TORO MID-MOUNT Z SERVICE MANUAL Table of Contents – Page 1 of 3 SPECIFICATIONS ENGINE Z100 SERIES Z250 SERIES Z280 SERIES UNIT DIMENSIONS Z100 SERIES Z250 SERIES Z280 SERIES HYDRAULIC SYSTEM TORQUE SPECIFICATIONS HYDRAULIC HOSES & FITTINGS CHASSIS MAINTENANCE RECOMMENDED MAINTENANCE SCHEDULE CHECKING THE OIL LEVEL CHANGING OIL AND FILTER SERVICING THE AIR CLEANER REMOVING THE FILTERS INSTALLING THE FILTERS SERVICING MODELS EQUIPPED WITH THE HEAVY-DUTY AIR CLEANER USING THE FILTER MINDER REMOVING THE AIR CLE
TORO MID-MOUNT Z SERVICE MANUAL Table of Contents – Page 2 of 3 ENGINE EXTERNAL ALTERNATOR REMOVE & REPLACE ENGINE REMOVE & REPLACE AIR-COOLED ENGINE REMOVE & REPLACE LIQUID-COOLED RADIATOR REMOVE & REPLACE LIQUID-COOLED MOWERS MODELS EQUIPPED WITH ELECTRONIC FUEL INJECTION (EFI) HYDRAULIC SYSTEMS HYDRAULIC SYSTEM, TYPICAL DESCRIPTION GENERAL HYDRAULIC ASSEMBLY GUIDELINES REPLACING THE PUMP DRIVE BELT PUMP REMOVAL ADJUSTING THE HYDRAULIC PUMP NEUTRAL WHEEL MOTOR R & R CHASSIS MOTION CONTROL LINKAGE - REMOVE
TORO MID-MOUNT Z SERVICE MANUAL Table of Contents – Page 3 of 3 ELECTRICAL SYSTEMS - CONTINUED ELECTRIC PTO CLUTCH REMOVAL SOLENOID PURPOSE HOW IT WORKS TESTING STARTER, ELECTRIC PURPOSE HOW IT WORKS TESTING SWITCH, PTO/CLUTCH PURPOSE HOW IT WORKS TESTING BRAKE SWITCH PURPOSE HOW IT WORKS TESTING INTERLOCK MODULE PURPOSE HOW IT WORKS TESTING HOURMETER PURPOSE HOW IT WORKS TESTING MOTION CONTROL SWITCH PURPOSE HOW IT WORKS TESTING KEY SWITCH PURPOSE HOW IT WORKS TESTING SEAT SWITCH PURPOSE HOW IT WORKS TESTI
Mid-Mount Z Service Manual
PREFACE ABOUT THIS MANUAL This service manual was written expressly for the Toro Mid-Mount Z product line. The Toro Company has made every effort to make the information in this manual complete and correct. This manual was written for the service technician; basic mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
TABLE OF CONTENTS SPECIFICATIONS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Z100 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Z250 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Z280 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Servicing the Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Spark Plug(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Spark Plug(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS CHASSIS Motion Control Linkage - Remove and Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1 Adjusting the Handle Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2 Replacing the Parking Brake and Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 4 Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS ELECTRICAL SYSTEMS (cont’d) iv Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS ELECTRICAL SYSTEMS (cont’d) Mercury Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33 How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 33 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THIS PAGE INTENTIONALLY LEFT BLANK vi Mid-Mount Z Service Manual
SPECIFICATIONS ENGINE Z100 Series Model Manufacturer HP Oil Capacity High Idle Low Idle Cooling System 74170 Kawasaki 17 1.9 Qts. 3600 ± 100 1500 Air-Cooled 74171 Kohler 22 2 Qts. 3600 ± 100 1500 Air-Cooled 74172 Kohler 20 2 Qts. 3600 ± 100 1500 Air-Cooled 74173 Kawasaki 19 2 Qts. 3600 ± 100 1500 Air-Cooled 74174 Kohler 23 2 Qts. 3600 ± 100 1500 Air-Cooled 74175 Kawasaki 23 2 Qts. 3600 ± 100 1500 Air-Cooled 74176 Kawasaki 17 2 Qts.
SPECIFICATIONS UNIT DIMENSIONS Z100 Series Model Wheel Length Width Height Weight Base lb. Tires Tire Pressure Rear Front Rear Front 74176 50” 78” 55” 40” 885 23” x 9.50-12” 13” x 5.00”-6” 13 PSI 13 PSI 74178 50” 78” 65” 40” 910 23” x 9.50-12” 13” x 5.00”-6” 13 PSI 13 PSI 74179 50” 78” 65” 40” 910 23” x 9.50-12” 13” x 5.00”-6” 13 PSI 13 PSI 74197 50” 78” 65” 40” 910 23” x 9.50-12” 13” x 5.00”-6” 13 PSI 13 PSI 74198 50” 78” 65” 40” 910 23” x 9.
