Service Manual

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Z Master 500 Series

Gasoline Engine Models

Service Manual

LCE Products

Summary of content (168 pages)

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LCE Products Z Master 500 Series Gasoline Engine Models Service Manual
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ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
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TABLE OF CONTENTS SAFETY INFORMATION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SPECIFICATIONS Kawasaki Liquid Cooled Product Shots . . . . . . . . . . . . . . . Kohler EFI Product Shots . . . . . . . . . . . . . . . . . . . . Kohler Gas Product Shots . . . . . . . . . . . . . . . . . . . . Kawasaki Gas Product Shots . . . . . . . . . . . . . . . . . . . Engines . . . . .
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TABLE OF CONTENTS CHASSIS cont. Motion Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Motion Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 HYDRAULIC SYSTEM Hydrostatic Pump Removal . . . . . Hydrostatic Pump Installation . . . . Wheel Motor Removal . . . . . . . Wheel Motor Installation . . . . . . Adjusting the Handle Neutral . . . . Setting the Hydraulic Pump Neutral . .
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TABLE OF CONTENTS ELECTRICAL cont. Kawasaki A/C (Air Cooled) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Kawasaki L/C (Liquid Cooled) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 6-21 MOWER DECKS/PTO Electric PTO Clutch Removal . . . . Electric PTO Clutch Installation . . . . Mower Deck Removal (52, 60, 72”) . . Mower Deck Installation (52, 60, 72”) . Mower Spindle Removal . . . . . . Mower Spindle Installation . . . . . Mower Spindle Disassembly . . . .
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SAFETY INFORMATION Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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SAFETY INFORMATION SAFETY INFORMATION General Information General Information This symbol means WARNING or This symbol means WARNING or PERSONAL SAFETY INSTRUCTION PERSONAL SAFETY INSTRUCTION - read the instruction because it has to - read the instruction because it has to do with withyour yoursafety. safety.Failure Failuretotocomply comply do with the instruction may result with the instruction may result inin personalinjury injuryor oreven evendeath. death.
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SPECIFICATIONS Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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SPECIFICATIONS Kawasaki Liquid Cooled Product Shots 2 2-2 Fig 001 DSC-2861a Fig 003 DSC-3792a Fig 002 DSC-2860a Fig 004 DSC-2864a Z Master 500 Gas Series Service Manual
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SPECIFICATIONS Kohler EFI Product Shots 2 Fig 005 DSC-2865b Fig 007 DSC-2867a Fig 006 DSC-2866a Fig 008 DSC-2868a Z Master 500 Gas Series Service Manual 2-3
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SPECIFICATIONS Kohler Gas Product Shots 2 2-4 Fig 009 DSC-2870a Fig 011 DSC-2875a Fig 010 DSC-2869a Fig 012 DSC-2874a Z Master 500 Gas Series Service Manual
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SPECIFICATIONS Kawasaki Gas Product Shots 2 Fig 013 DSC-2877a Fig 015 DSC-2880a Fig 014 DSC-2879a Fig 016 DSC-2882a Z Master 500 Gas Series Service Manual 2-5
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SPECIFICATIONS Engines 2 Output Make High Idle Low Idle Charging Coil 20 HP (14.9kW) Kohler OHV V-Twin Air Cooled 3750 +50/-100 RPM 1500 RPM 15 AMP 23 HP (17.2 kW) Kohler OHV V-Twin Air Cooled 3750 +50/-100 RPM 1500 RPM 15 AMP 25 HP (18.6 kW) Kawasaki OHV V-Twin Air Cooled 3750 +50/-100 RPM 3000 + 100 Int’l 1500 RPM 13 AMP 27 HP (20.1 kW) Kohler OHV V-Twin Air Cooled 3750 +50/-100 RPM 1500 RPM 15 AMP 27 HP (20.
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SPECIFICATIONS Dimensions and Weight ROPS Height Model Width Weight Folded Upright Deck Deflector Length 23 hp Kohler/52” TF Deck 1140 lbs (517kg) 53” (134cm) 72” (183cm) 53.7” (136cm) 68” (173cm) 79.5” (202cm) 23 hp Kohler/60” TF Deck 1215 lbs (551kg) 53” (134cm) 72” (183cm) 61.7” (157cm) 76” (193cm) 81.5” (207cm) 25 hp Kawasaki/60” TF Deck 1215 lbs (551kg) 53” (134cm) 72” (183cm) 61.7” (157cm) 76” (193cm) 81.
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SPECIFICATIONS Traction System 2 Hydraulic Pumps Twin Hydro-Gear BDP/PJ Series variable displacement hydrostatic with shock valves Pump Drive Self-tensioning belt drive Wheel Motors Twin Parker-Ross Torqmotor™ positive displacement with 1.25 inch heavy duty tapered shafts Ground Speeds Infinitely variable: Forward: 0 - 10 mph (16.1 km/hr) Reverse: 0 - 6.3 mph (10.1 km/hr) Release Valves Contained in pumps.
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SPECIFICATIONS Cutting Decks Configuration Side discharge, mid-mounted rotary with three blades. Construction 7 gauge, high strength 50,000 psi steel, 5-1/2” deep, advanced, super flow system, welded construction. 3/8” steel discharge reinforcement plate doubles as bagger attachment point. Discharge Right hand as viewed from operator seat. Rubber chute, spring biased down toward operating position. Adjustable flow control baffle. Blade Tip Speed 18,000 + ft/min at high idle 152cm mower – 4600.
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SPECIFICATIONS General Specifications Greasing and Lubrication: Grease: No. 2 general purpose lithium base or molybdenum grease. Where to Add Grease: See Check Service Reference Aid decal below (Fig. 017). 2 Fig 018 1. Cap 2. Baffle Fig 017 fig. 55 m-5615 3. Cold fluid level - full 4. Hot fluid level - full fig. 50 decal Hydraulic System Oil Capacity: 4 quarts (3.
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SPECIFICATIONS Model and Serial Number Location The unit model and serial number plate is located on the right hand side of the unit, below the right side motion control lever (Fig. 019). 2 Fig 019 DSC-2351 Fig 020 configuration Engine Model and Serial Number Identification: Consult the appropriate engine manufacture’s service literature for the location and translation of the engine model and serial number information. Hydrostatic Pumps Model and Serial Number: The label above (Fig.
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SPECIFICATIONS Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. 2 These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts (SAE J995 Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) In-lb # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24
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SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size 2 Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m M10 X 1.
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SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread 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 1/64 0.015625 0.397 0.03125 0.794 3/64 0.046875 1.191 0.0625 1.588 5/64 0.078125 1.984 1/32 2 1/16 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 2.381 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.21875 5.556 0.234375 5.953 0.2500 6.350 0.265625 6.747 0.28125 7.144 19/64 0.296875 7.541 0.3125 7.541 21/64 0.
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SPECIFICATIONS U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.9078 0.4536 28.
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SPECIFICATIONS 2 THIS PAGE INTENTIONALLY LEFT BLANK.
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CHASSIS Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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CHASSIS Caster Fork Assembly Removal 4. Remove the Belleville washers and caster fork and wheel assembly (Fig. 023). 1. Raise the front of the unit off the ground, allowing enough clearance to remove the castor fork from the bottom of the hub. 2. With a hammer and chisel, remove the top grease cap (Fig. 021). 3 Fig 023 DSC-1533 Replacing the Caster Bearings Fig 021 mvc-1531 1. Remove the top tapered roller bearing (Fig. 024). 3. Remove the locknut (Fig. 022).
