Page 1
LCE Products
Z Master 500 Series
Gasoline Engine Models
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 knowledge and mechanical/electrical skills are assumed. The Table of Contents lists
the systems and the related topics covered in this manual.
The following service materials are available in addition to this service manual:
Hydrostatic Pumps: Hydro-Gear BDP-10A/16A/21L - Service and Repair Manual
Form #492-4789
Wheel Motors: Parker/Ross Wheel Motor Service Manual
Form #492-4753
Gas Engine: Through engine manufacturer
Hydraulic Troubleshooting: Interactive hydraulic troubleshooting and failure analysis on compact disk
Form #492-4777
Electrical Troubleshooting: Interactive electrical troubleshooting and wiring diagrams on compact disk
Form #492-9143
Z Master 500 Series gasoline engine machines, model years 2004 and 2005 are covered in this
manual. This manual may also be specied for use on later model products.
The hydrostatic drive system is precision machinery. Maintain strict cleanliness control during all
stages of service and repair. Cover or cap all hose ends and ttings whenever they are exposed.
Even a small amount of dirt or other contamination can severely damage the system.
We are hopeful that you will nd this manual a valuable addition to your service shop. If you have
any questions or comments regarding this manual, please contact us at the following address:
The Toro Company
LCE Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
The Toro Company reserves the right to change product specications or this manual without
notice.
Copyright© All Rights Reserved
©2005 The Toro Company
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Page 4
TABLE OF CONTENTS
SAFETY INFORMATION
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
Kawasaki Liquid Cooled Product Shots . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler EFI Product Shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler Gas Product Shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki Gas Product Shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specications
Greasing and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model and Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . .
Available Service Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) . . . . . . . . . .
Other Torque Specications
SAE Grade 8 Steel Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . . . . . . . . . . .
Wheel Bolts and Lug Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
US to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
2-2
2-3
2-4
2-5
2-6
2-7
2-7
2-7
2-8
2-8
2-8
2-8
2-9
2-10
2-11
2-11
2-12
2-13
2-14
2-15
2-15
2-15
2-15
2-16
2-17
CHASSIS
Caster Fork Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Caster Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caster Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Removal and Bearing Replacement . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Removal
Left Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Side Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . .
Hood Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Band Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Band Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Lift Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Lift Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3-2
3-4
3-5
3-6
3-7
3-7
3-8
3-8
3-8
3-10
3-10
3-10
3-11
3-13
3-13
3-13
3-17
iZ Master 500 Gas Series Service Manual
Page 5
TABLE OF CONTENTS
CHASSIS cont.
Motion Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM
Hydrostatic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Handle Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the RH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the LH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing to Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE
Kohler Air-Cooled Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler Air-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki Air-Cooled Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki Air-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . .
28 HP Kohler EFI Air-Cooled Engine Removal . . . . . . . . . . . . . . . . . . . . . .
28 HP Kohler EFI Air-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . . .
Kohler Electronic Fuel Injection (EFI) Models
EFI Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EFI Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 HP Kawasaki Liquid-Cooled Engine Removal . . . . . . . . . . . . . . . . . . . . .
27 HP Kawasaki Liquid-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . .
Cooling Fan Assembly Removal - 27 HP Kawasaki Liquid-Cooled Engine . . . . . . . . . . . .
Cooling Fan Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-20
3-22
4-2
4-4
4-7
4-9
4-12
4-14
4-14
4-15
4-16
4-17
4-18
4-18
4-20
4-21
5-2
5-5
5-8
5-10
5-13
5-19
5-24
5-25
5-26
5-33
5-41
5-43
ELECTRICAL
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Gauge Liquid-Cooled Engine Only . . . . . . . . . . . . . . . . . . . . . .
Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler EFI Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler A/C (Air Cooled) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . .
ii Z Master 500 Gas Series Service Manual
6-2
6-2
6-4
6-6
6-7
6-8
6-9
6-11
6-12
6-14
6-14
6-15
6-16
6-17
6-17
6-18
6-19
Page 6
TABLE OF CONTENTS
ELECTRICAL cont.
Kawasaki A/C (Air Cooled) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki L/C (Liquid Cooled) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . .
MOWER DECKS/PTO
Electric PTO Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Deck Removal (52, 60, 72”) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Deck Installation (52, 60, 72”) . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mower Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Mower Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower
Setting up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Front-to-Rear Mower Pitch . . . . . . . . . . . . . . . . . . . . . . . . .
6-20
6-21
7-2
7-4
7-8
7-11
7-14
7-15
7-16
7-19
7-24
7-25
7-27
7-28
7-29
iiiZ Master 500 Gas Series Service Manual
Page 7
TABLE OF CONTENTS
THIS PAGE INTENTIONALLY LEFT BLANK.
iv Z Master 500 Gas Series Service Manual
Page 8
SAFETY INFORMATION
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks/PTO . . . . . . . . .
1-1Z Master 500 Gas Series Service Manual
6
7
Page 9
SAFETY INFORMATION
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.
The riding mower and attachment operator's manual
contain safety information and operating tips for safe
operating practices. Operator's manuals are available
through your Toro parts source or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
General Information
1
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
Z Master Z500 Series Zero-turn Riding Mower.
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...
The riding mower and attachment operator’s manual
contain safety information and operating tips for safe
operating practices. Operator’s manuals are available
through your Toro parts source or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
Avoid injury from batteries...
Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes, and clothing. Battery gases can
explode. Keep cigarettes, sparks, and ames away from
the battery.
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...
Do not touch the engine, mufer, or other components
which may increase in temperature during operation,
while the unit is running or shortly after is has been
running.
Avoid res and explosions...
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...
Never operate an engine in a conned area without
proper ventilation.
1-2 Z Master 500 Gas Series Service Manual
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.
Avoid modications...
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.
Page 10
SPECIFICATIONS
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks/PTO . . . . . . . . .
2-1Z Master 500 Gas Series Service Manual
6
7
Page 11
2
SPECIFICATIONS
Kawasaki Liquid Cooled Product
Shots
Fig 001 DSC-2861a
Fig 002 DSC-2860a Fig 004 DSC-2864a
Fig 003 DSC-3792a
2-2 Z Master 500 Gas Series Service Manual
Page 12
Kohler EFI Product Shots
SPECIFICATIONS
2
Fig 005 DSC-2865b
Fig 006 DSC-2866a
Fig 007 DSC-2867a
Fig 008 DSC-2868a
2-3Z Master 500 Gas Series Service Manual
Page 13
2
SPECIFICATIONS
Kohler Gas Product Shots
Fig 009 DSC-2870a
Fig 010 DSC-2869a Fig 012 DSC-2874a
Fig 011 DSC-2875a
2-4 Z Master 500 Gas Series Service Manual
Page 14
Kawasaki Gas Product Shots
SPECIFICATIONS
2
Fig 013 DSC-2877a
Fig 014 DSC-2879a
Fig 015 DSC-2880a
Fig 016 DSC-2882a
2-5Z Master 500 Gas Series Service Manual
Page 15
SPECIFICATIONS
Engines
Output Make High Idle Low Idle Charging Coil
2
20 HP (14.9kW) Kohler
OHV V-Twin
Air Cooled
23 HP (17.2 kW) Kohler
OHV V-Twin
Air Cooled
25 HP (18.6 kW) Kawasaki
OHV V-Twin
Air Cooled
27 HP (20.1 kW) Kohler
OHV V-Twin
Air Cooled
27 HP (20.1 kW) Kawasaki
OHV V-Twin
Liquid Cooled
28 HP (20.8 kW) Kohler
OHV V-Twin
EFI Air-Cooled
3750 +50/-100 RPM 1500 RPM 15 AMP
3750 +50/-100 RPM 1500 RPM 15 AMP
3750 +50/-100 RPM
3000 + 100 Int’l
3750 +50/-100 RPM 1500 RPM 15 AMP
3750 +50/-100 RPM 2250 RPM 30 AMP
3750 +50/-100 RPM 1500 RPM 25 AMP
1500 RPM 13 AMP
2-6 Z Master 500 Gas Series Service Manual
Page 16
SPECIFICATIONS
Dimensions and Weight
ROPS Height Width
Model Weight Folded Upright Deck Deector Length
23 hp Kohler/52” TF Deck 1140 lbs
(517kg)
23 hp Kohler/60” TF Deck 1215 lbs
(551kg)
25 hp Kawasaki/60” TF Deck 1215 lbs
(551kg)
27 hp Kohler/52” TF Deck 1176 lbs
(533kg)
27 hp Kohler/60” TF Deck 1215 lbs
(551kg)
27 hp Kohler/72” TF Deck 1280 lbs
(583kg)
27 hp Kawasaki LC/60”TF Deck 1330 lbs
(603kg)
27 hp Kawasaki LC/72”TF Deck 1395 lbs
(633kg)
28 hp Kohler EFI/60” TF Deck 1254 lbs
(569kg)
28 hp Kohler EFI/72” TF Deck 1319 lbs
(598kg)
53”
(134cm)
53”
(134cm)
53”
(134cm)
53”
(134cm)
53”
(134cm)
53”
(134cm)
53”
(134cm)
53”
(134cm)
53”
(134cm)
53”
(134cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
72”
(183cm)
53.7”
(136cm)
61.7”
(157cm)
61.7”
(157cm)
53.7”
(136cm)
61.7”
(157cm)
73.6”
(187cm)
61.7”
(157cm)
73.6”
(187cm)
61.7”
(157cm)
73.6”
(187cm)
68”
(173cm)
76”
(193cm)
76”
(193cm)
68”
(173cm)
76”
(193cm)
88”
(223cm)
76”
(193cm)
88”
(223cm)
76”
(193cm)
88”
(223cm)
79.5”
(202cm)
81.5”
(207cm)
81.5”
(207cm)
79.5”
(202cm)
81.5”
(207cm)
84.5”
(215cm)
81.5”
(207cm)
84.5”
(215cm)
81.5”
(207cm)
84.5”
(215cm)
2
Construction
Frame Assembly Consists of front and rear frames bolted together
Front Frame Welded 2 x 2 x .188 structural steel tube
Rear Frame Welded tube and fabricated steel
Fuel System
Tanks Dual fuel tanks containing large ll necks and vented caps
Mounted above the drive wheels
Capacity 12 gallons (45.4l) [6 gallons per tank]
Check Valve In-line check valves (Selector valve on EFI units)
Fuel Filter 40 micron, replaceable in-line lter
2-7Z Master 500 Gas Series Service Manual
Page 17
2
SPECIFICATIONS
Traction System
Hydraulic Pumps Twin Hydro-Gear BDP/PJ Series variable displacement hydrostatic with shock valves
Pump Drive Self-tensioning belt drive
Wheel Motors Twin Parker-Ross Torqmotor™ positive displacement with 1.25 inch heavy duty
tapered shafts
Ground Speeds Innitely variable: Forward: 0 - 10 mph (16.1 km/hr)
Reverse: 0 - 6.3 mph (10.1 km/hr)
Release Valves Contained in pumps. Allow unit to be moved without engine running
Hydraulic Fluid Mobil 1, 15W50 (Synthetic motor oil)
System Capacity 2.1 quarts (2.0l)
Deck Drive
Clutch Warner® Electromagnetic “Mag-Stop” with 200 ft-lb. (271 Nm) rating
Type Mule drive from engine to deck
Take-Up Spring-loaded idler system
Tires
Rear Drive Tires 4-ply with “Turf Master” tread
24” x 12.0” – 12 [Models with 62” or 72” deck]
23” x 9.5” – 12 [Models with 52” deck]
Front Caster Tires 4-ply with smooth tread
13” x 6.5” – 6
Tire Pressure 13 psi (90 kpa)
Electrical System
Voltage 12 volt, negative ground
Battery Type BCI group U1
Fuses Blade Type
2-8 Z Master 500 Gas Series Service Manual
Page 18
SPECIFICATIONS
Cutting Decks
Conguration Side discharge, mid-mounted rotary with three blades.