SPECIFICATIONS HYDRAULIC SYSTEM Model Pumps Motors Fluid Type Fluid Capacity Z100 Series (2) Hydro-Gear BDP10A (2) Ross MB15 Torquemotors Mobil 1 15W20 Synthetic 2.1 Qts. Z250 Series (2) Hydro-Gear BDP10A (2) Ross MB15 Torquemotors Mobil 1 15W20 Synthetic 2.1 Qts. Z280 Series (2) Hydro-Gear BDP10A (2) Ross MB15 Torquemotors Mobil 1 15W20 Synthetic 2.1 Qts. TORQUE SPECIFICATIONS Hydraulic Hoses & Fittings Item Torque Fitting to hydraulic oil tank 50 - 70 ft. lbs.
THIS PAGE INTENTIONALLY LEFT BLANK 1-4 Mid-Mount Z Service Manual
MAINTENANCE Recommended Maintenance Schedule Maintenance Service Interval After first 5 hours Maintenance Procedure • Hydraulic fluid—check level • Engine Oil—check • Hydraulic filter—change Each Use • • • • Oil—check level Safety System—check Mower Housing—clean Engine Cooling System—clean1 Every 5 Hours • • • • • • • • Cutting Blades—check Blade Spindle Bearings—grease Every 25 Hours Chassis—grease1 Linkage bushings—oil1 Hydraulic fluid—check level Foam Air Cleaner—service1 Battery—check electrolyt
MAINTENANCE Checking the Oil Level 3. Place a pan below the oil drain. Rotate oil drain valve to allow oil to drain (Figure 2). Note: Check oil when engine is cold. 1. Disengage the power take off (PTO) and turn the ignition key to off. Move levers to neutral locked position and apply parking brake. Remove the key. 2. Clean around the oil dipstick so dirt cannot fall into the filler hole and damage the engine. 3. Pull the oil dipstick and wipe the metal end clean (Figure 1).
MAINTENANCE Viscosity: See table below 2. Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Figure 3). Servicing the Air Cleaner Primary Filter: Clean or replace after every 200 operating hours. Safety Filter: Replace after every 600 operating hours. Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. Figure 3 (1) (2) (3) (4) (5) (6) (7) (8) Foam Element Paper Element Rubber Seal Air Cleaner Base 3.
MAINTENANCE Installing the Filters 1. Important To prevent engine damage, always operate the engine with both air filters and cover installed. Start by visually checking the condition of the primary element. If the element is visually dirty, replace the primary element. Do not attempt to clean it. 2. Reset the gauge by depressing the button in the bottom of the canister until the plunger returns to the lowest point (Figure 4). 1. If installing new filters, check each filter for shipping damage.
MAINTENANCE Removing the Air Cleaner 1. 2. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key. Remove spark plug wire(s). Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Figure 5). Important Do not exceed 100 psi and keep the hose at least 2 inches from the filter. Replace air filters if they are damaged or cannot be cleaned.
MAINTENANCE 3. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Loosen the retaining clips and remove the air cleaner cover (Figure 6). Figure 6 (1) Retaining Clip (2) Air Cleaner Cover Important Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, or cannot be cleaned thoroughly. m-4382 (3) Air Filter Cleaning the Paper Elements 1.
MAINTENANCE Servicing the Cooling System 3. With the engine cool, remove the radiator cap (Figure 8). Checking the Radiator Coolant 4. If the coolant level is low, add a 50/50 mixture of permanent antifreeze and water until the radiator is completely full without overflowing. 5. Install the radiator cap. Completely seat the cap by pushing down and turning it until it stops. 6. Add a 50/50 coolant mix to the overflow bottle and fill it to the indicator line on the bottle, if required (Figure 8).
MAINTENANCE 4. Remove debris from the screen on the engine cover. 5. Tilt the engine cover forward. 6. Remove debris from the radiator core and engine (Figure 8). Important Do not damage the radiator cooling fins. 7. Inspect the seals on the engine cover and replace them if needed. 8. Close the engine cover and tilt the seat back. 3. With the engine cool, drain the coolant by loosening the drain cock in the right rear corner (Figure 9). 4.
MAINTENANCE 6. Drain the coolant from the overflow bottle. Inspecting the Cooling System 7. Remove the radiator cap and add a 50/50 mixture of permanent antifreeze and water until the radiator is completely full. Inspect the radiator and the hoses initially and after the first 8 operating hours. 8. Wait 2 minutes and check if the coolant stays up to the full level. Add a 50/50 mixture of permanent antifreeze and water until the radiator is completely full, if required.
