Toro Titan Z4800 User manual

Residential Products
2007 - 2008
Titan™ Z4800 & Z5200
Service 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.
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manufacturer’s service and repair instructions.
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The hydrostatic transaxle is a sophisticated piece of machinery. Maintain strict cleanliness control during all stages of
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other contamination can severely damage the system.
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comments regarding this manual, please contact us at the following address:
The Toro Company
Residential and Landscape Contractor Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
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ABOUT THIS MANUAL
Copyright© All Rights Reserved
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ABOUT THIS MANUAL
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TABLE OF CONTENTS
SAFETY INFORMATION
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SPECIFICATIONS
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RPM.........................................................................................................................................
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+\GURVWDWLF*URXQG'ULYH6\VWHP ..................................................................................................
Cutting Deck...................................................................................................................................
Dimensions.....................................................................................................................................
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CHASSIS
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/XEULFDWLRQ......................................................................................................................................
Front Caster Fork Bearing Replacement........................................................................................
Front Caster Fork Bearing Removal........................................................................................
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Caster Wheel Assembly Replacement...........................................................................................
Caster Wheel Assembly Removal............................................................................................
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/HIW+DQG)HQGHU)XHO7DQN5HSODFHPHQW .................................................................................
/HIW+DQG)HQGHU)XHO7DQN5HPRYDO..................................................................................
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5LJKW+DQG)HQGHU5HPRYDO .................................................................................................
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6HDW%R[5HSODFHPHQW.................................................................................................................
6HDW%R[5HPRYDO .................................................................................................................
6HDW%R[,QVWDOODWLRQ ..............................................................................................................
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+2&$VVHPEO\)URQW5HDU6KDIW$VVHPEO\5HPRYDO.....................................................
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ELECTRICAL
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Purpose....................................................................................................................................
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Testing......................................................................................................................................
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Purpose....................................................................................................................................
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Testing......................................................................................................................................

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TABLE OF CONTENTS
ELECTRICAL cont.
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Testing......................................................................................................................................
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Purpose....................................................................................................................................
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Testing......................................................................................................................................
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Purpose....................................................................................................................................
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Testing......................................................................................................................................
Coil Resistance Measurement.................................................................................................
Measuring Clutch Current Draw...............................................................................................
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Purpose....................................................................................................................................
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Testing......................................................................................................................................
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Testing....................................................................................................................................
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Testing.................................................................................................................................... 
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Testing....................................................................................................................................
Fuse Block....................................................................................................................................
Purpose..................................................................................................................................
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Purpose..................................................................................................................................
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Testing....................................................................................................................................
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.RKOHU(QJLQHFRQW................................................................................................................

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TABLE OF CONTENTS
MOWER DECK
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,GOHU$UP$VVHPEO\,QVWDOODWLRQ .............................................................................................. 
)L[HG,GOHU3XOOH\5HSODFHPHQW....................................................................................................
)L[HG,GOHU3XOOH\5HPRYDO ....................................................................................................
)L[HG,GOHU3XOOH\,QVWDOODWLRQ .................................................................................................
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Mower Deck Replacement ...........................................................................................................
Mower Deck Removal............................................................................................................
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/HYHOLQJWKH0RZHU'HFN .............................................................................................................
$GMXVWLQJWKH%ODGH6ORSH ............................................................................................................
Mower Belt Maintenance..............................................................................................................
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Mower Belt Replacement .............................................................................................................
Mower Belt Removal..............................................................................................................
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ENGINE
Engine Replacement......................................................................................................................
Engine Removal.......................................................................................................................
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HYDROSTATIC DRIVE SYSTEM
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+\GUR'ULYH%HOW5HPRYDO........................................................................................................
+\GUR'ULYH%HOW,QVWDOODWLRQ.....................................................................................................
Motion Control Damper Replacement............................................................................................
Motion Control Damper Removal.............................................................................................
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Motion Control Pivot Assembly Replacement.................................................................................
Motion Control Pivot Removal .................................................................................................
Motion Control Pivot Disassembly.........................................................................................
Motion Control Pivot Assembly..............................................................................................
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Transaxle Replacement................................................................................................................
Transaxle Removal................................................................................................................
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TABLE OF CONTENTS
HYDROSTATIC DRIVE SYSTEM cont.
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Tracking Adjustment.....................................................................................................................
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Troubleshooting............................................................................................................................

