Toro 74237, 74237CP, 74238, 74238CP, 74239 Service Manual

...
4.3 (3)

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 specified 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 fittings whenever they are exposed.

Even a small amount of dirt or other contamination can severely damage the system.

We are hopeful that you will find 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 specifications 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

1-2

SPECIFICATIONS

 

 

Kawasaki Liquid Cooled Product Shots . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-2

Kohler EFI Product Shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-3

Kohler Gas Product Shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-4

Kawasaki Gas Product Shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-5

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-6

Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-7

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-7

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-7

Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8

Deck Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-8

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-8

Cutting Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-9

General Specifications

 

 

Greasing and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10

Model and Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . .

2-11

Available Service Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-12

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . .

2-13

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) . . . . . . . . . .

 

2-14

Other Torque Specifications

 

 

SAE Grade 8 Steel Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-15

Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . . . . . . . . . . .

2-15

Wheel Bolts and Lug Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-15

Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . . . . . . . . . . .

2-15

Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

2-16

US to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-17

CHASSIS

 

 

Caster Fork Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Replacing the Caster Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Caster Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

Front Wheel Removal and Bearing Replacement . . . . . . . . . . . . . . . . . . . . .

3-5

Fuel Tank Removal

 

 

Left Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6

Left Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7

Right Side Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . .

3-7

Hood Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

Hood Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

Brake Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 3-8

Brake Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 3-10

Brake Band Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10

Brake Band Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10

Brake Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11

Brake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13

Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13

Deck Lift Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13

Deck Lift Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17

Z Master 500 Gas Series Service Manual

i

TABLE OF CONTENTS

CHASSIS cont.

 

 

 

Motion Control Assembly Removal .

. . . . . . . . . . . . . . . . . . . . . . . . .

.

3-20

Motion Control Assembly Installation

. . . . . . . . . . . . . . . . . . . . . . . . .

.

3-22

HYDRAULIC SYSTEM

Hydrostatic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Hydrostatic Pump Installation

. . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. 4-4

Wheel Motor Removal . .

. . . . . . . . . . . . . . . . . . . . . . . . .

.

.

.

.

. 4-7

Wheel Motor Installation .

. . . . . . . . . . . . . . . . . . . . . . . . .

.

.

.

.

. 4-9

Adjusting the Handle Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12

Setting the Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14

Setting the RH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . .

4-14

Setting the LH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . .

4-15

Adjusting the Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16

Replacing the Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17

Purging the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-18

Hydraulic Flow Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Pushing the Machine by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-20

Changing to Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21

ENGINE

 

 

Kohler Air-Cooled Engine Removal . . . . . . . . . . . . . . . . . .

. . . . . . . . . 5-2

Kohler Air-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5

Kawasaki Air-Cooled Engine Removal . . . . . . . . . . . . . . . . .

. . . . . . . . . 5-8

Kawasaki Air-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . .

5-10

28 HP Kohler EFI Air-Cooled Engine Removal . . . . . . . . . . . . . . . . . . . . . .

5-13

28 HP Kohler EFI Air-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . . .

5-19

Kohler Electronic Fuel Injection (EFI) Models

 

 

EFI Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-24

EFI Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-25

27 HP Kawasaki Liquid-Cooled Engine Removal . . . . . . . . . . . . . . . . . . . . .

5-26

27 HP Kawasaki Liquid-Cooled Engine Installation . . . . . . . . . . . . . . . . . . . . .

5-33

Cooling Fan Assembly Removal - 27 HP Kawasaki Liquid-Cooled Engine . . . . . . . . . . . .

5-41

Cooling Fan Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-43

ELECTRICAL

 

 

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6

Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7

Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8

Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9

Seat Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-11

Temperature Gauge Liquid-Cooled Engine Only . . . . . . . . . . . . . . . . . . . . . .

6-12

Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-14

Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-14

Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-15

Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-16

Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-17

Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-17

Kohler EFI Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-18

Kohler A/C (Air Cooled) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . .

6-19

ii

Z Master 500 Gas Series Service Manual

TABLE OF CONTENTS

ELECTRICAL cont.

 

 

 

 

 

 

Kawasaki A/C (Air Cooled) Wiring Diagram . . .

. . . . . . . . . . . . . . . . . . . . .

6-20

Kawasaki L/C (Liquid Cooled) Wiring Diagram . .

. . . . . . . . . . . . . . . . . . . . .

6-21

MOWER DECKS/PTO

 

 

 

 

 

 

Electric PTO Clutch Removal . . . . . . . .

. .

. . . . . . . . . . .

