Toro 74410, 74412, 74413, 74414, 74415 Service Manual
...
LCE Products
Z Master Z400
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
©2006 The Toro Company
THIS PAGE INTENTIONALLY LEFT BLANK.
TABLE OF CONTENTS
Safety Information
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specications
Machine Prole Photos
Z 400 Estate Series 19 hp Kawasaki OHV V-Twin . . . . . . . . . . . . . . . . . . . .
Z 400 Estate Series 18 hp Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . .
Z 450 Pro Performance Series 20 hp Kohler OHV V-Twin . . . . . . . . . . . . . . . . .
Z 100 Series 19 hp Kawasaki KAI OHV V-Twin . . . . . . . . . . . . . . . . . . . . .
Z 450 Pro Performance Series 23 hp Kawasaki OHV V-Twin . . . . . . . . . . . . . . . .
Z 440 Pro Value Series 19 hp Kawasaki KAI OHV V-Twin . . . . . . . . . . . . . . . . .
Engine Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Z 400 Series Manual Specications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Decks continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Aid Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-9
2-9
2-10
2-10
2-10
2-11
2-12
2-13
2-13
2-13
2-15
2-16
2-17
2-18
2-19
2-20
2-21
Chassis
Caster Fork Assembly Removal Estate Series with bushing front casters . . . . . . . . . . . . .
Caster Fork Assembly Installation Estate Series with bushing front casters . . . . . . . . . . . .
Caster Fork Assembly Removal Pro 100/400 Series with tapered roller front casters . . . . . . . .
Caster Fork Assembly Installation Pro 100/400 Series with tapered roller front casters . . . . . . . .
Front Wheel Removal and Bearing Replacement Estate Series . . . . . . . . . . . . . . . . .
Pro 100/400 Series with tapered roller front casters . . . . . . . . . . . . . . . . . . . .
Fuel Tank Removal
Left Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Side Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . .
Fuel Check Valve
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Shut Off Valve
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pro 400 Series V-Twin Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3-3
3-4
3-6
3-8
3-12
3-14
3-16
3-16
3-16
3-16
3-16
3-17
3-17
3-17
3-17
iZ Master Z400 Service Manual
TABLE OF CONTENTS
Chassis continued
Parking Brake Handle/Shaft Assembly Removal All models . . . . . . . . . . . . . . . . . .
Parking Brake Handle/Shaft Assembly Installation All models . . . . . . . . . . . . . . . . .
Brake Bar Removal (Estate Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Band Removal (Pro Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Band Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shaft Removal (Pro Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Lift Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deck Lift Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System
Hydrostatic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Arm Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Handle Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the LH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the RH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing to Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18
3-20
3-20
3-21
3-21
3-22
3-23
3-23
3-25
3-25
3-28
3-31
3-33
4-2
4-4
4-7
4-9
4-9
4-10
4-10
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-18
4-21
4-21
Engine
Kawasaki FH580V 19 hp Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Kawasaki FH580V 19 hp Engine Installation . . . . . . . . . . . . . . . . . . . . . . . .
Kohler V-Twin 20 hp Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler V-Twin 20 hp Engine Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler 18 hp Single Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Kohler 18 hp Single Cylinder Install . . . . . . . . . . . . . . . . . . . . . . . . . . .
Z 100 Series FH580V (KAI) 19 hp Kawasaki Removal . . . . . . . . . . . . . . . . . . . .
Z 100 Series FH580V (KAI) 19 hp Kawasaki Install . . . . . . . . . . . . . . . . . . . . .
Electrical
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Z Master Z400 Service Manual
5-2
5-6
5-12
5-18
5-24
5-28
5-34
5-39
6-2
6-2
6-3
6-5
6-6
6-7
6-8
TABLE OF CONTENTS
Electrical continued
Seat Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematics
74412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74413 and 74415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74416 and 74417 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74411TE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74416TE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Decks
Mower Deck Removal Estate Series . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Deck Installation Estate Series . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Deck Removal Z 400 Series (48” and 50” Decks) . . . . . . . . . . . . . . . . . . .
Mower Deck Installation Z 400 Series (48” and 50” Decks) . . . . . . . . . . . . . . . . . .
Mower Deck Removal Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . . . . .
Mower Deck Installation Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Removal Pro 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Installation Pro 100 Series . . . . . . . . . . . . . . . . . . . . . . . . .