MAINTENANCE 5. Install a new filter and move the hose clamps close to the filter (Figure 12). 6. Wipe up any spilled fuel. 3. Remove the spark plug(s) and metal washer. Checking the Spark Plug 1. Open fuel shut-off valve on console. Servicing the Spark Plug Look at the center of the spark plug(s) (Figure 14). If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.
MAINTENANCE Greasing and Lubrication 3. Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 15). Grease more frequently when operating conditions are extremely dusty or sandy. Remove grease zerk in hole. Reinstall hex plug and cap. Where to Add Grease Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Figure 15). Where to Add Light Oil or Spray Lubrication Lubricate the machine in the following areas with spray type lubricant or light oil.
THIS PAGE INTENTIONALLY LEFT BLANK 2 - 12 Mid-Mount Z Service Manual
ENGINE External Alternator Remove & Replace 1. 3. Remove the alternator adjustment bolt and pivot bolt. Disconnect the battery negative cable. Figure 18 Figure 16 2. 0507-001 4. Remove the lower engine protection bracket and set the coolant recovery bottle off to the side. 0508-003 Remove the alternator belt and rotate the alternator to gain access to the wiring. A B C Figure 19 Figure 17 Mid-Mount Z Service Manual 0508-002 (A) Ground Wire (B) Exciter Wire 0508-004 (C) Output Wire 5.
ENGINE Engine Remove & Replace Air-Cooled 1. Disconnect the negative battery cable. 2. Remove the PTO clutch anchor bolt from the clutch guard. 3. Remove the clutch guard and clutch guard brackets (Figure 20). 5. Disconnect the PTO clutch electrical plug and main wiring harness connector (Figure 21). 6. Release the tension from the drive belt by raising the lever against the spring tension and remove the belt from the PTO pulley (Figure 22). Figure 22 7. Figure 20 4.
ENGINE 9. Using a suitable pry bar, release the idler pulley spring tension and remove the hydraulic pump drive belt. 2. Remove the pins from the radiator cover and lift off the cover. Figure 26 Figure 24 1023-012 10. Remove the 4 engine mounting bolts. 3. 0507-002 Remove the radiator cap and open the drain petcock to drain the coolant into a suitable container. 11.
ENGINE 4. To drain the block, remove the drain bolts. NOTE: apply sealant to the bolt threads during reassembly. 7. Remove the bolts securing the overflow bottle to the engine guard. Figure 30 Figure 28 5. 6. 0507-004 Loosen the radiator hose clamps at the water pump and thermostat housing and remove the hoses from the fittings. 8. Remove the 7 bolts securing the radiator support to the engine guard. 9. Carefully lift the radiator assembly from the unit.
ENGINE 10. Remove the hose clamp from the air cleaner duct at the carburetor. Figure 32 0507-008 12. Remove the 6 bolts securing the rear bumper to the engine guard. Figure 34 0507-010 11. Remove the 2 bolts securing the air cleaner to the frame and remove the air cleaner. 13. Remove the bolts securing the engine guard bars to the brackets.
ENGINE 14. Remove the bolts holding the engine guard to the frame, and then remove the guard. 16. Remove the alternator output and ground wires. Figure 38 Figure 36 0507-012 15. Disconnect the positive battery cable and main power feed from the starter. Then separate the engine harness connector and electric clutch connector. Then remove the engine ground wires. 0507-014 17. Lift the lever on the deck belt tension pulley and remove the belt.
ENGINE 18. Remove the control wires for the carburetor choke and throttle control. Figure 40 20. Make sure the fuel selector is in the off position. Then remove the fuel line from the carburetor. CAUTION: Gasoline is extremely flammable. Drain into a suitable container and keep away from any source of combustion. 0507-016 19. Use a bar to release the drive belt tension and remove the belt. Figure 42 0507-018 21. Remove the bolts securing the engine base to the chassis.
ENGINE Radiator Remove & Replace Liquid-Cooled Mowers 1. 3. Remove the radiator cap and open the drain petcock to drain the coolant into a suitable container. Disconnect the negative battery cable. Figure 46 Figure 44 2. 0507-001 4. Remove the pins from the radiator cover and lift off the cover. Figure 45 5. 3-8 To drain the block, remove the drain bolts. NOTE: Apply sealant to the bolt threads during reassembly.
ENGINE 6. 9. Unplug the electrical connections from the temperature sender and fan motor. Carefully lift the radiator assembly from the unit. Figure 50 Figure 48 7. 0507-005 10. Remove the hose clamps from the radiator fittings. Remove the overflow hose from the radiator. Figure 51 Figure 49 8. 0507-007 0507-021 0507-020 Remove the 7 bolts securing the radiator support to the engine guard.