Construction 7 gauge, high strength 50,000 psi steel, 5-1/2” deep, advanced, super ow system, welded
construction. 3/8” steel discharge reinforcement plate doubles as bagger attachment point.
Discharge Right hand as viewed from operator seat. Rubber chute, spring biased down toward
operating position. Adjustable ow control bafe.
Blade Tip Speed 18,000 + ft/min at high idle
152cm mower – 4600.7 m/min @3000 RPM
Height of Cut Adjustable from the seat with range 1.5” – 5” in 1/4” increments (3.8cm - 12.7cm)
Deck Suspension Deck suspended from machine by four lift chains, and attached to rear wheel supports by
two struts.
Belt Covers 16-gauge, formed steel covers. Attached with swell latches.
Gauge Wheels 52” Cutting Deck – Five adjustable gauge wheels to reduce scalping: three on front of
deck (one on left-hand side and two in center) and two on rear of deck (left and right
sides). Wheels have four adjustment positions.
60”, 72”, and 152cm Cutting Decks – Six adjustable gauge wheels to reduce scalping: four
on front of deck (one each left-hand and right-hand sides, and two center) and two on rear
of deck (left and right sides). Wheels have four positions.
Lubrication Fittings:
Front Castor Pivots 2 removable plugs (1 per side) for periodic lubrication.
Front Castor
Wheels
Lift Assembly 5 ttings.
Mule Drive Idler 1 tting.
Brake Arms 2 ttings (1 per side).
Rear Deck Struts 2 ttings (1 per side).
Deck Spindles 3 ttings (1 per spindle).
Hydraulic Pump
Drive Tensioner
2 ttings (1 per side).
1 tting.
2
2-9Z Master 500 Gas Series Service Manual
Page 19
2
SPECIFICATIONS
General Specications
Greasing and Lubrication:
Grease: No. 2 general purpose lithium base or molybdenum grease.
Where to Add Grease: See Check Service Reference Aid decal below (Fig. 017).
Fig 018 g. 55 m-5615
1. Cap 3. Cold uid level - full
2. Bafe 4. Hot uid level - full
Fig 017 g. 50 decal
Hydraulic System Oil Capacity: 4 quarts (3.8 l)
Fluid Type: Mobil 1 15w50 synthetic motor oil or equivalent synthetic oil
Fluid Level: Check the uid level while the uid is warm. The uid should be between cold
and hot.
Note: The uid level should be to the top of the hot level of the bafe,
when the uid is hot (Fig. 018 above).
2-10 Z Master 500 Gas Series Service Manual
Page 20
SPECIFICATIONS
Model and Serial Number Location The unit model and serial number plate is located on the right hand side of
the unit, below the right side motion control lever (Fig. 019).
2
Fig 019 DSC-2351
Engine Model and Serial Number
Identication:
Hydrostatic Pumps Model and Serial
Number:
Consult the appropriate engine manufacture’s service literature for the
location and translation of the engine model and serial number information.
The label above (Fig. 020), is located on the pump housing. It identies the
model and conguration of the BDP pump.
Fig 020 conguration
Available Service Manuals
Hydrostatic Pumps: Hydro-Gear BDP-10A/16A/21L – Service and Repair Manual
Form # 492-4789
Wheel Motors: Parker/Ross Wheel Motor Service Manual
Form # 492-4753
Engine: Engine manufacturer
Hydraulic Troubleshooting: Interactive hydraulic troubleshooting and failure analysis on compact disk
Form #492-4777
Electrical Troubleshooting: Interactive electrical troubleshooting and wiring diagrams on compact disk
Form #492-9143
2-11Z Master 500 Gas Series Service Manual
Page 21
SPECIFICATIONS
2
Torque Specifications
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.
These torque specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in the
service manual. The following factors shall be
considered when applying torque: cleanliness of the
fastener, use of a thread sealant (Loctite), degree of
lubrication on the fastener, presence of a prevailing
torque feature, hardness of the surface underneath of
the fastener’s head, or similar condition which affects
the installation.
As noted in the following tables, torque values should
be reduced by 25% for lubricated fasteners to
achieve the similar stress as a dry fastener. Torque
values may also have to be reduced when the fastener
is threaded into aluminum or brass. The specific
torque value should be determined based on the
aluminum or brass material strength, fastener size,
length of thread engagement, etc.
Fastener Identification
Inch Series Bolts and Screws
(A) Grade 1
(B) Grade 5
Figure A
(C) Grade 8
The standard method of verifying torque shall be
performed by marking a line on the fastener (head or
nut) and mating part, then back off fastener 1/4 of a
turn. Measure the torque required to tighten the
fastener until the lines match up.
Figure B
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
2-12 Z Master 500 Gas Series Service Manual
Page 22
SPECIFICATIONS
SAE Grade 8 Bolts, Screws,
Studs, & Sems with Regular
2
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, &
Thread Size
# 6 - 32 UNC
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8 - 32 UNC
# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10 - 24 UNC
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 17 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
8 with Thin
Height Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
10 ± 2 13 ± 2 147 ± 23
13 ± 2 25 ± 5 282 ± 30
18 ± 2 30 ± 5 339 ± 56
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
15 ± 2 170 ± 20 23 ± 2 260 ± 20
29 ± 3 330 ± 30 41 ± 4 460 ± 45
42 ± 4 475 ± 45 60 ± 6 674 ± 70
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
2
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the
minimum proof load specified in SAE J429. The
tolerance is approximately
value. Thin height nuts include jam nuts.
± 10% of the nominal torque
2-13Z Master 500 Gas Series Service Manual
Page 23
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
2
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm
M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 53 ± 5 ft-lb 72 ± 7 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 92 ± 9 ft-lb 125 ± 12 N-m
M16 X 2.0 166 ± 15 ft-lb 225 ± 20 N-m 229 ± 22 ft-lb 310 ± 30 N-m
M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 37 ft-lb 610 ± 50 N-m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Strong Nuts)
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately
the nominal torque value. Thin height nuts include jam nuts.
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts (
Class 10 or Strong Nuts)
± 10% of
2-14 Z Master 500 Gas Series Service Manual
Page 24
Other Torque Specifications
SPECIFICATIONS
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
3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb
1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non-lubricated fasteners.
Thread Cutting Screws
Thread
Size
No. 6 18 20 20 ± 5 in-lb
Threads per Inch
Type A Type B
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
(Zinc Plated Steel)
Baseline Torque*
2
No. 8 - 32 UNC 30 ± 5 in-lb
No.10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors
in-lb X 11.2985 - N-cm
ft-lb X 1.3558 = N-m
No. 8 15 18 30 ± 5 in-lb
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and
finish must be considered when determining specific
torque values. All torque values are based on nonlubricated fasteners.
N-cm X - 0.08851 = in-lb
N-cm X 0.73776 - ft-lb
2-15Z Master 500 Gas Series Service Manual
Page 25
2
SPECIFICATIONS
Equivalents and Conversions
Decimal and Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
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 2.381 19/32 0.59375 15.081
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.541 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm
2-16 Z Master 500 Gas Series Service Manual
Page 26
Linear
Measurement
Area
Volume
Weight
Pressure
Work
Liquid Volume
Liquid Flows
Temperature
SPECIFICATIONS
U.S. to Metric Conversions
To Convert Into Multiply By
Miles
Yards
Feet
Feet
Inches
Inches
Inches
Square Miles
Square Feet
Square Inches
Acre
Cubic Yards
Cubic Feet
Cubic Inches
Tons (Short)
Pounds
Ounces
Pounds/Sq. In. Kilopascal
Foot-pounds
Foot-pounds
Inch-pounds
Quarts
Gallons
Gallons/Minute Liters/Minute
Fahrenheit Celsius
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
Square Kilometers
Square Meters
Square Centimeters
Hectare
Cubic Meters
Cubic Meters
Cubic Centimeters
Metric Tons
Kilograms
Grams
Newton-Meters
Kilogram-Meters
Kilogram-Centimeters
Liters
Liters
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
6.895
1.356
0.1383
1.152144
0.9463
3.785
3.785
1. Subtract 32°
2. Multiply by 5/9
2
2-17Z Master 500 Gas Series Service Manual
Page 27
2
SPECIFICATIONS
THIS PAGE INTENTIONALLY LEFT BLANK.