Mower Spindle Removal Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . . .
Mower Spindle Installation Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . .
Mower Spindle Disassembly Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . .
Mower Spindle Assembly Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . . .
Mower Spindle Disassembly Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . .
Mower Spindle Assembly Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mower Deck Drive Belt All Z 400 models . . . . . . . . . . . . . . . . . . . .
Replacing the Mower Deck Drive Belt Z 100 Series . . . . . . . . . . . . . . . . . . . . .
Adjusting the Mower Belt Tension Z 100 Series . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Mower Belt Tension Z 400 Series . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower at 3 Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting up the Machine All models . . . . . . . . . . . . . . . . . . . . . . . . . .
Leveling the Mower Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Front-to-Rear Mower Pitch . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9
6-11
6-12
6-12
6-13
6-13
6-15
6-16
6-17
6-18
6-19
6-20
6-21
6-22
6-23
7-2
7-4
7-6
7-8
7-10
7-12
7-15
7-16
7-16
7-18
7-18
7-20
7-23
7-24
7-24
7-26
7-27
7-28
7-29
7-29
7-30
7-31
iiiZ Master Z400 Service Manual
TABLE OF CONTENTS
THIS PAGE INTENTIONALLY LEFT BLANK.
iv Z Master Z400 Service Manual
SAFETY INFORMATION
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks . . . . . . . . . . .
1-1Z Master Z400 Service Manual
6
7
SAFETY INFORMATION
SAFETY INFORMATION
General Information
This symbol means WARNING or
PERSONAL SAFETY INSTRUCTION
- read the instruction because it has to
do with your safety. Failure to comply
with the instruction may result in
personal injury or even death.
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
SAFETY INFORMATION
General Information
This symbol means WARNING or
PERSONAL SAFETY INSTRUCTION
- read the instruction because it has to
do with your safety. Failure to comply
with the instruction may result in
personal injury or even death.
The riding mower and attachment operator's manual
contain safety information and operating tips for safe
operating practices. Operator's manuals are available
through your Toro parts source or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
General Information
1
This 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 Z400
Series Zero-turn Riding Mower.
Think Safety First
Avoid unexpected starting of engine...
Always turn off the engine and disconnect the spark
plug wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations...
This symbol means WARNING or
PERSONAL SAFETY INSTRUCTION
- read the instruction because it has to
do with your safety. Failure to comply
with the instruction may result in
personal injury or even death.
The riding mower and attachment operator’s manual
contain safety information and operating tips for safe
operating practices. Operator’s manuals are available
through the Internet, 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.
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.
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 Z400 Service Manual
SPECIFICATIONS
Safety Information . . . . . . . . .
Specications . . . . . . . . . . .
Chassis . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . .
Engine . . . . . . . . . . . . . . .
1