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CHASSIS 2. Remove bottom seal and tapered roller bearing (Fig. 025). Fig 025 4. With a driver and hammer, install new tapered bearing cups. The bearing cups are tapered; make sure the tapered/thicker end of the cup is installed inward for the top and bottom end (Fig. 027). Tap the bearing cups in until they seat against the step in the caster hub. 3 DSC-1535 3. With a driver and hammer, remove both the bottom and top tapered bearing cups (Fig. 026). Fig 027 DSC-1537 5.
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CHASSIS 6. Install the lower bearing and seal, with the open end of the seal facing up (Fig. 029). 2. Install the upper bearing. 3. Install the Belleville (spring) washers as shown in (Fig. 031). A. Dust Cap B. Locknut C. Spring Washers A B C 3 Fig 029 DSC-1538 Castor Fork Assembly Fig 031 washers line art 1. Install the castor fork into the frame (Fig. 030). 4.
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CHASSIS 5. Remove the plug located on the side of the hub on the frame for the castor fork. Install a grease fitting, and pump grease into the housing until grease is passing through the upper bearing (Fig. 033). Front Wheel Removal and Bearing Replacement 1. Raise the front of the unit off the ground. 2. Remove the wheel bolt from the fork (Fig. 035). 3 Fig 033 DSC-1540 Fig 035 DSC-1543 6. Remove the grease fitting and install the grease plug. 7. Install the grease cap on the caster hub (Fig. 034).
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CHASSIS 4. Pack both tapered wheel bearings. Reassemble per Fig. 036. Pump grease into the wheel bearings through the grease fitting located on the rim (Fig. 037). 3 3. Remove the 4 screws retaining the control panel and control panel shield to the tank (Fig. 039). Fig 039 Fig 037 DSC-3092 DSC-1547 Fuel Tank Removal 4. Carefully remove the control panel and control panel shield by lifting the panel and sliding toward the middle of the unit.
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CHASSIS 6. Located under the rear portion of the fuel tank, remove the 2 nuts, springs, and washers from the fuel tank studs (Fig. 041). 8. Remove the fuel tank from the frame (Fig. 043). Fig 043 Fig 041 DSC-3099 DSC-3095 Note: Rear tire removed for clarity. Left Side Fuel Tank Installation Reverse the order of removal. 7. On the inside of the frame under the rear portion of the fuel tank, remove the nut, spring, and washer from the fuel tank stud (Fig. 042).
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CHASSIS Hood Assembly Removal Hood Assembly Installation 1. Unhook the two rubber latches located on the rear of the hood. Reverse the order of removal. 2. Remove the two hairpins, clevis pins, and washers located in the front left and right lower side of the hood (Fig. 044). Brake Lever Removal 1. Release the parking brake (forward position). 2. Remove the cotter pin and clevis pin from the brake rod yoke (Fig. 046). 3 Fig 044 DSC-1579 3.
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CHASSIS 4. Remove the brake shaft cotter pin (Fig. 048). Fig 048 6. Using a hammer and punch, drive both brake lever control bearings from the brake pivot (Fig. 050). DSC-1620 Fig 050 5. Slide the brake shaft out of the frame pivot bushings (Fig 049). DSC-1622 7. Inspect the brake shaft and bushings for excessive wear. Replace any worn or broken components (Fig. 051). A B Fig 049 DSC-1621 Fig 051 A. Brake lever B. Bushings Z Master 500 Gas Series Service Manual C DSC-1623 C.
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CHASSIS Brake Lever Installation 3. Remove bolts, brake band retainer, spacers, and brake band (Fig. 053). Reverse the order of removal B A Brake Band Removal C 1. Raise the left rear tire off the ground (Fig. 052). D 3 Fig 053 A. 3 Bolts B. Brake Band Retainer Fig 052 DSC-1624 DSC-1626 C. 3 Spacers D. Brake Band Brake Band Installation 1. Install the brake band around the wheel hub (Fig. 054). 2. Remove the four wheel lug bolts.
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CHASSIS 2. Install the 3 bolts, brake band retainer, brake band, and spacers and tighten (Fig. 055). Fig 055 2. On the left side of the machine, remove both clevis spring pins, one from the brake rod and the other from the brake shaft (Fig. 056). 3 DSC-1631 Fig 056 DSC-3100 3. Install tire assembly and the 4 wheel bolts. 3. On the right side remove the clevis spring clip from the brake shaft (Fig. 057). Brake Shaft Removal 1. Raise the rear end of the unit and remove the right and left rear tires.
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CHASSIS 4. On the right side, remove the two bolts and nuts holding the flange bearing (Fig. 058). 3 Fig 058 6. Remove the brake shaft from the left side of the unit (Fig. 060). Fig 060 DSC-3104 5. On the left side, remove the two bolts and nuts holding the flange bearing (Fig. 059). 7. Inspect the brake shaft and flange bearings for excessive wear (Fig. 061). C A C B Fig 061 DSC-3105 A. Brake shaft B. Flange bearings 3-12 D D B Fig 059 DSC-3106 DSC-3107 C. Bolts D.
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CHASSIS Brake Shaft Installation Reverse the order of removal. 3. If an adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 062). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on the opposite side of the unit. Adjusting the Parking Brake 4. Turn the nuts clockwise to shorten the spring length and counterclockwise to lengthen the spring. Check the parking brake for proper adjustment. 5.
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CHASSIS 3. With the mower deck in the transport position, place a 4”x 4” block under each corner of the deck. Lower the mower deck onto the support blocks to remove the weight from the support chains (Fig. 064). 5. Remove hex nut from RH rear deck lift assembly. Repeat procedure for LH rear deck lift assembly (Fig. 066). 3 Fig 066 Fig 064 DSC-1650 DSC-1648 4. Loosen jam nuts on deck lift rods until deck support springs are fully extended. Repeat procedure for both deck lift rods (Fig. 065). 6.
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CHASSIS 7. Remove hex bolt, nut, and lift lever bushing from the lower deck lift plate mounting location (Fig. 068). Fig 068 DSC-1652 8. Loosen the top hex head flange nut at the deck lift plate mounting location. Pivot the INNER deck lift plate up and back toward the RH motion control lever (Fig. 069). 9. Lift the floor pan assembly to its fully opened position (Fig. 070). Fig 070 10.
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CHASSIS 11. Remove retainer clip from lift lever grip assembly (Fig. 072). 3 Fig 072 DSC-1656 12. When removing the lift lever grip assembly, you may experience interference with the RH floor pan hinge or the front edge of the RH motion control plate, or both (Fig. 073). A 13. If the lift lever grip assembly contacts the RH floor pan hinge, loosen the RH floor pan hinge mounting hardware. Push the RH hinge upward. Re-tighten the RH floor pan hinge mounting hardware (Fig. 074). Fig 074 14.
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CHASSIS 15. Carefully slide the lift lever grip assembly out of its carrier frame pivot (Fig. 076). Fig 076 DSC-1667 Deck Lift Lever Installation 2. Install lift lever grip assembly into front frame pivot location (Fig. 078). Fig 078 DSC-1670 3. Install retainer clip to lift lever grip assembly (Fig. 079). 1. For ease of installation, make sure deck lift arm plates, bushing, and hardware are installed on the lift lever grip assembly prior to installation (Fig. 077).