2-18 Z Master 500 Gas Series Service Manual
Page 28
CHASSIS
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks/PTO . . . . . . . . .
3-1Z Master 500 Gas Series Service Manual
6
7
Page 29
CHASSIS
3
Caster Fork Assembly Removal
1. Raise the front of the unit off the ground, allowing
enough clearance to remove the castor fork from the
bottom of the hub.
2. With a hammer and chisel, remove the top grease
cap (Fig. 021).
4. Remove the Belleville washers and caster fork and
wheel assembly (Fig. 023).
Fig 023 DSC-1533
Replacing the Caster Bearings
Fig 021 mvc-1531
3. Remove the locknut (Fig. 022).
Fig 022 DSC-1532
1. Remove the top tapered roller bearing (Fig. 024).
Fig 024 DSC-1534
3-2 Z Master 500 Gas Series Service Manual
Page 30
CHASSIS
2. Remove bottom seal and tapered roller bearing (Fig.
025).
Fig 025 DSC-1535
3. With a driver and hammer, remove both the bottom
and top tapered bearing cups (Fig. 026).
4. With a driver and hammer, install new tapered
bearing cups. The bearing cups are tapered; make
sure the tapered/thicker end of the cup is installed
inward for the top and bottom end (Fig. 027). Tap the
bearing cups in until they seat against the step in the
caster hub.
3
Fig 027 DSC-1537
Fig 026 DSC-1536
5. Pack the upper and lower tapered bearings prior to
installation (Fig. 028).
Fig 028 DSC-1539
3-3Z Master 500 Gas Series Service Manual
Page 31
CHASSIS
3
6. Install the lower bearing and seal, with the open end
of the seal facing up (Fig. 029).
Fig 029 DSC-1538
Castor Fork Assembly
2. Install the upper bearing.
3. Install the Belleville (spring) washers as shown in
(Fig. 031).
A. Dust Cap
B. Locknut
C. Spring Washers
A
B
C
Fig 031 washers line art
1. Install the castor fork into the frame (Fig. 030).
Fig 030 DSC-1533
4. Install the locknut and tighten until the spring
washers are at, then back off 1/4 turn to properly
set the preload on the bearings (Fig. 032).
Fig 032 DSC-1532
3-4 Z Master 500 Gas Series Service Manual
Page 32
CHASSIS
5. Remove the plug located on the side of the hub on
the frame for the castor fork. Install a grease tting,
and pump grease into the housing until grease is
passing through the upper bearing (Fig. 033).
Fig 033 DSC-1540
6. Remove the grease tting and install the grease
plug.
Front Wheel Removal and Bearing
Replacement
1. Raise the front of the unit off the ground.
2. Remove the wheel bolt from the fork (Fig. 035).
3
Fig 035 DSC-1543
7. Install the grease cap on the caster hub (Fig. 034).
Fig 034 DSC-1541
3. Remove bearing spacers and the front caster
spacer. Remove the seals located on each side of
the wheel and both the tapered bearings (Fig. 036).
A. Bearing Spacer D. Caster Spacer
B. Bearing Seal E. Retaining wheel nut
C. Taper Bearing F. Retaining wheel bolt
B
C
D
E
B
C
AA
F
Fig 036 DSC-1546
3-5Z Master 500 Gas Series Service Manual
Page 33
CHASSIS
3
4. Pack both tapered wheel bearings. Reassemble
per Fig. 036. Pump grease into the wheel bearings
through the grease tting located on the rim (Fig.
037).
Fig 037 DSC-1547
Fuel Tank Removal
3. Remove the 4 screws retaining the control panel and
control panel shield to the tank (Fig. 039).
Fig 039 DSC-3092
4. Carefully remove the control panel and control panel
shield by lifting the panel and sliding toward the
middle of the unit.
Left Side Fuel Tank Removal
1. Disconnect the negative battery cable from the
battery. Drain the fuel tanks.
2. Remove the fuel hose clamp at the bottom of the
fuel tank (Fig. 038).
Note: DO NOT disconnect any cables or wiring.
5. Remove the bolt, lock washer, and nut located under
the front of the fuel tank (Fig. 040).
Fig 040 DSC-3094
Fig 038 DSC-3091
3-6 Z Master 500 Gas Series Service Manual
Page 34
CHASSIS
6. Located under the rear portion of the fuel tank,
remove the 2 nuts, springs, and washers from the
fuel tank studs (Fig. 041).
Fig 041 DSC-3095
Note: Rear tire removed for clarity.
8. Remove the fuel tank from the frame (Fig. 043).
Fig 043 DSC-3099
Left Side Fuel Tank Installation
3
7. On the inside of the frame under the rear portion of
the fuel tank, remove the nut, spring, and washer
from the fuel tank stud (Fig. 042).
Fig 042 DSC-3098
Reverse the order of removal.
Right Side Fuel Tank Removal and
Installation
Follow the same procedures for the Left Side Tank
Removal and Installation except skip the instructions for
removing the control panel.
3-7Z Master 500 Gas Series Service Manual
Page 35
CHASSIS
3
Hood Assembly Removal
1. Unhook the two rubber latches located on the rear of
the hood.
2. Remove the two hairpins, clevis pins, and washers
located in the front left and right lower side of the
hood (Fig. 044).
Hood Assembly Installation
Reverse the order of removal.
Brake Lever Removal
1. Release the parking brake (forward position).
2. Remove the cotter pin and clevis pin from the brake
rod yoke (Fig. 046).
Fig 044 DSC-1579
3. Lift the hood and remove the stop lanyards located
on each side of the hood. Remove the hood from the
frame of the unit (Fig. 045).
Fig 045 DSC-1581
Fig 046 DSC-1618
3. Lift the oor pan assembly to access the brake lever
shaft and cotter pin (Fig. 047).
Fig 047 DSC-1619
3-8 Z Master 500 Gas Series Service Manual
Page 36
CHASSIS
4. Remove the brake shaft cotter pin (Fig. 048).
Fig 048 DSC-1620
5. Slide the brake shaft out of the frame pivot bushings
(Fig 049).
6. Using a hammer and punch, drive both brake lever
control bearings from the brake pivot (Fig. 050).
3
Fig 050 DSC-1622
7. Inspect the brake shaft and bushings for excessive
wear. Replace any worn or broken components
(Fig. 051).
Fig 049 DSC-1621
A
B
Fig 051 DSC-1623
A. Brake lever C. Cotter pin
B. Bushings
C
3-9Z Master 500 Gas Series Service Manual
Page 37
CHASSIS
3
Brake Lever Installation
Reverse the order of removal
Brake Band Removal
1. Raise the left rear tire off the ground (Fig. 052).
3. Remove bolts, brake band retainer, spacers, and
brake band (Fig. 053).
A
B
C
D
Fig 053 DSC-1626
A. 3 Bolts C. 3 Spacers
B. Brake Band Retainer D. Brake Band
Fig 052 DSC-1624
2. Remove the four wheel lug bolts.
Brake Band Installation
1. Install the brake band around the wheel hub (Fig.
054).
Fig 054 DSC-1629
3-10 Z Master 500 Gas Series Service Manual
Page 38
CHASSIS
2. Install the 3 bolts, brake band retainer, brake band,
and spacers and tighten (Fig. 055).
Fig 055 DSC-1631
3. Install tire assembly and the 4 wheel bolts.
2. On the left side of the machine, remove both clevis
spring pins, one from the brake rod and the other
from the brake shaft (Fig. 056).
3
Fig 056 DSC-3100
3. On the right side remove the clevis spring clip from
the brake shaft (Fig. 057).
Brake Shaft Removal
1. Raise the rear end of the unit and remove the right
and left rear tires.
Note: To prevent the unit from rolling, block the two
front tires.
Fig 057 DSC-3101
3-11Z Master 500 Gas Series Service Manual
Page 39
CHASSIS
3
4. On the right side, remove the two bolts and nuts
holding the ange bearing (Fig. 058).
Fig 058 DSC-3104
5. On the left side, remove the two bolts and nuts
holding the ange bearing (Fig. 059).
6. Remove the brake shaft from the left side of the unit
(Fig. 060).
Fig 060 DSC-3106
7. Inspect the brake shaft and ange bearings for
excessive wear (Fig. 061).
Fig 059 DSC-3105
C C
D
A
B
Fig 061 DSC-3107
A. Brake shaft C. Bolts
B. Flange bearings D. Nuts
D
B
3-12 Z Master 500 Gas Series Service Manual
Page 40
CHASSIS
Brake Shaft Installation
Reverse the order of removal.
Adjusting the Parking Brake
Check the parking brake for proper adjustment.
1. Disengage the brake lever (lever down).
2. Measure the length of the spring. The measurement
should be 2-3/4” (70mm) between the washers (Fig.
062).
3. If an adjustment is necessary, loosen the jam nut
below the spring and tighten the nut directly below
the yoke (Fig. 062). Turn the nut until the correct
measurement is obtained. Tighten the two nuts
together and repeat on the opposite side of the unit.
4. Turn the nuts clockwise to shorten the spring length
and counterclockwise to lengthen the spring.
5. Engage the parking brake, lever up.
6. Measure the distance between the trunnion roller
and the collar on the brake rod. The measurement
should be 3/16 - 1/4” (5 - 8mm) (Fig. 062).
7. If adjustment is necessary, loosen the jam nut
directly below the yoke. Turn the bottom rod until the
correct measurement is obtained (Fig. 062). Tighten
the jam nut at the yoke.