2
3
4
5
Electrical . . . . . . . . . . . . . .
Mower Decks . . . . . . . . . . .
2-1Z Master Z400 Service Manual
6
7
2
SPECIFICATIONS
Z 400 Estate Series
19 hp Kawasaki OHV V-Twin
Fig 001 DSC-4765a
Fig 002 DSC-4766a Fig 004 DSC-4768a
Fig 003 DSC-4767a
2-2 Z Master Z400 Service Manual
Z 400 Estate Series
18 hp Kohler
SPECIFICATIONS
2
Fig 005 DSC-4842a
Fig 006 DSC-4843a Fig 008 DSC-4846a
Fig 007 DSC-4844a
2-3Z Master Z400 Service Manual
2
SPECIFICATIONS
Z 450 Pro Performance Series
20 hp Kohler OHV V-Twin
Fig 009 DSC-4833a
Fig 010 DSC-4834a Fig 012 DSC-4838a
Fig 011 DSC-4835a
2-4 Z Master Z400 Service Manual
SPECIFICATIONS
Z 100 Series
19 hp Kawasaki KAI OHV V-Twin
Fig 013 DSC-0437a Fig 015 DSC-0440a
2
Fig 014 DSC-0436a
Fig 016 DSC-0435a
2-5Z Master Z400 Service Manual
2
SPECIFICATIONS
Z 450 Pro Performance Series
23 hp Kawasaki OHV V-Twin
Fig 017 DSC-0444a
Fig 018 DSC-0445a Fig 020 DSC-0448a
Fig 019 DSC-0442a
2-6 Z Master Z400 Service Manual
Z 440 Pro Value Series
19 hp Kawasaki KAI OHV V-Twin
SPECIFICATIONS
2
Fig 021 DSC-0452a
Fig 022 DSC-0451a Fig 024 DSC-0450a
Fig 023 DSC-0455a
2-7Z Master Z400 Service Manual
SPECIFICATIONS
Engines
Output Make High Idle Low Idle Charging Coil
2
19 HP (14.2kW) Kawasaki
OHV V-Twin Forced Air Cooled
18 HP (13.4kW) Kohler
OHV Single Forced Air Cooled
19 HP (14.2kW) Kawasaki
OHV V-Twin Forced Air Cooled
20 HP (14.9kW) Kohler
OHV V-Twin Forced Air Cooled
23 HP (17.1kW) Kawasaki
OHV V-Twin Forced Air Cooled
19 HP (14.2kW) Kawasaki
OHV V-Twin Forced Air Cooled
3650 + 100 RPM 1500 RPM 13 AMP
3650 + 100 RPM 1500 RPM 13 AMP
3650 + 100 RPM 1500 RPM 13 AMP
3650 + 100 RPM 1500 RPM 13 AMP
3650 + 100 RPM 1500 RPM 13 AMP
3650 + 100 RPM 1500 RPM 13 AMP
Dimensions and Weight
ROPS Height Width
Model Weight Folded Upright Deck Deector Length
19 HP Kawasaki
52” 7-Gauge Deck
18 HP Kohler
48” 7-Gauge Deck
924 lbs
(419.2kg)
889 lbs
(407.78kg)
51”
(129.54cm)
51”
(129.54cm)
69”
(175.26cm)
69”
175.26cm)
53.7”
(136.4cm)
49.7”
(126.24cm)
68”
(172.72cm)
64”
(162.56cm)
78”
(198cm)
78”
(198cm)
19 HP Kawasaki
44” SFS Deck
19 HP Kawasaki
48” TF Deck
20 HP Kohler
52” TF Deck
19 HP Kawasaki
52” TF Deck
23 HP Kawasaki
52” TF Deck
23 HP Kawasaki
48” TF Deck
19 HP Kawasaki
44” SFS Deck (112cm)
23 HP Kawasaki
52” TF Deck (132cm)
2-8 Z Master Z400 Service Manual
941 lbs
(426.83kg)
1010 lbs
(458.13kg)
1092 lbs
(495-32kg)
1092 lbs
(495-32kg)
1092 lbs
(495-32kg)
1067 lbs
(483-98kg)
941 lbs
(426.83kg)
1092 lbs
(495.32kg)
52”
(132.08cm)
52”
(132.08cm)
52”
(132.08cm)
52”
(132.08cm)
52”
(132.08cm)
52”
(132.08cm)
52”
(132.08cm)
52”
(132.08cm)
70”
(177.8cm)
70”
(177.8cm)
70”
(177.8cm)
70”
(177.8cm)
70”
(177.8cm)
70”
(177.8cm)
70”
(177.8cm)
70”
(177.8cm)
47”
(119.38cm)
49.7”
(126.24cm)
53.7”
(136.4cm)
53.7”
(136.4cm)
53.7”
(136.4cm)
49.7”
(126.24cm)
47”
(119.38cm)
53.7”
(136.4cm)
61.3”
(155.7cm)
64”
(162.56cm)
68”
(172.72cm)
68”
(172.72cm)
68”
(172.72cm)
64”
(162.56cm)
61.3”
(155.7cm)
68”
(172.72cm)
78”
(198cm)
78”
(198cm)
78”
(198cm)
78”
(198cm)
78”
(198cm)
78”
(198cm)
78”
(198cm)
78”
(198cm)
SPECIFICATIONS
Z 400 Series Manual Specications
Frame Assembly Consists of front and rear frames bolted together
Front Frame Welded 2 x 2 x .188” structural steel tube, 7 Gauge front cross member
Rear Frame Welded tube and fabricated steel
Fuel System
Tanks Dual fuel tanks containing large ll necks and vented caps. Rotational
molded high density polyethylene. Mounted above drive wheels.
