Service Manual

ManualsBrandsToro ManualsRiding ProductsZ Master Professional 7500-D Series Riding Mower, With 60in TURBO FORCE Rear Discharge Mower

LCE Products

Service Manual

Z Master 7500-D Series

Issued: March 2018

Summary of content (178 pages)

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LCEPr oduct s ZMast er7500DSer i es Ser vi ceManual I ssued:Mar ch2018
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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. We are hopeful that service technicians will find this manual a valuable addition to service shops.
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ABOUT THIS MANUAL This icon is used to denote Critical Processes or actions that if missed, could greatly impact your safety, lead to mechanical failure, or improper product/ part use. Please pay close attention to these steps as they are distinguished throughout the manual.
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Safety....................................................................................................................................... 1-1 Specifications......................................................................................................................... 2-1 Troubleshooting..................................................................................................................... 3-1 Engine...................................................................................
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SAFETY Table of Contents Think Safety First................................................................................................................... 1-2 Additional Safety.................................................................................................................... 1-5 Z Master 7500-D Series Service Manual March 2018 - Digital Edition 1-1 Table of Contents Safety Icons........................................................................................................
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SAFETY DANGER: This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING: This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION: This safety symbol means caution. When you see this symbol, carefully read the instructions that follow.
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SAFETY Think Safety First (Cont.) 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. Avoid electrical shock… Never touch electrical wires or components while the engine is running. They can be sources of shock. Deenergize the system if you are having to do repairs. If testing electrical components ensure you are working in a dry environment. Hydraulic System...
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SAFETY Think Safety First (Cont.) Fire Extinguishers… The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil.
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SAFETY Riding Products… Roll Over Protection Systems (R.O.P.S.) should not be removed or modified in anyway. Blades and cutting system should be in good operational order before using. If available, a seat belt should always be worn when operating with R.O.P.S. up. Snow Products... Watch for icy walkways when operating snow products. Ensure the area is cleared of any objects that could become entangled or thrown. Turf Products... Aerator’s could puncture underground cables or irrigation systems.
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SPECIFICATIONS Table of Contents General Specifications........................................................................................................... 2-2 Torque Specifications............................................................................................................ 2-4 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series)..................... 2-6 Equivalents and Conversions....................................................................................
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SPECIFICATIONS General Specifications Model Hp/Deck 74060 74064 74072 37/60SD 37/60RD 37/72SD Engine Yanmar Diesel Engine Model 3TNV88C High Idle 3000 ± 50 RPM Low Idle 1400 ± 50 RPM Engine Oil CJ-4 or higher SAE 10W-30 or 5W-30 (all temperatures); SAE 15W-40 (above 0°F) Oil Capacity 7 qts. CARB Yes EPA Yes Fuel Capacity 12 gal. Battery 12V Goup 26; 540 CCA Hydraulic Drive System Transmission Kanzaki KPS-18T Transmission Lubricant Prem. Trans/Hyd Tractor Fluid 108-1184 (5 gal.
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SPECIFICATIONS General Specifications (Cont.) Model 74074 Hp/Deck 74096 37/72RD 37/96RD Engine Yanmar Diesel Engine Model 3000 ± 50 RPM Low Idle 1400 ± 50 RPM Engine Oil Specifications 3TNV88C High Idle CJ-4 or higher SAE 10W-30 or 5W-30 (all temperatures); SAE 15W-40 (above 0°F) Oil Capacity 7 qts. CARB Yes EPA Yes Fuel Capacity 12 gal. Battery 12V Goup 26; 540 CCA Hydraulic Drive System Transmission Kanzaki KPS-18T Transmission Lubricant Prem.
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SPECIFICATIONS Torque Specifications The 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 for all fasteners which do not have a specific requirement identified in the service manual.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 8 or Better Nut) In-lb. In-lb. N-cm In-lb. N-cm In-lb.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb. N-cm in-lb. N-cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lbs. N-m ft-lbs. N-m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) SAE Grade 8 Steel Set Screws Recommended Torque Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb. 73 ± 12 in-lb. 5/16 - 18 UNC 215 ± 35 in-lb. 145 ± 20 in-lb. 3/8 - 16 UNC 35 ± 10 ft-lb. 18 ± 3 ft-lb. 1/2 - 13 UNC 75 ± 15 ft-lb. 50 ± 10 ft-lb. Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb. 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb. 108 ± 14 N-m M12 X 1.25 Class 8.
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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.
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SPECIFICATIONS Linear Measurement Area Volume Weight Pressure Work To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.
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TROUBLESHOOTING Table of Contents Troubleshooting General Troubleshooting Table.............................................................................................
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TROUBLESHOOTING Problem The starter does not crank The engine does not start, starts hard, or fails to keep running Engine loses power The engine overheats Possible Cause Next Step...
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TROUBLESHOOTING The machine does not drive The machine vibrates abnormally Hydraulic oil leaks from machine Possible Cause The drive system is in bypass Check and set bypass to operational mode There is air in the system Follow procedure to ensure it is properly purged of air The oil is incorrect Replace the oil with the approved type and quantity, purge the system The hydraulic oil level is low or too hot Add hydraulic oil to the reservoir or let it cool down The engine mounting bolts are loose
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TROUBLESHOOTING Problem Traction response is sluggish No traction in either direction Possible Cause Next Step...
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ENGINE Table of Contents Engine Exploded View 1........................................................................................................ 4-2 Engine Exploded View 2........................................................................................................ 4-3 Engine Exploded View 3........................................................................................................ 4-4 Engine Exploded View 4........................................................................
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ENGINE Engine Exploded View 1 A B C E D G F Figure 1 A. Air Shield B. Cross Channel C. RH Bumper Plate D. Exhaust Plate 4-2 Table of Contents E. Center Bumper Plate F. Power Frame G.
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ENGINE Engine Exploded View 2 A C D E F A B Engine B D E F Figure 2 A. Lock Nut B. Flat Washer C. Flywheel Housing Z Master 7500-D Series Service Manual March 2018 - Digital Edition D. Isolator Mount E. Thrust Washer F.
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ENGINE Engine Exploded View 3 A B C D E F Figure 3 A. Air Hose B. Yanmar Engine C. Iso Mount 4-4 Table of Contents D. Air Cleaner Asm. E. Snubbing Washer F.
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ENGINE Engine Exploded View 4 A B C D E C F G M H I N Engine L J O K Figure 4 A. Top Cooling Bracket B. RH Radiator Support C. Elbow Fitting D. Cooling Asm. E. Hose F. Upper Radiator Hose G. Top Shroud H. Bottom Shroud Z Master 7500-D Series Service Manual March 2018 - Digital Edition I. Bulb Seal J. LH Radiator Support K. Lower Radiator Hose L. Hydraulic Tube Asm. M. Fuel Hose N. Hydraulic Tube Asm. O.
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ENGINE Engine Exploded View 5 A B F C E D Figure 5 A. RH Tank Suction B. LH Tank Suction C. RH Tank Return 4-6 Table of Contents D. LH Tank Return E. Engine Return F.
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ENGINE Yanmar Engine Replacement DANGER While testing the machine with the engine running, hands, feet, and clothing could get caught in moving parts, causing serious personal injury. Keep bystanders away from the machine. DANGER Do not remove the radiator cap when the engine operates, or immediately after it stops. If not, hot water can spout out from the radiator. Only remove the radiator cap when it is at a sufficiently low temperature to touch with bare hands.
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 4. Remove the rear wheels. 5. Remove the two carriage bolts and two button head screws securing the skid plate to the machine (Figure 6). Figure 6 6. Remove the rear bumper. NOTE: Bumper mount holes are slotted (Figure 7).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 7. Remove the negative cable first, then the positive cable from the battery (Figure 8). Figure 8 Engine 8. Remove the left and right side covers, see “Left Tank Cover Removal,” chapter 5, page 5-17 and see “Right Tank Cover Removal,” chapter 5, page 5-19. 9. Remove the seat, see “Seat Removal,” chapter 5, page 5-23. 10. Remove the front seat mount, see “Front Seat Mount Removal,” chapter 5, page 5-25. 11.