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CHASSIS 4. Install bushing into rear lift arm cross shaft (Fig. 080). 6. Rotate deck lift plate (inner) downward until lower mounting holes line up with hole in carrier frame and deck lift plate (outer). From the outside of the frame, install hex bolt, spacer, and flanged lock nut as shown. Tighten bolt (Fig. 082). A B C A 3 Fig 080 DSC-1674 A. Bushing Fig 082 5. Install hex bolt through deck lift plates and rear lift arm cross shaft bushing. Install nylock nut and tighten (Fig. 081). A.
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CHASSIS 8. Raise lift lever grip assembly until deck mount swivels rest against deck rod jam nuts. Install HOC pin into deck lift plate height of cut holes that correspond to the 3” (7.62cm) HOC position (Fig. 084). A 10. Install Hex nut on end of deck lift rod. Tighten against deck mount swivel. Repeat procedure for opposite side deck lift rod (Fig. 086). B 3 Fig 086 Fig 084 A. Rear deck mount swivel DSC-1681 B. HOC Pin 9. Install lower “stop” bolt through inner and outer deck lift plates.
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CHASSIS 12. Untie the floor pan assembly and lower. Return motion control lever to its neutral locked position. 3. Remove (4) pocket mounting bolts (Fig. 090). Motion Control Assembly Removal 1. Remove both floor pan assembly hinge bolts (Fig. 088). 3 Fig 090 DSC-3108 4. Remove pocket (Fig. 091). Fig 088 DSC-1686 2. Remove floor pan assembly (Fig. 089).
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CHASSIS 5. Remove the two bolts retaining the lever assembly to the control arm shaft (Fig. 092). Fig 092 DSC-2062 6. Disconnect Motion Control Dampener from motion control assembly (Fig. 093). Fig 093 Z Master 500 Gas Series Service Manual DSC-1695 7. Disconnect neutral switch wire harness from neutral switch (Fig. 094). Fig 094 DSC-3110 8. Remove bolt and nut that retains the ball joint to the motion control (Fig. 095).
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CHASSIS 9. Remove the cotter pin and clevis pin through the adjustable yoke for the neutral return bolt (Fig. 096). 3 Fig 096 11. Remove the two bolts and nuts that retain the flange bearing on the outside of the motion control (Fig. 098). DSC-2064 Fig 098 10. Remove the two bolts and nuts that retain the flange bearing on the inside of the motion control (Fig. 097). Fig 097 DSC-2066 DSC-2067 12. Remove the motion control from the frame (Fig. 099).
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HYDRAULIC SYSTEM Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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HYDRAULIC SYSTEM Hydrostatic Pump Removal Note: Cleanliness is a key factor in a successful repair of any hydrostatic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals. Protect all exposed sealing areas and open cavities from damage and foreign material. 4. Lift the engine shield.
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HYDRAULIC SYSTEM 6. Remove bolt, washer, and nut located between ball joint and control arm that retains the tracking link rod to the hydro control arm (Fig. 103). 8. Remove the hose clamp around the case drain hydraulic hose, located on the left side of the hydrostatic pump (Fig. 105). Note: It may be necessary to move the hydro lever forward in order to remove the bolt. A Fig 105 Fig 103 DSC-2998 A. Case drain hose clamp 4 DSC-2994 7.
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HYDRAULIC SYSTEM 10. Loosen and remove the two bolts and nuts retaining the hydrostatic pump to the frame (Fig. 107). Hydrostatic Pump Installation Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 1. Install the hydrostatic pump to the frame. Install and tighten the two bolts and nuts (Fig. 109). Fig 107 DSC-3000 Note: Engine shield removed for clarity. 4 11.
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HYDRAULIC SYSTEM 3. Install the case drain hose and hose clamp onto the pump case drain fitting, located around the left side of the hydrostatic pump (Fig. 111). Fig 111 5. Install the bolt, washer, and nut between the ball joint and control arm to secure the tracking link rod to the hydro control arm (Fig. 113). Tighten the bolt and nut. DSC-2998 Fig 113 4. Install the two high pressure hydraulic lines, located at the bottom of the hydrostatic pump (Fig. 112). DSC-2994 4 6.
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HYDRAULIC SYSTEM Apply some anti-seize compound to the shaft (Fig. 114). Install the pulley to the shaft. Fig 114 8. Using a pry bar, release the spring tension on the idler assembly and install the pump drive belt (Fig. 116). DSC-3066 Fig 116 4 7. Align the outer edge of the hydrostatic pump pulley, using a straight edge, to the outer edge of the engine drive pulley (Fig. 115). Tighten the two set screws once alignment is achieved. DSC-3068 Note: The engine shield has been removed for clarity. 9.
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HYDRAULIC SYSTEM 10. Install the battery positive and then the negative cable to the battery. 3. Apply the parking brake and remove the cotter pin from the wheel motor output shaft (Fig. 119). 11. Check the hydraulic fluid in the reservoir tank. Add oil if necessary. Air will need to be purged in the system. Follow procedures on Purging the Hydraulic System, page 4-18. 12. Check the neutral adjustment. Follow procedures on Adjusting the Handle Neutral, page 4-12.
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HYDRAULIC SYSTEM 5. Remove the 3 bolts securing the brake band to the actuator (Fig. 121). 7. Install wheel puller on to the hub and remove the hub from motor output shaft (Fig. 123). Note: Toro Wheel Puller, P/N TOR 4097, is available through SPX (formerly OTC) 1-800-533-0492. Fig 121 4 DSC-3072 Fig 123 DSC-3074 6. Remove the brake band from the hub (Fig. 122). 8. Clean any dirt or debris away from the hydraulic line fittings. Remove the hydraulic lines.
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HYDRAULIC SYSTEM 9. Remove the front two wheel motor bolts, lock washers, spacers, and nuts (Fig. 125). Fig 125 11. Remove the back two bolts, lock washers, spacers, and nuts and remove the wheel motor from the frame (Fig. 127). DSC-3076 Fig 127 10. Swing the brake linkage forward out of the way of the wheel motor. It may be necessary to loosen the back two bolts to remove the spacers (Fig. 126). DSC-3078 4 12.
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HYDRAULIC SYSTEM Note: There are two different spacers used on the wheel motors (Fig. 128). The short spacers are used in the front of the wheel motors(with the brake linkage) and the long spacers are used to retain the back of the wheel motor. A 2. Align the brake linkage with the two front bolt holes (Fig. 130). B Fig 130 4 Fig 128 A. Front Spacer (short) DSC-3081 DSC-3079 B. Back Spacer (long) 3.
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HYDRAULIC SYSTEM 4. Torque the bolts to 80 to 90 ft-lbs. (108 to 122 Nm) (Fig. 132). 6. Install wheel hub assembly, making sure the woodruff key is in place (Fig. 134). Note: It is recommended to replace the wheel hub assembly prior to installation. Fig 132 DSC-3085 Fig 134 DSC-3087 5. Install and tighten the two hydraulic lines to the wheel motor (Fig. 133). 7. Install the nut on the wheel motor shaft, DO NOT tighten (Fig. 135).