ENGINE 11. Remove the 6 bolts securing the lower radiator support to the radiator, and then lift off the support. Figure 52 0507-022 12. Carefully work the hoses free from the radiator fittings. Figure 53 13. Turn the radiator over. Remove the 6 bolts securing the upper radiator support to the radiator and remove the support. Figure 54 14. If it is necessary to remove the electric fan assembly, remove the 4 nuts and bolts securing it to the lower radiator support.
ENGINE Models Equipped With Electronic Fuel Injection (EFI) 3. The diagnostic plug is installed on the right side of the machine near the starter. For engine specific service or diagnostics procedures consult the engine manufacture’s service manuals. The following are the locations of components which are EFI related but mounted to the unit’s chassis. 1. The fuel pressure regulator is mounted to the right side of the frame behind the rear tire. Figure 58 Figure 56 2.
THIS PAGE INTENTIONALLY LEFT BLANK 3 - 12 Mid-Mount Z Service Manual
HYDRAULIC SYSTEMS Hydraulic System, Typical Ref. No. 1 2 3 5 6 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 24 Qty.
HYDRAULIC SYSTEMS Description Replacing the Pump Drive Belt The hydraulic system consists of a fluid reservoir supplying 2 Hydro-Gear BDP-10L hydrostatic pumps through a spin-on filter. The pumps are controlled by adjustable wrap around handles through a bellcrank and linkage to the pump control lever. These pumps also feature a bypass valve which may be opened to allow the unit to be pushed by hand. Check pump drive belt for wear after every 50 hours of operation. 1.
HYDRAULIC SYSTEMS Pump Removal 1. 4. Clean the pump of any dirt and debris that may be around the hoses to prevent dirt from entering the hydraulic system (Figure 61). Mark the location of the wheel motor supply hoses as to which fitting they go on the wheel motor. Remove the hose fittings to the pump and install caps to keep dirt out. Figure 63 Figure 61 2. 5. Remove the control rod from the trunion lever (Figure 62). Figure 62 3.
HYDRAULIC SYSTEMS Refer to "Replacing the Parking Brake and Linkage" on page 5 - 4. 4. Loosen locknut at ball joint on pump control rod (Figure 65). DANGER Mechanical or hydraulic jacks may fail to support machine and cause a serious injury. • Use jack stand when supporting machine. • Do not use hydraulic jacks. 1. This adjustment must be made with drive wheels turning. First raise the frame and block up so drive wheels can rotate freely.
HYDRAULIC SYSTEMS 8. Open throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, re-adjust if necessary. 9. Repeat on opposite side of unit. Tighten locknuts against ball joints. WARNING 4. Remove the cotter pin (A) (Figure 67) from the wheel motor output shaft. Then loosen the nut (B) (Figure 67) securing the hub to the output shaft. Release the parking brake. 5. Remove the 3 bolts securing the brake band (C) (Figure 67) to the brake actuator.
HYDRAULIC SYSTEMS 8. Remove the front two wheel motor mounting bolts and swing the brake linkage out of the way (Figure 70). 9. Remove the rear two wheel motor mounting bolts and then remove the wheel motor from the chassis (Figure 70).
CHASSIS Motion Control Linkage - Remove and Replace 1. 5. Remove the control link from the bell crank (Figure 73). Remove the 6 bolts securing the console to the rear frame assembly. Then, carefully lower the console to gain access to the motion control linkage (Figure 71). C A Figure 73 (A) Clevis Pin (B) Control Rod Figure 71 2. 1023-014 Remove the electrical plug from the neutral switch (Figure 72). Figure 72 1023-013 (C) Inner Bearing Bolts 6.
CHASSIS 9. Carefully remove the bell crank from the chassis (Figure 75). 3. Check where lever is relative to notch in console (should be centered allowing lever to pivot outward to the neutral lock position) (Figure 76). 4. If adjustment is needed, loosen the nut against the yoke. 5.
CHASSIS Control Linkage, Typical Ref. No. 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 Qty. 2 4 2 2 2 2 2 4 1 2 1 1 2 4 2 2 Description Adjustable Yoke Belleville Washer Control Damper RH Ball Joint Nylon Flanged Bushing Neutral Return Bolt Neutral Return Spring HH Screw RH Lever/Grip ASM Pump Control Arm WLD LH Motion Control RH Motion Control Pump/Lever Linkage Side Flange Bearing LH Thread Ball Joint Control Shaft Arm Mid-Mount Z Service Manual Ref. No.