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 13. Remove the gold bracket on the hydro (Figure 9). Figure 9 14. Disconnect the four torque motor hoses from the transmission and cap/plug the lines and fittings (Figure 10). NOTE: If the lines and fittings are not capped/plugged there will be leakage.
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 15. Disconnect the vent line hose from both torque motors and cap/plug the lines and fittings (Figure 11). A B A Figure 11 A. Straight Fitting B. Vent Line Asm. 16. Cut the zip ties securing the wire harness to the heat deflector panel. Engine 17. Remove the fasteners securing the heat deflector panel. Remove the panel. 18. Remove the operator’s floor pan from the machine. 19.
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 21. Remove the six bolts (three per side) securing the air shield and cross channel to the machine (Figure 13). B A C C D A Figure 13 A. HHF Screw B. Air Shield C. NI HF Nut D. Cross Channel 22. Disconnect the global power port and alarm (Figure 14). Figure 14 23. Disconnect the wire harness clip retainers. 24. Lift the air shield and cross channel from the machine.
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 25. Remove the radiator drain plug. Using a clean bucket, drain the engine coolant (Figure 15). Tech Tip: Using an eight-point socket will reduce plug damage. NOTE: Properly dispose of engine coolant. Plug can be installed once radiator is empty. Engine Figure 15 26. Remove the upper radiator hose. 27. Disconnect the overflow hose from the top of the radiator. 28. Cut the zip tie securing the drain hose.
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 29. Disconnect the two bolts securing the radiator to the bulk head (Figure 16). Figure 16 30. Remove the air intake hose from between the air cleaner and radiator. 31. Remove the lower radiator hose from water pump. 32. Remove the four screws (two per side) securing the radiator shroud to the radiator brackets (Figure 17).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 33. Drain the transmission cooler by loosening the lower transmission cooler line (Figure 18). Tech Tip: By loosening the top transmission cooler line will allow fluid to drain faster. Figure 18 Engine 34. Once draining has completed, fully disconnect the upper and lower transmission cooler lines. 35. Remove the radiator. 36. Remove the two lock nuts securing the RH ROPS brace to the radiator bracket (Figure 19).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 37. Remove the two lock nuts securing the RH ROPS brace to the ROPS (Figure 20). Figure 20 38. Remove the RH ROPS brace from the ROPS with overflow tank intact (Figure 21).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 39. Disconnect the air intake hose from the air cleaner to the engine (Figure 22). Figure 22 Engine 40. Disconnect the harness plug from the air filter sensor (Figure 23).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 41. Disconnect electrical connections (Figure 24). Figure 24 42. LH ROPS brace removal, repeat steps 35-37. Brace will be removed with power distribution, ECU, and air canister intact (Figure 25).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 43. Remove the two chassis grounds from the machine (Figure 26). Figure 26 Engine 44. Remove the six bolts (three per side) of the radiator brackets (Figure 27).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 45. Remove the three torx screws and lock nuts securing the exhaust plate to the machine. Remove the exhaust plate (Figure 28). Figure 28 46. Remove the four nuts on the two exhaust clamps (Figure 29).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 47. Remove the exhaust tube. 48. Disconnect the electrical connections from the fuel pump. 49. Disconnect and mark the fuel lines from the front side of the fuel pump and water separator (Figure 30). 50. Disconnect the two transmission cooler lines from the bulk head fittings above right torque motor. Remove cooler lines (Figure 31).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 51. Disconnect and plug the 2 front side transmission cooler lines from the bulk head plate. NOTE: Residual hydraulic oil may be in the lines. 52. Loosen, but do not remove, the two RH torque motor hoses and pivot to gain access to the bulk head plate mounting bolts. 53. Remove the bulk head plate (Figure 32). Figure 32 54. Remove the hydraulic line from the bottom of the auxiliary pump (controls deck lift and fold) (Figure 33).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 55. Remove the two transmission mount bolts located on the bell housing (accessible on bottom of machine) (Figure 34). Figure 34 Engine 56. Remove the two motor mount bolts (LH and RH) located on the rear frame (Figure 35).
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ENGINE Yanmar Engine Replacement (Cont.) Removal (Cont.) 57. Use an overhead hoist, attached at the designated lift points, raise engine slightly and ensure the engine and transmission are free of the chassis (Figure 36). Tech Tip: Raising the rear of the engine first and lifting at an angle, may assist in removal. Figure 36 58. Continue to slightly raise and move the engine rearward until engine is free of the machine. NOTE: Drive shaft spline will separate on its own during engine removal (Figure 37).
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ENGINE Yanmar Engine Replacement (Cont.) Installation 1. Remove the front half of the deck drive shaft from the gear box, see “Deck Replacement - 96 in. Deck,” chapter 6, page 6-14. 2. Install the front half of the drive shaft onto the rear shaft (splined). 3. Collapse the two halves of drive shaft together and secure to the transmission assembly. Engine NOTE: Once the drive shaft is cleared during install, it can move freely (Figure 38). Figure 38 4.
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ENGINE Yanmar Engine Replacement (Cont.) Installation (Cont.) 5. When aligned, loosely install the two transmission mounts and finger tighten. NOTE: Make sure transmission iso-mounts and bushings are in place before bolt install (Figure 39). Figure 39 6. Slowly lower the engine until the engine mounts are aligned. 7. Install the two engine mount bolts and tighten. 8. Tighten the two transmission mount bolts. 9. Connect fuel pump harness. 10. Connect two fuel lines to fuel pump and water separator. 11.
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ENGINE Yanmar Engine Replacement (Cont.) Installation (Cont.) 18. Install the upper and lower radiator hose. 19. Loosely install the cooler lines connections in the following order: - Cooler lines at Radiator - Cooler lines at Bulk Head Plate - Transmission at Bulk Head Plate Tech Tip: Avoid cross threading that could potentially damage the component. 20.
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ENGINE Yanmar Engine Replacement (Cont.) Installation (Cont.) 29. Connect the electrical lines (Figure 40). Figure 40 30. Attach and tighten the vent lines to the torque motors. Torque to 30 ± 3 ft-lbs. (40 ± 4 Nm). NOTE: Ensure proper orientation of vent lines to avoid unwanted contact. 31. Attach torque motor hydraulic lines to transmission. Torque to 67 ± 7 ft-lbs. (90 ± 9 Nm). 32. Install the air intake hose from the radiator bracket to the air cleaner.
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ENGINE Yanmar Engine Replacement (Cont.) Installation (Cont.) 34. Install the rear bumper. 35. Install the motion control linkage to the transmission and secure with washer and e-clip (Figure 41). Figure 41 Engine 36. Install the gold bracket on the hydro reservoir. 37. Install a zip tie on the hydraulic cooler hose (Figure 42).
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ENGINE Yanmar Engine Replacement (Cont.) Installation (Cont.) 38. Install the two carriage bolts and two screws securing the skid plate to the machine (Figure 43). Tech Tip: Insert the carriage bolts towards the front of the machine first, pivot the skid plate into position, then install the rear bolts. Figure 43 39. Install the air shield and cross channel into position on the machine. Secure with six (three per side) bolts. 40.
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ENGINE Yanmar Engine Replacement (Cont.) Installation (Cont.) 50. Install the left and right side covers, see “Left Tank Cover Installation,” chapter 5, page 5-18 and see “Right Tank Cover Installation,” chapter 5, page 5-20. 51. Install the operator’s floor pan onto the machine. 52. Refill radiator with proper coolant as outlined in the operator’s manual. 53. Connect the positive terminal first, then the negative terminal last to the battery. 54. Check the hydraulic fluid reservoir level. 55.