Capacity 10 gallons (37.8 l) [5 gallons per tank]
Check Valve In-line check valves
Fuel Filter 15 micron, replaceable in-line lter
Traction System
Models with 7-Gauge Deck Models with SFS and TF Decks
Hydraulic Pumps HydroGear 10cc BDP-10A with
2300psi shock valve
Pump Drive
Wheel Motors Parker TE Series (13.9cc) HydroGear HGM-15E (15.4cc)
Ground Speeds Innitely variable:
Forward: 0-7.2 mph (11.6 km/hr)
Reverse: 0-4.2 mph (6.7 km/hr)
Release Valves
Hydraulic Fluid
System Capacity
Contained in Pumps. Allow unit to be moved without engine running.
Mobil 1 Extended Performance 15W-50 Synthetic
Self-tensioning belt drive
2.1 quarts (2.0 liters)
HydroGear 10cc BDP-10A with no shock valve
Innitely variable:
Forward: 0-8.3 mph (13.3 km/hr)
Reverse: 0-5.5 mph (8.8 km/hr)
2
2-9Z Master Z400 Service Manual
SPECIFICATIONS
Deck Drive
Models with 7-Gauge Deck Models with SFS and TF Decks
Clutch Warner Electromagnetic “Mag-Stop” with
120 ft-lbs. (162.7 Nm) rating
Type
Take-Up
Deep B-Groove pulley with belt from engine to deck
Spring Idler system
Warner Electromagnetic “Mag-Stop” with
175 ft-lbs. (237-3 Nm) rating
2
Tires
Models with 7-Gauge Deck Models with SFS and TF Decks
Rear Drive Tires 4-ply with “turf master” tread
20” x 10” – 10”
Front Caster Tires 4-ply with smooth tread
11” x 4” – 5”
Tire Pressure
20# rear and 25# front if equipped with mechanical bagger
13psi (90 KPA)
Electrical System
Voltage 12 volt, negative ground
Battery Type 230 CCA
Fuses Blade type. Located by LH Side Control
4-ply with “turf master” tread
23” x 9.5” – 12” [Except as noted]
4-ply with smooth tread
13” x 5” – 6” [Except as noted]
2-10 Z Master Z400 Service Manual
SPECIFICATIONS
Cutting Decks
48” (121.9cm)
&
52” (132.1cm)
7-Gauge Deck
Conguration
Construction 7-Gauge,
High Strength
50,000 psi
(3515.3 Kg-f
/ 59cm)
steel welded
construction.
3/8” (9.5mm)
steel
discharge
reinforcement
plate
Discharge Rubber
Blade Tip
Speed
Height of Cut
Rubber discharge chute, spring
biased down toward operating
position
Adjustable from the seat with range of 1.5” (38mm) – 4.5” (114mm) in .25” (6.4mm) increments.
44” (111.8cm)
SFS Deck
Side Discharge, mid-mounted rotary with three blades.
Drawn 12
gauge steel
super ow
system deck
with welded
mounting
brackets and
gage wheel
brackets. 1/2”
(12.7mm)
diameter steel
reinforcement
rod on left
side. 11 gauge
steel front
reinforcement
plate doubles
as bagger
attachment
point
48” (121.9cm)
TF Deck
7 Gauge, High Strength
50,000 psi (3515.3 Kg-f /
59cm) steel 5” (12.7cm)
advanced Turbo Force ow
system, welded construction.
3/8” (9.5mm) steel discharge
reinforcement plate doubles
as a bagger attachment point.
Rubber discharge chute, spring
biased down toward operating
position. Adjustable ow
control bafe.
18,000+ ft/min (548.640cm/min) at high idle
52” (132.1cm)
TF Deck
112cm (44”)
SFS Deck
Drawn 12
gauge steel
super ow
system deck
with welded
mounting
brackets and
gage wheel
brackets. 1/2”
(12.7mm)
diameter steel
reinforcement
rod on left
side. 11 gauge
steel front
reinforcement
plate doubles
as bagger
attachment
point.
discharge
chute, spring
biased down
toward
operating
position
132cm (52”)
TF Deck
7 Gauge,
High Strength
50,000 psi
(3515.3 Kg-f
/ 59cm) steel
5” (12.7cm)
advanced
Turbo Force
ow system,
welded
construction.