Deck Lift Lever Removal
3
Fig 062 g. 74 m-3788
1. Brake lever 4. Collar on brake rod
2. Spring, 2-3/4” (70mm) 5. 3/16 - 1/4” (5-7mm)
3. Adjusting nuts 6. Jam nut and yoke
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. Remove the lower stop bolt from the deck lift plate
(Fig. 063).
Fig 063 DSC-1647
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CHASSIS
3
3. With the mower deck in the transport position, place
a 4”x 4” block under each corner of the deck. Lower
the mower deck onto the support blocks to remove
the weight from the support chains (Fig. 064).
Fig 064 DSC-1648
4. Loosen jam nuts on deck lift rods until deck support
springs are fully extended. Repeat procedure for
both deck lift rods (Fig. 065).
5. Remove hex nut from RH rear deck lift assembly.
Repeat procedure for LH rear deck lift assembly
(Fig. 066).
Fig 066 DSC-1650
6. Lower lift lever grip assembly to its lowest position.
Rear deck swivel mounts should clear deck lift rods
on both sides. The mower deck lift linkage should
now be fully unloaded (Fig. 067).
Fig 065 DSC-1649
A
Fig 067 DSC-1651
A. Lift Lever at lowest position
3-14 Z Master 500 Gas Series Service Manual
Page 42
CHASSIS
7. Remove hex bolt, nut, and lift lever bushing from the
lower deck lift plate mounting location (Fig. 068).
Fig 068 DSC-1652
8. Loosen the top hex head ange nut at the deck lift
plate mounting location. Pivot the INNER deck lift
plate up and back toward the RH motion control
lever (Fig. 069).
9. Lift the oor pan assembly to its fully opened
position (Fig. 070).
3
Fig 070 DSC-3112
10. Remove hex bolt, bushing, and nylock nut
connecting the deck lift arm plates to the mower
deck rear cross-shaft lift assembly (Fig. 071).
Fig 069 DSC-1653
Fig 071 DSC-1655
3-15Z Master 500 Gas Series Service Manual
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CHASSIS
3
11. Remove retainer clip from lift lever grip assembly
(Fig. 072).
Fig 072 DSC-1656
12. When removing the lift lever grip assembly, you may
experience interference with the RH oor pan hinge
or the front edge of the RH motion control plate, or
both (Fig. 073).
13. If the lift lever grip assembly contacts the RH oor
pan hinge, loosen the RH oor pan hinge mounting
hardware. Push the RH hinge upward. Re-tighten
the RH oor pan hinge mounting hardware (Fig.
074).
Fig 074 DSC-1661
14. If the lift lever grip assembly contacts the RH motion
control plate, tilt and hold the oor pan assembly
slightly forward. Move the RH motion control lever
out of the neutral lock position and push it in the full
forward position. Using a tie strap or wire, tie the
oor pan assembly to the motion control arm to hold
the oor pan assembly in place (Fig. 075).
A
Fig 073 DSC-1657
A. RH Floor pan hinge B. RH Motion control plate
3-16 Z Master 500 Gas Series Service Manual
B
Fig 075 DSC-1665
Page 44
CHASSIS
15. Carefully slide the lift lever grip assembly out of its
carrier frame pivot (Fig. 076).
Fig 076 DSC-1667
Deck Lift Lever Installation
1. For ease of installation, make sure deck lift arm
plates, bushing, and hardware are installed on the lift
lever grip assembly prior to installation (Fig. 077).
2. Install lift lever grip assembly into front frame pivot
location (Fig. 078).
3
Fig 078 DSC-1670
3. Install retainer clip to lift lever grip assembly (Fig.
079).
A
B
C
D
E
Fig 077 DSC-1668
A. Plate D. Bolt
B. Nut E. Plate
C. Bushing
Fig 079 DSC-1672
3-17Z Master 500 Gas Series Service Manual
Page 45
CHASSIS
3
4. Install bushing into rear lift arm cross shaft (Fig.
080).
A
Fig 080 DSC-1674
A. Bushing
6. Rotate deck lift plate (inner) downward until lower
mounting holes line up with hole in carrier frame and
deck lift plate (outer). From the outside of the frame,
install hex bolt, spacer, and anged lock nut as
shown. Tighten bolt (Fig. 082).
A
Fig 082 DSC-1677
B
C
5. Install hex bolt through deck lift plates and rear
lift arm cross shaft bushing. Install nylock nut and
tighten (Fig. 081).
A
A
Fig 081 DSC-1675
A. Rear lift arm plates B. Hex bolt
B
A. Hex bolt B. Spacer
C. Flanged locknut
7. Align rear deck mount swivels with ends of deck lift
rod (Fig. 083).
B
A
Fig 083 DSC-1680
A. Rear deck mount B. Lift rod
swivel
3-18 Z Master 500 Gas Series Service Manual
Page 46
CHASSIS
8. Raise lift lever grip assembly until deck mount
swivels rest against deck rod jam nuts. Install
HOC pin into deck lift plate height of cut holes that
correspond to the 3” (7.62cm) HOC position (Fig.
084).
A
Fig 084 DSC-1681
A. Rear deck mount B. HOC Pin
swivel
9. Install lower “stop” bolt through inner and outer deck
lift plates. Install nylock nut and tighten until hex nut
and bolt are seated rmly against the deck lift plates.
DO NOT over-tighten or deck lift plates will deform
inward causing HOC pin assembly to bind (Fig. 085).
B
10. Install Hex nut on end of deck lift rod. Tighten
against deck mount swivel. Repeat procedure for
opposite side deck lift rod (Fig. 086).
3
Fig 086 DSC-1683
11. Raise mower deck to the transport position. Remove
support blocks. Check deck level adjustment (refer
to Mower Deck Leveling page 7-27). Readjust
compression spring length by turning front nut.
Spring should be compressed to a length of 11-1/2”
(29.2cm) between washers. Lock the front nut into
position by tightening the spring jam nut (Fig. 087).
Fig 085 DSC-1682
Fig 087 DSC-1685
3-19Z Master 500 Gas Series Service Manual
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CHASSIS
3
12. Untie the oor pan assembly and lower. Return
motion control lever to its neutral locked position.
Motion Control Assembly Removal
1. Remove both oor pan assembly hinge bolts (Fig.
088).
3. Remove (4) pocket mounting bolts (Fig. 090).
Fig 090 DSC-3108
4. Remove pocket (Fig. 091).
Fig 088 DSC-1686
2. Remove oor pan assembly (Fig. 089).
Fig 089 DSC-1689
Fig 091 DSC-3109
3-20 Z Master 500 Gas Series Service Manual
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CHASSIS
5. Remove the two bolts retaining the lever assembly
to the control arm shaft (Fig. 092).
Fig 092 DSC-2062
6. Disconnect Motion Control Dampener from motion
control assembly (Fig. 093).
7. Disconnect neutral switch wire harness from neutral
switch (Fig. 094).
3
Fig 094 DSC-3110
8. Remove bolt and nut that retains the ball joint to the
motion control (Fig. 095).
Fig 093 DSC-1695
Fig 095 DSC-3111
3-21Z Master 500 Gas Series Service Manual
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CHASSIS
3
9. Remove the cotter pin and clevis pin through the
adjustable yoke for the neutral return bolt (Fig. 096).
Fig 096 DSC-2064
10. Remove the two bolts and nuts that retain the ange
bearing on the inside of the motion control (Fig.
097).
11. Remove the two bolts and nuts that retain the ange
bearing on the outside of the motion control (Fig.
098).
Fig 098 DSC-2067
12. Remove the motion control from the frame (Fig.
099).
Fig 097 DSC-2066
Fig 099 DSC-2068
Motion Control Assembly Installation
Reverse the order of removal.
3-22 Z Master 500 Gas Series Service Manual
Page 50
HYDRAULIC SYSTEM
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks/PTO . . . . . . . . .
4-1Z Master 500 Gas Series Service Manual
6
7
Page 51
HYDRAULIC SYSTEM
4
Hydrostatic Pump Removal
Note: Cleanliness is a key factor in a successful
repair of any hydrostatic system. Thoroughly
clean all exposed surfaces prior to any type
of maintenance. Cleaning all parts by using
a solvent wash and air drying is usually
adequate. As with any precision equipment,
all parts must be kept free of foreign material
and chemicals. Protect all exposed sealing
areas and open cavities from damage and
foreign material.
Upon removal, all seals, O-rings, and gaskets should be
replaced. During installation, lightly lubricate all seals,
O-rings and gaskets with clean petroleum jelly prior to
installation.
This procedure shows the LH Hydrostatic Pump being
removed. Use these same procedures to remove the RH
Hydrostatic Pump.
1. Disconnect the negative and then the positive
battery cable from the battery.
2. Using compressed air, clean the area around the
hydrostatic pump to make sure it is free from any dirt
and debris.
4. Lift the engine shield. Using a pry bar, relieve the
spring tension on the idler assembly and remove the
pump drive belt (Fig. 101).
Fig 101 DSC-2991
5. Loosen the two square head set-screws located on
the pump sheave and remove the pulley (Fig. 102).
3. Remove the seat prop rod from the seat and the
frame (Fig. 100).
Fig 100 DSC-2986
Fig 102 DSC-2993
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HYDRAULIC SYSTEM
6. Remove bolt, washer, and nut located between ball
joint and control arm that retains the tracking link rod
to the hydro control arm (Fig. 103).
Note: It may be necessary to move the hydro lever
forward in order to remove the bolt.
Fig 103 DSC-2994
8. Remove the hose clamp around the case drain
hydraulic hose, located on the left side of the
hydrostatic pump (Fig. 105).
A
Fig 105 DSC-2998
A. Case drain hose clamp
4
7. Remove the two high pressure hydraulic lines,
located at the bottom of the hydrostatic pump (Fig.
104).
Note: Cap the hose and the tting to prevent entry
of dirt and debris. Mark or tag one of the
hoses to ensure correct reassembly.
9. Remove the pump suction hydraulic line, located on
top of the hydrostatic pump (Fig. 106).
