Toro 74268, 74268CP, 74268TE, 74269, 74269CP Service Manual
...
LCE Products
Z Master Z597
Diesel Series
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 safety 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
Diesel Engine: Briggs & Stratton Daihatsu 3 Cylinder Liquid-Cooled Engine Repair Manual
Form #492-0670
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
The Z Master 597 model years 2004 and 2005 are covered in this manual. The 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specications
Machine Prole Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available Service Manuals / Service Aids . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . . .
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) . . . . . . . . . . . . . .
Other Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis
Caster Fork Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Caster Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caster Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Removal and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Band Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Band Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Cross Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Lift Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Lift Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
3-2
3-3
3-4
3-5
3-6
3-6
3-8
3-8
3-11
3-11
3-12
3-12
3-13
3-16
3-17
3-17
3-18
3-18
3-20
3-22
3-23
3-26
3-29
3-32
Hydraulic System
Hydrostatic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fan Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fan Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fan Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4-5
4-8
4-10
4-13
4-14
4-16
4-17
4-20
iZ Master Z597 Diesel Service Manual
TABLE OF CONTENTS
Hydraulic System continued
Setting the Hydrostatic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Handle Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the LH Hydrostatic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the RH Hydrostatic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Fan Pump Flow Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Traction Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing to Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fan Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing and Tensioning the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensioning the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Water from the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23
4-24
4-25
4-26
4-27
4-28
4-30
4-31
4-32
4-33
4-34
5-2
5-11
5-21
5-21
5-25
5-28
5-29
5-29
5-30
5-31
5-32
5-32
5-33
5-34
Electrical
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual-Tone Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volt Meter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2
6-2
6-2
6-4
6-5
6-6
6-7
6-9
6-10
6-11
6-13
6-15
6-16
6-17
6-18
6-19
6-20
6-20
6-21
6-22
6-24, 25
ii Z Master Z597 Diesel Service Manual
TABLE OF CONTENTS
Mower Decks
Electric PTO Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Deck Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Jackshaft Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Jackshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Jackshaft and Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Hand Mower Idler Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . .
Right Hand Mower Idler Assembly Installation . . . . . . . . . . . . . . . . . . . . . . .
Left Hand Mower Idler Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Left Hand Mower Idler Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mower Spindle Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Mower Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Front-to-Rear Mower Pitch . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7-5
7-8
7-13
7-18
7-20
7-24
7-29
7-31
7-32
7-32
7-34
7-36
7-38
7-39
7-41
7-46
7-46
7-47
7-48
7-50
iiiZ Master Z597 Diesel Service Manual
TABLE OF CONTENTS
THIS PAGE INTENTIONALLY LEFT BLANK.
iv Z Master Z597 Diesel Service Manual
SAFETY INFORMATION
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks . . . . . . . . . . .
1-1Z Master Z597 Diesel Service Manual
6
7
SAFETY INFORMATION
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.
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 Z597 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
General Information
This symbol means WARNING or
1
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 Z597 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...
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.
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
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 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 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 it 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 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 Z597 Diesel Service Manual
SPECIFICATIONS
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks . . . . . . . . . . .
2-1Z Master Z597 Diesel Service Manual
6
7
2
SPECIFICATIONS
MACHINE PROFILE PHOTOS
Fig 001 DSC-2789
Fig 002 DSC-2790 Fig 004 DSC-2794
Fig 003 DSC-2792
2-2 Z Master Z597 Diesel Service Manual
SPECIFICATIONS
Item Specication
Engine Briggs & Stratton® Vanguard™ Daihatsu® 27 Horsepower Diesel Engine
RPM setting High RPM Setting (no load) 3850 + 50 (International: 3450 + 50)
Low RPM Setting 1750
Fuel Capacity 12 gallons (45.4 liters) Diesel Fuel
Length Z597 – 60” (152.4cm) TF Deck - 81.5” (207cm)
Z597 – 72” (182.9cm) TF Deck - 84.5” (214.6cm)
Width Z597 – 60” (152.4cm) TF Deck - 61.7” (156.7cm) - Deector 76” (193cm)
Z597 – 72” (182.9cm) TF Deck - 73.6” (186.9cm) - Deector 88” (223.5cm)
Height 74” (188cm) ROPS Height Upright
55” (140cm) ROPS Folded
Weight Z597 – 60” (152.4cm) TF Deck - 1630 lbs. (739.36kg)
Z597 – 72” (182.9cm) TF Deck - 1695 lbs. (768.84kg)
Traction System (2) Hydro-Gear BDP-21A, 21cc/rev with system check relief (Pump)
(2) Parker/Ross MB18, 17.1 cir 1 ¼“ Tapered Shaft (Wheel Motor)
Ground Speed Forward: Innite 0 – 12 mph
Reverse: Innite 0 – 8 mph
Tires Rear: 26” x 12” – 12
Front: 13” x 6.5” – 6
Tire Pressure Rear: 13 psi (90kPa)
Front: 13 psi (90kPa)
Attachment Drive 200 ft-lb. electromagnetic clutch (271.16 Nm)
2
Battery BCI Group Size: 26
540 cold cranking amps.