1-12007 - 2008 Titan Z Service Manual
1
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.
The Titan™ Z4800 and Z5200 operator’s manuals
contain safety information and operating tips for safe
operating practices. Operator’s manuals are available
online, through your Toro parts source, or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
Think Safety First
Avoid unexpected starting of engine...
Always turn off the engine and disconnect the spark plug
wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations...
Stay clear of all moving parts whenever the engine is
running. Treat all normally moving parts as if they were
moving whenever the engine is running or has the
potential to start.
Avoid burns...
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which may increase in temperature during operation,
while the unit is running or shortly after it has been
running.
$YRLG¿UHVDQGH[SORVLRQV
Avoid spilling fuel and never smoke while working with
any type of fuel or lubricant. Wipe up any spilled fuel
or oil immediately. Never remove the fuel cap or add
fuel when the engine is running. Always use approved,
labeled containers for storing or transporting fuel and
lubricants.
Avoid asphyxiation...
1HYHURSHUDWHDQHQJLQHLQDFRQ¿QHGDUHDZLWKRXW
proper ventilation.
Avoid injury from batteries...
Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes and clothing. Battery gases can
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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...
Always clear the area of bystanders before starting or
testing powered equipment.
Avoid injury due to projectiles...
Always clear the area of sticks, rocks or any other debris
that could be picked up and thrown by the powered
equipment.
$YRLGPRGL¿FDWLRQV
Never alter or modify any part unless it is a factory
approved procedure.
Avoid unsafe operation...
Always test the safety interlock system after making
adjustments or repairs on the machine. Refer to the
Electrical section in this manual for more information.
!

1-2 2007 - 2008 Titan Z Service Manual
1
SAFETY INFORMATION
THIS PAGE INTENTIONALLY LEFT BLANK.

SPECIFICATIONS
2-12007 - 2008 Titan Z Service Manual
2
(QJLQH6SHFL¿FDWLRQV
Model Briggs & Stratton Kohler
74812 44K777-0123-E1
24 HP
74814 44K777-0123-E1
24 HP
74816 SV820-0012
23 HP
74818 SV820-0012
23 HP
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
Charging Capacity 16 amps 15 amps
Battery Voltage 12 volt 12 volt
Polarity Negative Ground Negative Ground
Battery Type BCI Group U1
280 CCA BCI Group U1 260 CCA
Fuses (1) 25 amp (1) 20 amp
(1) 15 amp
(1) 25 amp
(1) 10 amp
(1) 15 amp

SPECIFICATIONS
2-2 2007 - 2008 Titan Z Service Manual
2
Hydrostatic Ground Drive System
Dimensions
Overall Width
Overall Height Weight
Without deck With deck
'HÀHFWRU
up 'HÀHFWRU down
48” Deck 45.5” (116cm) 48.3”
(122cm) 59.4” (151cm) 74812 – 42.2” (107cm) 74816 – 41.8” (106cm) 645 lb. (293kg)
52” Deck 47.0” (119cm) 53.0”
(135cm) 64.2” (163cm) 74814 – 42.2” (107cm) 74818 – 41.8” (106cm) 660 lb. (299kg)
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
Cutting Deck
48” Deck 52” Deck
Cutting Width 48” (122cm) 52” (132cm)
Discharge Side
Blade Size (3 ea.) 16.25” (41.3cm) 18.00” (45.7cm)
Blade Spindles Solid steel spindle shafts with no maintenance bearings.
Deck Drive Electric clutch mounted on vertical engine shaft. Blades are driven by one
belt (w/self-tensioning idler) direct from engine.
Maximum turf protection is
provided by anti-scalp rollers 3 rollers (48” & 52”)
Cutting Height Adjustment A foot deck lift lever is used to adjust the cutting height from 1-1/2” (3.8cm)
to 4-1/2” (11.4cm) in 1/2” (1.3cm) increments.

SPECIFICATIONS
2-32007 - 2008 Titan Z Service Manual
2
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. (95 - 122 Nm)
Clutch Mounting Bolt
(secured w/threadlocker) 50 - 55 ft-lbs. (68 - 75 Nm) 50 - 55 ft-lbs. (68 - 75 Nm)
Spark Plug 15 ft-lbs. (20 Nm) 15 ft-lbs. (20 Nm)

SPECIFICATIONS
2-4 2007 - 2008 Titan Z Service Manual
2
THIS PAGE INTENTIONALLY LEFT BLANK.