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CHASSIS Table of Contents Chassis Exploded View 1...................................................................................................... 5-3 Chassis Exploded View 2...................................................................................................... 5-4 Chassis Exploded View 3...................................................................................................... 5-5 Chassis Exploded View 4.........................................................................
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CHASSIS Table of Contents Motion Control Damper........................................................................................................ 5-29 Removal........................................................................................................................ 5-29 Installation.................................................................................................................... 5-30 Adjusting the Motion Control Damper.....................................................
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CHASSIS Chassis Exploded View 1 F D B A E C E E E J I G L H K M K N P M L B O J H O I O O Q F Figure 1 A. RH Motion Control Lever B. NI HF Nut C. HH Screw D. RH Steering Handle Asm. E. RH Motion Control and Bushing Asm. F. Leaf Spring G. Flat Washer H. Spring Washer I. HF Nut Z Master 7500-D Series Service Manual March 2018 - Digital Edition J. Jam Nut K. Motion Control Damper L. Threaded Hub M. Front Linkage Rod Asm. N. LH Steering Handle Asm. O. LH Motion Control and Bushing Asm. P.
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CHASSIS Chassis Exploded View 2 H G A F E I J C J G H F E B C D Figure 2 A. Brake Lever Grip B. Side Flange Bearing C. Upper Brake Link D. Brake Shaft Asm. E. Turnbuckle Asm. 5-4 Table of Contents F. Brake Bellcrank with Bushing G. Compression Spring H. NI Flange Nut I. Trunion Pin J.
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CHASSIS Chassis Exploded View 3 A B C D E E Chassis F Figure 3 A. Suspension Seat B. Seat Latch Plate C. Seat Plate Frame Z Master 7500-D Series Service Manual March 2018 - Digital Edition D. Tilt Seat Support Plate E. Isolator Seat F.
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CHASSIS Chassis Exploded View 4 A H G F E B C C B D B B I E Figure 4 A. Hood Asm. B. Flat Washer C. Hair Cotter Pin D. Hood Prop E. Torx Screw 5-6 Table of Contents F. Flat Washer G. Clip H. RH Tank Cover I.
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CHASSIS Chassis Exploded View 5 A B C D E F Chassis G H Figure 5 A. Grease Cap B. NI Lock Nut C. Bellville Washer D. Flat Washer Z Master 7500-D Series Service Manual March 2018 - Digital Edition E. Cone Taper Roller Bearing F. Grease Seal G. Caster Fork H. Wheel and Tire Asm.
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CHASSIS Chassis Exploded View 6 A B C D E F H I G J Figure 6 A. HH Screw B. Flat Washer C. Plain Washer D. Rubber Washer E. Spacer Tube F. RH Fuel Tank Asm. 5-8 Table of Contents G. Clamp H. HH Screw I. Flat Washer J. LH Fuel Tank Asm. K.
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CHASSIS Caster Fork Assembly and Bearing Removal 1. Park the machine on a level surface, disengage the PTO and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Raise and support the unit so that the front wheels are off the ground and secure with jack stands. 3. Remove the caster cap (Figure 7). Figure 7 4. Support the underside of the caster wheel and remove the lock nut securing the caster bearing assembly. Chassis 5.
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CHASSIS Caster Fork Assembly and Bearing (Cont.) Removal (Cont.) 5. Remove the six spring washers and one large flat washer from the caster fork shaft. NOTE: Take note of the washer orientation. 6. Remove the front caster fork from the frame. Inspect the caster fork shaft for wear or damage (Figure 8). NOTE: Avoid damaging seals and bearings while removing the caster fork. Figure 8 7. Remove lower caster bearing seal (Figure 9).
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CHASSIS Caster Fork Assembly and Bearing (Cont.) Removal (Cont.) 8. Remove the upper and lower taper bearings from the frame (Figure 10). Inspect bearing races for damage and excessive wear. Figure 10 Chassis 9. Replace the bearings and races if worn.
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CHASSIS Caster Fork Assembly and Bearing (Cont.) Installation 1. Clean the surface inside the axle bearing area. 2. Manually grease all bearings. 3. Set the lower bearing into place (Figure 11). H G F E D D C B A Figure 11 A. Wheel and Tire Asm. B. Caster Fork C. Grease Seal D. Cone Taper Roller Bearing 5-12 Table of Contents E. Flat Washer F. Bellville Washer G. NI Lock Nut H.
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CHASSIS Caster Fork Assembly and Bearing (Cont.) Installation (Cont.) 4. Install the lower seal until flush with the frame tube. 5. Set the caster fork into place. NOTE: Avoid damaging seals and bearings when installing the caster fork. 6. Insert one flat washer and six spring washers (Figure 12). Spring washer orientation is two curved down, two curved up, two curved down. Figure 12 Chassis 7. Install lock nut. 8. Manually rotate caster fork two rotations to verify range of motion. 9.
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CHASSIS Caster Wheel Assembly Replacement Disassembly 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Raise and support the unit so that the front wheels are off the ground. 3. Remove the caster wheel from the caster fork. 4. Remove the seal guards from the wheel hub. 5. Remove one of the spacer nuts from the axle assembly.
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CHASSIS Caster Wheel Assembly Replacement (Cont.) Assembly 1. Ensure that the wheel is clean and free of debris or excessive wear. 2. Pack the two tapered bearings with grease. 3. Insert one bearing and one new seal into the wheel. 4. Insert the assembled spacer nut and axle into the wheel. 5. With the open end of the wheel facing up, fill the area inside the wheel, around the axle, full of grease. 6. Insert the second bearing and seal into the wheel. 7.
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CHASSIS Caster Wheel Assembly Replacement (Cont.) Installation 1. Pack the caster wheel tapered roller bearing with high temperature grease. 2. Install the bearing into the wheel hub. 3. Install grease seal into the wheel hub. 4. Repeat steps 1, 2, and 3 on the other side of the caster wheel. 5. Fill the center of the wheel hub with high temperature grease. 6. Position the caster axle through the bearing and seal assembly. 7. Install a spacer nut onto both ends of the caster axle.
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CHASSIS Left Tank Cover Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the four screws located on the outside of the left tank cover. 3. Remove the two screws and washers located on the inside of the left tank cover. NOTE: Only the inside screws use washers 4. Raise the hood to provide clearance for tank cover removal. Chassis 5.
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CHASSIS Left Tank Cover (Cont.) Installation 1. With hood raised, install the tank cover. 2. Place the left tank cover on the machine. 3. Insert the two washers and two screws loosely on the inside of the machine. 4. Insert the four screws located on the outside of the of the left tank cover and tighten all six fasteners.
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CHASSIS Right Tank Cover WARNING Never touch electrical wires or components while the engine is running. They can be sources of electrical shocks. Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the three screws securing the control panel to the machine. 3. Disconnect the negative terminal first, then the positive terminal on the battery. Chassis 4.
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CHASSIS Right Tank Cover (Cont.) Installation 1. Raise the hood to install the right tank cover. 2. Ensure proper harness routing for the control panel (Figure 14). Figure 14 3. Align fuel line routing with right tank cover (Figure 15). Figure 15 4. Thread harness through the right tank cover while placing on the machine. 5. Insert the two washers and two screws loosely on the inside of the machine. NOTE: Only the inside screws use washers 6.
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CHASSIS Fuel Tank DANGER Do not open a fuel system under high pressure. The fluid under high pressure that stays in fuel lines can cause serious injury. Do not disconnect or repair the fuel lines, sensors, or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure. DANGER Fuel is very flammable and explosive under some conditions. Do not smoke or let flames or sparks in your work area. Removal 1.
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CHASSIS Fuel Tank (Cont.) Installation 1. Place fuel tank on the machine. 2. Loosely install the fuel tank mount bolt, washers, spacer, and lock nut. 3. Loosely install the two fuel tank clamps and lock nuts. 4. Tighten all three mounting fasteners. 5. Install the supply, return and vent lines to the fuel tank. 6. Install the left or right tank cover, see “Left Tank Cover Installation,” chapter 5, page 5-18 or see “Right Tank Cover Installation,” chapter 5, page 5-20.
