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 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 |
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General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1-2 |
||
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1-2 |
||
Specifications |
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Machine Profile Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-2 |
||
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 |
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Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 |
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General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-5 |
||
Available Service Manuals / Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . |
2-6 |
||
Torque Specifications . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . 2-7 |
||
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . . . |
2-8 |
||
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) . . |
. . . . . . . . . . . . 2-9 |
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Other Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 |
|||
Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-11 |
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U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2-12 |
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Chassis |
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Caster Fork Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-2 |
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Replacing the Caster Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-3 |
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Caster Fork Assembly . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . 3-4 |
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Front Wheel Removal and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . |
3-5 |
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Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-6 |
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Right Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-6 |
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Right Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-8 |
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Left Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-8 |
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Left Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-11 |
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Hood Assembly Removal . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . 3-11 |
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Hood Assembly Installation . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . 3-12 |
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Throttle Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-12 |
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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-13 |
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Brake Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-16 |
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Brake Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-17 |
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Brake Band Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-17 |
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Brake Band Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-18 |
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Brake Cross Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-18 |
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Brake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-20 |
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Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-22 |
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Deck Lift Lever Removal . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . 3-23 |
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Deck Lift Lever Installation . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . 3-26 |
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Motion Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-29 |
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Motion Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3-32 |
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Hydraulic System |
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Hydrostatic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-2 |
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Hydrostatic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-5 |
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Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-8 |
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Wheel Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-10 |
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Purging the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-13 |
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Hydraulic Fan Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-14 |
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Hydraulic Fan Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-16 |
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Hydraulic Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-17 |
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Hydraulic Fan Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-20 |
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Z Master Z597 Diesel Service Manual |
i |
TABLE OF CONTENTS
Hydraulic System continued |
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Setting the Hydrostatic Pump Neutral . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . 4-23 |
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Adjusting the Handle Neutral . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-24 |
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Setting the LH Hydrostatic Pump Neutral . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-25 |
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Setting the RH Hydrostatic Pump Neutral . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-26 |
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Adjusting the Tracking . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-27 |
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Hydraulic Flow Testing Procedure . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-28 |
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Cooling Fan Pump Flow Testing Procedure . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-30 |
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Replacing the Traction Pump Drive Belt . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-31 |
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Pushing the Machine by Hand . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . |
4-32 |
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Changing to Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-33 |
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Hydraulic Schematic . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
4-34 |
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Engine |
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Engine Removal . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
5-2 |
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Engine Installation . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
5-11 |
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Cooling System . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . 5-21 |
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Removing the Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 |
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Radiator Installation . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . 5-25 |
||||
Checking the Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5-28 |
||||