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HYDRAULIC SYSTEM 8. Install spacers, brake band retainer, and brake band around the wheel hub and tighten all three retainer bolts (Fig. 136). 10. Check the park brake and adjust park brake if necessary. Refer to Adjusting the Parking Brake, page xxx. 11. Install rear wheel and wheel lug nuts and tighten. 12. Reconnect the battery negative cable to the battery. 13. Check the hydraulic fluid in the reservoir tank. Add oil if necessary. Air will need to be purged in the system.
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HYDRAULIC SYSTEM 5. Move the lever to the neutral position but not locked (Fig. 138). Fig 138 1. 2. 3. 4. 5. 6. Clevis pin in slot Nut against yoke Adjustment bolt Pump rod Double nuts Jam nuts fig. 59 m-6278 7. 8. 9. 10. 11. Spring Pivot shaft Yoke Locknut Ball joint 6. Pull lever back until the clevis pin (on arm below pivot shaft) just begins to contact the end of the slot (just beginning to put pressure on the spring) (Fig. 138). 7.
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HYDRAULIC SYSTEM Setting the Hydraulic Pump Neutral Note: Adjust handle neutral before making the following adjustment. See Adjusting the Handle Neutral, page 4-12. 3. Disconnect the electrical connector at the switch, located between the frame cross member and the hydraulic tank. Temporarily install a jumper wire across the terminals in the wiring harness connector (Fig. 141). Note: This adjustment must be made with the drive wheels turning. 1.
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HYDRAULIC SYSTEM 2. Adjust the pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or slightly creeping in reverse (Fig. 142). Setting the LH Hydraulic Pump Neutral 1. Loosen the locknuts at the pump ball joint on the motion control rod (Fig. 143). Fig 142 DSC-3117 Fig 143 3. Move motion control lever forward and reverse, then back to neutral. Wheel must stop turning or slightly creep in reverse. 4. Open engine throttle to fast.
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HYDRAULIC SYSTEM 3. Adjust pump rod length by rotating the double nuts in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 144). Fig 144 Adjusting the Tracking The right hand pump has a knob for adjusting the tracking (Fig. 145). DSC-3120 Fig 145 4 4. Move the motion control lever forward and reverse, then back to neutral. The wheel must stop turning or slightly creep in reverse. 5. Open the throttle to fast.
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HYDRAULIC SYSTEM 2. Stop the machine and set the parking brake. Replacing the Pump Drive Belt 3. Unlatch the seat and tilt the seat forward to access the tracking knob. 1. Pull the spring loaded idler down and remove traction belt from the engine and hydro pump pulleys (Fig. 148). Remove belt between the pulleys. Note: Determine the left and right sides of the machine from normal operating position. 4. To make the machine go right, turn the knob towards the right side of the machine (Fig. 147).
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HYDRAULIC SYSTEM Purging the Hydraulic System The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system. 1. Raise the machine so the wheels are off the ground and supported with jack stands (Fig. 150). 3. When the wheel begins to spin on its own, keep it engaged until the wheel drives smoothly (minimum 2 minutes). 4. Check the hydraulic fluid level and add fluid as required to maintain proper level. 5.
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HYDRAULIC SYSTEM 2. Clean any dirt or debris away from the hydraulic line fittings. Remove the hydraulic lines. Make sure you mark which hydraulic line goes to which fitting on the wheel motor. If the hydraulic lines are reversed, the motor will operate in the opposite direction. Note: Make sure you cap the fittings to prevent dirt from entering the system (Fig. 153). Fig 153 4. Check the hydraulic reservoir and fill as needed with Mobil 1, 15w50 oil. 5.
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HYDRAULIC SYSTEM 11. With the unit at full engine throttle speed, slowly rotate the “T” handle of the flow tester restrictor valve clockwise until the pressure gauge reads approximately 1000 to 1200 psi (69 to 83 bar). CAUTION: DO NOT operate the machine for extended period of time at high pressure. 12. Record the difference or “flow droop” of the pump. For the Hydro-Gear BDP 10A and BDP 12 pump, maximum allowable “flow droop” is 1.5 gpm. Any droop greater than 1.5 gpm (6.
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HYDRAULIC SYSTEM Changing to Machine Operation 1. Rotate the bypass valves clockwise 1 turn to operate the machine (Fig. 157). Note: Do not over-tighten the by-pass valves. Fig 157 4 DSC-3130 Note: The machine will not drive unless the by-pass valves are turned in.
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HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
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ENGINE Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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ENGINE Kohler Air-Cooled Engine Removal 4. Remove the air cleaner end cap and slide the air cleaner assembly out of the bracket (Fig. 160). 1. Remove the battery negative cable from the battery. 2. Remove the bolt, spacer, spring, and nut on the top of the air cleaner bracket (Fig. 158). Fig 160 Fig 158 5 DSC-2956 DSC-2958 5. Loosen the clamps and remove the throttle and choke cable from the engine control levers (Fig. 161). 3. Remove the air cleaner hose on the engine (Fig. 159). A B Fig 161 A.
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ENGINE 6. Remove the tie strap securing the choke/throttle cables to the bracket located on the valve cover (Fig. 162). 8. With a pry bar, relieve spring tension on the idler assembly and remove pump drive belt (Fig. 164). Fig 164 Fig 162 DSC-2963 DSC-2961 7. Turn the fuel shut off valve OFF. Remove the fuel line hose clamp at the engine and remove the fuel line (Fig. 163). 9. Remove two red cables from the starter solenoid (Fig. 165).
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ENGINE 10. Remove the blue wire from the starter solenoid (Fig. 166). Fig 166 12. Unplug the electric PTO clutch harness from the clutch. Remove the tie strap holding the clutch wire to the PTO stop rod (Fig. 168). DSC-2965 Fig 168 11. Unplug the engine wiring harness from the main electrical harness (Fig. 167). DSC-2966 13. Remove the mower drive belt from the electric PTO clutch, refer to Replacing the Mower Belt page 7-24. 14. Remove the 4 engine mounting bolts, spring washers, and nuts.
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ENGINE 15. Connect lift chains/straps to the engine lift brackets. Raise the engine from the frame of the unit (Fig. 170). Fig 170 3. Install the mower drive belt around the electric PTO clutch; refer to Replacing the Mower Belt page 7-24. 4. Plug the electric PTO clutch harness into the clutch (Fig. 172). Secure the clutch wire to the PTO stop rod with a tie strap. DSC-2969 Kohler Air-Cooled Engine Installation 1. Lower the engine to the frame of the unit. 2.
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ENGINE 6. Attach the two red cables to the starter solenoid (Fig. 174). 8. Install the fuel line to the engine and install a hose clamp. Turn the fuel shut off valve to the ON position (Fig. 176). A B Fig 174 DSC-2964 Fig 176 7. Install hydrostatic pump drive belt, using a pry bar to relieve the tension on the spring loaded idler pulley (Fig. 175). 5 A Fuel Valve DSC-2971 B Fuel Line Clamp 9. Install the throttle and choke cables to the throttle linkage.
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ENGINE 10. Secure the throttle and choke cables to the bracket located on the engine valve cover with a tie strap (Fig. 178). 12. Install the bolt, spacer, spring, and nut on the top of the air cleaner bracket and tighten (Fig. 180). Fig 180 Fig 178 DSC-2956 DSC-2972 11. Install the air cleaner assembly through the air cleaner assembly bracket and install the air cleaner end cap (Fig. 179). 13. Install the hose to the engine and tighten the hose clamp (Fig. 181).
