Toro TITAN Max Service Manual
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Toro TITAN Max Service Manual

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Form No. 3442-428 Rev A
TITAN® Max Service Manual
Published: XX 2020
© 2020—The Toro® Company
Original Instructions (EN)
8111 Lyndale Avenue South
Contact us at www.Toro.com.
Bloomington, MN 55420
All Rights Reserved

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  • Page 1 Form No. 3442-428 Rev A TITAN® Max Service Manual Published: XX 2020 © 2020—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision History Page 2 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 3 The Toro Company RLC/SWS Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or make changes to this manual without notice. TITAN® Max Service Manual Page 3 Preface...
  • Page 4 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S. components) that may have been removed •...

  • Page 5: Table Of Contents

    Table of Contents Preface ........................ 3 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–3 Chapter 3: Troubleshooting ................3–1 General Troubleshooting ................3–3 Chapter 4: Engine ................... 4–1 General Information ..................
  • Page 6 Preface Page 6 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 TITAN® Max Service Manual Page 1–1 Safety 3442-428 Rev A...

  • Page 8: Safety Instructions

    Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow.
  • Page 9 Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders…...
  • Page 10 Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish.
  • Page 11 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–3 Equivalents and Conversions......................2–8 U.S. to Metric Conversions ........................ 2–9 TITAN® Max Service Manual Page 2–1 Specifications and Maintenance 3442-428 Rev A...

  • Page 12: Specifications

    Specifications TITAN® Max Specifications Model 76601 Engine 26 HP Kohler with Pro Air Cleaner Engine Model KT745-3094 Engine Displacement 747cc Engine Speed 3600 ± 100 Engine Oil Capacity 1.9 L (64 fl oz) with oil filter Frame/Axle Width Fully Welded Tubular Frame Deck Size 152.4 cm (60 inches) Deck Configuration...

  • Page 13: Torque Specifications

    Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
  • Page 14 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–4 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 15 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 5, & 8 Studes & Sems with Studs & Sems with Regular Studs &...
  • Page 16 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Height Nuts (Class 10 or stronger Nuts) in-lb N •...
  • Page 17 SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 1/2 - 13 UNC 75 ±...
  • Page 18 Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375...
  • Page 19 U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Measurement Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Area Square Inches...
  • Page 20 Specifications and Maintenance: Torque Specifications Page 2–10 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 21 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 TITAN® Max Service Manual Page 3–1 Troubleshooting 3442-428 Rev A...
  • Page 22 GEARS The Systematic approach to defining, diagnosing and solving problems. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...

  • Page 23: General Troubleshooting

    General Troubleshooting Problem Possible Cause Corrective Action The starter does not crank The blade control switch (PTO) is Move the blade-control switch (PTO) to engaged. the disengaged position. The parking brake is not engaged. Set the parking brake. The motion-control levers are not in the Ensure that the motion-control levers Neutral-Lock position.
  • Page 24 General Troubleshooting (continued) Problem Possible Cause Corrective Action The engine overheats The engine load is excessive. Reduce the ground speed. The oil level in the crankcase is low. Add oil to the crankcase. The cooling fins and the air passages Remove the obstruction and thoroughly above the engine are plugged.
  • Page 25 General Troubleshooting (continued) Problem Possible Cause Corrective Action The clutch does not engage The fuse is blown. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. There is a low voltage supply at the Check the coil resistance, battery clutch.
  • Page 26 Troubleshooting: General Troubleshooting Page 3–6 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 27 Chapter 4 Engine Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 Engine Replacement.......................... 4–4 TITAN® Max Service Manual Page 4–1 Engine 3442-428 Rev A...
  • Page 28 General Information The Titan Max uses A 26 HP 747cc Kohler twin cylinder OHV 4 cycle engine with a pro air cleaner (KT745-3094). Engine: General Information Page 4–2 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 29 Service and Repairs Engine Assembly g341898 Figure 3 Engine PTO Clutch Oil Drain Hose Assembly Flat Idler Pulley Muffler Idler Arm Assembly V-belt Engine Sheave Clutch Anchor TITAN® Max Service Manual Page 4–3 Engine: Service and Repairs 3442-428 Rev A...
  • Page 30 Engine Replacement Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.