Replacing the Fan Pump Drive Belt . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . 5-29 |
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Replacing and Tensioning the Alternator Belt . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
5-29 |
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Replacing the Alternator Belt . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
5-30 |
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Tensioning the Alternator Belt . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . 5-31 |
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Servicing the Fuel Filter . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
5-32 |
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Draining Water from the Fuel Filter . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
5-32 |
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Changing the Fuel Filter . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . |
5-33 |
|||
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 |
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Electrical |
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Electrical System . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
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6-2 |
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General . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . |
. . . 6-2 |
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Relays . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-2 |
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PTO Switch . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-4 |
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Ignition Switch . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . |
. . . 6-5 |
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Neutral Safety Switch . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-6 |
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Park Brake Switch . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-7 |
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Seat Switch . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-9 |
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Delay Module . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-10 |
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Dual-Tone Alarm . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-11 |
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Glow Plug Controller . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-13 |
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Temperature Sender . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-15 |
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Oil Pressure Switch . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-16 |
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Water Temperature Gauge . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-17 |
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Hour Meter . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-18 |
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Volt Meter Gauge . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-19 |
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Electric PTO Clutch . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . 6-20 |
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Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6-20 |
||||
Measuring Clutch Current Draw . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-21 |
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Fuel Filter Sensor . . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-22 |
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Electrical Schematic . . . . . . . . . . . . . . . . |
. . . . . . . . . . |
. . |
. . . . . |
6-24, 25 |
|
ii |
Z Master Z597 Diesel Service Manual |
TABLE OF CONTENTS
Mower Decks |
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Electric PTO Clutch Removal . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-2 |
PTO Clutch Installation . . . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-5 |
Mower Deck Removal . . . . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . 7-8 |
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Mower Deck Installation . . . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . 7-13 |
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Mower Spindle Removal . . . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-18 |
Mower Spindle Disassembly . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-20 |
Mower Spindle Assembly . . . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . 7-24 |
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Mower Jackshaft Assembly Removal . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-29 |
Mower Jackshaft Installation . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . 7-31 |
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Mower Jackshaft and Pulley Assembly . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-32 |
Right Hand Mower Idler Assembly Removal . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-32 |
Right Hand Mower Idler Assembly Installation . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-34 |
Left Hand Mower Idler Assembly Removal . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-36 |
Left Hand Mower Idler Assembly Installation . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-38 |
Replacing the Mower Spindle Belt . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-39 |
Replacing Mower Drive Belts . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . 7-41 |
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Leveling the Mower . . . . . . . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . 7-46 |
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Setting up the Machine . . . . . . . . . . . |
. . . . . . . . . . . . . . . . . . . . 7-46 |
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Leveling the Mower Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
7-47 |
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Adjusting the Front-to-Rear Mower Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 |
||||
Adjusting the Compression Spring . . . . . . . . |
. . . . . . |
. . . . . . . . . |
. . . . . |
7-50 |
Z Master Z597 Diesel Service Manual |
iii |
TABLE OF CONTENTS
THIS PAGE INTENTIONALLY LEFT BLANK.
iv |
Z Master Z597 Diesel Service Manual |
SAFETY INFORMATION
Safety Information . . . . . . . . . 1
Specifications . . . . . . . . . . . |
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2 |
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Chassis . . . . . . . . . . . . . . |
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3 |
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Hydraulic System . . . . . . . . . |
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4 |
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Engine . . . . . . . . . . . . . . . |
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5 |
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Electrical . . . . . . . . . . . . . . |
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6 |
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Mower Decks . . . . . . . . . . . |
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7 |
Z Master Z597 Diesel 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 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.
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.
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 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 . . . . . . . . . 1
Specifications . . . . . . . . . . . |
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2 |
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Chassis . . . . . . . . . . . . . . |
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3 |
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Hydraulic System . . . . . . . . . |
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4 |