CHASSIS Replacing the Parking Brake and Linkage 1. Remove the negative battery cable. 2. Raise the drive wheels and place the unit on safety stands. 3. Remove the tire and wheel assemblies. 4. Remove the 3 bolts securing the brake band to the brake pivot (Figure 77). 6. Using the special puller, remove the brake hub from the wheel motor (Figure 79). Figure 79 7. Figure 77 5. Remove the 3 clevis pins from the brake rods and remove the brake rods from the brake shaft (Figure 80).
CHASSIS 8. To remove the brake brackets, remove the 2 bolts at the front of the wheel motor and remove the bracket (Figure 81). 10. Then remove the brake shaft bearing bolts at either end of the shaft (Figure 83). Figure 83 Figure 81 9. 1227-001 To remove the brake shaft, first remove the hydraulic fluid reservoir which is held in place by 2 cap screws and nuts (Figure 82). Figure 82 Mid-Mount Z Service Manual 1030-006 1030-009 11. Then lift the brake shaft out of the chassis. 12.
CHASSIS 13. To remove the brake handle, remove the cotter pin from the brake handle pivot shaft (Figure 85). Figure 85 1030-003 14. Then, pull the brake handle out of the brass bearing (Figure 86).
CHASSIS Parking Brake, Typical Ref. No. 1 2 3 4 5 6 7 9 6 10 11 12 13 14 15 Qty. 2 2 3 1 1 2 2 2 2 4 4 2 4 2 2 Description Control Bearing Brake Spring Brake Rod Brake Lever/Grip ASM Brake Shaft Brake Bracket Spacer Washer Brake Bank Brake Bracket Short Wheel Spacer Long Wheel Spacer Side Flange Bearing Brake Linkage Yoke Trunion Pin Wheel Hub Mid-Mount Z Service Manual Ref. No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Qty.
CHASSIS Adjusting the Parking Brake 5. Engage parking brake. A. Measure the distance between the trunnion roller and the collar on brake rod. Measurement should be 3/16 - 1/4 in. (5 -7mm) (Figure 88). Check parking brake for proper adjustment. 1. Disengage brake lever (lever down). 2. Measure the length of the spring. Measurement should be 2.75 in. (70mm) between washers (Figure 87). 3/16 - 1/4 in. (5-7mm) 2.75 in. (70mm) Figure 88 6. Figure 87 1227-011 3.
CHASSIS Description - Fuel System The Z Master fuel system consists of dual fuel tanks with a total capacity of 12 gallon for the 200 Series and 10 gallons for the 100 Series. Fuel is routed to a 3 position selector valve, then to a fuel filter and the engine fuel pump. The left fuel tank houses an electrical panel containing the key switch, PTO switch, and temperature gauge on liquid-cooled models. Ref. No. 1 2 3 5 6 8 8 9 10 11 12 13 14 15 Qty.
CHASSIS Fuel Tank - Remove and Replace 3. 1. Remove the battery negative cable. 2. Drain the fuel tank. To do this, first place the fuel selector valve in the off position. Then, remove the fuel line from the fuel filter. Place the fuel line into a suitable container (Figure 89). Use the fuel valve to select the tank to be removed (Figure 90). If the left tank is to be removed, remove the electrical control panel from the tank (Figure 91). Figure 91 4. 1030-030 Remove the tire.
CHASSIS 5. Remove the bolt securing the front of the fuel tank to the frame (Figure 93). Figure 93 6. 8. Remove the fuel line from the fitting at the front of the tank (Figure 95). 1030-033 Figure 95 Remove the nut and spring assembly securing the rear of the fuel tank to the frame (Figure 94). Reverse these steps to reinstall. 1030-032 NOTE: When replacing the nut, spring, and washer assemblies, only tighten the nut so that approximately 1/8” (3.2mm) of threads are exposed (Figure 96). 1/8” (3.
CHASSIS Replace Front Wheel Bearings 4. 1. Raise the front of the unit so that the front wheels are off the ground. 2. Remove the through bolt holding the wheel to the caster assembly (Figure 97). Remove the 2 wheel spacers (Figure 99). Figure 99 5. Figure 97 3. 1030-024 Remove the bearing seal (Figure 100). 1030-021 Remove the sleeve that passes through the wheel bearings(Figure 98).
CHASSIS 6. Remove the wheel bearing (Figure 101). Figure 101 7. 8. 1030-020 Drive the bearing race out from the opposite side of the wheel using a long drift (Figure 102). Figure 102 Mid-Mount Z Service Manual Clean the bearing and bearing race and inspect for signs of pitting or other damage (Figure 103). 1030-018 Figure 103 9. 1030-017 Press a new race into the wheel hub (Figure 104).