  • Page 31: Chapter 4: Engine

    Engine Removal (continued) g335895 Figure 6 10. Disconnect the black engine ground wire. g344817 Figure 7 11. Disconnect the fuel supply line at the fuel filter. TITAN® Max Service Manual Page 4–5 Engine: Service and Repairs 3442-428 Rev A...
  • Page 32 Engine Removal (continued) g349637 Figure 8 12. Disconnect the throttle cable. Throttle Cable Assembly Removal (page 5–26) 13. Disconnect the choke cable. Choke Control Assembly Removal (page 5–29) 14. Disconnect the clutch wire from the clutch. 15. Remove the (7/16 x 3 inch) clutch mounting screw and 2 washers. Slip the clutch off of the crankshaft.
  • Page 33 Engine Installation (continued) 9. Install the hydrostatic drive belt onto the machine. Hydrostatic Drive Belt Installation (page 7–8) 10. Install the deck drive belt onto the mower deck. Deck Drive Belt Installation (page 6–12) 11. Connect the clutch wire to the clutch. 12.
  • Page 34 Engine Installation (continued) g335893 Figure 11 17. Connect the fuel supply line to the fuel filter. g349637 Figure 12 18. Install the engine guard. 19. Open the fuel supply valve. Engine: Service and Repairs Page 4–8 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 35 Engine Installation (continued) g344221 Figure 13 20. Fill the crankcase with approved oil and verify proper oil level. 21. Connect the battery by installing the positive cable first, then the negative cable to the battery. 22. Verify the proper function of the unit. 23.
  • Page 36 Engine: Service and Repairs Page 4–10 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 37 Chapter 5 Chassis Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 Caster Assembly and Bearing Replacement..................5–8 Caster Wheel Service ........................5–11 Left Console Replacement....................... 5–13 Right Console Replacement ......................5–16 Seat Replacement ........................... 5–19 Fuel Tank Replacement ........................5–22 Roll Over Protection System (ROPS) Replacement .................

  • Page 38: General Information

    General Information The Titan Max series uses a 11 GA fully welded frame with a Roll Over Protection System (ROPS). Chassis: General Information Page 5–2 TITAN® Max Service Manual 3442-428 Rev A...

  • Page 39: Service And Repairs

    Service and Repairs Chassis Assembly 1 g341890 Figure 14 Control Panel Assembly Muffler Guard RH Pod Cover Muffler Guard Bracket Choke Control Cable RH Motion Control Cover RH Console LH Console Bracket Throttle Control Cable LH Console Upper Rear Trim LH Cover RH Console Support LH Motion Control Cover...
  • Page 40 Chassis Assembly 2 g341888 Figure 15 Frame ROPS Assembly Floor Mat Step Plate Rubber Grommet Backer Plate Floor Pan Assembly Fascia Plate Chassis: Service and Repairs Page 5–4 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 41 Chassis Assembly 3 g341892 Figure 16 Seat Fixed Seat Plate TITAN® Max Service Manual Page 5–5 Chassis: Service and Repairs 3442-428 Rev A...
  • Page 42 Chassis Assembly 4 g341891 Figure 17 Fuel Hose Assembly Vent Hose Assembly Fuel Tank Chassis: Service and Repairs Page 5–6 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 43 Chassis Assembly 5 g341894 Figure 18 Grease Cap Front Caster Wheel Assembly TITAN® Max Service Manual Page 5–7 Chassis: Service and Repairs 3442-428 Rev A...

  • Page 44: Caster Assembly And Bearing Replacement

    Caster Assembly and Bearing Replacement Caster Assembly and Bearing Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.
  • Page 45 Caster Assembly and Bearing Removal (continued) g342956 Figure 21 8. Inspect the 2 bearings for wear or damage. Replace if necessary. 9. Inspect the inside of the axle bearing area for damage or excessive wear. Caster Assembly and Bearing Installation 1.
  • Page 46 Caster Assembly and Bearing Installation (continued) g342957 Figure 22 4. Apply anti-seize to fork shaft before installing. 5. Install the caster from the bottom side of the frame and place flat washer on top of the bearing. 6. Install the (0.313-18NC x 0.750 inch) screw and tighten to the caster shaft. Torque the screw to 22.597 ±...

  • Page 47: Caster Wheel Service

    Caster Wheel Service Caster Wheel Disassembly 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.
  • Page 48 Caster Wheel Disassembly (continued) g342890 Figure 26 8. Inspect the bearings for wear or damage and replace if necessary. Caster Wheel Assembly 1. Ensure that the wheel is clean and free of debris or excessive wear. 2. Using a (1 1/6 inch) socket and hammer, install the 2 bearings into the caster wheel.