3/8” (9.5mm)
steel
discharge
reinforcement
plate doubles
as a bagger
attachment
point.
Rubber
discharge
chute, spring
biased down
toward
operating
position.
Adjustable
ow control
bafe.
2
2-11Z Master Z400 Service Manual
SPECIFICATIONS
Cutting Decks cont.
2
48” (121.9cm)
&
52” (132.1cm)
7-Gauge Deck
Deck
Suspension
Belt Covers Plastic HDPE
Gage Wheels Three
Deck
suspended
from machine
by four lift
chains, and
attached to
front cross
member by at
strut arms and
cross brace.
The deck is
pulled along
the ground.
deck covers.
Attached with
swell latches.
adjustable
gage wheels
to reduce
scalping on
the front of
deck (one on
the left-hand
side and two
in the center).
Wheels
have four
adjustment
positions.
44” (111.8cm)
SFS Deck
Deck suspended from machine by four lift chains, and attached to rear
wheel supports by two struts. The deck is pulled along the ground.
14-gauge,
formed steel
covers with
access holes
to allow
greasing of
outer spindles
without
removal.
Attached with
draw latches.
Three adjustable gage wheels to reduce scalping: three on front of deck (one
on left-hand side and two in center). Wheels have four adjustment positions.
Rear gage wheels are optional.
48” (121.9cm)
TF Deck
Plastic HDPE deck covers.
Attached with swell latches.
52” (132.1cm)
TF Deck
112cm (44”)
SFS Deck
14-gauge,
formed steel
covers with
access holes
to allow
greasing of
outer spindles
without
removal.
Attached with
draw latches.
132cm (52”)
TF Deck
Plastic HDPE
deck covers.
Attached with
swell latches.
2-12 Z Master Z400 Service Manual
SPECIFICATIONS
4 3 2 1
D
C
B
NOTES:
12. MUST NOT SHOW LOSS OF ADHESION OR LEGIBILITY
AFTER 15 MINUTES IMMERSION IN GASOLINE.
11. MUST BE PROVIDED BY A SILKSCREEN VENDOR.
10. MUST BE PROVIDED IN ROLL DISPENSE, SHEET FORM
OR SPLIT BACKING.
9. MUST HAVE TEDLAR CLEAR OVER LAMINATE FOR ABRASION,
GASOLINE RESISTANCE.
8. MUST COMPLY WITH (TURF) ANSI B71.4-1999 WHEN
APPLIED TO PAINTED METAL OR POLYETHYLENE
FOR A PERIOD OF 24 HOURS.
7. ORIGINAL ARTWORK SHALL BE PROVIDED BY TORO
ENGINEERING DEPARTMENT, BLOOMINGTON, MN.
6. DECAL SHALL LOSE NONE OF ITS INITIAL PROPERTIES
OR DIMENSIONS WHEN STORED BY TORO FOR ONE
YEAR AT TEMPERATURES BELOW 100
o
F AND OUT OF
DIRECT SUNLIGHT. DURING STORAGE, ADHESIVE
SHALL NOT MIGRATE OR LOSE EFFECTIVENESS.
5. ARTWORK MUST BE CENTERED ON DECAL WITHIN
±.030 UNLESS OTHERWISE SPECIFIED.
4. LETTERING COLOR: TORO CORDLESS BLUE NO. 500-97.
3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26.
2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-41.
1. MATERIAL: AVERY MX3200 WITH 1 MIL. TEDLAR CLEAR OVER
4 3 2 1
D
C
B
NOTES:
12. MUST NOT SHOW LOSS OF ADHESION OR LEGIBILITY
AFTER 15 MINUTES IMMERSION IN GASOLINE.
11. MUST BE PROVIDED BY A SILKSCREEN VENDOR.
10. MUST BE PROVIDED IN ROLL DISPENSE, SHEET FORM
OR SPLIT BACKING.
9. MUST HAVE TEDLAR CLEAR OVER LAMINATE FOR ABRASION,
GASOLINE RESISTANCE.
8. MUST COMPLY WITH (TURF) ANSI B71.4-1999 WHEN
APPLIED TO PAINTED METAL OR POLYETHYLENE
FOR A PERIOD OF 24 HOURS.
7. ORIGINAL ARTWORK SHALL BE PROVIDED BY TORO
ENGINEERING DEPARTMENT, BLOOMINGTON, MN.