Fig 106 DSC-2999
Fig 104 DSC-2996
4-3Z Master 500 Gas Series Service Manual
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HYDRAULIC SYSTEM
10. Loosen and remove the two bolts and nuts retaining
the hydrostatic pump to the frame (Fig. 107).
Fig 107 DSC-3000
Note: Engine shield removed for clarity.
Hydrostatic Pump Installation
Note: As a reminder, prior to connecting the
hydraulic lines, the O-rings should be
replaced with new ones and lightly lubricated
with petroleum jelly.
1. Install the hydrostatic pump to the frame. Install and
tighten the two bolts and nuts (Fig. 109).
4
11. Remove the hydrostatic pump from the frame (Fig.
108).
Fig 109 DSC-3000
2. Install the pump suction hydraulic line, located on
top of the hydrostatic pump, that comes from the
hydraulic lter (Fig. 110).
Fig 108 DSC-3002
12. For service work on the pump refer to the HydroGear BDP10A/16A/21L Service Manual, form
#492-4789.
Fig 110 DSC-2999
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HYDRAULIC SYSTEM
3. Install the case drain hose and hose clamp onto the
pump case drain tting, located around the left side
of the hydrostatic pump (Fig. 111).
Fig 111 DSC-2998
5. Install the bolt, washer, and nut between the ball
joint and control arm to secure the tracking link rod
to the hydro control arm (Fig. 113). Tighten the bolt
and nut.
Fig 113 DSC-2994
4. Install the two high pressure hydraulic lines, located
at the bottom of the hydrostatic pump (Fig. 112).
Fig 112 DSC-2996
6. Install the key in the hydrostatic pump shaft.
4
Note: Before installing the pulley, replace the set
screws. The end of the set screws have a
knurled cup point for retention and must not
be re-used.
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HYDRAULIC SYSTEM
4
Apply some anti-seize compound to the shaft (Fig.
114). Install the pulley to the shaft.
Fig 114 DSC-3066
7. Align the outer edge of the hydrostatic pump pulley,
using a straight edge, to the outer edge of the
engine drive pulley (Fig. 115). Tighten the two set
screws once alignment is achieved.
8. Using a pry bar, release the spring tension on the
idler assembly and install the pump drive belt (Fig.
116).
Fig 116 DSC-3068
Note: The engine shield has been removed for
clarity.
9. Install the seat prop rod to the frame (Fig. 117).
A
B
Fig 115 DSC-3067
A. Pump pulley B. Engine pulley
4-6 Z Master 500 Gas Series Service Manual
Fig 117 DSC-2986
Page 56
HYDRAULIC SYSTEM
10. Install the battery positive and then the negative
cable to the battery.
11. Check the hydraulic uid in the reservoir tank. Add
oil if necessary. Air will need to be purged in the
system. Follow procedures on Purging the Hydraulic
System, page 4-18.
12. Check the neutral adjustment. Follow procedures on
Adjusting the Handle Neutral, page 4-12.
Wheel Motor Removal
This procedure is the same for both the right and left
wheel motors.
1. Disconnect the battery negative cable.
2. Raise the rear wheels of the machine off the ground
and support frame with jackstands. Remove the rear
wheel (Fig. 118).
3. Apply the parking brake and remove the cotter pin
from the wheel motor output shaft (Fig. 119).
Fig 119 DSC-3070
4. Loosen and remove nut securing hub to the wheel
motor output shaft (Fig. 120).
4
Fig 118 DSC-3069
Fig 120 DSC-3071
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HYDRAULIC SYSTEM
4
5. Remove the 3 bolts securing the brake band to the
actuator (Fig. 121).
Fig 121 DSC-3072
6. Remove the brake band from the hub (Fig. 122).
7. Install wheel puller on to the hub and remove the
hub from motor output shaft (Fig. 123).
Note: Toro Wheel Puller, P/N TOR 4097, is available
through SPX (formerly OTC) 1-800-533-0492.
Fig 123 DSC-3074
Fig 122 DSC-3073
8. Clean any dirt or debris away from the hydraulic line
ttings. Remove the hydraulic lines.
Note: Make sure to cap the ttings and hoses
to prevent dirt from entering the hydraulic
system (Fig. 124).
Fig 124 DSC-3075
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HYDRAULIC SYSTEM
9. Remove the front two wheel motor bolts, lock
washers, spacers, and nuts (Fig. 125).
Fig 125 DSC-3076
10. Swing the brake linkage forward out of the way of
the wheel motor. It may be necessary to loosen the
back two bolts to remove the spacers (Fig. 126).
11. Remove the back two bolts, lock washers, spacers,
and nuts and remove the wheel motor from the
frame (Fig. 127).
Fig 127 DSC-3078
12. For service work on the wheel motor refer to the
Parker/Ross Service Manual, Form #492-4753.
4
Fig 126 DSC-3077
Wheel Motor Installation
Note: As a reminder, prior to connecting the
hydraulic lines, the O-rings should be
replaced with new ones and lightly lubricated
with petroleum jelly.
4-9Z Master 500 Gas Series Service Manual
Page 59
HYDRAULIC SYSTEM
4
Note: There are two different spacers used on the
wheel motors (Fig. 128). The short spacers
are used in the front of the wheel motors(with
the brake linkage) and the long spacers are
used to retain the back of the wheel motor.
A B
Fig 128 DSC-3079
A. Front Spacer (short) B. Back Spacer (long)
2. Align the brake linkage with the two front bolt holes
(Fig. 130).
Fig 130 DSC-3081
3. Install the two bolts, short spacers, lock washers,
and nuts through the wheel motor, brake linkage and
the frame (Fig. 131).
1. Install wheel motor in the frame. Loosely install the
back two bolts, long spacers, lock washers and nuts
(Fig. 129).
Fig 129 DSC-3080
Fig 131 DSC-3082
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HYDRAULIC SYSTEM
4. Torque the bolts to 80 to 90 ft-lbs. (108 to 122 Nm)
(Fig. 132).
Fig 132 DSC-3085
5. Install and tighten the two hydraulic lines to the
wheel motor (Fig. 133).
6. Install wheel hub assembly, making sure the
woodruff key is in place (Fig. 134).
Note: It is recommended to replace the wheel hub
assembly prior to installation.
Fig 134 DSC-3087
4
Fig 133 DSC-3086
7. Install the nut on the wheel motor shaft, DO NOT
tighten (Fig. 135).
Fig 135 DSC-3088
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HYDRAULIC SYSTEM
4
8. Install spacers, brake band retainer, and brake band
around the wheel hub and tighten all three retainer
bolts (Fig. 136).
Fig 136 DSC-3089
9. Engage the parking brake, torque the wheel hub nut
to 125 ft-lbs. (169 Nm) (Fig. 137). Install the cotter
key through the nut and motor wheel shaft.
Note: Re-torque nut at 100 hours, and every 500
hours thereafter. Washer 1-523157 can be
added under nut to keep cotter pin engaged
with nut castellations.
10. Check the park brake and adjust park brake if
necessary. Refer to Adjusting the Parking Brake,
page xxx.
11. Install rear wheel and wheel lug nuts and tighten.
12. Reconnect the battery negative cable to the battery.
13. Check the hydraulic uid in the reservoir tank. Add
oil if necessary. Air will need to be purged in the
system. Follow the procedures on Purging the
Hydraulic System, page 4-18.
Adjusting the Handle Neutral
If motion control levers do not align, or move easily into
the console notch, adjustment is required. Adjust each
lever, spring and rod separately.
Note: Motion control levers must be installed
correctly. See Installing the Motion Control
Levers in the set up instructions.
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Unlatch the seat and tilt the seat forward.
4. Begin with either the left or right motion control lever.
Fig 137 DSC-3090
4-12 Z Master 500 Gas Series Service Manual
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HYDRAULIC SYSTEM
5. Move the lever to the neutral position but not locked
(Fig. 138).
Fig 138 g. 59 m-6278
1. Clevis pin in slot 7. Spring
2. Nut against yoke 8. Pivot shaft
3. Adjustment bolt 9. Yoke
4. Pump rod 10. Locknut
5. Double nuts 11. Ball joint
6. Jam nuts
6. Pull lever back until the clevis pin (on arm below
pivot shaft) just begins to contact the end of the slot
(just beginning to put pressure on the spring) (Fig.
138).
7. Check where the control lever is relative to notch in
console (Fig. 139). It should be centered allowing
lever to pivot outward to the neutral lock position.
Fig 139 g 58 m-6282
1. Neutral locked position 3. Neutral position
2. Control lever
4
8. Check where the control lever is relative to notch in
console (Fig. 139). It should be centered allowing
lever to pivot outward to the neutral lock position.
9. If adjustment is needed, loosen the nut and jam nut
against the yoke (Fig. 138).
10. Apply slight rearward pressure on the motion
control lever, turn the head of the adjustment bolt
in the appropriate direction until the control lever is
centered in neutral lock position (Fig. 139).
Note: Keeping rearward pressure on the lever will
keep the pin at the end of the slot and allow
the adjustment bolt to move the lever to the
appropriate position.
11. Tighten the nut and jam nut (Fig. 138).
12. Repeat on the opposite side of the machine.
4-13Z Master 500 Gas Series Service Manual
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HYDRAULIC SYSTEM
Setting the Hydraulic Pump Neutral
Note: Adjust handle neutral before making the
following adjustment. See Adjusting the
Handle Neutral, page 4-12.
Note: This adjustment must be made with the drive
wheels turning.
1. Raise the frame and block up the machine so drive
wheels can rotate freely (Fig. 140).
3. Disconnect the electrical connector at the switch,
located between the frame cross member and the
hydraulic tank. Temporarily install a jumper wire
across the terminals in the wiring harness connector
(Fig. 141).
Fig 141 DSC-3116
4
Fig 140 DSC-3114
2. Slide the seat fully forward, unlatch the seat and tilt
the seat forward. Disconnect the prop rod for the
seat.