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Engine . . . . . . . . . . . . . . . |
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5 |
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Electrical . . . . . . . . . . . . . . |
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6 |
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Mower Decks . . . . . . . . . . . |
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7 |
Z Master Z597 Diesel Service Manual |
2-1 |
SPECIFICATIONS
MACHINE PROFILE PHOTOS
2
Fig 001 |
DSC-2789 |
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Fig 003 |
DSC-2792 |
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Fig 002 |
DSC-2790 |
Fig 004 |
DSC-2794 |
2-2 |
Z Master Z597 Diesel Service Manual |
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SPECIFICATIONS |
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Item |
Specification |
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Engine |
Briggs & Stratton® Vanguard™ Daihatsu® 27 Horsepower Diesel Engine |
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RPM setting |
High RPM Setting (no load) 3850 + 50 (International: 3450 + 50) |
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Low RPM Setting 1750 |
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Fuel Capacity |
12 gallons (45.4 liters) Diesel Fuel |
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Length |
Z597 |
– 60” (152.4cm) TF Deck - 81.5” (207cm) |
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Z597 |
– 72” (182.9cm) TF Deck - 84.5” (214.6cm) |
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Width |
Z597 |
– 60” (152.4cm) TF Deck - 61.7” (156.7cm) - Deflector 76” (193cm) |
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Z597 |
– 72” (182.9cm) TF Deck - 73.6” (186.9cm) - Deflector 88” (223.5cm) |
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Height |
74” (188cm) ROPS Height Upright |
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55” (140cm) ROPS Folded |
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Weight |
Z597 |
– 60” (152.4cm) TF Deck - 1630 lbs. (739.36kg) |
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Z597 |
– 72” (182.9cm) TF Deck - 1695 lbs. (768.84kg) |
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Traction System |
(2) Hydro-Gear BDP-21A, 21cc/rev with system check relief (Pump) |
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(2) Parker/Ross MB18, 17.1 cir 1 ¼“ Tapered Shaft (Wheel Motor) |
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Ground Speed |
Forward: Infinite 0 – 12 mph |
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Reverse: Infinite 0 – 8 mph |
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Tires |
Rear: |
26” x 12” – 12 |
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Front: 13” x 6.5” – 6 |
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Tire Pressure |
Rear: |
13 psi (90kPa) |
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Front: 13 psi (90kPa) |
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Attachment Drive |
200 ft-lb. electromagnetic clutch (271.16 Nm) |
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Battery |
BCI Group Size: 26 |
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540 cold cranking amps. |
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Z Master Z597 Diesel Service Manual |
2-3 |
SPECIFICATIONS
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Item |
Specification |
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Mower Deck |
TURBO FORCE |
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Deck Construction |
Fabricated, High Strength 7-gauge Steel/with Bull-nose Bumper |
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Deck Depth |
5 ½” (13.97cm) |
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Mower Baffles |
Adjustable Discharge Baffle |
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2 |
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Spindle Housing |
9 3/8” (23.8cm) Diameter Cast Iron |
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Spindle Shaft/Bearings |
1” (2.54cm) Shaft / Tapered Roller |
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Blade Tip Speed |
18,500+ ft/min (5,638+ m/min) |
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Blades |
¼” (.635cm) Heat Treated Steel |
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Discharge Chute |
5/16” (.79cm) Rubber |
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Cutting Height |
1-1/2” – 5” (3.81 - 12.7cm) |
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Carrier Frame Construction |
2” x 2” x 3/16” (5.08 x 5.08 x .476cm) Steel |
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Anti-scalp Rollers |
6 |
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Certification |
ANSI, CARB, EPA, OSHA |
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2-4 |
Z Master Z597 Diesel Service Manual |
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SPECIFICATIONS |
General Specifications |
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Greasing and Lubrication: |
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Grease: |
No. 2 general purpose lithium base or molybdenum grease. |
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Where to Add Grease: |
See Check Service Reference Aid decal below. |
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2
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Fig 006 |
fig. 55 m-5615 |
1. |
Cap |
3. |
Cold fluid level - full |
2. |
Baffle |
4. |
Hot fluid level - full |
Fig 005 |
fig. 50 decal |
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Hydraulic System Oil Capacity: |
4 quarts (3.8 l) |
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Fluid Type: |
Mobil 1 15W – 50 synthetic motor oil or equivalent synthetic oil |
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Fluid Level: |
Check the fluid level while the fluid is warm. The fluid should be between cold |
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and hot. |
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Note: The fluid level should be to the top of the hot level of the baffle, |
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when the fluid is hot (Fig. 006 above). |
Z Master Z597 Diesel Service Manual |
2-5 |
SPECIFICATIONS
Model and Serial Number |
The unit model and serial number plate is located on the right hand side of the |
Location |
unit, below the right side motion control lever (Fig. 007). |
2
Fig 007 DSC-2351 Fig 008 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. |
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Hydrostatic Pumps Model and Serial |
The label above (Fig. 008), can be located on the pump housing. It |
Number: |
identifies the model and configuration of the BDP pump. |
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Available Service Manuals / Service Aids
Hydrostatic Pumps: |
Hydro-Gear BDP-10A/16A/21L – Service and Repair Manual |
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Form # 492-4789 |
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Wheel Motors: |
Parker/Ross Wheel Motor Service Manual |
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Form # 492-4753 |
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Diesel Engine: |
Briggs & Stratton Daihatsu 3 Cylinder Liquid-Cooled Engine Repair Manual |
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Form # 492-0670 |
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Hydraulic Troubleshooting: |
Interactive hydraulic troubleshooting and failure analysis on compact disk |
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Form #492-4777 |
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Electrical Troubleshooting: |
Interactive electrical troubleshooting and wiring diagrams on compact disk |
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Form #492-9143 |
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2-6 |
Z Master Z597 Diesel Service Manual |
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 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.