6. DECAL SHALL LOSE NONE OF ITS INITIAL PROPERTIES
OR DIMENSIONS WHEN STORED BY TORO FOR ONE
YEAR AT TEMPERATURES BELOW 100
o
F AND OUT OF
DIRECT SUNLIGHT. DURING STORAGE, ADHESIVE
SHALL NOT MIGRATE OR LOSE EFFECTIVENESS.
5. ARTWORK MUST BE CENTERED ON DECAL WITHIN
±.030 UNLESS OTHERWISE SPECIFIED.
4. LETTERING COLOR: TORO CORDLESS BLUE NO. 500-97.
3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26.
2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-41.
Lubrication Fittings
48”/52” (132.1cm/121.9cm)
SFS and TF Decks
7-Gauge Decks
Front Caster Pivots 2 removable plugs (1 per side) for periodic lubrication
Front Caster Wheels n/a 2 ttings (1 per side)
Lift Assembly 5 ttings
Brake Arms 2 ttings (1 per side)
Rear Deck Struts 2 ttings (1 per side)
Deck Spindles 3 ttings (1 per spindle)
Pump Idler Pivot 1 tting
General Specications
Greasing and Lubrication:
Grease: No. 2 general purpose lithium base or molybdenum grease
Where to add grease: See Service Aid and Belt Routing decals below (Fig. 025, 026, 027, 028).
Service Aid Decals
SERVICE AID AND BELT ROUTING
11 12
SERVICE AID AND BELT ROUTING
11 12
1
3
10
9
6
3
5
4
13
4
Fig 025 108-4050
19 hp Kawasaki / 44” SFS Deck
2
Every 10 hours (daily):
3
1. Check engine oil
Every 50 hours:
2. Check hydraulic oil
3. Check tire pressure--13 psi
4. Grease blade spindle bearings
5. Grease front wheel bearings
6. Grease deck lift linkage
9
7. Grease belt idler
Every 250 hours:
78
8. Inspect belt and tension
9. Grease brake linkage
10. Grease belt idler
6
Every 1000 hours (yearly):
11. Inspect covers and
safety systems
12. Inspect fasteners and hoses
13. Grease front caster pivot
3
5
See operator's manual for
additional details.
13
108-4050
Fig 026 107-1687A
19 hp Kawasaki / 52” 7-Gauge Deck
18 hp Kohler / 48” 7-Gauge Deck
19 hp Kawasaki / 48” TF Deck
20 hp Kohler / 52” TF Deck
19 hp Kawasaki / 52” TF Deck
23 hp Kawasaki / 52” TF Deck
23 hp Kawasaki / 48” TF Deck
1
3
10
8
9
6
3
5
4
13
13
2
Every 10 hours (daily):
3
1. Check engine oil
Every 50 hours:
2. Check hydraulic oil
3. Check tire pressure--13 psi
4. Grease blade spindle bearings
5. Grease front wheel bearings
6. Grease deck lift linkage
8
7. Grease belt idler
7
Every 250 hours:
8. Grease brake linkage
6
9. Inspect belt and tension
10. Grease belt idler
Every 1000 hours (yearly):
11. Inspect covers and
safety systems
12. Inspect fasteners and hoses
3
13. Grease front caster pivot
5
See operator's manual for
additional details.
107-1687
2
2-13Z Master Z400 Service Manual
SPECIFICATIONS
4 3 2 1
D
C
B
NOTES:
12. MUST NOT SHOW LOSS OF ADHESION OR LEGIBILITY
AFTER 15 MINUTES IMMERSION IN GASOLINE.
11. MUST BE PROVIDED BY A SILKSCREEN VENDOR.
10. MUST BE PROVIDED IN ROLL DISPENSE, SHEET FORM
OR SPLIT BACKING.
9. MUST HAVE TEDLAR CLEAR OVER LAMINATE FOR ABRASION,
GASOLINE RESISTANCE.
8. MUST COMPLY WITH (TURF) ANSI B71.4-1999 WHEN
APPLIED TO PAINTED METAL OR POLYETHYLENE
FOR A PERIOD OF 24 HOURS.
7. ORIGINAL ARTWORK SHALL BE PROVIDED BY TORO
ENGINEERING DEPARTMENT, BLOOMINGTON, MN.