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ENGINE Kawasaki Air-Cooled Engine Removal 3. Loosen the throttle and choke cable clamps and disconnect both cables (Fig. 183). 1. Remove the battery negative cable from the battery. 2. Remove the air cleaner cover (Fig. 182). Note: This engine has a standard air cleaner cover. If engine is equipped with a heavy duty air cleaner assembly, remove the complete air cleaner assembly. A B Fig 183 A. Choke Cable Fig 182 DSC-2973 DSC-2975 B. Throttle Cable 4.
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ENGINE 5. Disconnect the electric PTO clutch wire from the clutch (Fig. 185). 9. Disconnect three wires going from the main harness to the engine (Fig. 187). • Violet wire to the Regulator/Rectifier • White wire to the Engine Magneto wire • Pink wire to the Fuel Solenoid A Fig 185 C DSC-2977 6. Remove the tie strap securing the electric PTO clutch wire to the PTO stop bracket. 7. Remove the mower drive belt from the electric PTO clutch; refer to Replacing the Mower Belt page 7-24. 8.
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ENGINE 11. With a pry bar, relieve tension on the spring loaded idler and remove the pump drive belt (Fig. 189). Fig 189 DSC-2982 12. Remove the 4 engine bolts, spring washers, and nuts mounting the engine to the frame. There are two ground wires located on the left front engine mount bolt (Fig. 190). 13. Connect a lift chain to the lift points on the engine. Raise the engine from the frame (Fig. 191). Fig 191 DSC-2984 Kawasaki Air-Cooled Engine Installation 1. Lower the engine to the frame of unit.
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ENGINE Note: The front left engine mounting bolt has two ground cables (Fig. 192). Tighten the bolts. 5. Connect the three wires going from the main harness to the engine (Fig. 194). • • • Violet wire to the Regulator/Rectifier White wire to the Engine Magneto wire Pink wire to the Fuel Solenoid A Fig 192 C DSC-2983 3. Install the mower drive belt around the electric PTO clutch, refer to Replacing the Mower Belt page 7-24. 4. Plug the electric PTO clutch harness into the clutch (Fig. 193).
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ENGINE 7. Install the fuel line to the engine and tighten the hose clamp. Turn the fuel shut off valve ON (Fig. 196). A 9. Connect the throttle and choke cables to the engine control linkage. Position the throttle control in the idle position. Make sure the choke lever is pushed down to the “Off” position when connecting the cable. Tighten both cable clamps (Fig. 198). A B Fig 196 A Fuel Valve B DSC-2985 B Fuel Line Clamp Fig 198 8.
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ENGINE 11. Install the engine air cleaner cover on the engine Fig. 200). 2. Loosen the hose clamp on the air intake hose (Fig. 201). Note: This unit has a standard air cleaner assembly. Fig 201 Fig 200 DSC-2883 DSC-2973 12. Install the battery negative cable to the battery. 3. Loosen and remove the bolt, spacer, spring, and nut retaining the air cleaner assembly to the air cleaner bracket (Fig. 202). 13. Test operate engine; adjust choke and throttle cables as required.
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ENGINE 4. Remove the air cleaner cap and slide the air cleaner assembly out of the air cleaner bracket (Fig. 203). Fig 203 DSC-2885 5. Remove the fuel line clamp located on the engine fuel rail and remove hose (Fig. 204). 6. Remove the tie strap securing the throttle cable to the bracket on the valve cover (Fig. 205). Fig 205 DSC-2887 7. Remove the throttle cable from the engine throttle linkage (Fig. 206).
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ENGINE 8. Remove the tie strap securing the fuel pump and electric clutch harness to the AC voltage wires coming from the stator (Fig. 207). 10. Remove the tie strap securing the electric PTO wires to the electric PTO clutch stop (Fig. 209). Fig 209 Fig 207 DSC-2909 DSC-2889 9. Unplug the electric clutch harness from the electric clutch (Fig. 208). 11. Remove the mower deck drive belt. Note: Refer to Mower Deck Removal page 7-8. 12. Using a pry bar, release tension on the Hydro pump drive belt.
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ENGINE 13. Remove the 3 red wires located at the starter solenoid (Fig. 211). Fig 211 15. Remove the ground cables located on the lower left side of the base of the engine (Fig. 213). One bolt goes into the side of the engine block and the other is the engine mounting bolt and nut. DSC-2894 Fig 213 14. Remove the blue wire from the starter solenoid (Fig. 212). DSC-2901 16. Disconnect the engine harness connector from the main wiring harness (Fig. 214).
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ENGINE 17. Remove the wire clamp bolted to the frame, located on the left side of the engine (Fig. 215). Fig 215 DSC-2904 18. Remove the wire connector located at the bottom of the ECU (Electronic Control Unit). First, remove the red retainer clip (Fig. 216). Next, remove the multi-pin connector from the ECU (Fig. 217). Fig 217 DSC-2908 19. Remove the wire clip located on the side of the ECU that retains the test plug connector (Fig. 218).
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ENGINE 20. Remove the two fuse holders, located in front of the ECU unit (Fig. 219). 22. Unplug the tan wire connector (Fig. 221). ECU Fig 221 Fig 219 DSC-2915 hidden fuses 21. Unplug the left and center relay from their connectors. Remove 2 bolts and nuts retaining the connectors to the frame (Fig. 220). 23. Remove the remaining 3 bolts, washer, and nuts retaining the engine to the frame (Fig. 222). Raise the engine out of the frame.
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ENGINE 28 HP Kohler EFI Air-Cooled Engine Installation 3. Install the two left relays to the frame using two bolts and washers (Fig. 224). Plug the remaining two relays into the harness. 1. Lower the engine to the frame. Install 2 bolts, washers, and nuts on the right side of the engine. On the left side, mount only the bolt, washer, and nut to the rear engine mount. Tighten the bolts. 2. Connect the two tan wires, one from the engine harness and the other from the main harness (Fig. 223).
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ENGINE 5. Install the clamp holding the test plug connector to the side of the ECU control (Fig. 226). Fig 226 DSC-2910 6. Install a tie strap around the electric PTO harness and the PTO electric clutch stop rod (Fig. 227). 7. Install the wire connector to the bottom of the ECU (Fig. 228). Fig 228 DSC-2908 Install the red retainer clip on the wire connector (Fig. 229).
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ENGINE 8. Install the wire clamp to the frame on the left side of the engine (Fig. 230). Fig 230 DSC-2904 9. Connect the engine harness connector to the main harness (Fig. 231). 10. Install the two sets of ground wires on the left side of the engine as shown (Fig. 232). Fig 232 DSC-2901 11. Install the blue wire to the starter solenoid terminal (Fig. 233). 5 A Fig 231 DSC-2903 Fig 233 DSC-2895 A.
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ENGINE 12. Install three red wires to the starter solenoid stud (Fig. 234). 14. Install the mower deck drive belt around the electric PTO clutch. Refer to Replacing the Mower Belt page 7-24. 15. Install the PTO clutch harness to the PTO clutch (Fig. 236). Fig 234 DSC-2894 13. Install the hydro pump drive belt, using a pry bar to relieve the spring tension on the idler pulley (Fig. 235). Fig 236 DSC-2891 16.