Setting the RH Hydraulic Pump
Neutral
1. Start the engine, open the throttle half way and
release the park brake.
Note: The motion control lever must be in neutral
while making any adjustments.
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HYDRAULIC SYSTEM
2. Adjust the pump rod length by rotating the knob, in
the appropriate direction, until the wheel is still or
slightly creeping in reverse (Fig. 142).
Fig 142 DSC-3117
3. Move motion control lever forward and reverse, then
back to neutral. Wheel must stop turning or slightly
creep in reverse.
4. Open engine throttle to fast. Make sure wheel
remains stopped or slightly creeps in reverse, adjust
if necessary.
Setting the LH Hydraulic Pump
Neutral
1. Loosen the locknuts at the pump ball joint on the
motion control rod (Fig. 143).
Fig 143 DSC-3118
4
2. Start the engine, open the engine throttle half way
and release the parking brake.
Note: Motion control lever must be in neutral while
making any adjustments.
Note: The front nut on the pump rod has left-hand
threads.
4-15Z Master 500 Gas Series Service Manual
Page 65
HYDRAULIC SYSTEM
3. Adjust pump rod length by rotating the double nuts in
the appropriate direction, until wheel is still or slightly
creeps in reverse (Fig. 144).
Fig 144 DSC-3120
Adjusting the Tracking
The right hand pump has a knob for adjusting the
tracking (Fig. 145).
Fig 145 DSC-3117
4
4. Move the motion control lever forward and reverse,
then back to neutral. The wheel must stop turning or
slightly creep in reverse.
5. Open the throttle to fast. Make sure the wheel
remains stopped or slightly creeps in reverse;
readjust if necessary.
6. Tighten the locknuts at the ball joints.
7. After both pump neutrals are set, shut off the
machine.
8. Remove the jumper wire from the wiring harness
connector and reconnect to the seat switch.
9. Reinstall the prop rod and lower the seat into
position.
10. Remove the jack stands.
Important: Adjust the handle neutral and hydraulic
pump neutral before adjusting the
tracking. Refer to Adjusting the Handle
Neutral on page 4-12 and Setting the
Hydraulic Pump Neutral page 4-14.
1. Push both control levers forward the same distance
(Fig. 146). The machine should travel in a straight
line. If not, proceed to step 2.
Fig 146 DSC-3121
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HYDRAULIC SYSTEM
2. Stop the machine and set the parking brake.
3. Unlatch the seat and tilt the seat forward to access
the tracking knob.
Note: Determine the left and right sides of the
machine from normal operating position.
4. To make the machine go right, turn the knob towards
the right side of the machine (Fig. 147).
Replacing the Pump Drive Belt
1. Pull the spring loaded idler down and remove
traction belt from the engine and hydro pump pulleys
(Fig. 148). Remove belt between the pulleys.
Fig 148 DSC-3122
Fig 147 g. 57 m-6280
1. Pump rod 3. Tracking knob
2. Turn this way to 4. Turn this way to
track left track right
5. To make the machine go left, turn the knob towards
the left side of the machine (Fig. 147, above).
6. Repeat this adjustment until the tracking is correct.
4
2. Install new belt around engine and hydro pump
pulleys (Fig. 149).
Fig 149 pump belt routing
3. Pull spring loaded idler down and align below
traction belt. Release pressure on spring loaded
idler.
4-17Z Master 500 Gas Series Service Manual
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HYDRAULIC SYSTEM
Purging the Hydraulic System
The traction system is self bleeding, however, it may be
necessary to bleed the system if uid is changed or after
work is performed on the system.
1. Raise the machine so the wheels are off the ground
and supported with jack stands (Fig. 150).
3. When the wheel begins to spin on its own, keep it
engaged until the wheel drives smoothly (minimum 2
minutes).
4. Check the hydraulic uid level and add uid as
required to maintain proper level.
5. Repeat this procedure on the opposite wheel.
Hydraulic Flow Testing Procedure
Note: Cleanliness is a key factor in successful ow
testing of the hydraulic system. Thoroughly
clean all exposed surfaces prior to any type
of maintenance. Cleaning all parts by using
a solvent wash and air drying is usually
adequate. As with any precision equipment,
all parts must be kept free of foreign material
and chemicals. Protect all exposed sealing
areas and open cavities from damage and
foreign material.
4
Fig 150 DSC-3123
2. Start the engine and run at low idle speed. Slowly
engage the motion control lever. If the wheel does
not rotate immediately, it may be necessary to spin
the wheel by hand to start purging air that is trapped
in the system (Fig. 151).
Flow tester P/N 70661, contact your DSM to
order.
1. Lift the back of the unit so the rear tires (left and
right) is off the ground. Place jack stands under the
rear frame to support the unit. Remove the rear tire;
in this case the left rear tire is being removed (Fig.
152).
Note: Be careful not to place jack stands near
any moving parts or areas not capable of
supporting the weight of the machine.
Fig 151 DSC-3124
Fig 152 DSC-3125
4-18 Z Master 500 Gas Series Service Manual
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HYDRAULIC SYSTEM
2. Clean any dirt or debris away from the hydraulic line
ttings. Remove the hydraulic lines. Make sure you
mark which hydraulic line goes to which tting on the
wheel motor. If the hydraulic lines are reversed, the
motor will operate in the opposite direction.
Note: Make sure you cap the ttings to prevent dirt
from entering the system (Fig. 153).
4. Check the hydraulic reservoir and ll as needed with
Mobil 1, 15w50 oil.
5. Disconnect the electric PTO clutch from the wiring
harness to prevent accidental engagement of the
mower deck.
6. Disconnect the seat switch from the harness.
Temporarily install a jumper wire across the harness
(Fig. 155). Move the seat back to the operating
position.
Fig 153 DSC-3126
3. Connect the hydraulic hose ttings to the hydraulic
ow tester and tighten the ttings (Fig. 154). If the
ow tester is bidirectional, make sure to connect
hoses correctly.
4
Fig 155 DSC-3116
7. Verify the restrictor valve on the hydraulic ow tester
is in the fully “Opened” position.
8. Start the machine. Run the unit for approximately 5
minutes to warm the oil in the hydrostatic pumps.
9. Release the parking brake and bring both levers to
the inside neutral position. Run the engine at full
RPM.
10. Stroke the left hand hydrostatic lever fully forward.
Very slowly, rotate the “T” handle of the adjustable
ow tester restrictor valve until the pressure gauge
reaches 300 psi (21 bar). Record the measured ow
(gallons/liters per minute).
Fig 154 DSC-3128
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HYDRAULIC SYSTEM
4
11. With the unit at full engine throttle speed, slowly
rotate the “T” handle of the ow tester restrictor
valve clockwise until the pressure gauge reads
approximately 1000 to 1200 psi (69 to 83 bar).
CAUTION: DO NOT operate the machine for
extended period of time at high pressure.
12. Record the difference or “ow droop” of the pump.
For the Hydro-Gear BDP 10A and BDP 12 pump,
maximum allowable “ow droop” is 1.5 gpm. Any
droop greater than 1.5 gpm (6.8 liters/min) is
considered unacceptable and the pump should be
replaced barring any other potential causes.
13. Return the motion control lever to neutral position
and return the levers to the neutral locked position.
Engage the parking brake. Slow the engine speed to
idle and turn the ignition switch to the OFF position.
14. Disconnect the hydraulic ow tester from the
hydraulic lines.
15. Re-connect the hydraulic lines to the wheel motor.
Tighten ttings.
Pushing the Machine by Hand
Important: Always push the machine by hand. Never
tow the machine because hydraulic
damage may occur.
1. Disengage the power take off (PTO) and turn the
ignition key to OFF. Move the levers to the neutral
position and apply the parking brake.
2. Rotate the by-pass valves counterclockwise 1 turn to
push. This allows hydraulic uid to by-pass the pump
enabling the wheels to turn (Fig. 156).
16. Check the hydraulic reservoir and ll as necessary
to the “Hot” level mark, see, Checking the Hydraulic
Fluid page 2-10.
17. Re-install the left rear tire and lower the unit to the
ground. Remove the temporary jumper cable for the
seat and reconnect the seat switch. Reconnect the
connector for the electric PTO clutch.
Fig 156 DSC-3130
Important: Do not rotate the by-pass valves more
than 1 turn or the valves can come out of
the body and cause uid to run out.
3. Disengage the parking brake before pushing.
4-20 Z Master 500 Gas Series Service Manual
Page 70
Changing to Machine Operation
1. Rotate the bypass valves clockwise 1 turn to operate
the machine (Fig. 157).
Note: Do not over-tighten the by-pass valves.
HYDRAULIC SYSTEM
Fig 157 DSC-3130
Note: The machine will not drive unless the by-pass
valves are turned in.
4
4-21Z Master 500 Gas Series Service Manual
Page 71
HYDRAULIC SYSTEM
THIS PAGE INTENTIONALLY LEFT BLANK.
4
4-22 Z Master 500 Gas Series Service Manual
Page 72
ENGINE
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks/PTO . . . . . . . . .
6
7
Page 73
ENGINE
Kohler Air-Cooled Engine Removal
1. Remove the battery negative cable from the battery.
2. Remove the bolt, spacer, spring, and nut on the top
of the air cleaner bracket (Fig. 158).
Fig 158 DSC-2956
4. Remove the air cleaner end cap and slide the air
cleaner assembly out of the bracket (Fig. 160).
Fig 160 DSC-2958
5. Loosen the clamps and remove the throttle and
choke cable from the engine control levers (Fig.
161).
5
3. Remove the air cleaner hose on the engine (Fig.
159).
A
B
Fig 161 DSC-2959
A. Throttle Cable B. Choke Cable
Fig 159 DSC-2957
5-2 Z Master 500 Gas Series Service Manual
Page 74
ENGINE
6. Remove the tie strap securing the choke/throttle
cables to the bracket located on the valve cover (Fig.
162).
