Toro 74237, 74237CP, 74238, 74238CP, 74239 Service Manual
...
LCE Products
Z Master 500 Series
Gasoline Engine Models
Service Manual
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
THIS PAGE INTENTIONALLY LEFT BLANK.
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
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
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
TABLE OF CONTENTS
THIS PAGE INTENTIONALLY LEFT BLANK.
iv Z Master 500 Gas Series Service Manual
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
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.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
2
SPECIFICATIONS
THIS PAGE INTENTIONALLY LEFT BLANK.
2-18 Z Master 500 Gas Series Service Manual
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
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
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
Loading...