  • Page 49: Left Console Replacement

    Caster Wheel Assembly (continued) g342889 Figure 28 5. Assemble the caster wheel onto the caster fork. 6. Install the (1/2–13 x 8.38 inch) screw and (0.50-13 inch) nut securing the wheel to the caster fork. Torque the screw to 8.47 ± 0.90 N • m (75 ± 8 in-lb). g342888 Figure 29 Screw...

  • Page 50: Chapter 5: Chassis

    Left Console Removal (continued) 4. Remove the (T30) torx screw securing the left console to the chassis. g342987 Figure 30 Torx Screw 5. Remove the 2 screws (T30) securing the left console bracket to the chassis. g342988 Figure 31 6. Remove the fuel cap and disconnect the keeper line. Note: Ensure the keeper line does not fall into the fuel tank.
  • Page 51 Left Console Removal (continued) g342993 Figure 32 7. Remove the left console from the machine. 8. Replace the fuel cap. Left Console Installation 1. Remove the fuel cap from the gas tank. 2. Lower the left console into place. Ensuring the left console seats properly on the support.

  • Page 52: Right Console Replacement

    Left Console Installation (continued) g342988 Figure 34 5. Install the (T30) torx screw securing the LH console to the chassis. g342987 Figure 35 Torx Screw 6. Install the battery onto the battery tray and secure with the battery strap. 7. Connect the battery by installing the positive cable first, then the negative cable to the battery.
  • Page 53 Right Console Removal (continued) g343007 Figure 36 4. Remove the 2 (T25) screws securing the console to the console bracket on the underside of the console. 5. Remove the (10–14 x 1/2 inch) plastic screw securing the control panel assembly to the console. 6.
  • Page 54 Right Console Installation 1. Lower the console into place, while moving the control panel assembly through the opening in the console and into position. Verify the console seats properly on the supports. Note: Before securing the control panel to the console, ensure that all cables and electrical connections are seated firmly in place on the underside of the control panel assembly.

  • Page 55: Seat Replacement

    Right Console Installation (continued) 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. Seat Replacement Seat Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key.
  • Page 56 Seat Removal (continued) g344219 Figure 41 6. Disconnect the seat switch from the seat. g344220 Figure 42 7. Remove the seat from the seat plate. Seat Installation 1. With the seat plate tipped forward, hold the seat on the seat plate. 2.
  • Page 57 Seat Installation (continued) g344220 Figure 43 3. Install the 2 wire retainers to the bottom of the seat and seat plate. g344219 Figure 44 4. Install the 2 (5/16-18 inch) nuts and 2 (0.312-18 x 1.000 inch) carriage screws securing the seat plate to the chassis. Torque the screws to 22.597 ± 2.82 N •...

  • Page 58: Fuel Tank Replacement

    Seat Installation (continued) g344224 Figure 45 Carriage Screw 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. Fuel Tank Replacement Fuel Tank Removal Note: The fuel pick-up system is designed to pull fuel from any part of the tank in low fuel situations as well as reducing the affect of debris in the tank.
  • Page 59 Fuel Tank Removal (continued) g344221 Figure 47 4. Remove the left and rights consoles from the machine. Left Console Removal (page 5–13) Right Console Removal (page 5–16) 5. Remove the seat from the machine. Seat Removal (page 5–19) 6. Disconnect the fuel supply line and the 2 vent lines from the fuel tank. g336088 Figure 48 Vent Hose Assembly...

  • Page 60: Roll Over Protection System (Rops) Replacement

    Fuel Tank Installation (continued) g336088 Figure 49 Vent Hose Assembly Fuel Shut-Off Valve Fuel Supply Line 4. Install the seat onto the machine. Seat Installation (page 5–20) 5. Install the left and right consoles. Left Console Installation (page 5–15) Right Console Installation (page 5–18) 6.
  • Page 61 Roll Over Protection System (ROPS) Removal (continued) Note: For easier access, remove the left and right side consoles. Left Console Removal (page 5–13) Right Console Removal (page 5–16) 4. Support the ROPS assembly and remove the 2 screws, 4 washers, and 2 nuts securing the LH ROPS assembly to the chassis.