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CHASSIS Seat WARNING Heavy Object, To Avoid Muscle Strain Or Back Injury, Use Lifting Aids And Proper Lifting Techniques When Removing Or Replacing heavy objects. Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Slide the seat all the way forward on the adjustment tracks. 3. Tilt seat forward. 4 Disconnect the seat switch from the bottom of the seat.
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CHASSIS Seat (Cont.) Installation NOTE: Assistance will be needed. 1. Place the seat on the machine. 2. With the seat latched in the down position, install the two back nuts securing the seat frame to the seat isolator. 3. Tilt the seat forward. 4. Install the two front nuts securing the seat frame to the seat isolator. 5. Route seat switch harness through the seat frame. Connect the seat switch. 6. Drop the seat back down to the operator’s position.
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CHASSIS Front Seat Mount Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the operator’s seat, see “Seat Removal,” chapter 5, page 5-23. 3. Mark the location of the motion control plate with tape to assure proper alignment upon installation (Figure 16). Figure 16 4. Remove the four screws (two on each side) securing each left and right motion control covers to the machine.
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CHASSIS Front Seat Mount (Cont.) Removal (Cont.) 8. Using a blunt punch and hammer, remove the two vent line clips. 9. Using a flat head screw driver, remove the remaining harness clip. NOTE: The clips are intended for a one time use and will need to be replaced. 10. Remove the two lock nuts securing the hydraulic fluid tank to the front seat mount. NOTE: The U-bolt will drop once lock nuts are removed but should not fall through. 11. Remove the four screws located in the corners of the seat mount. 12.
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CHASSIS Front Seat Mount (Cont.) Installation 1. Before placing the seat mount on the machine, replace vent line zip ties and retainer clips as needed (Figure 18). Figure 18 2. Place the seat mount on the machine. 3. Install vent line retaining clips in appropriate mount location. 4. Install the four screws located in the corners of the seat mount. Chassis 5. Place the U-bolt into the correct position then place the lock nuts on the U-bolt, tighten. 6.
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CHASSIS Front Seat Mount (Cont.) Installation (Cont.) 8. Place the left and right motion control covers on the machine. NOTE: Make sure to align the covers with tape marks placed during the removal process. 9. Secure the motion control covers with four screws (two on each side). 10. Slide the floor pan onto the machine. 11. Install the operator’s seat, see “Seat Installation,” chapter 5, page 5-24.
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CHASSIS Motion Control Damper Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the nut securing the damper ball joint to the frame (Figure 19). NOTE: You will need a T-40 Torx wrench to hold the bolt while removing. Figure 19 Chassis 3. Remove the nut securing the damper to the motion control assembly (Figure 20). Figure 20 4. Remove the damper assembly.
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CHASSIS Motion Control Damper (Cont.) Installation 1. Install the damper with ball joint end that has the Belleville washer into the frame. Torque the lock nut to 200 in-lbs. (22.6 Nm) (Figure 21). Figure 21 2. Install the other end of the damper to the motion control assembly, normally in the center hole and tighten the lock nut to 200 in-lbs. (22.6 Nm).
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CHASSIS Adjusting the Motion Control Damper NOTE: The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance (Figure 22). A B C E D Figure 22 D. Medium Resistance (Medium Feel) E. Least Resistance (Softest Feel) Chassis A. Torque the lock nut to 200 in-lbs. (22.6 Nm) B. Most Resistance (Firmest Feel) C.
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CHASSIS Motion Control Assembly Removal NOTE: This procedure is performed on the left hand motion control assembly; follow the same procedure for the right hand side. 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the two screws retaining the LH motion control cover assembly. 3. Remove the two bolts and nuts retaining the LH steering handle assembly to the LH lever-control motion. 4.
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CHASSIS Motion Control Assembly (Cont.) Removal (Cont.) 8. Remove the bolt securing the pivot hub and the LH motion control to the frame (Figure 24). Figure 24 Chassis 9. Remove the pivot hub from the LH motion control (Figure 25). Figure 25 10. Remove the wire harness anchor from the LH motion control. 11. Remove the neutral switch from the LH motion control. 12. Remove the carriage bolt and nut retaining the leaf spring to the LH motion control. 13.
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CHASSIS Motion Control Assembly (Cont.) Installation 1. Install the four new flange bushings in the LH motion control. 2. Install motion control lever in the LH motion control. 3. Install the flat washer on motion control lever. 4. Install the two spring washers with the crown side of the washers facing out. 5. Install the nut and tighten so it is snug. 6. Install the spring leaf with carriage bolt and nut. 7. Install the neutral switch to the motion control lever. 8.
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CHASSIS Adjusting the Motion Control Neutral Lock Pivot NOTE: The flanged nut can be adjusted to obtain a more desired motion control lever resistance when moving it to the neutral lock position (Figure 26). A B Figure 26 1. Loosen the jam nut. 2. Tighten or loosen the flanged nut to the desired feel. For more resistance, tighten the flange nut. For less resistance, loosen the flange nut. Chassis 3. Tighten the jam nut.
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CHASSIS Roll Over Protection System (ROPS) Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Slide the operator’s seat all the forward and flip upwards. 3. Remove the hood from the machine, see “Engine Cover Removal,” chapter 5, page 5-40. 4. Cut the three zip ties securing the wire harness retainer to the heat deflector panel (Figure 27). Figure 27 5.
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CHASSIS Roll Over Protection System (ROPS) (Cont.) Removal (Cont.) 6. Disconnect the vent lines from the upper ROPS tube on both sides of the machine (Figure 28). Figure 28 7. Lay the ROPS down. 8. Remove the two carriage bolts, one on each side. NOTE: Will need assistance to continue. 9. Lift the ROPs straight up to remove. Chassis 10. Remove the two spacers from lower ROPS and set aside (Figure 29).
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CHASSIS Roll Over Protection System (ROPS) (Cont.) Removal (Cont.) 11. Remove the four upper bolts securing the lower ROPS tubes (Figure 30). Figure 30 12. Remove the four lower bolts securing the lower ROPS tubes (Figure 31). Figure 31 13. Remove the lower ROPS tubes from the machine.
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CHASSIS Roll Over Protection System (ROPS) (Cont.) Installation 1. Install the lower ROPS tubes onto the machine. 2. Install the four lower bolts securing the lower ROPS tubes to the machine. Torque to 100-110 ft-lbs. (135-149 Nm). 3. Install the four upper bolts securing the lower ROPS tubes to the machine. Torque to 100-110 ft-lbs. (135-149 Nm). 4. Install the two spacers, one on each side, in the hole for the lower ROPS. NOTE: Will need assistance to continue. 5.
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CHASSIS Engine Cover WARNING Heavy Object, To Avoid Muscle Strain Or Back Injury, Use Lifting Aids And Proper Lifting Techniques When Removing Or Replacing heavy objects. Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Release the hood latches on both sides and lift up to lock position. NOTE: Will need assistance before continuing. 3.
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CHASSIS Engine Cover (Cont.) Installation 1. Using two people, one on each side of the hood, slide the hood to the left on the hinge pins until aligned. 2. With one person supporting the hood, place the washer and cotter pin onto the hinge pin. 3. Install the prop bracket on the pin. 4. While one person is supporting the hood, place the washer and cotter pin onto the prop bracket. Chassis 5. Close the hood and secure with the hood latches.
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DECK Table of Contents Deck System Exploded View 1.............................................................................................. 6-3 Deck System Exploded View 2.............................................................................................. 6-4 Deck System Exploded View 3.............................................................................................. 6-5 Deck System Exploded View 4....................................................................................