CHASSIS 10. Pack the bearing with grease and install it on the race (Figure 105). Front Caster Bearings - Remove & Replace 1. Figure 105 1030-025 11. Press a new bearing seal into the hub (Figure 106). Figure 107 2. Figure 106 1030-011 Hold the caster assembly stationary and loosen the bearing adjustment nut (Figure 108). 1030-027 12. Reverse steps 1-4 to reassemble. 5 - 14 Remove the dust cap at the top of the caster assembly (Figure 107). Figure 108 1030-010 3.
CHASSIS 6. Inspect the tapered caster bearings and races for pitting or other damage (Figure 109). Figure 109 1030-017 7. Pack the bearings with grease and reinstall in the housing. Press in a new seal. 8. Reassemble the caster into the bearings (Figure 110). Figure 110 9. 1030-012 Tighten the bearing adjustment nut until there is a slight drag felt in the bearings. 10. Replace the dust cap.
CHASSIS Wheel and Caster Assembly Ref. No. 1 2 3 4 5 7 8 11 21 22 5 - 16 Qty.
MOWER DECKS Replacing the PTO Drive Belt 3. Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn drive belt. Replace the PTO drive belt if any of these conditions are evident. 1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Remove the clutch retaining strap from machine frame and unplug clutch terminal from wire harness (Figure 111).
MOWER DECKS 5. Install clutch retaining strap and plug clutch terminal into main wire harness (Figure 111). 6. Check belt tension. The center bolt of spring loaded idler must be between the two alignment holes (A) in left support plate (Figure 114). Note: Check position of center bolt in Low Height of Cut. The center bolt must be at or below the top alignment hole. 8. Check belt tension again.
MOWER DECKS Mower Deck Removal 5. 1. Raise the handle on the mower deck drive belt tensioning pulley to release the belt tension and slide the belt off the idler pulley. 2. Slip the belt off the deck drive pulley. 3. Remove the bolt and spacer from the mower deck belt guide and remove the belt from the deck (Figure 118). Remove the struts from the deck by first removing the nut and bolt that holds the pin to the deck. Slide the pin out of the strut to release it from the deck (Figure 120).
MOWER DECKS Spindle Repair 9. 1. Stop the engine, remove the key and engage the parking brake. 2. Remove covers from the cutting unit. 3. Using a floor jack raise the machine until you can access the underside the cutting unit. 4. Support the machine using a properly rated jack stand. 5. Remove the spindle shaft from the spindle housing. It may need to be pressed out of the housing. Note: The lower bearing spacer will remain on the spindle shaft. 10.
MOWER DECKS 11. Remove the seals, note the direction of the seals. This will be important during reassembly. The upper seal faces inward, and the lower seal faces outward (Figure 127). If the lower seal is installed incorrectly, the lower bearing spacer will crush the seal and allow dirt into the assembly, causing bearing failure to occur. B. Look for dirt in the grease. Dirt in the grease indicates a bad seal or a worn lower bearing spacer.
MOWER DECKS 14. A large snap ring is still inside the spindle housing. It locates the matched bearing set in the bore of the spindle housing. There is no need to remove and replace this snap ring (Figure 125). E. Pulley assembly - If the shaft shows signs of wear, inspect the pulley for excessive wear in the splines. If excessive wear is found, replace the pulley. Excessive wear of the splines will show up as a sharp edge on the splines. NOTE: New bearings are only available in matched sets.
MOWER DECKS 19. Pack both bearings with grease. Smearing grease on the outside of the bearing is not enough lubrication. Pack the bearing by hand or use a bearing packing tool. 20. With the spindle upside down, set the lower bearing in the bearing cup. Now install the lower seal. Use a seal driver to prevent damage (Figure 127). NOTE: Remember to install the seal with the lip facing out. 26. Slide the pulley down onto the shaft and secure with the washer and nut.
MOWER DECKS (A) (B) (C) (D) (E) (F) (G) (H) (I) (J) (K) (L) (M) (N) (O) (P) (Q) (R) (S) (T) (U) 6-8 Zerk Nut Pulley Spindle Housing Bearing Cup Small Spacer Snap Ring Bearing Cone Bearing Spacer Grease Axis Hole Blade Bolt Spring Washer Blade Spindle Shaft Seal Bearing Cup Machined “C” Spacer Large Spacer Bearing Cone Seal Hardened Washer Mid-Mount Z Service Manual
MOWER DECKS Deck Mounting, Typical Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Mid-Mount Z Service Manual Qty.
MOWER DECKS Leveling the Mower 5. 1. Position mower on a flat surface. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s). 2. Check tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa). 3. Set anti-scalp rollers to top holes or remove them completely for this adjustment. 4.