  • Page 62: Throttle Cable Assembly Replacement

    Roll Over Protection System (ROPS) Installation (continued) 3. Torque the ROPS connecting hardware to 122–135.58 N • m (90–100 ft-lb). 4. If the left and right consoles were removed, install the left and right consoles. Left Console Installation (page 5–15) Right Console Installation (page 5–18) 5.
  • Page 63 Throttle Cable Assembly Removal (continued) g344236 Figure 54 8. Remove the throttle cable from the throttle plate, noting the position of the cable in the plate. 9. Pull the throttle cable assembly through the console and out of the machine. Throttle Cable Assembly Installation 1.
  • Page 64 Throttle Cable Assembly Installation (continued) g336055 Figure 56 4. Install the throttle cable from the throttle plate. 5. Move the throttle control lever to the slow idle position. 6. Place the z-bend of the throttle cable in the throttle plate on the engine in the position previously noted.

  • Page 65: Choke Control Assembly Replacement

    Throttle Cable Assembly Installation (continued) 13. Connect the battery by installing the positive cable first, then the negative cable to the battery. 14. Verify the proper function of the unit. Choke Control Assembly Replacement Choke Control Assembly Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key.

  • Page 66: Park Brake Handle Assembly Replacement

    Choke Control Assembly Installation (continued) 6. Place the z-bend of the choke cable in the choke plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8. Ensure that the choke control lever is pressed down fully and tighten the cable clamp.

  • Page 67: Motion Control Assembly Replacement

    Park Brake Handle Assembly Installation 1. Connect the upper brake linkage to the brake shaft. 2. With the park brake handle hardware orientated as shown, install the (0.375-16 x 1.500 inch) screw and (3/8-16 inch) flange nut. 3. With the park brake shaft in disengaged position and the park brake lever in the lower position, rotate the upper brake linkage until the end aligns with the hole in the park brake lever.
  • Page 68 Motion Control Assembly Removal (continued) g336044 Figure 61 9. Lower the motion control assembly through the frame toward the center of the machine, remove the assembly. Motion Control Assembly Installation 1. Raise and support the unit so that the front wheels are off the ground, block rear wheels.
  • Page 69 Motion Control Assembly Installation (continued) g336043 Figure 63 5. Adjust the nut on the motion control assembly until the motion control nut is centered in the control plate slot. 6. Install the motion control damper to the motion control assembly, secure with a (5/16-18 inch) shoulder screw.
  • Page 70 Chassis: Service and Repairs Page 5–34 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 71 Chapter 6 Mower Deck Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 Mower Deck Replacement ......................... 6–5 Deck Drive Belt Replacement ......................6–10 Mower Spindle Replacement ......................6–14 Belt Tensioner Replacement ......................6–17 TITAN® Max Service Manual Page 6–1 Mower Deck 3442-428 Rev A...

  • Page 72: General Information

    General Information The Titan Max uses a 60 inch fabricated deck and a 4-point lift system. This includes a front deck strut for lateral stability. All units have a 0.59–1.77 cm (1.5-4.5 inch) height of cut range and are built from 10 GA steel.

  • Page 73: Service And Repairs

    Service and Repairs Mower Deck Assembly 1 g344576 Figure 64 Deck Drive Belt Deflector Plate Idler Pulley Chute Pin Flat Idler Pulley Spindle Assembly RH Belt Cover Cutoff Baffle Bearing Shield Anti Scalp Roller LH Belt Cover Deck Step Deck Assembly Drive Blade Sheave Idler Arm Spindle Shaft...
  • Page 74 Mower Deck Assembly 2 g341897 Figure 65 Lift Link Rear Deck Lift Shaft Transport Lock Rod Deck Lift Gusset Transport Lock Plate Flange Bushing Grommet Deck Strut Assembly Lower Hoc Angle Deck Chain Assembly Bracket Assembly Deck Lift Shaft Mower Deck: Service and Repairs Page 6–4 TITAN®...

  • Page 75: Mower Deck Replacement

    Mower Deck Replacement Mower Deck Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.