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DECK Table of Contents (Cont.) Deck Wings........................................................................................................................... 6-27 Removal........................................................................................................................ 6-27 Installation.................................................................................................................... 6-30 Spindle Assembly Rebuild...................................................
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DECK Deck System Exploded View 1 A C B Deck D Figure 1 A. RH Wing Shield Asm. B. V-Belt Z Master 7500-D Series Service Manual March 2018 - Digital Edition C. Pulley Idler D.
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DECK Deck System Exploded View 2 A D B E A C B C F G I H J I K L M Figure 2 A. Roll Pin B. NI Lock Nut C. HH Screw D. Driveshaft Asm. E. Gearbox Asm. F. V-Belt G. Pulley 6-4 Table of Contents H. V-Idler I. Extension Spring J. Idler Pulley K. Flat Idler Pulley L. Center Deck Asm. M.
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DECK Deck System Exploded View 3 A B C B D E A B F E G E G F Deck E Figure 3 A. Deck Fold Cylinder Asm. B. Fitting C. Hose Asm. D. Hose Asm. Z Master 7500-D Series Service Manual March 2018 - Digital Edition E. Locking Cotter Pin F. Cylinder Pin Eye G.
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DECK Deck System Exploded View 4 A C B B B A B E D G F F Figure 4 A. Pivot Rod Cover B. Torsion Spring C. RH Shield Hinge Panel D. LH Center Shield 6-6 Table of Contents E. LH Shield Hinge Panel F. Deck Pin G. RH Fold Arm Asm.
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DECK Deck System Exploded View 5 C A B B D E B F C A B A N G H I M J J H I K L Deck K Figure 5 A. Lock Nut B. Thrust Washer C. Deck Strut Asm. D. Panhard Rod Asm. E. HH Screw F. HH Screw G. Front Deck Lift Z Master 7500-D Series Service Manual March 2018 - Digital Edition H. Trunnion I. Deck Lift Link Adjuster J. Deck Lift Adjuster K. HHF Shoulder Screw L. Rear Deck Lift M. Jam Nut N.
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DECK Deck System Exploded View 6 A B C D Figure 6 A. LH Shield Asm. B. V-Belt 6-8 Table of Contents C. Pulley Idler D.
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DECK Deck System Exploded View 7 A D B Deck C Figure 7 A. RH Wing Deck Asm. B. Deck Asm. Z Master 7500-D Series Service Manual March 2018 - Digital Edition C. LH Wing Deck Asm. D. Tunnel Discharge Asm.
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DECK Deck System Exploded View 8 A B C D C A E F G I Figure 8 A. NI HF Nut B. Roll Pin C. HH Screw D. Driveshaft Asm. E. Tunnel Discharge Asm. 6-10 Table of Contents F. HH Screw G. Sleeve Bushing H. Lock Nut I. Deck Asm.
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DECK Deck System Exploded View 9 A C B D E E F F Q P O N G M H L K J Deck I Figure 9 A. RH Belt Cover B. Reverse Drive Cover C. BB Belt D. NI Flange Nut E. Dust Shield F. V Idler G. Gearbox Asm. H. Pulley I. Deck Asm. Z Master 7500-D Series Service Manual March 2018 - Digital Edition J. Blade Screw K. Heavy Blade Bolt Washer L. Atomic Blade M. Spindle Asm. N. Pulley O. NI HF Nut P. LH Belt Cover Q. Idler Mount Asm.
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DECK Deck System Exploded View 10 - 96 in. Deck A C B A D E Figure 10 A. Straight Fitting B. Elbow Fitting C. Lift and Fold Valve 6-12 Table of Contents D. Lift Cylinder E. Hose Asm.
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DECK Deck System Exploded View 11 - 60 & 72 in. Deck A D B C Deck E Figure 11 A. Deck Lift Valve Asm. B. Elbow Fitting C. Straight Fitting Z Master 7500-D Series Service Manual March 2018 - Digital Edition D. Lift Cylinder E. Hose Asm.
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DECK Deck Replacement - 96 in. CAUTION The blades are sharp: contacting a blade could result in serious personal injury. Always wear eye protection and gloves when handling blades. Removal 1. Park the machine on a level surface, disengage the PTO and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2.
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DECK Deck Replacement - 96 in. (Cont.) Removal (Cont.) 5. Locate and disconnect the three wire connectors located near the hydraulic lines (96 in. only) (Figure 13). Figure 13 6. Raise and secure the rear of the machine using jack stands. 7. Remove the rear wheels. Deck 8. Remove the two deck strut bolts (one per side) and the panhard rod bolt (Figure 14).
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DECK Deck Replacement - 96 in. (Cont.) Removal (Cont.) 9. Place the wheel back on the machine. Torque to 95 ft-lbs. (129 Nm). 10. Remove the jack stands and lower the machine. 11. Before removing the deck drive shaft mark the orientation of the deck drive shaft and gear box shaft (for roll pin orientation) (Figure 15). Figure 15 12. Remove the roll pin from the deck drive shaft using a roll pin punch (Figure 16).
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DECK Deck Replacement - 96 in. (Cont.) Removal (Cont.) 13. Remove the two pinch bolts from the deck drive shaft. 14. Slide the deck drive shaft off the gear box. WARNING Hands and feet could get pinched or caught, causing personal injury. Keep bystanders away from the machine. CAUTION Once the deck lift links are removed, the front end of the machine may become unbalanced. Secure the rear of the machine with jack stands. 15. Remove the deck lift links from the four corners of the deck. Deck 16.
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DECK Deck Replacement - 96 in. (Cont.) Removal (Cont.) 17. Roll the deck assembly out and away from under the machine. 18. Slowly lower the front of the machine back to level ground, then secure the rear of the machine with jack stands to avoid unwanted tipping.
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DECK Deck Replacement - 96 in. (Cont.) Installation 1. Using assistance, remove the jack stands from the rear and slowly tip the front of the machine back until rear bumper makes contact with the ground. Secure the front of the machine with an overhead hoist. 2. Roll the deck under the machine. Aligning the deck struts and the panhard rod (do not connect at this time). 3. Using assistance, Lower the front of the machine until the front caster wheels contact the ground. 4.
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DECK Belt Replacement Removal NOTE: All three belts on the 96 in. belts are different. 1. Park the machine on a level surface, disengage the PTO and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Lower the deck into the full-down position. NOTE: Steps 3-9 are 96 in. only. 3. Remove the two lock nuts and two carriage bolts securing the inner belt guard (Figure 18). Figure 18 4. Remove the two lynch pins securing the outer belt guard to the deck. 5.
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DECK Belt Replacement (Cont.) Removal (Cont.) 7. Using a 3/8 in. drive, place the drive into the square hole located on the wing belt idler assembly. Rotate the idler assembly counter-clockwise to release tension and remove belt (Figure 19). Figure 19 NOTE: For center belt, use a ½ in. drive and rotate clockwise. 8. Remove the belt. 9. Repeat for opposite side. 10. Remove center belt by rotating idler arm assembly clockwise with ½ drive breaker bar.
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DECK Belt Replacement (Cont.) Installation 1. Install the center belt on the machine rotating the idler assembly clockwise with a ½ in. drive. 2 Install the left and right belts on the machine rotating the idler assembly counter-clockwise with a 3/8 in. drive. 3. Install the floor pan. 4. Install the two lynch pins securing the outer belt guard to the deck. Repeat for opposite side. 5. Install the two lock nuts and two carriage bolts securing the inner belt guard. Repeat for opposite side.
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DECK Gearbox Replacement Removal 1. Park the machine on a level surface, disengage the PTO and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove all belts, see “Belt Removal,” chapter 6, page 6-20. 3. Remove the three lock nuts, flat washers, and isolators from the gear box mount (Figure 20). Figure 20 4. Remove the gearbox. Installation 1. Install the gearbox onto the deck. 2.