2-3Z Master Z597 Diesel Service Manual
2
SPECIFICATIONS
Item Specication
Mower Deck TURBO FORCE
Deck Construction Fabricated, High Strength 7-gauge Steel/with Bull-nose Bumper
Deck Depth 5 ½” (13.97cm)
Mower Bafes Adjustable Discharge Bafe
Spindle Housing 9 3/8” (23.8cm) Diameter Cast Iron
Spindle Shaft/Bearings 1” (2.54cm) Shaft / Tapered Roller
Blade Tip Speed 18,500+ ft/min (5,638+ m/min)
Blades ¼” (.635cm) Heat Treated Steel
Discharge Chute 5/16” (.79cm) Rubber
Cutting Height 1-1/2” – 5” (3.81 - 12.7cm)
Carrier Frame Construction 2” x 2” x 3/16” (5.08 x 5.08 x .476cm) Steel
Anti-scalp Rollers 6
Certication ANSI, CARB, EPA, OSHA
2-4 Z Master Z597 Diesel Service Manual
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.
2
Fig 006 g. 55 m-5615
1. Cap 3. Cold uid level - full
2. Bafe 4. Hot uid level - full
Fig 005 g. 50 decal
Hydraulic System Oil Capacity: 4 quarts (3.8 l)
Fluid Type: Mobil 1 15W – 50 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. 006 above).
2-5Z Master Z597 Diesel Service Manual
SPECIFICATIONS
2
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. 007).
Fig 007 DSC-2351
Engine Model and Serial Number
Identication:
Consult the appropriate engine manufacture’s service literature for the
location and translation of the engine model and serial number information.
Fig 008 conguration
Hydrostatic Pumps Model and Serial
Number:
The label above (Fig. 008), can be located on the pump housing. It
identies the model and conguration of the BDP pump.
Available Service Manuals / Service Aids
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
Diesel Engine: Briggs & Stratton Daihatsu 3 Cylinder Liquid-Cooled Engine Repair Manual
Form # 492-0670
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
2-6 Z Master Z597 Diesel Service Manual
SPECIFICATIONS
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
2
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
2-7Z Master Z597 Diesel Service Manual
SPECIFICATIONS
SAE Grade 8 Bolts, Screws,
Studs, & Sems with Regular
2
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
2
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)
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: 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
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.
2-8 Z Master Z597 Diesel Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
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)
2
± 10% of
2-9Z Master Z597 Diesel Service Manual
SPECIFICATIONS
Other Torque Specifications
2
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*
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
2-10 Z Master Z597 Diesel Service Manual
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
2-11Z Master Z597 Diesel Service Manual
2
SPECIFICATIONS
U.S. to Metric Conversions
To Convert Into Multiply By
Miles
Yards
Linear
Measurement
Area
Volume
Weight
Pressure
Work
Liquid Volume
Liquid Flows
Temperature
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
2-12 Z Master Z597 Diesel Service Manual
CHASSIS
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks . . . . . . . . . . .
3-1Z Master Z597 Diesel 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. 009).
3. Remove the locknut (Fig. 010).
Fig 010 DSC-1532
4. Remove the Belleville washers, caster fork and
wheel assembly (Fig. 011).
Fig 009 mvc-1531
Fig 011 DSC-1533
3-2 Z Master Z597 Diesel Service Manual
CHASSIS
Replacing the Caster Bearings
1. Remove the top tapered roller bearing (Fig. 012).
Fig 012 DSC-1534
2. Remove bottom seal and tapered roller bearing (Fig.
013).