. .

.

. . . . . 7-2

Electric PTO Clutch Installation . . . . . . . .

. .

. . . . . . . . . . .

. .

.

. . . . . 7-4

Mower Deck Removal (52, 60, 72”) . . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-8

Mower Deck Installation (52, 60, 72”) . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-11

Mower Spindle Removal . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-14

Mower Spindle Installation . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-15

Mower Spindle Disassembly . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-16

Mower Spindle Assembly . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-19

Replacing the Mower Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-24

Adjusting the Mower Belt Tension . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-25

Leveling the Mower

 

 

 

 

 

 

Setting up the Machine . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

7-27

Leveling the Mower Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-28

Adjusting the Front-to-Rear Mower Pitch . . . .

. . . . . . . . . . . . . . . . . . . . .

7-29

Z Master 500 Gas Series Service Manual

iii

TABLE OF CONTENTS

THIS PAGE INTENTIONALLY LEFT BLANK.

iv

Z Master 500 Gas Series Service Manual

SAFETY INFORMATION

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks/PTO . . . . . . . . . 7

Z Master 500 Gas Series Service Manual

1-1

SAFETY INFORMATION

General Information

This symbol means WARNING or PERSONAL SAFETY INSTRUCTION - read the instruction because it has to

1 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.

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

Think Safety First

Avoid unexpected starting of engine...

Always turn off the engine and disconnect the spark plug wire(s) before cleaning, adjusting, or repair

Avoid lacerations and amputations...

Stay clear of all moving parts whenever the engine is running. Treat all normally moving parts as if they were moving whenever the engine is running or has the potential to start.

Avoid burns...

Do not touch the engine, muffler, or other components which may increase in temperature during operation, while the unit is running or shortly after is has been running.

Avoid fires 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 confined area without proper ventilation.

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 flames away from the battery.

Avoid injury due to inferior parts...

Use only original equipment parts to ensure that important safety criteria are met.

Avoid injury to bystanders...

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 modifications...

Never alter or modify any part unless it is a factory approved procedure.

Avoid unsafe operation...

Always test the safety interlock system after making adjustments or repairs on the machine. Refer to the Electrical section in this manual for more information.

1-2

Z Master 500 Gas Series Service Manual

SPECIFICATIONS

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks/PTO . . . . . . . . . 7

Z Master 500 Gas Series Service Manual

2-1

SPECIFICATIONS

Kawasaki Liquid Cooled Product

Shots

2

Fig 001

DSC-2861a

 

Fig 003

DSC-3792a

 

 

 

 

 

 

 

 

 

 

Fig 002

DSC-2860a

Fig 004

DSC-2864a

2-2

Z Master 500 Gas Series Service Manual

SPECIFICATIONS

Kohler EFI Product Shots

2

Fig 005

DSC-2865b

 

Fig 007

DSC-2867a

 

 

 

 

 

 

 

 

 

 

Fig 006

DSC-2866a

Fig 008

DSC-2868a

Z Master 500 Gas Series Service Manual

2-3

SPECIFICATIONS

Kohler Gas Product Shots

2

Fig 009

DSC-2870a

 

Fig 011

DSC-2875a

 

 

 

 

 

 

 

 

 

 

Fig 010

DSC-2869a

Fig 012

DSC-2874a

2-4

Z Master 500 Gas Series Service Manual

SPECIFICATIONS

Kawasaki Gas Product Shots

2

Fig 013

DSC-2877a

 

Fig 015

DSC-2880a

 

 

 

 

 

 

 

 

 

 

Fig 014

DSC-2879a

Fig 016

DSC-2882a

Z Master 500 Gas Series Service Manual

2-5

SPECIFICATIONS

Engines

 

 

Output

Make

High Idle

Low Idle

Charging Coil

 

 

20 HP (14.9kW)

Kohler

3750

+50/-100 RPM

1500 RPM

15 AMP

 

 

 

OHV V-Twin

 

 

 

 

 

 

 

Air Cooled

 

 

 

 

 

 

 

 

 

 

 

 

 

 

23 HP (17.2 kW)

Kohler

3750

+50/-100 RPM

1500 RPM

15 AMP

 

 

 

OHV V-Twin

 

 

 

 

2

 

 

Air Cooled

 

 

 

 

 

 

 

 

 

 

 

 

25 HP (18.6 kW)

Kawasaki

3750

+50/-100 RPM

1500 RPM

13 AMP

 

 

 