CHASSIS
3-12007 - 2008 Titan Z Service Manual
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The unit model and serial number plate is located on the
frame behind the seat on the left side (Fig. 001).
A. Read the instructions before
servicing or performing
maintenance.
B. Time interval.
C. Check oil level.
D. Refer to Operator’s Manual for
grease instructions.
E. Check hydraulic oil level and
refer to Operator’s manual for
further instructions.
F. Check tire pressure.
Fig. 001 IMG-0162
The unit should be greased every 25 hours, or more
often when operated in dusty, dirty, or sandy conditions.
Located under the seat is a diagram showing mainten-
ance points (Fig. 002).
Fig. 002 grease points line art
Note: Grease Type: NGLI grade #2 multi-purpose
gun grease.
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pivots.

CHASSIS
3-2 2007 - 2008 Titan Z Service Manual
3
0RZHUGHFNLGOHUJUHDVH¿WWLQJGHFNUHPRYHGIRUFODULW\
(Fig. 004):
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving parts
to stop before leaving the operating position.
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bearings.
5. Wipe up any excess grease.
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Fig. 003 IMG-0179a
Fig. 004 IMG-0675
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CHASSIS
3-32007 - 2008 Titan Z Service Manual
3
Front Caster Fork Bearing
5HSODFHPHQW
Front Caster Fork Bearing Removal
4. Slide the caster fork assembly out of the front axle
bearings (Fig. 008).
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.
3. Remove the hex head bolt and washer securing the
caster fork assembly to the front axle (Fig. 007).
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 fork assembly from the front
axle assembly (Fig. 006).
Fig. 006 IMG-0163a
Fig. 007 IMG-0164
Fig. 008 IMG-0165

CHASSIS
3-4 2007 - 2008 Titan Z Service Manual
3
Front Caster Fork Bearing Installation
3. Lower the machine to the ground and remove the
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5. Using a drift punch and hammer, tap the lower ball
bearing out of the front axle frame (Fig. 009).
6. With a drift punch and hammer, tap the upper ball
bearing out of the front axle frame (Fig. 010).
1. Install the upper and lower ball bearings into the
front axle frame (Fig. 011).
Fig. 009 IMG-0166
Fig. 010 IMG-0167
Fig. 011 IMG-0168
2. Slide the caster fork assembly into the front axle
frame, through the upper and lower ball bearings.
Install a washer and bolt to secure the caster as-
sembly to the front axle frame (Fig. 012).
Fig. 012 IMG-0169

CHASSIS
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3
&DVWHU:KHHO$VVHPEO\5HSODFHPHQW
Caster Wheel Assembly Removal
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each side of the wheel rims (Fig. 016).
4. Remove the wheel spanner from the wheel
assembly (Fig. 015).
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).
Fig. 013 IMG-0163a
3. Remove the bolt, washers and nut securing the
caster wheel assembly to the caster fork (Fig. 014).
Fig. 014 IMG-0171
Fig. 015 IMG-0172
Fig. 016 IMG-0174a

CHASSIS
3-6 2007 - 2008 Titan Z Service Manual
3
Caster Wheel Assembly Installation
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(Fig. 017).
2. Slide the wheel spanner into the wheel assembly
(Fig. 018).
3. Position the wheel assembly into the caster fork
VRWKHYDOYHVWHPDQGJUHDVH¿WWLQJDUHIDFLQJWKH
inside (Fig. 019).
Fig. 017 IMG-0175a
Fig. 018 IMG-0172
Fig. 019 IMG-0176
4. Position a washer on both sides of the wheel be-
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the wheel axle bolt through the fork and wheel
assembly (Fig. 020).
Fig. 020 IMG-0177

CHASSIS
3-72007 - 2008 Titan Z Service Manual
3
Left Hand Fender & Fuel Tank
5HSODFHPHQW
Left Hand Fender & Fuel Tank Removal
6. Grease the wheel assembly (Fig. 022). Refer to
“Lubrication” on page 3-1.
5. Install a nut onto the wheel axle bolt to secure the
wheel assembly to the caster fork (Fig. 021).
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. 023).
Fig. 021 IMG-0171
Fig. 022 IMG-0179
Fig. 023 IMG-0180a
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