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DECK Deck Hydraulics (Deck Fold Cylinder) WARNING Keep body and hands away from pinhole leaks or nozzles that eject hydraulic fluid under pressure. Use paper or cardboard, not hands, to search for leaks. Serious injury may occur if hydraulic fluid is injected into the skin. WARNING When disconnecting or replacing a hydraulic hose, be sure to relieve all pressure from the system by stopping the engine and lowering or supporting the implement.
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DECK Deck Hydraulics (Deck Fold Cylinder) (Cont.) Removal (Cont.) 8. Remove the screws securing deck-stop bracket to the machine (Figure 21). Figure 21 Deck 9. Remove the locking cotter pins (two on each cylinder) on both ends of the deck fold cylinder (Figure 22). Figure 22 10. Remove the deck fold cylinder by pulling to the outside of the deck.
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DECK Deck Hydraulics (Deck Fold Cylinder) (Cont.) Installation 1 Install the deck fold cylinder onto the deck. 2. Install the locking cotter pins (two on each cylinder) on both ends of the deck fold cylinder. 3. Install the screws securing the deck-stop bracket to the machine. 4. Verify the hydraulic lines are cleaned from debris, attach the hydraulic lines to the lift cylinder. 5. Install the center floor pan. 6. Install the two lynch pins securing the outer belt guard to the deck.
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DECK Deck Wings Removal 1. Park the machine on a level surface, disengage the PTO and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Release the pressure from the hydraulic system before servicing any hydraulic related component, see “Releasing Pressure from the Hydraulic System,” chapter 7, page 7-6. 3. Place the deck in the Full-Down position. 4. Remove the belts and covers, see “Belt Removal,” chapter 6, page 6-20. 5.
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DECK Deck Wings (Cont.) Removal (Cont.) 7. Remove the locking cotter pin from the outer wing ram lift pin (Figure 24). Figure 24 8. Support the wing with a floor jack (Figure 25).
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DECK Deck Wings (Cont.) Removal (Cont.) 9. Remove the front and rear cap screws securing the deck pins (Figure 26). TECH TIP: Wiggling the deck wing up and down may benefit in pin removal. Figure 26 Deck 10. While supporting, roll the wing from the center deck to separate from the machine (Figure 27).
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DECK Deck Wings (Cont.) Installation 1. Roll the wing towards the center deck section and align. 2. Install the front and rear deck pins and secure with bolts. 3. Install the locking cotter pin to the outer wing ram lift pin. 4. Install the two cap screws securing the wing stop bracket. 5. Lower the center deck. 6. Install the rear tire, remove the jack stand. 7. Install the belt, see “Belt Installation,” chapter 6, page 6-22. 8.
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DECK Spindle Assembly Rebuild Disassembly A B C D E F D G Figure 28 A. NI Lock Nut B. Washer C. Spindle Hub Asm. with Studs D. Ball Bearing E. Spindle Hub Asm. with Studs F. Bearing Spacer G. Bearing Spindle Ball Shaft 1. Park the machine on a level surface, disengage the PTO and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the belt, see “Belt Removal,” chapter 6, page 6-20. 3. Remove the blade. Deck 4.
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DECK Spindle Assembly Rebuild (Cont.) Disassembly (Cont.) 6. Remove the fasteners securing the spindle to the deck (from bottom) (Figure 29). Figure 29 7. Lift spindle assembly from the deck. 8. Remove the housing ring (if applicable) (Figure 30).
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DECK Spindle Assembly Rebuild (Cont.) Disassembly (Cont.) 9. Place the spindle assembly in a bench vice and securely clamp onto the hex shank on the bottom of the spindle shaft (Figure 31). Figure 31 Deck 10. With spindle assembly firmly secured, remove the lock nut that captures the top side of the spindle shaft (Figure 32).
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DECK Spindle Assembly Rebuild (Cont.) Disassembly (Cont.) 11. Remove lock nut, washer, and hub (Figure 33 and 34). Figure 33 Figure 34 12. Slide spindle shaft out of spindle housing.
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DECK Spindle Assembly Rebuild (Cont.) Disassembly (Cont.) 13. Move bearing spacer to the side in order to gain access to the inner race of the bottom bearing (Figure 35). Figure 35 14. Gently tap inner race of lower bearing to remove from the housing. Alternate in a star pattern to avoid binding when removing (Figure 36). Deck NOTE: Bearings may be damaged during removal. Replace as needed.
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DECK Spindle Assembly Rebuild (Cont.) Disassembly (Cont.) 15. Remove bearing spacer. 16. Rotate spindle housing and repeat bearing removal for opposite side. 17. Inspect spindle housing for internal or external damage (Figure 37).
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DECK Spindle Assembly Rebuild (Cont.) Assembly 1. Clean and inspect all surfaces. 2. Using the appropriate sized bearing driver, install the upper bearing until seated. NOTE: Gently tap driver to avoid damaging the bearing during install. 3. Rotate spindle assembly and install bearing spacer. 4. With appropriate bearing driver, install remaining bearing until seated. 5. Install spindle shaft into housing. NOTE: Ensure proper orientation of spindle. 6.
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DRIVE Table of Contents Drive System Exploded View 1............................................................................................. 7-2 Drive System Exploded View 2............................................................................................. 7-3 Wheel Motor Exploded View.................................................................................................. 7-5 Releasing Pressure from the Hydraulic System ...............................................................
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DRIVE Drive System Exploded View 1 A H M N K I B O L J G F D C E Figure 1 A. Hose Asm. B. Hose Clamp C. Hose Clamp D. Return Hose E. Hydraulic Tank Support Rod F. Hydraulic Reservoir Asm. G. Hydraulic Tank Support Rod H. Suction Hose 7-2 Table of Contents I. Hose Clamp J. Hose Clamp K. Hose Clamp L. Hose M. Hose N. Tube Asm. O.
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DRIVE Drive System Exploded View 2 B C C C A Drive Figure 2 A. Hose Asm. B. Hose (Routed) C.
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DRIVE Drive System Exploded View 2 (Cont.) A Figure 3 A. Transmission Asm.
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DRIVE Wheel Motor Exploded View A D E E E B C B A. RH Wheel Motor B. Motor Plate C. LH Wheel Motor Z Master 7500-D Series Service Manual March 2018 - Digital Edition Drive Figure 4 D. Hydraulic Hose E.
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DRIVE Releasing Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system. WARNING Keep body and hands away from pinhole leaks or nozzles that eject hydraulic fluid under pressure. Use paper or cardboard, not hands, to search for leaks. Serious injury may occur if hydraulic fluid is injected into the skin.
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DRIVE Drive System Removal NOTE: Before beginning removal process both the machine and work area must be clean. 1. Park the machine on a level surface, disengage the PTO and set the parking brake. 2. Release the pressure from the hydraulic system before servicing any hydraulic related component, see “Releasing Pressure from the Hydraulic System,” chapter 7, page 7-6. 3. Move the deck to the full-downward position. Stop the engine, wait for all moving parts to stop and remove the key. 4.
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DRIVE Drive System (Cont.) Removal (Cont.) 12. Loosen the reservoir clamps. Remove all seven reservoir lines. Tech Tip: Slide the clamps away from the end of the hose and lightly tighten to not lose any clamps for reassemble. 13. Remove the two nuts securing the hydro tank front mount and remove the front hydro tank mount bracket. 14. Slide the hydro tank up and slightly backwards, then lift out of the machine (Figure 6). NOTE: Residual fluid my spill while removing the tank. Figure 6 15.
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DRIVE Drive System (Cont.) Removal (Cont.) 16. Remove the roll pin from the deck drive shaft using a drift punch (Figure 8). Figure 8 17. Remove the two pinch bolts from the deck drive shaft. 18. Slide the deck drive shaft off the gear box. 19. Disconnect the two main reservoir line hoses. 20. Disconnect the output line to the gear pump (Figure 9). Drive NOTE: Mark the location of the wheel motor hoses.