Fig 162 DSC-2961
7. Turn the fuel shut off valve OFF. Remove the fuel
line hose clamp at the engine and remove the fuel
line (Fig. 163).
8. With a pry bar, relieve spring tension on the idler
assembly and remove pump drive belt (Fig. 164).
Fig 164 DSC-2963
9. Remove two red cables from the starter solenoid
(Fig. 165).
A
B
Fig 163 DSC-2962
A Fuel Valve B Fuel Line
5
Fig 165 DSC-2964
5-3Z Master 500 Gas Series Service Manual
Page 75
ENGINE
10. Remove the blue wire from the starter solenoid (Fig.
166).
Fig 166 DSC-2965
11. Unplug the engine wiring harness from the main
electrical harness (Fig. 167).
12. Unplug the electric PTO clutch harness from the
clutch. Remove the tie strap holding the clutch wire
to the PTO stop rod (Fig. 168).
Fig 168 DSC-2966
13. Remove the mower drive belt from the electric PTO
clutch, refer to Replacing the Mower Belt page 7-24.
5
14. Remove the 4 engine mounting bolts, spring
washers, and nuts.
Note: The front left engine mount has two ground
cables (Fig. 169).
Fig 167 DSC-2970
Fig 169 DSC-2967
5-4 Z Master 500 Gas Series Service Manual
Page 76
ENGINE
15. Connect lift chains/straps to the engine lift brackets.
Raise the engine from the frame of the unit (Fig.
170).
Fig 170 DSC-2969
Kohler Air-Cooled Engine Installation
3. Install the mower drive belt around the electric PTO
clutch; refer to Replacing the Mower Belt page 7-24.
4. Plug the electric PTO clutch harness into the clutch
(Fig. 172). Secure the clutch wire to the PTO stop
rod with a tie strap.
Fig 172 DSC-2966
1. Lower the engine to the frame of the unit.
2. Install the engine with 4 mounting bolts, spring
washers, and nuts.
Note: The front left engine mounting bolt has the
two ground cables (Fig. 171). Tighten the
bolts.
5. Connect the blue wire to the starter solenoid terminal
as shown (Fig. 173).
5
Fig 173 DSC-2965
Fig 171 DSC-2967
5-5Z Master 500 Gas Series Service Manual
Page 77
ENGINE
5
6. Attach the two red cables to the starter solenoid (Fig.
174).
Fig 174 DSC-2964
7. Install hydrostatic pump drive belt, using a pry bar to
relieve the tension on the spring loaded idler pulley
(Fig. 175).
8. Install the fuel line to the engine and install a hose
clamp. Turn the fuel shut off valve to the ON
position (Fig. 176).
A
B
Fig 176 DSC-2971
A Fuel Valve B Fuel Line Clamp
9. Install the throttle and choke cables to the
throttle linkage. Position the throttle lever so it is
approximately 1/2” (12.7mm) from the full throttle
position. Make sure the choke lever is pushed down
to the OFF position. Then tighten both cable clamps
(Fig. 177).
A
Fig 175 DSC-2963
B
Fig 177 DSC-2959
A Throttle Cable B Choke Cable
5-6 Z Master 500 Gas Series Service Manual
Page 78
ENGINE
10. Secure the throttle and choke cables to the bracket
located on the engine valve cover with a tie strap
(Fig. 178).
Fig 178 DSC-2972
11. Install the air cleaner assembly through the air
cleaner assembly bracket and install the air cleaner
end cap (Fig. 179).
12. Install the bolt, spacer, spring, and nut on the top of
the air cleaner bracket and tighten (Fig. 180).
Fig 180 DSC-2956
13. Install the hose to the engine and tighten the hose
clamp (Fig. 181).
Fig 179 DSC-2958
5
Fig 181 DSC-2957
14. Install the battery negative cable to the battery.
15. Test operate engine; adjust choke and throttle cables
as required. Check engine low and high idle are to
specication.
5-7Z Master 500 Gas Series Service Manual
Page 79
ENGINE
Kawasaki Air-Cooled Engine Removal
1. Remove the battery negative cable from the battery.
2. Remove the air cleaner cover (Fig. 182).
Note: This engine has a standard air cleaner cover.
If engine is equipped with a heavy duty air
cleaner assembly, remove the complete air
cleaner assembly.
3. Loosen the throttle and choke cable clamps and
disconnect both cables (Fig. 183).
A
B
Fig 183 DSC-2975
A. Choke Cable B. Throttle Cable
5
Fig 182 DSC-2973
4. On the right side of the engine, next to the engine
oil lter, is the oil pressure sending unit. Remove the
wire from the sending unit (Fig. 184).
Fig 184 DSC-2976
5-8 Z Master 500 Gas Series Service Manual
Page 80
ENGINE
5. Disconnect the electric PTO clutch wire from the
clutch (Fig. 185).
Fig 185 DSC-2977
6. Remove the tie strap securing the electric PTO
clutch wire to the PTO stop bracket.
7. Remove the mower drive belt from the electric PTO
clutch; refer to Replacing the Mower Belt page 7-24.
9. Disconnect three wires going from the main harness
to the engine (Fig. 187).
• Violet wire to the Regulator/Rectier
• White wire to the Engine Magneto wire
• Pink wire to the Fuel Solenoid
A
B
C
Fig 187 DSC-2980
A. Violet Wire C. Pink Wire
B. White Wire
8. Remove the red heavy gauge wire from the solenoid
to the engine starter (Fig. 186).
Fig 186 DSC-2978
10. Turn the fuel shut-off OFF. Remove the fuel line
clamp at the engine and remove the fuel line (Fig.
188).
A
B
Fig 188 DSC-2981
A Fuel Valve B Fuel Line Clamp
5
5-9Z Master 500 Gas Series Service Manual
Page 81
ENGINE
11. With a pry bar, relieve tension on the spring loaded
idler and remove the pump drive belt (Fig. 189).
Fig 189 DSC-2982
12. Remove the 4 engine bolts, spring washers, and
nuts mounting the engine to the frame. There are
two ground wires located on the left front engine
mount bolt (Fig. 190).
13. Connect a lift chain to the lift points on the engine.
Raise the engine from the frame (Fig. 191).
Fig 191 DSC-2984
Kawasaki Air-Cooled Engine
Installation
1. Lower the engine to the frame of unit.
5
2. Install the engine with 4 mounting bolts, spring
washers, and nuts.
Fig 190 DSC-2983
5-10 Z Master 500 Gas Series Service Manual
Page 82
ENGINE
Note: The front left engine mounting bolt has two
ground cables (Fig. 192). Tighten the bolts.
Fig 192 DSC-2983
3. Install the mower drive belt around the electric PTO
clutch, refer to Replacing the Mower Belt page 7-24.
4. Plug the electric PTO clutch harness into the clutch
(Fig. 193). Secure the clutch wire to the PTO stop
rod with a tie strap.
5. Connect the three wires going from the main
harness to the engine (Fig. 194).
• Violet wire to the Regulator/Rectier
• White wire to the Engine Magneto wire
• Pink wire to the Fuel Solenoid
A
B
C
Fig 194 DSC-2980
A. Violet Wire C. Pink Wire
B. White Wire
6. Install the red heavy gauge wire from the solenoid to
the engine starter (Fig. 195).
5
Fig 193 DSC-2977
Fig 195 DSC-2978
5-11Z Master 500 Gas Series Service Manual
Page 83
ENGINE
7. Install the fuel line to the engine and tighten the hose
clamp. Turn the fuel shut off valve ON (Fig. 196).
A
B
Fig 196 DSC-2985
A Fuel Valve B Fuel Line Clamp
9. Connect the throttle and choke cables to the engine
control linkage. Position the throttle control in the idle
position. Make sure the choke lever is pushed down
to the “Off” position when connecting the cable.
Tighten both cable clamps (Fig. 198).
A
B
Fig 198 DSC-2975
5
A Choke Cable B Throttle Cable
8. Plug the wire into the oil pressure sending unit
located next to the engine oil lter (Fig. 197).
10. Install the hydrostatic pump drive belt, using a pry
bar to release the tension on the spring loaded idler
pulley (Fig. 199).
Fig 197 DSC-2976
Fig 199 DSC-2982
5-12 Z Master 500 Gas Series Service Manual
Page 84
ENGINE
11. Install the engine air cleaner cover on the engine
Fig. 200).
Note: This unit has a standard air cleaner assembly.
Fig 200 DSC-2973
12. Install the battery negative cable to the battery.
2. Loosen the hose clamp on the air intake hose (Fig.
201).
Fig 201 DSC-2883
3. Loosen and remove the bolt, spacer, spring, and nut
retaining the air cleaner assembly to the air cleaner
bracket (Fig. 202).
13. Test operate engine; adjust choke and throttle cables
as required. Check engine low and high idle are to
specication.
28 HP Kohler EFI Air-Cooled Engine
Removal
Note: If welding on an EFI equipped machine, be
sure to disconnect the negative ground cable
on the battery and disconnect the ECU.
1. Disconnect the negative battery cable from the
battery.
5
Fig 202 DSC-2884
5-13Z Master 500 Gas Series Service Manual
Page 85
ENGINE
4. Remove the air cleaner cap and slide the air cleaner
assembly out of the air cleaner bracket (Fig. 203).
Fig 203 DSC-2885
5. Remove the fuel line clamp located on the engine
fuel rail and remove hose (Fig. 204).
6. Remove the tie strap securing the throttle cable to
the bracket on the valve cover (Fig. 205).
Fig 205 DSC-2887
7. Remove the throttle cable from the engine throttle
linkage (Fig. 206).
5
Fig 204 DSC-2886
Fig 206 DSC-2888
5-14 Z Master 500 Gas Series Service Manual
Page 86
ENGINE
8. Remove the tie strap securing the fuel pump and
electric clutch harness to the AC voltage wires
coming from the stator (Fig. 207).
Fig 207 DSC-2889
9. Unplug the electric clutch harness from the electric
clutch (Fig. 208).