2
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Figure A |
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Inch Series Bolts and Screws |
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(A) Grade 1 |
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(C) Grade 8 |
(B) Grade 5 |
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Figure B
Metric Bolts and Screws
(A) Class 8.8 |
(B) Class 10.9 |
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Z Master Z597 Diesel Service Manual |
2-7 |
SPECIFICATIONS
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
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Grade 1, 5, & |
SAE Grade 1 Bolts, Screws, |
SAE Grade 5 Bolts, Screws, |
SAE Grade 8 Bolts, Screws, |
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Thread Size |
8 with Thin |
Studs, & Sems with Regular |
Studs, & Sems with Regular |
Studs, & Sems with Regular |
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Height Nuts |
Height Nuts (SAE J995 |
Height Nuts (SAE J995 |
Height Nuts (SAE J995 |
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Grade 2 or Stronger Nuts) |
Grade 2 or Stronger Nuts) |
Grade 2 or Stronger Nuts) |
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In-lb |
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In-lb |
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N-cm |
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In-lb |
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N-cm |
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In-lb |
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N-cm |
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# 6 - 32 UNC |
10 |
± 2 |
13 |
± 2 |
147 |
± 23 |
15 |
± |
2 |
170 |
± |
20 |
23 |
± 2 |
260 |
± |
20 |
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# 6 - 40 UNF |
17 |
± |
2 |
190 |
± |
20 |
25 |
± 2 |
280 |
± |
20 |
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# 8 - 32 UNC |
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29 |
± |
3 |
330 |
± |
30 |
41 |
± 4 |
460 |
± |
45 |
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2 |
13 |
± 2 |
25 |
± 5 |
282 |
± 30 |
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# 8 - 36 UNF |
31 ± 3 |
350 ± 30 |
43 |
± 4 |
31 ± 3 |
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# 10 - 24 UNC |
18 |
± 2 |
30 |
± 5 |
339 |
± 56 |
42 |
± 4 |
475 |
± |
45 |
60 |
± 6 |
674 |
± 70 |
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#10 - 32 UNF |
48 |
± 4 |
540 |
± |
45 |
68 |
± 6 |
765 |
± 70 |
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1/4 - 20 UNC |
48 |
± 7 |
53 |
± 7 |
599 |
± 79 |
100 |
± 10 |
1125 ± 100 |
140 |
± 15 |
1580 |
± 170 |
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1/4 - 28 UNF |
53 |
± 7 |
65 ± 10 |
734 ± 113 |
115 ± 10 |
1300 |
± |
100 |
160 |
± 15 |
1800 |
± 170 |
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5/16 - 18 UNC |
115 ± 15 |
105 |
± 17 |
1186 ± 169 |
200 |
± 25 |
2250 |
± |
280 |
300 |
± 30 |
3390 |
± 340 |
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5/16 - 24 UNF |
138 |
± 17 |
128 |
± 17 |
1446 |
± 192 |
225 |
± 25 |
2540 |
± |
280 |
325 |
± 30 |
3670 |
± 340 |
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ft-lb |
ft-lb |
N-m |
ft-lb |
N-m |
ft-lb |
N-m |
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3/8 - 16 UNC |
16 |
± 2 |
16 |
± 2 |