3. With a driver and hammer, remove both the bottom
and top tapered bearing cups (Fig. 014).
Fig 014 DSC-1536
4. With a driver and hammer, install new 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. 015). Tap the bearing
cups in until they seat against the step in the caster
hub.
3
Fig 013 DSC-1535
Fig 015 DSC-1537
3-3Z Master Z597 Diesel Service Manual
CHASSIS
3
5. Pack the upper and lower tapered bearings prior to
installation (Fig. 016).
Fig 016 DSC-1539
6. Install the lower bearing and seal, with the open end
of the seal facing up (Fig. 017).
Castor Fork Assembly
1. Install the castor fork into the frame (Fig. 018).
Fig 018 DSC-1533
2. Install the upper bearing.
Fig 017 DSC-1538
3. Install the Belleville (spring) washers as shown in
(Fig. 019).
A. Dust Cap
B. Locknut
C. Spring Washers
A
B
C
Fig 019 washers line art
3-4 Z Master Z597 Diesel Service Manual
CHASSIS
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. 020).
Fig 020 DSC-1532
6. Remove the grease tting and install the grease
plug.
7. Install the dust cap on the caster hub (Fig. 022).
3
Fig 022 DSC-1541
5. Remove the plug located on the side of the hub
on the frame for the castor fork. Install a grease
tting. Pump grease into the housing until grease is
passing through the upper bearing (Fig. 021).
Fig 021 DSC-1540
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. 023).
Fig 023 DSC-1543
3-5Z Master Z597 Diesel Service Manual
CHASSIS
3
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. 024).
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 024 DSC-1546
Fuel Tank Removal
Right Side Fuel Tank Removal
1. Disconnect the negative battery cable. Empty the
fuel tank.
2. Remove the fuel hose at the bottom of the fuel tank
(Fig. 026).
4. Pack both tapered wheel bearings. Reassemble
per Fig. 024. Pump grease into the wheel bearings
through the grease tting located on the rim (Fig.
025).
Fig 025 DSC-1547
Fig 026 DSC-1548
3. Remove the fuel return line located on the inside of
the fuel tank (Fig. 027).
Fig 027 DSC-1549
3-6 Z Master Z597 Diesel Service Manual
CHASSIS
4. Remove the front bolt, spacer, washer, and nut that
secure the fuel tank bracket to the frame (Fig. 028).
Fig 028 DSC-1550
5. Remove the bolt, washer, and nut securing the left
rear of the fuel tank bracket to the frame (Fig. 029).
6. Remove bolt, washer, and nut securing the right rear
of the fuel tank bracket to the frame (Fig. 030).
3
Fig 030 DSC-1553
7. Remove the tank from the frame (Fig. 031).
Fig 029 DSC-1552
Fig 031 DSC-1555
3-7Z Master Z597 Diesel Service Manual
CHASSIS
3
8. Remove the fuel tank bracket by removing 3
locknuts and springs and 1 bolt (Fig. 032).
Fig 032 DSC-1556
Right Side Fuel Tank Installation
Reverse the order of removal.
Note: When tightening the nuts and springs on the
fuel tank bracket, Do Not over-tighten the
nuts. Tighten the nuts until there are three
threads showing on the threaded stud (Fig.
033).
A
B
C
D
E
Fig 033 3 thread above nut
A. Tank Stud D. Nut
B. Compression Spring E. 3 Threads
C. Tank mounting Plate
Left Side Fuel Tank Removal
1. Disconnect the negative battery cable. Empty the
fuel tank.
3-8 Z Master Z597 Diesel Service Manual
CHASSIS
2. Remove the 4 screws retaining the control panel and
control panel shield to the tank (Fig. 034).
Fig 034 DSC-1563
3. Carefully remove the control panel and control panel
shield by lifting the panel and sliding it to the middle
of the unit.
5. Remove the return fuel line, located on the inside of
the fuel tank (Fig. 036).
3
Fig 036 DSC-1565
6. Remove the fuel line, located under the front of the
fuel tank (Fig. 037).
NOTE: It is not necessary to disconnect any cables
or wiring.
4. Unplug the 3 connectors that plug into the delay
module (Fig. 035).
Fig 035 DSC-1578
Fig 037 DSC-1566
3-9Z Master Z597 Diesel Service Manual
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