10. Remove the tie strap securing the electric PTO wires
to the electric PTO clutch stop (Fig. 209).
Fig 209 DSC-2909
11. Remove the mower deck drive belt.
Note: Refer to Mower Deck Removal page 7-8.
Fig 208 DSC-2891
12. Using a pry bar, release tension on the Hydro pump
drive belt. Remove the hydro drive pump belt (Fig.
210).
5
Fig 210 DSC-2892
5-15Z Master 500 Gas Series Service Manual
Page 87
ENGINE
13. Remove the 3 red wires located at the starter
solenoid (Fig. 211).
Fig 211 DSC-2894
14. Remove the blue wire from the starter solenoid (Fig.
212).
15. Remove the ground cables located on the lower left
side of the base of the engine (Fig. 213). One bolt
goes into the side of the engine block and the other
is the engine mounting bolt and nut.
Fig 213 DSC-2901
16. Disconnect the engine harness connector from the
main wiring harness (Fig. 214).
5
Fig 212 DSC-2895
Fig 214 DSC-2903
5-16 Z Master 500 Gas Series Service Manual
Page 88
ENGINE
17. Remove the wire clamp bolted to the frame, located
on the left side of the engine (Fig. 215).
Fig 215 DSC-2904
18. Remove the wire connector located at the bottom of
the ECU (Electronic Control Unit). First, remove the
red retainer clip (Fig. 216).
Next, remove the multi-pin connector from the ECU
(Fig. 217).
Fig 217 DSC-2908
19. Remove the wire clip located on the side of the ECU
that retains the test plug connector (Fig. 218).
Fig 216 DSC-2907
5
Fig 218 DSC-2910
5-17Z Master 500 Gas Series Service Manual
Page 89
ENGINE
20. Remove the two fuse holders, located in front of the
ECU unit (Fig. 219).
ECU
Fig 219 hidden fuses
21. Unplug the left and center relay from their
connectors. Remove 2 bolts and nuts retaining the
connectors to the frame (Fig. 220).
22. Unplug the tan wire connector (Fig. 221).
Fig 221 DSC-2915
23. Remove the remaining 3 bolts, washer, and nuts
retaining the engine to the frame (Fig. 222). Raise
the engine out of the frame.
5
Fig 222 DSC-2916
Fig 220 DSC-2912
5-18 Z Master 500 Gas Series Service Manual
Page 90
ENGINE
28 HP Kohler EFI Air-Cooled Engine
Installation
1. Lower the engine to the frame. Install 2 bolts,
washers, and nuts on the right side of the engine.
On the left side, mount only the bolt, washer, and nut
to the rear engine mount. Tighten the bolts.
2. Connect the two tan wires, one from the engine
harness and the other from the main harness (Fig.
223).
3. Install the two left relays to the frame using two bolts
and washers (Fig. 224). Plug the remaining two
relays into the harness.
Fig 224 DSC-2912
Fig 223 DSC-2915
4. Install the two fuse holders in front of the ECU
control box (Fig. 225).
5
ECU
Fig 225 hidden fuses
5-19Z Master 500 Gas Series Service Manual
Page 91
ENGINE
5. Install the clamp holding the test plug connector to
the side of the ECU control (Fig. 226).
Fig 226 DSC-2910
6. Install a tie strap around the electric PTO harness
and the PTO electric clutch stop rod (Fig. 227).
7. Install the wire connector to the bottom of the ECU
(Fig. 228).
Fig 228 DSC-2908
Install the red retainer clip on the wire connector
(Fig. 229).
5
Fig 227 DSC-2917
Fig 229 DSC-2907
5-20 Z Master 500 Gas Series Service Manual
Page 92
ENGINE
8. Install the wire clamp to the frame on the left side of
the engine (Fig. 230).
Fig 230 DSC-2904
9. Connect the engine harness connector to the main
harness (Fig. 231).
10. Install the two sets of ground wires on the left side of
the engine as shown (Fig. 232).
Fig 232 DSC-2901
11. Install the blue wire to the starter solenoid terminal
(Fig. 233).
A
Fig 231 DSC-2903
A. Main harness to engine connector
5
Fig 233 DSC-2895
5-21Z Master 500 Gas Series Service Manual
Page 93
ENGINE
12. Install three red wires to the starter solenoid stud
(Fig. 234).
Fig 234 DSC-2894
13. Install the hydro pump drive belt, using a pry bar to
relieve the spring tension on the idler pulley (Fig.
235).
14. Install the mower deck drive belt around the electric
PTO clutch. Refer to Replacing the Mower Belt
page 7-24.
15. Install the PTO clutch harness to the PTO clutch
(Fig. 236).
Fig 236 DSC-2891
5
16. Secure the fuel pump and the electric clutch harness
to the AC voltage wires coming from the stator with a
tie strap (Fig. 237).
Fig 235 DSC-2892
Fig 237 DSC-2918
5-22 Z Master 500 Gas Series Service Manual
Page 94
ENGINE
17. Install the throttle cable to the engine throttle linkage.
Make sure the throttle contacts the stop with the
throttle control lever in the full speed position.
Tighten throttle housing clamp (Fig. 238).
Fig 238 DSC-2888
18. Fasten the throttle cable to the engine lift bracket
using a tie strap (Fig. 239).
19. Install the fuel line to the engine fuel rail. Tighten the
fuel line clamp (Fig. 240).
Fig 240 DSC-2920
20. Slide the air cleaner assembly into the air cleaner
bracket (Fig. 241).
Fig 239 DSC-2919
5
Fig 241 DSC-2885
5-23Z Master 500 Gas Series Service Manual
Page 95
ENGINE
21. Install the air cleaner assembly and air cleaner cap.
Install the bolt, spacer, spring and nut to the air lter
bracket. Tighten the bolt (Fig. 242).
Fig 242 DSC-2884
Kohler Electronic Fuel Injection (EFI)
Models
EFI Fuel System
For engine specic service or diagnostics procedures,
consult the engine manufacture’s service manual.
The following are the locations of components which are
EFI related but mounted to the unit’s chassis.
1. The fuel pressure regulator and fuel pump are
located in the back of the unit, under the right side
of the chassis, next to the mower idler pulleys (Fig.
244).
B
5
22. Install the air intake hose and tighten the hose clamp
(Fig. 243).
Fig 243 DSC-2883
23. Install the battery negative cable on the battery.
A
Fig 244 DSC-2948
A. Fuel Pressure B. Fuel Pump
Regulator
24. Test operate engine; adjust throttle cable as
required. Check engine low and high idle are to
specication.
5-24 Z Master 500 Gas Series Service Manual
Page 96
ENGINE
2. High pressure fuel lter is located under the seat
behind the hydraulic reservoir (Fig. 245).
Fig 245 DSC-2951
3. Dual ow fuel valve is located under the seat,
mounted to the frame (Fig. 246).
EFI Electrical System
1. The electronic control unit (ECU) is located next to
the engine starter, on the left rear side, mounted to
the frame (Fig. 247).
B
A
Fig 247 DSC-2950
A. ECU unit B. ECU test plug
Fig 246 DSC-2952
2. The Transient Voltage Supression (TVS) diode is
located on the left side of the engine, next to the
starter. (Fig. 248).
Fig 248 DSC-2953
5
5-25Z Master 500 Gas Series Service Manual
Page 97
ENGINE
The purpose of the TVS diode is to protect the ECU
unit from any high voltage spikes in the electrical
system, typically associated with the engagement
and disengagement of the PTO clutch (Fig. 249).
Fig 249 DSC-2955
3. Remove the right and left hair pins, washers and
clevis pins securing the hood. Remove the hood
assembly (Fig. 251).
Fig 251 DSC-2802
5
27 HP Kawasaki Liquid-Cooled
Engine Removal
1. Disconnect the negative and then the positive
battery cable and remove the battery from the unit.
2. Unlatch and open the engine hood. Remove the
bumper guard from the frame (Fig. 250).
4. Remove 4 bolts, washers, and nuts retaining the
engine shield. Remove the engine shield (Fig. 252).
Fig 252 DSC-2803
Fig 250 DSC-2800
5-26 Z Master 500 Gas Series Service Manual
Page 98
ENGINE
5. Remove the air deector (Fig. 253).
Fig 253 DSC-2804
6. Using a pry bar, relieve the idler pulley spring
tension and remove the pump drive belt (Fig. 254).
7. Drain the engine coolant through the engine drain
port, located on the engine block, next to the engine
oil lter (Fig. 255).
Fig 255 DSC-2806
8. Remove the tie strap from the overow hose located
next to the radiator cap (Fig. 256).
Fig 254 DSC-2805
5
Fig 256 DSC-2807
5-27Z Master 500 Gas Series Service Manual
Page 99
ENGINE
9. Remove the radiator inlet hose located on the right
side of the radiator (Fig. 257).
Fig 257 DSC-2808
10. Remove the radiator outlet hose, located on the left
rear of the radiator (Fig. 258).
11. Unplug the wire connector for the cooling fan (Fig.
259).
Fig 259 DSC-2812
12. Remove the 3 bolts, washers, and nuts retaining the
fan mounting plate (Fig. 260).
5
Fig 258 DSC-2809
Fig 260 DSC-2810
5-28 Z Master 500 Gas Series Service Manual
Page 100
ENGINE
13. Remove the 2 bolts, washers, and nuts on the right
and left side of the fan mounting plate (Fig. 261).
Fig 261 DSC-2813
14. Remove the fan mounting plate and radiator (Fig.
262).
15. Remove the hose clamp from the air cleaner
assembly (Fig. 263).
Fig 263 DSC-2815
16. Remove two bolts, washers, and nuts retaining the
air cleaner assembly to the left side radiator brace
(Fig. 264).
Fig 262 DSC-2814
Note: This allows better access to the battery bolt
and nut.
5
Fig 264 DSC-2817
5-29Z Master 500 Gas Series Service Manual
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