  • Page 76: Chapter 6: Mower Deck

    Mower Deck Removal (continued) g344398 Figure 68 6. Using a spring removal tool, remove the spring from the mower deck. g344399 Figure 69 7. Remove the deck drive belt from the PTO clutch. Mower Deck: Service and Repairs Page 6–6 TITAN®...
  • Page 77 Mower Deck Removal (continued) g344400 Figure 70 8. Remove the 2 (0.375-16 x 2.250 inch) carriage screws, 2 (3/8-16) nuts, and 2 washers securing the deck strut assembly to the frame. g344401 Figure 71 9. Remove the 2 (3/8 inch) LH upper shoulder screws and 2 (3/8-16 inch) washers securing the deck support chains to the deck lift shaft.
  • Page 78 Mower Deck Removal (continued) g344402 Figure 72 10. Raise and support the unit so that the front wheels are off the ground, block rear wheels. 11. Remove the mower deck. Mower Deck Installation 1. Raise and support the unit so that the front wheels are off the ground, block the rear wheels.
  • Page 79 Mower Deck Installation (continued) 5. Install the 2 (0.375-16 x 2.250 inch) carriage screws, 2 (3/8-16) nuts, and 2 washers securing the deck strut assembly to the frame. g344401 Figure 74 6. Install the deck drive belt to the PTO clutch. g344400 Figure 75 7.

  • Page 80: Deck Drive Belt Replacement

    Mower Deck Installation (continued) g344399 Figure 76 8. Install the floor pan onto the machine. g344398 Figure 77 9. Connect the battery by installing the positive cable first, then the negative cable to the battery. 10. Verify proper function of the unit. Deck Drive Belt Replacement Deck Drive Belt Removal 1.
  • Page 81 Deck Drive Belt Removal (continued) g344397 Figure 78 4. Lift and remove the floor pan from the machine. g344398 Figure 79 5. Using a spring removal tool, remove the spring from the mower deck. TITAN® Max Service Manual Page 6–11 Mower Deck: Service and Repairs 3442-428 Rev A...
  • Page 82 Deck Drive Belt Removal (continued) g344399 Figure 80 6. Remove the deck drive belt from the PTO clutch. g344400 Figure 81 7. Remove the 4 (0.250-20 x 0.500 inch) screws securing the LH belt cover to the mower deck. Remove the LH belt cover from the mower deck. Repeat on the RH side of the machine.
  • Page 83 Deck Drive Belt Installation (continued) g344400 Figure 82 5. Using a spring removal tool, install the spring onto the mower deck. g344399 Figure 83 6. Install the floor pan onto the machine. TITAN® Max Service Manual Page 6–13 Mower Deck: Service and Repairs 3442-428 Rev A...

  • Page 84: Mower Spindle Replacement

    Deck Drive Belt Installation (continued) g344398 Figure 84 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. 8. Verify proper function of the unit. Mower Spindle Replacement Mower Spindle Removal 1. Remove the mower deck. Mower Deck Removal (page 6–5) 2.
  • Page 85 Mower Spindle Removal (continued) 7. From the topside of the mower deck, remove the (0.750-16 inch) spindle lock nut and washer securing the each spindle shaft to the drive blade sheaves. g344425 Figure 86 8. Remove each drive blade sheave and spindle shaft from the mower deck. 9.
  • Page 86 Mower Spindle Installation (continued) g344427 Figure 88 2. Install the spacers into the bottom of the spindles. 3. Using a (32 mm) socket and a hammer, install the bottom bearings into the spindles. 4. Install the spindle assemblies into the mower deck. 5.

  • Page 87: Belt Tensioner Replacement

    Mower Spindle Installation (continued) g344425 Figure 90 9. Raise and support the mower deck. 10. From the underside of the mower deck, install the blade screw and washer securing each mower blade to the mower deck. Torque the screw to 135.58–149 N •...
  • Page 88 Belt Tensioner Removal (continued) 3. Remove the deck drive belt from the mower deck. Remove the (3/8-16 inch) nut securing the idler pulley to the idler arm. g344577 Figure 92 5. Remove the idler belt guide, washer, idler pulley, idler bushing, and screw (0.375-16 x 2.5 inch) from the idler arm.
  • Page 89 Belt Tensioner Removal (continued) g344578 Figure 94 7. Remove the 2 washers, 6 friction washers, and spacer from the mower deck. g344580 Figure 95 Screw Lift Lever Bushing Washer Idler Arm Friction Washer Washer 8. Remove the idler arm from the mower deck. 9.
  • Page 90 Belt Tensioner Installation (continued) g344579 Figure 96 Flange Nut Idler Bushing Belt Guide Idler Arm Washer Screw Flat Idler Pulley 3. Place the washer and 3 friction washers over the hole where the end of the idler arm will be installed 4.
  • Page 91 Belt Tensioner Installation (continued) 6. Install the (3/8-16 x 1.750 inch) screw and (5/16-18 inch) nut securing the end of the idler arm to the mower deck. Torque the screw to 40.67 ± 4.067 N • m (30 ± 3 ft-lb). g344578 Figure 98 7.
  • Page 92 Mower Deck: Service and Repairs Page 6–22 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 93 Chapter 7 Hydrostatic Drive System Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Hydrostatic Drive Transmission Replacement..................7–5 Hydrostatic Drive Belt Replacement....................7–8 TITAN® Max Service Manual Page 7–1 Hydrostatic Drive System 3442-428 Rev A...