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DRIVE Drive System (Cont.) Removal (Cont.) 21. Disconnect the four hoses connected to the wheel motor from the transmission assembly. 22. Disconnect the case drain hose. 23. Remove the motion control linkage from the transmission. 24. Attach a lift chain to the transmission case by installing two M8 X 1.25 bolts into the open threaded holes in the top of the transmission case (Figure 10 and 11).
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DRIVE Drive System (Cont.) Removal (Cont.) 25. Apply a slight amount of tension on the lift chain with an overhead hoist. 26. Remove the seven bolts connecting the transmission assembly to the bell housing. 27. Pull transmission assembly away from the bell housing and lift up with the overhead hoist (Figure 12).
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DRIVE Drive System (Cont.) Installation NOTE: Apply anti-seize to the transmission splines before reinstalling 1. Using an overhead hoist, two M8 X 1.25, and two flat washers, lower the transmission assembly into the machine. NOTE: When lowering the transmission assembly, align the drive shaft into position. 2. Place the seven bolts connecting the transmission assembly to the bell housing 30-35 ft-lbs. (40-47 Nm). 3. Disconnect the hoist from the transmission assembly.
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DRIVE Wheel Motor Replacement Removal 1. Park the machine on a level surface, disengage the PTO, and engage the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. NOTE: Make sure work area is clean. 2. Release the pressure from the hydraulic system before servicing any hydraulic related component, see “Releasing Pressure from the Hydraulic System,” chapter 7, page 7-6. 3. Raise the machine and secure with jack stands. 4. Remove the rear wheel. 5. Release the parking brake.
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DRIVE Wheel Motor Replacement (Cont.) WARNING Heavy Object, To Avoid Muscle Strain Or Back Injury, Use Lifting Aids And Proper Lifting Techniques When Removing Or Replacing heavy objects. Installation NOTE: Assistance is needed to perform the following procedure. 1. Place the mount plate onto the wheel motor, secure with 4 bolts. Torque to 75 ± 8 ft-lbs. (101 ± 10 Nm). 2. Position the wheel motor on the floor jack. 3. Lift the wheel motor into proper position. 4.
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DRIVE Priming the Hydraulic Pumps When the hydraulic system is flushed, the hydraulic system is charged, or the hydraulic components are installed, it is important to properly prime the hydraulic pumps. The hydraulic pump priming ensures that the gear pump and piston (traction) pump have sufficient fluid during initial start-up and running. The pumps can be primed by using a remote starter switch to crank the engine which allows the pumps to prime.
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DRIVE Flushing the Hydraulic System IMPORTANT: Flush the hydraulic system whenever there is a severe component failure or the system is contaminated. For example, the fluid appears milky, black, or contains metal particles. 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 20 minutes. 2. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch.
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DRIVE Charging the Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as wheel motors, gear pump, or lift cylinder, it is important that the hydraulic system is charged properly. Remove the air from the system and its components to reduce the chance of damage. IMPORTANT: Change the hydraulic fluid filter when repairing or replacing the hydraulic components. 1. Park the machine on a level surface and shut off the engine.
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DRIVE Charging the Hydraulic System (Cont.) 9. After the lift cylinder moves normally, proceed to step 11. 10. Operate the traction control levers in the forward and reverse directions. The drive wheels should rotate in the proper direction. 11. Adjust the traction control levers to the NEUTRAL position. See operator’s manual for additional information. 12. Lower the machine to the ground. 13.
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Z Master 7500-D Series Service Manual March 2018 - Digital Edition YANMAR3TNV80FT 2600/1400 RPM RPM Drive TOW VALVE 17.8 CID YANMAR3TNV88C 3000/1400 TOW VALVE 17.8 CID 4000 PSI 4000 PSI 0.031 in 0.031 in 1.1 CID 1.1 CID 1:0.691 1:1 1:1.025 1:1.025 GEARBOX PRESSURE VALVE 313+/-30 PSI PTO PRESSURE TEST PORT PTO CLUTCH CHARGE RELIEF 86+/-15 PSI CHARGE PRESSURE TEST PORT 0.031 in Charge Pump 0.37 CID 43 PSI PORT 1 PORT 2 OIL COOLER 0.37 CID Suction Screen 100 Mesh Gear Pump .
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7-20 Table of Contents RPM TOW VALVE 17.8 CID YANMAR3TNV88C 3000/1400 TOW VALVE 17.8 CID 4000 PSI 4000 PSI 0.031 in 0.031 in 1.1 CID 1.1 CID 1:0.691 1:1 1:1.025 1:1.025 GEARBOX PRESSURE VALVE 313+/-30 PSI PTO PRESSURE TEST PORT PTO CLUTCH CHARGE RELIEF 86+/-15 PSI CHARGE PRESSURE TEST PORT 0.031 in Charge Pump 0.37 CID 43 PSI PORT 1 PORT 2 .040 0.37 CID Line Filter Beta 11 = 200(ISO 16889) Suction Screen 100 Mesh Gear Pump C OIL COOLER LIFT CYLINDER 3 3.04 in disp.
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ELECTRICAL Table of Contents Electrical System Exploded View 1...................................................................................... 8-3 Electrical System Exploded View 2...................................................................................... 8-4 General Information............................................................................................................... 8-5 Fuse Block and Fuses................................................................................
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ELECTRICAL Table of Contents (Cont.) 37 HP Electrical Wiring Schematic..................................................................................... 8-19 60/72 in. Electrical Wiring Schematic................................................................................. 8-20 96 in. Electrical Wiring Schematic......................................................................................
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ELECTRICAL Electrical System Exploded View 1 C A B G F D E H I J K L N O Figure 1 A. Ignition Switch Asm. B. Switch C. Sealed PTO Switch D. Horizon LDU Module E. MCU Module F. Yanmar Wire Harness G. Engine Controller H. 12V Power Port Z Master 7500-D Series Service Manual March 2018 - Digital Edition I. Battery Cable Asm. J. Battery K. Switch L. Temperature Sensor M. Bail Switch N. Wire Harness O.
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ELECTRICAL Electrical System Exploded View 2 A A Figure 2 A. Proximity Switch Asm.
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ELECTRICAL General Information WARNING Never touch electrical wires or components while the engine is running. They can be sources of electrical shocks. Always use test equipment as directed by the manufacturer. WARNING When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first.
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ELECTRICAL Fuse Block and Fuses The fuse block houses the fuses that protect the electrical system from electrical surges (Figure 3). NOTE: Always use OEM fuses when replacing a damaged or blown fuse. Figure 3 Testing 1. Visual Inspection: The fuses used in this application may be visually inspected. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade (Figure 4). Bad Good Figure 4 2.
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ELECTRICAL Key/Ignition Switch The ignition switch (Figure 5) makes the proper connections for the starter, safety circuits, and accessories. Detents inside the switch control the three switch positions: OFF, RUN, and START. The START position is spring loaded so that it automatically returns to the RUN position when released. Ignition Switch Wiring Connections: A – Accessory B – Starting Circuit C – Operator Presence Switch, Safety Interlock Switches D – Battery Voltage In Figure 5 Testing 1.
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ELECTRICAL Control Module The control module (Figure 6) records hours of operation when the ignition key is ON and the PTO switch is ON. C B A D Figure 6 A. Hours Until Hydraulic Maintenance B. Battery Voltage C. Safety Interlocks (PTO, Brake, Neutral, OPC) D. Hours Until Engine Oil Maintenance Testing 1. With the ignition switch in the RUN position and the PTO switch closed (ON), verify battery voltage and ground to the control module.
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ELECTRICAL Operator’s Presence Switch (Seat Switch) With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the neutral switches. NOTE: The operator presence switch is part of the seat assembly. NORMALLY OPEN OCCUPANT SWITCH Figure 7 Testing 1. Disconnect the wire harness from the Operator Presence Switch, located on the bottom of the seat assembly. Electrical 2.