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ENGINE 17. Install the throttle cable to the engine throttle linkage. Make sure the throttle contacts the stop with the throttle control lever in the full speed position. Tighten throttle housing clamp (Fig. 238). 19. Install the fuel line to the engine fuel rail. Tighten the fuel line clamp (Fig. 240). Fig 240 Fig 238 DSC-2920 DSC-2888 18. Fasten the throttle cable to the engine lift bracket using a tie strap (Fig. 239). 20. Slide the air cleaner assembly into the air cleaner bracket (Fig. 241).
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ENGINE 21. Install the air cleaner assembly and air cleaner cap. Install the bolt, spacer, spring and nut to the air filter bracket. Tighten the bolt (Fig. 242). Kohler Electronic Fuel Injection (EFI) Models EFI Fuel System For engine specific service or diagnostics procedures, consult the engine manufacture’s service manual. The following are the locations of components which are EFI related but mounted to the unit’s chassis. 1.
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ENGINE 2. High pressure fuel filter is located under the seat behind the hydraulic reservoir (Fig. 245). EFI Electrical System 1. The electronic control unit (ECU) is located next to the engine starter, on the left rear side, mounted to the frame (Fig. 247). B A Fig 245 DSC-2951 3. Dual flow fuel valve is located under the seat, mounted to the frame (Fig. 246). Fig 247 A. ECU unit DSC-2950 B. ECU test plug 2.
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ENGINE The purpose of the TVS diode is to protect the ECU unit from any high voltage spikes in the electrical system, typically associated with the engagement and disengagement of the PTO clutch (Fig. 249). 3. Remove the right and left hair pins, washers and clevis pins securing the hood. Remove the hood assembly (Fig. 251). Fig 251 Fig 249 4. Remove 4 bolts, washers, and nuts retaining the engine shield. Remove the engine shield (Fig. 252). 27 HP Kawasaki Liquid-Cooled Engine Removal 5 1.
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ENGINE 5. Remove the air deflector (Fig. 253). Fig 253 7. Drain the engine coolant through the engine drain port, located on the engine block, next to the engine oil filter (Fig. 255). DSC-2804 Fig 255 6. Using a pry bar, relieve the idler pulley spring tension and remove the pump drive belt (Fig. 254). DSC-2806 8. Remove the tie strap from the overflow hose located next to the radiator cap (Fig. 256).
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ENGINE 9. Remove the radiator inlet hose located on the right side of the radiator (Fig. 257). Fig 257 DSC-2808 10. Remove the radiator outlet hose, located on the left rear of the radiator (Fig. 258). 11. Unplug the wire connector for the cooling fan (Fig. 259). Fig 259 DSC-2812 12. Remove the 3 bolts, washers, and nuts retaining the fan mounting plate (Fig. 260).
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ENGINE 13. Remove the 2 bolts, washers, and nuts on the right and left side of the fan mounting plate (Fig. 261). Fig 261 DSC-2813 14. Remove the fan mounting plate and radiator (Fig. 262). 15. Remove the hose clamp from the air cleaner assembly (Fig. 263). Fig 263 DSC-2815 16. Remove two bolts, washers, and nuts retaining the air cleaner assembly to the left side radiator brace (Fig. 264). Note: This allows better access to the battery bolt and nut.
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ENGINE 17. Unplug the two relays from the relay connectors. Remove the two bolts and nuts retaining the connectors to the right hand side plate (Fig. 265). Fig 265 DSC-2818 18. Remove the clamp and hose, located under the coolant overflow tank (Fig. 266). 5 Fig 266 19. Remove the two bolts and nuts on the right side of the machine used to hold the top rib to the right side radiator brace (Fig. 267). Remove the corresponding bolts and nuts on the left hand side. Fig 267 20.
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ENGINE 21. Remove the two bolts and nuts retaining the rear radiator mount to the frame (Fig. 269). 23. Loosen the clamps and remove the choke and throttle cables from the engine linkage (Fig. 271). A B Fig 269 DSC-2824 Fig 271 A. Choke Cable DSC-2827 B. Throttle Cable 22. Remove the rear support assembly from the frame (Fig. 270). 24. Release the belt tension on the mower drive belt and remove belt around the electric PTO clutch, follow procedures for Replacing the Mower Belt page 7-24. 25.
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ENGINE 26. Remove the three engine ground cables located on the lower right rear of the engine (Fig. 273). Fig 273 DSC-2829 27. Unplug the orange/black wire to the starter solenoid (Fig. 274). 28. Remove the 3 red wires from the starter solenoid (Fig. 275). Fig 275 DSC-3164 29. Unplug the black and white wiring connector from the wiring harness located on the right front side of the engine (Fig. 276). Note: The other two wiring connectors do not need to be disconnected.
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ENGINE 30. Turn the fuel shut-off valve to the OFF position. 31. Move the hose clamp and disconnect the fuel line on top of the engine (Fig. 277). 27 HP Kawasaki Liquid-Cooled Engine Installation 1. Lower the engine on to the frame. Install 4 bolts and spring washers through the frame and into the base of the engine. Tighten the bolts. 2. Connect the gas line on top of the engine and install the hose clamp (Fig. 279). B A Fig 277 A. Hose clamp DSC-2833 B. Fuel line 32.
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ENGINE 5. Install the 3 red wires to the starter solenoid post and tighten (Fig. 281). Fig 281 DSC-3164 6. Plug the orange/black wire to the starter solenoid (Fig. 282). 7. Install the 3 ground wires to the lower rear of the engine (Fig. 283). Fig 283 DSC-2829 8. Plug the wiring connector to the electric PTO clutch (Fig. 284).
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ENGINE 9. Install the mower drive belt around the electric PTO clutch; follow the procedures for Replacing the Mower Belt page 7-24. 12. Install the rear support assembly to the frame (Fig. 287). 10. Install the choke cable to the engine linkage; make sure the choke knob is pushed all the way in before tightening down the clamp (Fig. 285). Tighten the choke cable clamp. Fig 287 DSC-2826 13. Install two bolts and nuts connecting the rear radiator mount to the frame (Fig. 288). Fig 285 DSC-2838 5 11.
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ENGINE 14. Install the two bolts and nuts retaining the top and bottom strap guard located on the right side (Fig. 289). Install the corresponding bolts and nuts on the left side. 16. Install the hose and clamp, located under the coolant overflow tank (Fig. 291). Fig 291 Fig 289 5 DSC-2823 15. Install the two bolts and nuts located on the right side holding the top rib to the right side radiator brace (Fig. 290). Install the corresponding bolts and nuts on the left hand side.
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ENGINE 18. Install two bolts, washers, and nuts retaining the air cleaner assembly to the left side radiator brace (Fig. 293). 20. Install the fan mounting plate and radiator (Fig. 295). Note: Leave the air filter and air cleaner cover off until after you fill the coolant reservoir bottle. Fig 295 Fig 293 DSC-2817 DSC-2814 21. Install the 2 bolts and washers on the right and left side of the fan mounting plate (Fig. 296). 19.
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ENGINE 22. Install 3 bolts, washers, and nuts to the rear of the fan mounting plate (Fig. 297). Tighten all 7 bolts and nuts. 24. Install the radiator outlet hose clamp located on the left rear of the radiator (Fig. 299). Fig 299 Fig 297 DSC-2809 DSC-2841 23. Connect the wiring for the cooling fan (Fig. 298). 25. Install the radiator inlet hose and clamp located on the right side of the radiator (Fig. 300).