MOWER DECKS 8. Lift up on four top chain attachment bolts, in the slots, to take slack out of chains and tighten flange lock nuts. (Deck is still supported by two rear and one front blocks under mower.) 9. If bolts contact the end of slots, shorten or lengthen rod/swivel assemblies as required, for extra clearance, adjust each side same amount. Note: When properly adjusted, the front blade tip will be slightly lower than the rear blade tip. Refer to "Checking for Bent Blades" on page 6 - 11 to measure.
MOWER DECKS Adjusting the Compression Spring 1. Raise deck lift lever to the transport position, (Figure 133). Figure 133 2. 1228-005 Springs are compressed so the distance between the two large washers should be 11 in. (279mm) (Figure 134). 11 in. (279mm) Figure 134 Adjust by turning nut in front of each spring (Figure 134). Clockwise will shorten spring; counterclockwise will lengthen spring.
MOWER DECKS Spindle Assemblies, Typical Ref. No. 3 4 5 7 8 9 10 11 13 14 15 Qty. 1 1 1 1 1 1 1 8 8 4 2 Description Cap Screw Torsion Spring Belt Guide ASM Deflector Lock Nut HH Screw Flat Washer Flange Lock Nut HWH Screw Slotted Clamp Blade Bolt Mid-Mount Z Service Manual Ref. No. 17 18 19 20 21 22 23 26 Qty.
THIS PAGE INTENTIONALLY LEFT BLANK 6 - 14 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7-1
ELECTRICAL SYSTEMS Models 74170 74171 74172 74173 74174 74175 74200 74201 74202 74203 74204 74205 74209 Start Circuit 7-2 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Models 74170 74171 74172 74173 74174 74175 74200 74201 74202 74203 74204 74205 74209 Run Circuit Mid-Mount Z Service Manual 7-3
ELECTRICAL SYSTEMS 7-4 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Models 74211 74212 Start Circuit Mid-Mount Z Service Manual 7-5
ELECTRICAL SYSTEMS Models 74211 74212 Run Circuit 7-6 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7-7
ELECTRICAL SYSTEMS Models 74218 74219 Start Circuit 7-8 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Models 74218 74219 Run Circuit Mid-Mount Z Service Manual 7-9
ELECTRICAL SYSTEMS 7 - 10 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 11
ELECTRICAL SYSTEMS 7 - 12 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 13
ELECTRICAL SYSTEMS 7 - 14 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 15
ELECTRICAL SYSTEMS 7 - 16 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 17
ELECTRICAL SYSTEMS 7 - 18 Mid-Mount Z Service Manual
ELECTRICAL SYSTEMS Mid-Mount Z Service Manual 7 - 19
ELECTRICAL SYSTEMS Purpose Alternator (Kohler) The stator generates 25 amps of alternating current to charge the battery. How It Works A Whenever a magnet passes by a coil of wire on an iron core, electricity is produced. The amount will depend on the thickness of wire, the number of windings on each coil, the strength of the magnet, and the speed at which the magnet is moving. B This particular coil has 18 poles to produce 25 amps at 28 or more volts A.C. when the engine is running at 3600 rpm.
ELECTRICAL SYSTEMS Purpose Regulator/Rectifier The regulator/rectifier prevents battery boiling by shutting off the current when the battery has reached 14.7 volts. How It Works The voltage regulator rectifies the current so that the battery sees only positive current and voltage. The voltage level across the battery is very near constant because the battery has very low impedance. This regulator/rectifier, like many others, must be connected to the battery to function.
ELECTRICAL SYSTEMS Purpose Clutch This clutch electrically controls the engagement and disengagement of the PTO pulley. Electric How It Works The PTO clutch is composed of three major components: the field, the clutch plate, and the friction plate. The clutch plate always turns with the engine. The field is a coil of wire on an iron core which becomes an electro-magnet when power is applied. The friction plate is the only piece that can slide up and down on the crankshaft axis.
ELECTRICAL SYSTEMS Electric PTO Clutch Removal 5. 1. Remove the PTO clutch anchor bolt. 2. Remove the 4 bolts securing the PTO clutch guard and remove the guard (Figure 135). Rotate the clutch assembly until the anchor will clear the lower clutch guard. Then, slide the clutch assembly off of the crankshaft while holding the 2 clutch halves together (Figure 137). Figure 137 Figure 135 1023-011 3. Disconnect the clutch plug. 4.
ELECTRICAL SYSTEMS Purpose Solenoid The solenoid’s purpose is simply to protect the ignition switch from the high current drawn by the starter motor. How It Works The solenoid has really only two parts. One is a coil of wire wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part is a steel bar type switch. Because it is made of steel it can easily handle the high current loads produced by the starter motor.