6. DECAL SHALL LOSE NONE OF ITS INITIAL PROPERTIES
OR DIMENSIONS WHEN STORED BY TORO FOR ONE
YEAR AT TEMPERATURES BELOW 100
o
F AND OUT OF
DIRECT SUNLIGHT. DURING STORAGE, ADHESIVE
SHALL NOT MIGRATE OR LOSE EFFECTIVENESS.
5. ARTWORK MUST BE CENTERED ON DECAL WITHIN
±.030 UNLESS OTHERWISE SPECIFIED.
4. LETTERING COLOR: TORO CORDLESS BLUE NO. 500-97.
3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26.
2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-41.
1. MATERIAL: AVERY MX3200 WITH 1 MIL. TEDLAR CLEAR OVER
LAMINATE.
PRODUCT: Z 100 SERIES CE
4 3 2 1
D
C
B
NOTES:
12. MUST NOT SHOW LOSS OF ADHESION OR LEGIBILITY
AFTER 15 MINUTES IMMERSION IN GASOLINE.
11. MUST BE PROVIDED BY A SILKSCREEN VENDOR.
10. MUST BE PROVIDED IN ROLL DISPENSE, SHEET FORM
OR SPLIT BACKING.
9. MUST HAVE TEDLAR CLEAR OVER LAMINATE FOR ABRASION,
GASOLINE RESISTANCE.
8. MUST COMPLY WITH (TURF) ANSI B71.4-1999 WHEN
APPLIED TO PAINTED METAL OR POLYETHYLENE
FOR A PERIOD OF 24 HOURS.
7. ORIGINAL ARTWORK SHALL BE PROVIDED BY TORO
ENGINEERING DEPARTMENT, BLOOMINGTON, MN.
6. DECAL SHALL LOSE NONE OF ITS INITIAL PROPERTIES
OR DIMENSIONS WHEN STORED BY TORO FOR ONE
YEAR AT TEMPERATURES BELOW 100
o
F AND OUT OF
DIRECT SUNLIGHT. DURING STORAGE, ADHESIVE
SHALL NOT MIGRATE OR LOSE EFFECTIVENESS.
5. ARTWORK MUST BE CENTERED ON DECAL WITHIN
±.030 UNLESS OTHERWISE SPECIFIED.
4. LETTERING COLOR: TORO CORDLESS BLUE NO. 500-97.
3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26.
2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-41.
2
11 12
1
3
10
8
9
6
3
5
4
13
2
10
1.
3
50
2.
3.
4.
5.
8
6.
7
5
13
7.
250
6
8.
9.
10.
1000
11.
3
12.
13.
107-1686
Fig 027 107-1686A
23 hp Kawasaki / 132cm (52” TF Deck)
Fig 029 g. 55 m-5615
1. Cap 3. Cold uid level - full
2. Bafe 4. Hot uid level - full
11 12
1
3
10
9
6
3
5
4
13
4
Fig 028 108-4051
19 hp Kawasaki / 112cm (44” SFS Deck)
2-14 Z Master Z400 Service Manual
2
10
1.
3
50
2.
3.
4.
9
78
5
13
5.
6.
7.
250
6
8.
9.
10.
1000
11.
3
12.
13.
108-4051
SPECIFICATIONS
Hydraulic System Oil Capacity: 2.1 quarts (2.0 liters)
Fluid Type: Mobil 1 Extended Performance 15W-50 Synthetic
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. 000 above).
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. 000).
Fig 030 PICT-0046
Engine Model and Serial Number
Identication:
Hydrostatic Pumps Model and Serial
Number:
Consult the appropriate engine manufacture’s service literature for the
location and translation of the engine model and serial number information.
The label (Fig. 000), can be located on the pump housing. It identies the
model and conguration of the BDP pump.
2
Fig 031 conguration
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
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
2-15Z Master Z400 Service Manual
SPECIFICATIONS
2
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as
determined by Toro, either the recommended torque or
a torque that is unique to the application is clearly
identified and specified in the service manual.
These torque specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in the
service manual. The following factors shall be
considered when applying torque: cleanliness of the
fastener, use of a thread sealant (Loctite), degree of
lubrication on the fastener, presence of a prevailing
torque feature, hardness of the surface underneath of
the fastener’s head, or similar condition which affects
the installation.