  • Page 94: General Information

    General Information The Titan Max series of mowers use Hydro-Gear hydrostatic transaxle ZT-3100. The drive uses an engine oil with a minimum rating of 9.0 cst (55 SUS) at 110 ºC (230 ºF) and an API classification of SL is recommended. A 20W50 engine oil has been selected for use by the factory and is recommended for normal operating procedures.

  • Page 95: Service And Repairs

    Service and Repairs Hydrostatic Drive Assembly 1 g341889 Figure 99 Hydraulic Tank RH Transaxle Assembly Hydraulic Hose LH Transaxle Assembly Hydraulic Routed Hose Spacer Shaft Hydro Bypass Arm TITAN® Max Service Manual Page 7–3 Hydrostatic Drive System: Service and Repairs 3442-428 Rev A...
  • Page 96 Hydrostatic Drive Assembly 2 g341893 Figure 100 Brake Lever RH Control Handle Assembly RH Motion Control Assembly LH Control Handle Assembly Brake Bracket LH Motion Control Assembly Lower Brake Linkage Brake Shaft Adjustable Yoke Damper Upper Brake Linkage Hydrostatic Drive System: Service and Repairs Page 7–4 TITAN®...

  • Page 97: Hydrostatic Drive Transmission Replacement

    Hydrostatic Drive Transmission Replacement Hydrostatic Drive Transmission Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.
  • Page 98 Hydrostatic Drive Transmission Removal (continued) 11. Remove the (0.375-16 x 2.00 inch) screw that connects the transmission to the cross shaft. 12. Remove the 2 (0.312-18 x 2.250 inch) front hydro mounting screws and 2 (5/16-18 inch) nuts. 13. Remove the 2 (5/16-18 x 4.75 inch) rear hydro mounting screws and 2 (5/16-18 inch) nuts.
  • Page 99 Hydrostatic Drive Transmission Installation (continued) 3. Install the 2 (0.312-18 x 2.250 inch) front and 2 (5/16-18 x 4.75 inch) rear hydro mounting screws, washers, and (5/16-18 inch) nuts. Do not tighten at this time. 4. Torque the cross shaft screw to 61 ± 6.779 N • m (43 ± 5 ft-lb). 5.

  • Page 100: Hydrostatic Drive Belt Replacement

    Hydrostatic Drive Transmission Installation (continued) 18. Purge the air out of the system. Refer to the product Operator’s Manual the purging air procedures. 19. Adjust the neutral setting if necessary. Refer to the product Operator’s Manual for adjusting the neutral setting procedures. 20.
  • Page 101 Chapter 8 Electrical System Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Fuse Block and Fuses ........................8–4 Key/Ignition Switch ..........................8–4 Hour Meter ............................8–5 Operator Presence Switch (Seat Switch) ..................8–6 Neutral Switch - Left and Right ......................8–7 Parking Brake Switch ........................

  • Page 102: General Information

    General Information The Titan Max utilizes a 12VDC electrical system. The systems consist of a 300cca 12v battery. The system use 2 neutral lock switches on the motion control levers, seat switch, brake switch, blade engagement switch (PTO), ignition switch, 15 AMP main fuse, and 20 AMP charging system fuse. This system also uses a start relay, electric PTO clutch, hour meter, TVS diode, and starter solenoid.

  • Page 103: Service And Repairs

    Service and Repairs Electrical Assembly g341896 Figure 106 Module Assembly Solenoid Hour Meter Switch Ignition Key Battery Wire Harness Adapter Wire Harness Bungle Strap Battery Tray PTO Switch Bail Switch Ignition Switch TITAN® Max Service Manual Page 8–3 Electrical System: Service and Repairs 3442-428 Rev A...

  • Page 104: Fuse Block And Fuses

    The fuse block houses the fuses that protect the electrical system from electrical surges. Note: Always use Toro fuses when replacing a damaged or blown fuse. Fuse Block and Fuses Test 1. Visually inspect the fuses. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade.