OHV V-Twin

3000

+ 100 Int’l

 

 

 

 

 

 

 

 

 

 

Air Cooled

 

 

 

 

 

 

 

 

 

 

 

 

 

 

27 HP (20.1 kW)

Kohler

3750

+50/-100 RPM

1500 RPM

15 AMP

 

 

 

OHV V-Twin

 

 

 

 

 

 

 

Air Cooled

 

 

 

 

 

 

 

 

 

 

 

 

 

 

27 HP (20.1 kW)

Kawasaki

3750

+50/-100 RPM

2250 RPM

30 AMP

 

 

 

OHV V-Twin

 

 

 

 

 

 

 

Liquid Cooled

 

 

 

 

 

 

 

 

 

 

 

 

 

 

28 HP (20.8 kW)

Kohler

3750

+50/-100 RPM

1500 RPM

25 AMP

 

 

 

OHV V-Twin

 

 

 

 

 

 

 

EFI Air-Cooled

 

 

 

 

 

 

 

 

 

 

 

 

2-6

Z Master 500 Gas Series Service Manual

SPECIFICATIONS

Dimensions and Weight

 

 

 

 

 

ROPS Height

 

 

Width

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

 

Weight

 

Folded

Upright

 

 

Deck

Deflector

Length

 

 

23 hp Kohler/52” TF Deck

1140 lbs

 

53”

72”

 

 

53.7”

68”

79.5”

 

 

 

 

 

(517kg)

 

(134cm)

(183cm)

 

(136cm)

(173cm)

(202cm)

 

 

23 hp Kohler/60” TF Deck

1215 lbs

 

53”

72”

 

 

61.7”

76”

81.5”

 

 

 

 

 

(551kg)

 

(134cm)

(183cm)

 

(157cm)

(193cm)

(207cm)

 

 

25 hp Kawasaki/60” TF Deck

1215 lbs

 

53”

72”

 

 

61.7”

76”

81.5”

 

 

 

 

 

(551kg)

 

(134cm)

(183cm)

 

(157cm)

(193cm)

(207cm)

 

2

27 hp Kohler/52” TF Deck

1176 lbs

 

53”

72”

 

 

53.7”

68”

79.5”

 

 

 

 

(533kg)

 

(134cm)

(183cm)

 

(136cm)

(173cm)

(202cm)

 

 

 

 

 

27 hp Kohler/60” TF Deck

1215 lbs

 

53”

72”

 

 

61.7”

76”

81.5”

 

 

 

 

 

(551kg)

 

(134cm)

(183cm)

 

(157cm)

(193cm)

(207cm)

 

 

27 hp Kohler/72” TF Deck

1280 lbs

 

53”

72”

 

 

73.6”

88”

84.5”

 

 

 

 

 

(583kg)

 

(134cm)

(183cm)

 

(187cm)

(223cm)

(215cm)

 

 

27 hp Kawasaki LC/60”TF Deck

1330 lbs

 

53”

72”

 

 

61.7”

76”

81.5”

 

 

 

 

 

(603kg)

 

(134cm)

(183cm)

 

(157cm)

(193cm)

(207cm)

 

 

27 hp Kawasaki LC/72”TF Deck

1395 lbs

 

53”

72”

 

 

73.6”

88”

84.5”

 

 

 

 

 

(633kg)

 

(134cm)

(183cm)

 

(187cm)

(223cm)

(215cm)

 

 

28 hp Kohler EFI/60” TF Deck

1254 lbs

 

53”

72”

 

 

61.7”

76”

81.5”

 

 

 

 

 

(569kg)

 

(134cm)

(183cm)

 

(157cm)

(193cm)

(207cm)

 

 

28 hp Kohler EFI/72” TF Deck

1319 lbs

 

53”

72”

 

 

73.6”

88”

84.5”

 

 

 

 

 

(598kg)

 

(134cm)

(183cm)

 

(187cm)

(223cm)

(215cm)

 

 

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 fill 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 filter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Z Master 500 Gas Series Service Manual

2-7

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

 

Infinitely 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

2

 

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

 

 

 

 

 

 

 

 

Configuration

Side discharge, mid-mounted rotary with three blades.

 

 

Construction

7 gauge, high strength 50,000 psi steel, 5-1/2” deep, advanced, super flow 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 flow control baffle.

 

 

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)

 

 

2

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

2 fittings (1 per side).

 

 

 

Wheels

 

 

 

 

Lift Assembly

5 fittings.