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ENGINE 26. Install the overflow hose next to the radiator cap with a tie strap (Fig. 301). Fig 303 Fig 301 DSC-2853 27. Add a 50-50 mix of water and coolant to the radiator (Fig. 302) and the overflow bottle (Fig. 303). Fill to the line indicator of the overflow bottle. DSC-2855 28. Install the air filter and air cleaner cover. 29. With a suitable pry bar, relieve the spring tension on the idler pulley spring and install the hydraulic pump drive belt (Fig. 304).
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ENGINE 32. Install the engine hood assembly with 2 clevis pins, washers, and hair pins (Fig. 307). 30. Install the air deflector (Fig. 305). Fig 305 DSC-2804 Fig 307 31. Install the engine shield with 4 bolts, washers, and nuts and tighten (Fig. 306). DSC-2802 33. Install the rear bumper guard (Fig. 308). 5 Fig 306 DSC-2803 Fig 308 DSC-2800 34. Install the battery and connect the positive and then the negative battery cable. 35. Test operate engine; adjust choke and throttle cables as required.
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ENGINE Cooling Fan Assembly Removal 27 HP Kawasaki Liquid-Cooled Engine 4. Remove the crossbar located across the front of the radiator (Fig. 311). 1. Disconnect the negative battery cable. 2. Unlatch and open the engine hood. Remove the right and left hair pins located on the hood. Remove the hood assembly (Fig. 309). A Fig 311 DSC-2844 A. Crossbar support 5. Unplug the wire connector for the cooling fan (Fig. 312). Fig 309 DSC-2800 5 3.
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ENGINE 6. Drain the engine coolant through the engine drain bolt located on the engine block next to the engine oil filter (Fig. 313). 8. Remove the radiator inlet hose, located on the right side of the radiator (Fig. 315). Fig 315 Fig 313 DSC-2808 DSC-2806 7. Remove the tie strap around the overflow hose located next to the radiator cap (Fig. 314). 9. Remove the radiator outlet hose, located on the left rear of the radiator (Fig. 316).
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ENGINE 10. There are 6 bolts and washers located under the radiator retaining the radiator to the fan mounting plate. Remove all 6 bolts and washers. Remove the radiator (Fig. 317). Fig 317 DSC-2845 11. Remove the 4 bolts, washers, and nuts retaining the fan assembly to the fan mounting plate assembly (Fig. 318). 12. Before removing the fan assembly, remove two clamps located on the upper engine air duct. Remove the engine air intake duct (Fig. 319). Fig 319 DSC-2848 Note: Fan removed for clarity.
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ENGINE THIS PAGE INTENTIONALLY LEFT BLANK.
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ELECTRICAL Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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ELECTRICAL GENERAL Location Note: Interactive Electrical Troubleshooting CD, Form #492-9143 is also available. Air-Cooled Engine Models: Two relays located on the left side of the unit, between the engine and the frame (Fig. 321). RELAYS Purpose There are as many as three relays in a Z500 air-cooled or liquid cooled gas machine depending on model. B A Relays have 4 functions in the Z500 gas machine: 1. Start Relay 2. Kill Relay 3. Fan Relay (liquid cooled gas only) 4.
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ELECTRICAL Liquid-Cooled Engine Model: Three relays located on the right rear radiator support arms, next to the ROPS (Fig. 323). 1. Coil: Terminals 85 and 86 are connected to an internal coil. Applying 12 volts to either terminal energizes the coil turning it into an electromagnet. 2. Switch: Terminals 30, 87, and 87a are actually part of a single pole, double throw (SPDT) switch. Terminal 30 is the common lead.
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ELECTRICAL Testing 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 327). 1. Disconnect the relay from the harness. 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be from 70 to 90 ohms. There should be continuity between terminals 87a and 30 (Fig. 326). 85 87 87a 30 Fig 327 Relay not energized. 86 Fig 326 xl relay relay pin diagram PTO SWITCH Purpose 3.
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ELECTRICAL Location Testing The PTO switch is located in the control panel on the left side of the operator (Fig. 328). 1. Disengage the PTO, set the parking brake, and turn the ignition to the “OFF” position. Remove the key. 2. Remove the 4 screws holding the control panel to the fuel tank. 3. Disconnect the wiring harness from the PTO switch. 4. Press in the locking tabs, on each side of the switch, and pull the switch out of the control panel. 5.
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ELECTRICAL IGNITION SWITCH How It Works Purpose Detents inside the switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released (Fig. 331). The ignition switch provides the proper switching for the starter, accessories, and safety circuits. Location A B The ignition switch is located on the control panel, to the left side of the operator (Fig. 330).
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ELECTRICAL NEUTRAL SAFETY SWITCH Purpose Used to ensure the motion control handles are in neutral to start the unit. It is activated by moving the motion control handles to the neutral position (handles in the out position). This single pole plunger (normally open) type switch has two terminals. When the motion control handles are in the neutral position (handles in the out position), it pushes on the plunger, closing the contact, and connecting the terminals (Fig. 333).
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ELECTRICAL PARK BRAKE SWITCH How It Works Purpose In the start position it is used to ensure the park brake is “ON”. At the same time it allows current to flow through for the safety circuit. When the park brake is released in the “OFF” position it bypasses both neutral switches as long as the operator is in the seat thereby maintaining current for the safety circuit (Fig. 335).
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ELECTRICAL 2. Using a multimeter, follow the procedures listed below (Fig. 336). SEAT SWITCH Purpose A C B D The switch is in the safety circuit. If the engine is running and the operator vacates the seat with either the PTO engaged or the parking brake off, the engine will shut down. Note: With a delay module in the system, there will be a slight delay before the engine shuts down after the operator vacates the seat.
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ELECTRICAL For all models equipped with a standard seat, the seat switch is located between the frame cross-member and the rear of the hydraulic oil tank (Fig. 338). (Standard seat switch shown.) (Fig. 340) Fig 340 Fig 338 DSC-3154 DSC-3151 Testing How It Works 1. Disconnect the switch from the wiring harness. When the seat is vacated, the switch is open and there should be NO continuity between the two terminals.
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ELECTRICAL SEAT DELAY MODULE How It Works Purpose The seat delay module circuit board is made up with several different electrical components such as transient voltage suppressor, capacitor, transistors, carbon film resistors, diodes and a relay. The components work together to allow any short term voltage interruption in the seat switch and supplies temporary voltage to the safety circuit to keep the engine running (Fig. 342).
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ELECTRICAL 2. Remove the 4 bolts to the pocket. Remove the pocket. TEMPERATURE GAUGE Liquid-Cooled Engine Only 3. Connect a VOM positive lead to the violet wires on the module (Fig. 344). Connect the negative lead to the battery negative terminal. Purpose The purpose of the temperature gauge is to monitor the engine coolant temperature. Location The temperature gauge is located on the left side of the operator on the control panel (Fig. 345). Fig 344 6 DSC-3158 4.
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ELECTRICAL How It Works Testing When the engine coolant temperature increases the sending unit resistance decreases, which causes the needle on the water temperature gauge to increase (Fig. 346). Time-efficient testing is not possible. See information under Temperature Sender, page 6-14. Back side of the Temperature Gauge with terminal and wire locations (Fig. 347).