  • Page 105: Hour Meter

    g350861 Figure 108 Key/Ignition Switch Test 1. Remove the control panel from the right console. 2. Disconnect the ignition switch from the wire harness. 3. Using a digital multi-meter set to the OHM or Continuity setting, verify that continuity exists between the terminals listed for each switch position. 4.

  • Page 106: Operator Presence Switch (Seat Switch)

    Hour Meter Status Check (continued) g336418 Figure 109 Operator Presence Switch (Seat Switch) With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the neutral switches. Note: The operator presence switch is part of the seat assembly.

  • Page 107: Neutral Switch - Left And Right

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

  • Page 108: Starter Solenoid

    Starter Solenoid The solenoid is a remote switch that connects the battery to the starter motor when the ignition switch is turned to START. The solenoid protects the ignition switch from the high current drawn by the starter motor. g344833 Figure 113 Starter Solenoid Test 1.
  • Page 109 g336408 Figure 115 Note: The engine will not crank over when the PTO switch is in the ON position. All switches are supplied in parallel and feed into the Hour Meter. PTO Switch Test 1. Remove the control panel from the right console. 2.

  • Page 110: Electric Pto Clutch

    PTO Switch Test (continued) • Pin 2 and 5 should NOT have continuity (open) Electric PTO Clutch The PTO clutch electronically controls the engagement and disengagement of the PTO pulley (deck belt). The PTO clutch is composed of three major components: •...

  • Page 111: Service And Repairs

    Electric PTO Clutch Removal (continued) g344398 Figure 118 5. Using a spring removal tool, remove the spring from the mower deck. g344399 Figure 119 6. Remove the deck drive belt from the PTO clutch. TITAN® Max Service Manual Page 8–11 Electrical System: Service and Repairs 3442-428 Rev A...
  • Page 112 Electric PTO Clutch Removal (continued) g344400 Figure 120 7. Disconnect the clutch wire connector from the PTO clutch. g336161 Figure 121 8. Remove the screw and 2 spring washers securing the PTO clutch to the machine. 9. Remove the PTO clutch from the machine. Electric PTO Clutch Installation 1.
  • Page 113 Electric PTO Clutch Installation (continued) g336161 Figure 122 3. Install the deck drive belt onto the PTO clutch. g344400 Figure 123 4. Using the spring removal tool, install the spring onto the mower deck. TITAN® Max Service Manual Page 8–13 Electrical System: Service and Repairs 3442-428 Rev A...
  • Page 114 Electric PTO Clutch Installation (continued) g344399 Figure 124 5. Install the floor pan onto the machine. g344398 Figure 125 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. 7. Verify the proper function of the machine. Electric PTO Clutch-Coil Resistance Measurement Test If the PTO clutch is not engaging or is suspect as a cause of electrical problems, use the following electrical troubleshooting steps.
  • Page 115 Electric PTO Clutch-Coil Resistance Measurement Test (continued) g336410 Figure 126 5. See the PTO Clutch Electrical Specifications chart. Resistance (OHMs) AMP Draw Continuity to Ground 3.05 ± 5% 3.93 OPEN Electric PTO Clutch- PTO Clutch Continuity to Ground Test 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key.

  • Page 116: Tvs Diode

    Electric PTO Clutch- Measuring Clutch Current Draw (continued) g336411 Figure 127 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. 2.
  • Page 117 g336413 Figure 128 TVS Diode Testing If the main fuse blows each time the PTO clutch is engaged, check the TVS diode. 1. Disconnect the TVS diode from the harness. 2. Connect each lead of the meter to each terminal of the TVS diode. 3.
  • Page 118 Electrical System: Service and Repairs Page 8–18 TITAN® Max Service Manual 3442-428 Rev A...
  • Page 119 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 Kohler Engine Electrical Schematic ....................A–3 TITAN® Max Service Manual Page A–1 Foldout Drawings 3442-428 Rev A...

  • Page 120: Electrical Drawing Abbreviations

    Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color Black BR or BN Brown Blue Green Gray OR or OG Orange Pink R or RD T or TN Violet VIO or VT...

  • Page 121: Kohler Engine Electrical Schematic

    Kohler Engine Electrical Schematic g350654 , Drawing Rev A, Sheet 1 3442-428 Rev A Page A–3...

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