 

 

 

Mule Drive Idler

1 fitting.

 

 

 

Brake Arms

2 fittings (1 per side).

 

 

 

Rear Deck Struts

2 fittings (1 per side).

 

 

 

Deck Spindles

3 fittings (1 per spindle).

 

 

 

Hydraulic Pump

1 fitting.

 

 

 

Drive Tensioner

 

 

 

 

Z Master 500 Gas Series Service Manual

2-9

SPECIFICATIONS

General Specifications

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).

 

 

2

 

 

Fig 018

fig. 55 m-5615

1.

Cap

3.

Cold fluid level - full

2.

Baffle

4.

Hot fluid level - full

Fig 017

fig. 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 fluid level while the fluid is warm. The fluid should be between cold

 

and hot.

 

Note: The fluid level should be to the top of the hot level of the baffle,

 

when the fluid 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 Fig 020 configuration

Engine Model and Serial Number

Consult the appropriate engine manufacture’s service literature for the

Identification:

location and translation of the engine model and serial number information.

 

 

Hydrostatic Pumps Model and Serial

The label above (Fig. 020), is located on the pump housing. It identifies the

Number:

model and configuration of the BDP pump.

 

 

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

Z Master 500 Gas Series Service Manual

2-11

SPECIFICATIONS

Torque Specifications

Fastener Identification

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

2 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.

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 A

 

Inch Series Bolts and Screws

 

 

 

(A) Grade 1

 

(C) Grade 8

(B) Grade 5

 

 

 

 

 

 

 

 

 

 

 

Figure B

Metric Bolts and Screws

(A) Class 8.8

(B) Class 10.9

 

 

2-12

Z Master 500 Gas Series Service Manual

SPECIFICATIONS

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)

 

Grade 1, 5, &

SAE Grade 1 Bolts, Screws,

SAE Grade 5 Bolts, Screws,

SAE Grade 8 Bolts, Screws,

 

 

Thread Size

8 with Thin

Studs, & Sems with Regular

Studs, & Sems with Regular

Studs, & Sems with Regular

 

 

Height Nuts

Height Nuts (SAE J995

Height Nuts (SAE J995

Height Nuts (SAE J995

 

 

 

 

 

 

 

 

Grade 2 or Stronger Nuts)

Grade 2 or Stronger Nuts)

Grade 2 or Stronger Nuts)

 

 

 

In-lb

 

In-lb

 

N-cm

 

In-lb

 

N-cm

 

In-lb

 

N-cm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

# 6 - 32 UNC

10

± 2

13

± 2

147

± 23

15

± 2

170

± 20

23

± 2

260

±

20

 

 

# 6 - 40 UNF

17

± 2

190

± 20

25

± 2

280

±

20

 

 

 

 

 

 

 

 

 

 

# 8 - 32 UNC

 

 

 

 

 

 

29

± 3

330

± 30

41

± 4

460

±

45

 

 

13

± 2

25

± 5

282

± 30

2

# 8 - 36 UNF

31 ± 3

350 ± 30

43

± 4

31 ± 3

 

 

 

 

 

 

 

 

# 10 - 24 UNC

18

± 2

30

± 5

339

± 56

42

± 4

475

± 45

60

± 6

674

± 70

 

 

#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

 

 

 

ft-lb

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 ± 10% of the nominal torque value. Thin height nuts include jam nuts.

Z Master 500 Gas Series Service Manual

2-13

SPECIFICATIONS

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)

 

 

Thread Size

Class 8.8 Bolts, Screws, and Studs with

Class 10.9 Bolts, Screws, and Studs with

 

 

 

Regular Height Nuts

 

Regular Height Nuts (

 

 

 

 

 

(Class 8 or Strong Nuts)

 

Class 10 or Strong Nuts)

 

 

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

2

 

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.

Note: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.

2-14

Z Master 500 Gas Series Service Manual

SPECIFICATIONS

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Thread Size

Recommended Torque

 

 

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

 

 

 

Wheel Bolts and Lug Nuts

Thread Size

Recommended Torque**

 

 

 

 

 

 

 

7/16 - 20 UNF

65 ± 10 ft-lb

88 ± 14 N-m

 

 

Grade 5

 

 

 

 

 

 

1/2 - 20 UNF

80 ± 10 ft-lb

108 ± 14 N-m

 

 

Grade 5

 

 

 

 

 

2

M12 X 1.25

80 ± 10 ft-lb

108 ± 14 N-m

 

Class 8.8

 

 

 

 

 

 

M12 X 1.5

80 ± 10 ft-lb

108 ± 14 N-m

 

 

Class 8.8

 

 

 

 

 

 

 

 

 

 

 

** For steel wheels and non-lubricated fasteners.

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

 

 

 

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

 

 

 

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Threads per Inch

Baseline Torque*

 

 

Size

Type A

Type B

 

 

 

No. 6

18

20

20 ± 5 in-lb

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.