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ELECTRICAL Neutral Switch - Left and Right The neutral switch is a single pole plunger type switch (Figure 8 and 9) (normally open) with two terminals. When the plunger is depressed, the circuit closes and there is continuity between the terminals. Motion Control Levers in neutral position (OUT), the switch will have continuity (closed). Motion Control Levers in the operating position (IN), the switch will NOT have continuity (open).
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ELECTRICAL Parking Brake Switch The parking brake switch is a single pole plunger type switch (Figure 10 and 11) (normally open) with two terminals. When the plunger is depressed (parking brake ON), the circuit closes and there is continuity between the terminals. This allows battery voltage to flow to the rest of the safety interlock system. Parking Brake ON, the switch should have continuity (closed). Parking Brake OFF, the switch should NOT have continuity (open).
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ELECTRICAL Starter Solenoid The relay is a remote switch (Figure 12) that connects the battery to the starter motor when the ignition switch is turned to START. The relay protects the ignition switch from the high current drawn by the starter motor. Figure 12 Testing 1. Disconnect the relay from the wiring harness. 2. With a multi-meter set to the OHM setting, check to ensure that terminals 85 and 86 have approximately 7085Ω resistance (Figure 13). 3.
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ELECTRICAL PTO Switch The PTO switch (Figure 14) provides battery voltage from the ignition switch to the control module. Figure 14 Testing 1. Remove the control panel from the right console. 2. Disconnect the PTO switch from the wire harness. 3. With the switch in the OFF position (button pushed IN): - Terminal A and B should NOT have continuity (open) - Terminals B and C should have continuity (closed) Electrical 4.
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ELECTRICAL Deck Lift - Lower Switch The deck lift-lower switch (Figure 15 and 16) provides battery power to the solenoid valve, directing hydraulic pressure to the lift cylinder.
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ELECTRICAL PTO Solenoid Valve Coil The hydraulic system of the machine uses a solenoid valve coil (Figure 17) on the front of the transmission to engage and disengage the cutting deck. When the solenoid valve coil in energized, hydraulic flow is directed to operate the wet clutch, integral to the transmission. B C A Figure 17 A. Transmission B. Solenoid Valve and Coil C. Coil Connector Testing NOTE: Do not remove the solenoid from the cartridge for testing. 1.
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ELECTRICAL Fusible Link Harness The machine uses 3 fusible links (Figure 18 and 19) for the circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the main wire harness. If any of these links fail, current to the protected circuit stops. Ensure that the key switch is in the OFF position, disconnect the negative battery cable from the battery terminal, and then disconnect the positive cable from the battery.
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ELECTRICAL Deck Limit Switch (96 in. Deck Only) The deck limit switch prevents the cutting deck from being folded (Figure 20 and 21). Figure 20 Figure 21 Electrical Testing No testing procedure available. If the switch is suspected to be faulty, replace the switch.
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ELECTRICAL TVS Diode The TVS Diode protects the electrical system from current surges caused by PTO engagement and disengagement (Figure 22). Figure 22 Testing No testing procedure available. If the diode is suspected to be faulty, replace the diode.
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NO CONNECT \\\\ #1 #2 #3 CK Green Black Red Blue Black Violet 2 3 12 11 10 9 8 7 6 5 4 3 2 1 P9024 9 8 7 6 5 4 Red Yellow Yellow Violet Violet Blue Brown Orange White Yellow Orange Black Brown Red SP9002 SP9006 Violet Yellow \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\ 2 7 5 8 6 12 \\\\ \\\\ \\\\ Black 2 P9008 + 99-7411 POWER PORT PT02 - 1 P9008 \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\
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B \\\ GND PWR CAN LO CAN HI SW PWR NC 6 3 5 4 2 \\\\ \\\\\\ P18 1 \\\\\\ SP02 Red/White Red/White 1 7 5 \\ Red/White \\\\\ Red/White \\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ Black Black Black Green Green Green Yellow Yellow Yellow Black 2 \\\\\ 1 P10 1 \\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\ Red/Green Red/Green \\\\ \\\\ SP01 \\ \\\\ \\ Red/Green Red/Green Red/Green RUN OFF SB AA P15 I C \\ Orange Blue Red/White \\\\\\
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B \\\ 6 3 5 4 2 \\\\ \\\\\\ \\\\\\ SP02 Red/White Red/White 1 \\\\\ Black Black Black Black Green Green Green Black 2 \\\\\ 1 P10 1 \\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ P10 2 \\\\\ \\\\\ \\\\\\\\\\\\\\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\ Red/Green Red/Green \\\\ \\\\ SP01
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60/72 in. Hydraulic Schematic DECK CYLINDER C1-CYLINDER P2-AUX PUMP P3-TEMPERA TURE SENDER T-OIL COOLER 3.04 in3 DISP .75 X 6.9 in .040 DECK LIFT MANIFOLD P3 P2 S1 S2 .047” C1 CHARGE PRESSURE TEST PORT T PORT 2 OIL COOLER 4000 PSI 17.8 CID 1.1 CID TOW VALVE 43 PSI 1:1.025 0.031 in Line Filter Beta 11 = 200(ISO 16889) PRESSURE VALVE 313+/-30 PSI CHARGE RELIEF 86+/-15 PSI 0.031 in 1.1 CID 4000 PSI 17.8 CID GEARBOX 0.37 CID 1:1.025 0.
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96 in. Hydraulic Schematic WINGFOLD CYLINDER 1.25” BORE X 0.75” ROD X 3.5” STROKE LIFT CYLINDER 3 3.04 in disp. 3/4” x 6.9” .040 C B A 0.020 ” 0.020 ” S1 X CHARGE PRESSURE TEST PORT T P PORT 2 OIL COOLER 4000 PSI 17.8 CID 1.1 CID TOW VALVE 43 PSI 1:1.025 0.031 in Line Filter Beta 11 = 200(ISO 16889) PRESSURE VALVE 313+/-30 PSI CHARGE RELIEF 86+/-15 PSI 0.031 in 1.1 CID GEARBOX 4000 PSI 0.37 CID 1:1.025 17.8 CID 0.
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37 HP Electrical Wiring Schematic 126-9272 ENGINE SENSORS - HARNESS B-1 ENG10 P9022 10 Yellow 126-9272 ENGINE SENSORS - HARNESS B-2 ENG11 EGR GAS TEMP SENSOR P9023 Green Yellow Blue EXH TEMP SENSOR 11 CM SENSOR Green 3 Black Red Blue 5 6 7 CRANK REV Brown Red 2 4 CAM SPEED 8 9 Black Violet Orange Black Blue Yellow Yellow Blue Green Green Blue Brown Red Green Black Red Blue Black Violet Orange Black Yellow Orange White Blue Brown Red Yellow Violet 1 2 3 Yellow 4 Orange White #3 5 I
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60/72 in. Electrical Wiring Schematic S B Red/Green Red/Green Red/Green 82-2190 BRAKE Switch P11 SW03 2 \\\ P10 1 P10 2 Green/Gray \\\\\ Red/White Red/White Red/White Red/White Red/White \\ \\ \\\ SP03 \\ \\\\ \\\ \\\ \ \\\\\\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ Green/Brown \\\\ \\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ Green/Yellow \\\\\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ 82-2190 OPC Switch SW04 \\\\\ Black \\ \\ \\ \\\\\\\\\
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96 in. Electrical Wiring Schematic Red/Green Red/Green Red/Green Red/White Red/White Red/White Red/White Red/White Green/Gray \\ \\\ \\\\ \\\ \\\ \ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ P10 2 \\\\\ \\ SP03 \\ \\ \\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\ 1 SP04 Black Black Black Black \\\\\\\\\\\\\\\\\\\\\\\\\\\\ Red/Green Red/Green Violet/Red Black Black Gray/Violet Red/Green Red/Green Blue/Black P02 7 \\\\\\\\\ \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\
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LCEPr oduct s