ELECTRICAL SYSTEMS Purpose Starter The starter motor pushes the starter pinion into engagement with the flywheel, then rotates the starter motor to start the engine. Electric How It Works The starter motor is really just a collection of simple parts: FIELD: A coil of wire on an iron core that becomes an electromagnet when current is applied. It surrounds the armature. ARMATURE: Eight coils of wire on an iron core that become electromagnets when current is applied.
ELECTRICAL SYSTEMS Purpose Switch PTO/Clutch Typically used to turn on the electric blade clutch and to function as part of the safety interlock system. How It Works Contacts inside this DPDT switch electrically connect various terminals. It is actually just two SPDT switches tripped by a single lever. One of the SPDT switches is connected to the electric PTO clutch. When in the off position, this side of the switch is open. The other half of the switch is used by the safety interlock system.
ELECTRICAL SYSTEMS Purpose Brake Switch Senses the position of the parking brake handle. Insures that the parking brake is applied on start up and that the parking brake is released before operating the unit. How It Works When the brake is applied, both sets of contacts are closed. The contacts connected to the light blue wires are part of the interlock circuit and must be closed to provide ground for the starter solenoid.
ELECTRICAL SYSTEMS Purpose Interlock Module The interlock module monitors the status of the safety switch and prevents the engine from running if an unsafe condition exists. How It Works When the ignition switch is in the “ON” or “START” position, B+ to power the module is supplied to the blue wire from the “A” terminal of the ignition switch. The black wires are connected to the chassis ground and provide B- for the module internal circuit and also for the safety switches.
ELECTRICAL SYSTEMS Purpose Hourmeter The hourmeter keeps track of the amount of hours the engine has been running. How It Works When the ignition switch is in the “ON” position, power is supplied to the + terminal of the hourmeter from the “A” terminal (orange wire) of the ignition switch. When the engine is running, oil pressure closes the oil pressure switch supplying a ground to the - terminal of the hourmeter. Testing Connect B+ to the + terminal and ground to the terminal, the hourmeter should run.
ELECTRICAL SYSTEMS Purpose Motion Control Switch There are two motion control switches - one for each lever. They sense the position of the motion control levers. How It Works Each motion control switch has two pairs of contacts one normally open, one normally closed. When the control handles are out, the contacts connected to the light blue wires are closed providing a ground for the start solenoid. When the handles are in these, contacts are open preventing the starter from cranking.
ELECTRICAL SYSTEMS Key Switch Purpose The key switch provides proper switching of the start, run, stop, and interlock circuits. How It Works Detents inside the switch give it three positions: “OFF”, “RUN”, and “START”. The “START” position is spring loaded so the switch returns to the “RUN” position when the key is released. Testing 1. Disconnect the switch from the wiring harness. 2. Verify the conditions in the table. 3. There should not be continuity between any of the switch terminals and ground.
ELECTRICAL SYSTEMS Purpose Seat Switch To sense when the operator is in position on the seat. How It Works The seat switch is mounted to a spring loaded link so that the switch contacts are open when there is no operator on the seat. When the operator is in position, the linkage allows the switch plunger to extend closing the contacts. Testing With the seat switch removed from the unit, connect an ohmmeter across the contacts. When the plunger is extended, the meter should show continuity.
ELECTRICAL SYSTEMS Purpose Mercury Switch To shut the engine down when the tilt limit has been exceeded. How It Works A small amount of mercury is contained in the switch. When the tilt angle of the unit is less than 60°, the mercury connects the contacts in the switch. When the tilt angle exceeds 60°, the mercury flows away from the contacts causing the switch to open. Testing 1. Connect an ohmmeter across the switch. 2. When the switch is vertical, the meter should show continuity. 3.
ELECTRICAL SYSTEMS Purpose 20 Amp Fuse Fuses are electrical safety valves that protect wiring and electrical components from damage from high current flow by creating an open circuit. Fuses are rated for specific currents (amps). Never connect a jumper wire across a fuse. Never connect additional fuses in parallel. Always use the proper fuse. Always find and correct the reason for a blown fuse. Testing A blade type fuse may be checked visually. If the loop (A) is open, the fuse is blown.
ELECTRICAL SYSTEMS Wiring Harness, Typical Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Qty. 1 1 2 1 1 1 2 2 1 1 6 6 2 1 1 14 4 2 Description Battery Holddown Strap 230 CCA Battery Wing Nut Ground Wire Battery Insulator HH Screw Flat Washer HF Nut Seat Switch Spring Seat Spring Mount HH Screw HF Nut Ignition Key Normally Closed Switch Seat Switch Plate PPH Screw Tapped Plate Blade Type Fuse Mid-Mount Z Service Manual Ref. No. 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 37 Qty.
THIS PAGE INTENTIONALLY LEFT BLANK 7 - 36 Mid-Mount Z Service Manual
492-4758