Conversion Factors

 

in-lb X 11.2985 - N-cm

N-cm X - 0.08851 = in-lb

ft-lb X 1.3558 = N-m

N-cm X 0.73776 - ft-lb

Z Master 500 Gas Series Service Manual

2-15

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

2

 

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

 

 

 

SPECIFICATIONS

 

 

 

U.S. to Metric Conversions

 

 

 

 

 

 

 

 

 

 

 

 

 

 

To Convert

Into

Multiply By

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Miles

Kilometers

 

1.609

 

 

 

 

 

Yards

Meters

 

0.9144

 

 

 

 

Linear

Feet

Meters

 

0.3048

 

 

 

 

Feet

Centimeters

 

30.48

 

 

 

 

Measurement

Inches

Meters

 

0.0254

 

 

 

 

 

Inches

Centimeters

 

 

 

 

 

 

 

2.54

 

 

 

 

 

Inches

Millimeters

 

 

 

 

 

 

 

25.4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

Square Miles

Square Kilometers

 

2.59

 

 

 

Area

Square Feet

Square Meters

 

0.0929

 

 

 

Square Inches

Square Centimeters

 

 

 

 

 

 

6.452

 

 

 

 

 

Acre

Hectare

 

0.4047

 

 

 

 

 

Cubic Yards

Cubic Meters

 

0.7646

 

 

 

 

Volume

Cubic Feet

Cubic Meters

 

0.02832

 

 

 

 

 

Cubic Inches

Cubic Centimeters

 

16.39

 

 

 

 

 

Tons (Short)

Metric Tons

 

0.9078

 

 

 

 

Weight

Pounds

Kilograms

 

0.4536

 

 

 

 

 

Ounces

Grams

 

28.3495

 

 

 

 

Pressure

Pounds/Sq. In.

Kilopascal

 

6.895

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Foot-pounds

Newton-Meters

 

1.356

 

 

 

 

Work

Foot-pounds

Kilogram-Meters

 

0.1383

 

 

 

 

 

Inch-pounds

Kilogram-Centimeters

 

1.152144

 

 

 

 

Liquid Volume

Quarts

Liters

 

0.9463

 

 

 

 

Gallons

Liters

 

3.785

 

 

 

 

 

 

 

 

 

 

Liquid Flows

Gallons/Minute

Liters/Minute

 

3.785

 

 

 

 

 

 

 

 

 

 

 

 

Temperature

Fahrenheit

Celsius

1.

Subtract 32°

 

 

 

 

 

 

2.

Multiply by 5/9

 

 

 

 

 

 

 

 

 

Z Master 500 Gas Series Service Manual

2-17

SPECIFICATIONS

2

THIS PAGE INTENTIONALLY LEFT BLANK.

2-18

Z Master 500 Gas Series Service Manual

CHASSIS

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks/PTO . . . . . . . . . 7

Z Master 500 Gas Series Service Manual

3-1

Toro 74237, 74237CP, 74238, 74238CP, 74239 Service Manual

CHASSIS

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).

3

Fig 021

mvc-1531

4.Remove the Belleville washers and caster fork and wheel assembly (Fig. 023).

Fig 023

DSC-1533

Replacing the Caster Bearings

1. Remove the top tapered roller bearing (Fig. 024).

3. Remove the locknut (Fig. 022).

Fig 024

DSC-1534

Fig 022

DSC-1532

3-2

Z Master 500 Gas Series Service Manual

CHASSIS

2.Remove bottom seal and tapered roller bearing (Fig. 025).

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 025

DSC-1535

 

 

 

 

 

 

 

 

3.With a driver and hammer, remove both the bottom and top tapered bearing cups (Fig. 026).

Fig 027

DSC-1537

5.Pack the upper and lower tapered bearings prior to installation (Fig. 028).

Fig 026

DSC-1536

Fig 028

DSC-1539

Z Master 500 Gas Series Service Manual

3-3

Loading...
+ 138 hidden pages