22 |
± 3 |
30 |
± 3 |
41 |
± |
4 |
43 |
± 4 |
58 |
± 5 |
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3/8 - 24 UNF |
17 |
± 2 |
18 |
± 2 |
24 |
± 3 |
35 |
± 3 |
47 |
± |
4 |
50 |
± 4 |
68 |
± 5 |
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7/16 - 14 UNC |
27 |
± 3 |
27 |
± 3 |
37 |
± 4 |
50 |
± 5 |
68 |
± |
7 |
70 |
± 7 |
68 |
± 9 |
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7/16 - 20 UNF |
29 |
± 3 |
29 |
± 3 |
39 |
± 4 |
55 |
± 5 |
75 |
± |
7 |
77 |
± 7 |
104 ± 9 |
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1/2 - 13 UNC |
30 |
± 3 |
48 |
± 7 |
65 |
± 9 |
75 |
± 8 |
102 ± 11 |
105 |
± 10 |
142 |
± 14 |
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1/2 - 20 UNF |
32 |
± 3 |
53 |
± 7 |
72 |
± 9 |
85 |
± 8 |
115 |
± |
11 |
120 |
± 10 |
163 |
± 14 |
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5/8 - 11 UNC |
65 ± 10 |
88 ± 12 |
119 ± 16 |
150 |
± 15 |
203 |
± |
20 |
210 |
± 20 |
285 |
± 27 |
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5/8 - 18 UNF |
75 ± 10 |
95 ± 15 |
129 |
± 20 |
170 |
± 15 |
230 |
± |
20 |
240 |
± 20 |
325 |
± 27 |
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3/4 - 10 UNC |
93 ± 12 |
140 |
± 20 |
190 |
± 27 |
265 |
± 25 |
359 |
± |
34 |
374 |
± 35 |
508 |
± 47 |
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3/4 - 16 UNF |
115 ± 15 |
165 |
± 25 |
224 |
± 34 |
300 |
± 25 |
407 |
± |
34 |
420 |
± 35 |
569 |
± 47 |
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7/8 - 9 UNC |
140 |
± 20 |
225 |
± 25 |
305 |
± 34 |
430 |
± 45 |
583 |
± |
61 |
600 |
± 60 |
813 |
± 81 |
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7/8 - 14 UNF |
155 |
± 25 |
260 |
± 30 |
353 |
± 41 |
475 |
± 45 |
644 |
± |
61 |
660 |
± 60 |
895 |
± 81 |
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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.
2-8 |
Z Master Z597 Diesel Service Manual |
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 |
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Regular Height Nuts |
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Regular Height Nuts ( |
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(Class 8 or Strong Nuts) |
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Class 10 or Strong Nuts) |
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M5 X 0.8 |
57 ± 5 in-lb |
640 |
± 60 N-cm |
78 ± 7 in-lb |
885 ± 80 N-cm |
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M6 X 1.0 |
96 ± 9 in-lb |
1018 |
± 100 N-cm |
133 ± 13 in-lb |
1500 ± 150 N-cm |
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M8 X 1.25 |
19 |
± 2 ft-lb |
26 |
± 3 N-m |
27 |
± 2 ft-lb |
36 |
± |
3 N-m |
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M10 X 1.5 |
38 |
± 4 ft-lb |
52 |
± 5 N-m |
53 |
± 5 ft-lb |
72 |
± |
7 N-m |
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M12 X 1.75 |
66 |
± 7 ft-lb |
90 |
± 10 N-m |
92 |
± 9 ft-lb |
125 |
± |
12 N-m |
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2 |
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M16 X 2.0 |
166 |
± 15 ft-lb |
225 |
± 20 N-m |
229 |
± 22 ft-lb |
310 |
± |
30 N-m |
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M20 X 2.5 |
325 |
± 33 ft-lb |
440 |
± 45 N-m |
450 |
± 37 ft-lb |
610 |
± |
50 N-m |
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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.