As noted in the following tables, torque values should
be reduced by 25% for lubricated fasteners to
achieve the similar stress as a dry fastener. Torque
values may also have to be reduced when the fastener
is threaded into aluminum or brass. The specific
torque value should be determined based on the
aluminum or brass material strength, fastener size,
length of thread engagement, etc.
Fastener Identification
Inch Series Bolts and Screws
(A) Grade 1
(B) Grade 5
Figure A
(C) Grade 8
The standard method of verifying torque shall be
performed by marking a line on the fastener (head or
nut) and mating part, then back off fastener 1/4 of a
turn. Measure the torque required to tighten the
fastener until the lines match up.
Figure B
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
2-16 Z Master Z400 Service Manual
SPECIFICATIONS
SAE Grade 8 Bolts, Screws,
Studs, & Sems with Regular
2
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, &
Thread Size
# 6 - 32 UNC
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8 - 32 UNC
# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10 - 24 UNC
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 17 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
8 with Thin
Height Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
10 ± 2 13 ± 2 147 ± 23
13 ± 2 25 ± 5 282 ± 30
18 ± 2 30 ± 5 339 ± 56
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
15 ± 2 170 ± 20 23 ± 2 260 ± 20
29 ± 3 330 ± 30 41 ± 4 460 ± 45
42 ± 4 475 ± 45 60 ± 6 674 ± 70
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
2
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the
minimum proof load specified in SAE J429. The
tolerance is approximately
value. Thin height nuts include jam nuts.
± 10% of the nominal torque
2-17Z Master Z400 Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
2
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm
M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 53 ± 5 ft-lb 72 ± 7 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 92 ± 9 ft-lb 125 ± 12 N-m
M16 X 2.0 166 ± 15 ft-lb 225 ± 20 N-m 229 ± 22 ft-lb 310 ± 30 N-m
M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 37 ft-lb 610 ± 50 N-m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Strong Nuts)
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately
the nominal torque value. Thin height nuts include jam nuts.
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts (
Class 10 or Strong Nuts)
± 10% of
2-18 Z Master Z400 Service Manual
Other Torque Specifications
SPECIFICATIONS
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb
5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb
3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb
1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non-lubricated fasteners.
Thread Cutting Screws
Thread
Size
No. 6 18 20 20 ± 5 in-lb
Threads per Inch
Type A Type B
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
(Zinc Plated Steel)
Baseline Torque*
2
No. 8 - 32 UNC 30 ± 5 in-lb
No.10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors
in-lb X 11.2985 - N-cm
ft-lb X 1.3558 = N-m
No. 8 15 18 30 ± 5 in-lb
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and
finish must be considered when determining specific
torque values. All torque values are based on nonlubricated fasteners.
N-cm X - 0.08851 = in-lb
N-cm X 0.73776 - ft-lb
2-19Z Master Z400 Service Manual
2
SPECIFICATIONS
Equivalents and Conversions
Decimal and Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 16/32 0.53125 13.484
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.9375 2.381 19/32 0.59375 15.081
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.541 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm
2-20 Z Master Z400 Service Manual
Linear
Measurement
Area
Volume
Weight
Pressure
Work
Liquid Volume
Liquid Flows
Temperature
SPECIFICATIONS
U.S. to Metric Conversions
To Convert Into Multiply By
Miles
Yards
Feet
Feet
Inches
Inches
Inches
Square Miles
Square Feet
Square Inches
Acre
Cubic Yards
Cubic Feet
Cubic Inches
Tons (Short)
Pounds
Ounces
Pounds/Sq. In. Kilopascal
Foot-pounds
Foot-pounds
Inch-pounds
Quarts
Gallons
Gallons/Minute Liters/Minute
Fahrenheit Celsius
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
Square Kilometers
Square Meters
Square Centimeters
Hectare
Cubic Meters
Cubic Meters
Cubic Centimeters
Metric Tons
Kilograms
Grams
Newton-Meters
Kilogram-Meters
Kilogram-Centimeters
Liters
Liters
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
6.895
1.356
0.1383
1.152144
0.9463
3.785
3.785
1. Subtract 32°
2. Multiply by 5/9
2
2-21Z Master Z400 Service Manual
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