Checking the Hydraulic Oil Level These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or the oil has been changed. Check expansion tank and if necessary add MOBIL 1 15W-50 synthetic motor oil to the FULL COLD line (Fig. 505).
PAGE 170
HYDROSTATIC DRIVE SYSTEM Change the Hydraulic System Filter Service Interval: $IWHU WKH ¿UVW KRXUV 7KHQ HYHU\ 400 hours thereafter. 6. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. Note: Use only MOBIL 1 15W-50 synthetic motor oil. 7. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake. 1. Stop engine, wait for all moving parts to stop, and allow engine to cool.
PAGE 171
HYDROSTATIC DRIVE SYSTEM Troubleshooting ! WARNING Do not attempt any servicing or adjustments with the engine running. Use extreme caution while inspecting the drive belt assembly and all vehicle linkage! In many cases, problems with the ZT-2800™ are not related to a defective transaxle, but are caused by slipping drive belts, partially engaged bypass valves, and loose or damaged control linkages. Be sure to perform all applicable corrective actions listed below assuming the transaxle is faulty.
PAGE 172
2007 - 2008 Titan™ Z4800 & Z5200 Service Manual Form No.