Z Master Z597 Diesel Service Manual |
2-9 |
SPECIFICATIONS
Other Torque Specifications
SAE Grade 8 Steel Set Screws
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Thread Size |
Recommended Torque |
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Square Head |
Hex Socket |
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1/4 - 20 UNC |
140 ± 20 in-lb |
73 ± 12 in-lb |
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5/16 - 18 UNC |
215 ± 35 in-lb |
145 ± 20 in-lb |
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3/8 - 16 UNC |
35 ± 10 ft-lb |
18 ± 3 ft-lb |
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1/2 - 13 UNC |
75 ± 15 ft-lb |
50 ± 10 ft-lb |
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Wheel Bolts and Lug Nuts
Thread Size |
Recommended Torque** |
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7/16 - 20 UNF |
65 ± 10 ft-lb |
88 ± 14 N-m |
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Grade 5 |
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1/2 - 20 UNF |
80 ± 10 ft-lb |
108 ± 14 N-m |
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Grade 5 |
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M12 X 1.25 |
80 ± 10 ft-lb |
108 ± 14 N-m |
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Class 8.8 |
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M12 X 1.5 |
80 ± 10 ft-lb |
108 ± 14 N-m |
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Class 8.8 |
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** For steel wheels and non-lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size |
Baseline Torque* |
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No. 6 - 32 UNC |
20 |
± 5 in-lb |
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No. 8 - 32 UNC |
30 |
± 5 in-lb |
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No.10 - 24 UNC |
38 |
± 7 in-lb |
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1/4 - 20 UNC |
85 ± 15 in-lb |
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5/16 - 18 UNC |
110 |
± 20 in-lb |
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3/8 - 16 UNC |
200 ± 100 in-lb |
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Thread Cutting Screws
(Zinc Plated Steel)
Thread |
Threads per Inch |
Baseline Torque* |
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Size |
Type A |
Type B |
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No. 6 |
18 |
20 |
20 ± 5 in-lb |
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No. 8 |
15 |
18 |
30 ± 5 in-lb |
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No. 10 |
12 |
16 |
38 ± 7 in-lb |
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No. 12 |
11 |
14 |
85 ± 15 in-lb |
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* 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 |
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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 |
2-10 |
Z Master Z597 Diesel Service Manual |
SPECIFICATIONS
Equivalents and Conversions
Decimal and Millimeter Equivalents
Fractions |
Decimals |
mm |
Fractions |
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Decimals |
mm |
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1/64 |
0.015625 |
0.397 |
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33/64 |
0.515625 |
13.097 |
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1/32 |
0.03125 |
0.794 |
16/32 |
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0.53125 |
13.484 |
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3/64 |
0.046875 |
1.191 |
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35/64 |
0.546875 |
13.891 |
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1/16 |
0.0625 |
1.588 |
9/16 |
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0.5625 |
14.288 |
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5/64 |
0.078125 |
1.984 |
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37/64 |
0.578125 |
14.684 |
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2 |
3/32 |
0.9375 |
2.381 |
19/32 |
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0.59375 |
15.081 |
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1/8 |
0.1250 |
3.175 |
5/8 |
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0.6250 |
15.875 |
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9/64 |
0.140625 |
3.572 |
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41/64 |
0.640625 |
16.272 |
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5/32 |
0.15625 |
3.969 |
21/32 |
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0.65625 |
16.669 |
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11/64 |
0.171875 |
4.366 |
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43/64 |
0.671875 |
17.066 |
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3/16 |
0.1875 |
4.762 |
11/16 |
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0.6875 |
17.462 |
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13/64 |
0.203125 |
5.159 |
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45/64 |
0.703125 |
17.859 |
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7/32 |
0.21875 |
5.556 |
23/32 |
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0.71875 |
18.256 |
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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 |
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||
Z Master Z597 Diesel Service Manual |
2-11 |
SPECIFICATIONS
U.S. to Metric Conversions
|
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To Convert |
Into |
Multiply By |
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|
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|
|
|
Miles |
Kilometers |
|
1.609 |
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|
|
Yards |
Meters |
|
0.9144 |
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|
Linear |
Feet |
Meters |
|
0.3048 |
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|
Feet |
Centimeters |
|
30.48 |
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Measurement |
Inches |
Meters |
|
0.0254 |
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|
|
Inches |
Centimeters |
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|
|
|
|
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2.54 |
||
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Inches |
Millimeters |
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|
25.4 |
||
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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 |
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|
|
|
|
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|
Temperature |
Fahrenheit |
Celsius |
1. |
Subtract 32° |
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|
2. |
Multiply by 5/9 |
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||
2-12 |
Z Master Z597 Diesel Service Manual |
CHASSIS
Safety Information . . . . . . . . . 1
Specifications . . . . . . . . . . . |
|
2 |
|
Chassis . . . . . . . . . . . . . . |
|
3 |
|
Hydraulic System . . . . . . . . . |
|
4 |
|
Engine . . . . . . . . . . . . . . . |
|
5 |
|
Electrical . . . . . . . . . . . . . . |
|
6 |
|
Mower Decks . . . . . . . . . . . |
|
7 |
Z Master Z597 Diesel Service Manual |
3-1 |
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. 009).
3
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 |
3. With a driver and hammer, remove both the bottom |
|
and top tapered bearing cups (Fig. 014). |
1. Remove the top tapered roller bearing (Fig. 012). |
|
Fig 012 |
DSC-1534 |
2.Remove bottom seal and tapered roller bearing (Fig. 013).
|
|
|
|
|
|
|
3 |
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.
Fig 013 |
DSC-1535 |
Fig 015 |
DSC-1537 |
Z Master Z597 Diesel Service Manual |
3-3 |
CHASSIS
5. Pack the upper and lower tapered bearings prior to |
Castor Fork Assembly |
installation (Fig. 016). |
|
|
1. Install the castor fork into the frame (Fig. 018). |
|
|
|
|
3 |
|
|
|
|
Fig 016 |
DSC-1539 |
6.Install the lower bearing and seal, with the open end of the seal facing up (Fig. 017).
Fig 017 |
DSC-1538 |
Fig 018 |
DSC-1533 |
2.Install the upper bearing.
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 flat, then back off 1/4 turn to properly set the preload on the bearings (Fig. 020).
6.Remove the grease fitting and install the grease plug.
7.Install the dust cap on the caster hub (Fig. 022).
3
Fig 020 |
DSC-1532 |
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
fitting. Pump grease into the housing until grease is passing through the upper bearing (Fig. 021).
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 021 |
DSC-1540 |
Fig 023 |
DSC-1543 |
Z Master Z597 Diesel Service Manual |
3-5 |
CHASSIS
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 |
A B C C B A
3
D
E |
F |
|
|
|
|
Fig 024 |
DSC-1546 |
4.Pack both tapered wheel bearings. Reassemble per Fig. 024. Pump grease into the wheel bearings through the grease fitting located on the rim (Fig.
025).
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).
Fig 026 |
DSC-1548 |
3.Remove the fuel return line located on the inside of the fuel tank (Fig. 027).
Fig 025 |
DSC-1547 |
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).
6.Remove bolt, washer, and nut securing the right rear of the fuel tank bracket to the frame (Fig. 030).
3
Fig 028 |
DSC-1550 |
Fig 030 |
DSC-1553 |
5.Remove the bolt, washer, and nut securing the left rear of the fuel tank bracket to the frame (Fig. 029).
7. Remove the tank from the frame (Fig. 031).
Fig 031 |
DSC-1555 |
Fig 029 |
DSC-1552 |
Z Master Z597 Diesel Service Manual |
3-7 |
CHASSIS
8. Remove the fuel tank bracket by removing 3 |
Right Side Fuel Tank Installation |
locknuts and springs and 1 bolt (Fig. 032). |
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 |
3 |
Fig 032 |
DSC-1556 |
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).
5.Remove the return fuel line, located on the inside of the fuel tank (Fig. 036).
3
Fig 034 |
DSC-1563 |
Fig 036 |
DSC-1565 |
3.Carefully remove the control panel and control panel shield by lifting the panel and sliding it to the middle of the unit.
NOTE: It is not necessary to disconnect any cables or wiring.
4.Unplug the 3 connectors that plug into the delay module (Fig. 035).
6.Remove the fuel line, located under the front of the fuel tank (Fig. 037).
Fig 037 |
DSC-1566 |
Fig 035 |
DSC-1578 |
Z Master Z597 Diesel Service Manual |
3-9 |
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