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ELECTRICAL TEMPERATURE SENDER Testing Purpose It is not practical to test the sender in a shop environment. If the gauge is not reading at all, temporarily ground the lead at the sender. If the meter reads full scale, the ground wire and gauge are OK and the sender is bad. If the gauge does not respond, check for 12 VDC at gauge and continuity of the ground lead. If OK, the gauge is bad. Erratic readings can be either the gauge or sender. Replace the sender first, when diagnosing.
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ELECTRICAL How It Works VOLTMETER GAUGE Since a normal clock might be affected by variations in voltage and current, the hour meter is made up of an electric “winder” and a mechanical clock movement. When power is applied, a coil is energized to wind the movement. The movement unwinds in about 2 seconds. As it finishes its rotation, it re-energizes the coil so that the cycle can start over (Fig. 350). Purpose This gauge indicates the voltage across the battery.
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ELECTRICAL Testing Location 1. Remove the control panel from the tank by removing 4 screws. The electric clutch is located on the PTO end of the crankshaft (Fig. 352). 2. With a VOM, place the negative probe to the battery negative cable. Turn the ignition key to the RUN position. 3. Place the positive probe of the meter to the I (orange wire) terminal. You should read the DC battery voltage level on the meter. 4. Move the positive probe of the meter to the G (black wire) terminal.
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ELECTRICAL Testing Measuring Clutch Current Draw If the electric PTO clutch does not engage or is suspect as the cause of an electrical problem in the PTO circuit, use the following troubleshooting steps to determine whether the clutch has failed or another electrical problem exists. 1. Disengage the PTO, set the parking brake, turn the ignition key to OFF, and remove the key. 2. Loosen 4 bolts and remove the rear bumper plate loosening 4 bolts. 3. Disconnect the electric PTO clutch wire connector.
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ELECTRICAL Kohler EFI (Electric Fuel Injection) 6 6-18 Z Master 500 Gas Series Service Manual
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BK BK BN GND PTO CLUTCH VIO (NEUTRAL) SW5 W VIO Y SHOWN WITH LEVER IN NEUTRAL POSITION SHOWN WITH LEVER IN NEUTRAL POSITION Y SHOWN IN OFF POSITION GY SW4 (NEUTRAL) SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) BN SW2 (PTO) OR BK P1–B T K2 (START RELAY) P2–C Y SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT SW7 (TILT SW) SWITCH OPENS WHEN TILTED PAST 60 DEGREES FROM VERTICAL P1–A DELAY MODULE 100–6186 P1–C PK B KEY SW S I TERMINAL VIEW FROM BACK OF SWITCH A Y X NO CONNECTION
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GND BK BK PTO CLUTCH BN VIO VIO Y SHOWN WITH LEVER IN (NEUTRAL) NEUTRAL POSITION SW5 W SHOWN WITH SW4 LEVER IN (NEUTRAL) NEUTRAL POSITION SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) Y SHOWN IN OFF POSITION GY BN SW2 (PTO) OR BK P1–B T Y K2 (START RELAY) P2–C GY BN HOUR METER GY PK OR BN PK PK SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT SW7 (TILT SW) SWITCH OPENS WHEN TILTED PAST 60 DEGREES FROM VERTICAL TERMINAL VIEW FROM BACK OF SWITCH P1–A DELAY MODULE 100–6186 P1–C PK S
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ELECTRICAL Kawasaki L/C (Liquid Cooled) 6 Z Master 500 Gas Series Service Manual 6-21
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ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK.
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MOWER DECKS/PTO Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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MOWER DECKS/PTO Electric PTO Clutch Removal The electric PTO clutch removal and installation are similar on both the air cooled engine models and the liquid cooled model. The only difference is the clutch guard removal. The figure below points to the bolts that need to be removed in both units (Fig. 355). The procedure shows an air-cooled unit. This procedure is on the Air Cooled Engine Models and follows the same procedure for the Liquid Cooled Engine Model. 1.
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MOWER DECKS/PTO 3. Disconnect the electric PTO clutch connector from the clutch (Fig. 359). Fig 359 DSC-3135 4. Lift the floor pan and remove the right side mower belt cover (Fig. 360). Fig 360 Z Master 500 Gas Series Service Manual DSC-3136 5. Loosen the two nuts located on the idler plate to relieve tension on the belt (Fig. 361). Fig 361 DSC-3137 6. Slip the mower drive belt off the right mower spindle pulley (Fig. 362).
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MOWER DECKS/PTO 7. Remove the belt from the electric PTO clutch (Fig. 363). Fig 363 DSC-3139 8. Remove the electric PTO clutch bolt (Fig. 364). 9. Remove the electric PTO clutch from the engine crankshaft (Fig. 365). Fig 365 DSC-3141 Electric PTO Clutch Installation 1. Apply anti-seize compound to the engine crankshaft (Fig. 366).
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MOWER DECKS/PTO 2. Install the electric PTO clutch to the engine crankshaft (Fig. 367). Fig 367 4. Install the mower drive belt around the electric PTO clutch pulley (Fig. 369). Fig 369 DSC-3141 3. Apply medium strength threadlocking material to the bolt. Install the bolt and two spring washers to the crankshaft. Torque the bolt to 65 ft. lbs (88.13 Nm) (Fig. 368). DSC-3144 5.
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MOWER DECKS/PTO 6. Route the belt around all of the mower deck pulleys and install the belt around the right side mower spindle pulley (Fig. 371). 7. Install a 1/2” ratchet and extension, into the square hole in the idler plate (Fig. 373). Fig 373 Fig 371 DSC-3147 DSC-3146 Important: Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Figure 372. 8.
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MOWER DECKS/PTO 9. Tighten the pivot bolt on the idler plate once the adjustment is achieved (Fig. 375). Fig 375 11. Install the right belt cover on the mower deck. 12. Install the right and left top strap guards, with the clutch guard to the unit (Fig. 377). DSC-3149 Fig 377 10. Connect the PTO clutch connector to the clutch (Fig. 376). DSC-3134 13. Install and tighten the two bolts and nuts on the top strap guards and the two bolts in the clutch guard (Fig. 378).
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MOWER DECKS/PTO Mower Deck Removal (52, 60, 72”) 3. Slip the mower drive belt off the right mower spindle pulley (Fig. 381). 1. Lift the floor pan and remove the right hand belt cover (Fig. 379). Fig 381 Fig 379 DSC-3138 DSC-3136 4. Remove the belt around the electric PTO clutch pulley and the two rear idler pulleys (Fig. 382). 2. Loosen the two nuts located on the idler plate to relieve tension on the mower drive belt (Fig. 380).
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MOWER DECKS/PTO 5. Raise the mower deck to the transport position. Install a 4 x 4 wood block under the right side of the mower deck. Lower the deck to relieve tension on the lift chains on the right side (Fig. 383). 7. Remove the bolt and nut holding the right rear strut pin into the strut assembly (Fig. 385). Fig 385 Fig 383 DSC-2623 6. Remove the front and rear lift chains from the mower deck (Fig. 384). 8.
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MOWER DECKS/PTO Tie strap the strut assembly up so it will be out of the way of the mower deck when sliding it out under the frame. Remove the 4 x 4 block of wood from the right side of the deck and allow the deck to rest on the floor. 10. Push the lift handle to the lowest HOC position to overcome the tension of the lift assist springs. Use the hitch pin above the lift handle to lock the handle in the down position (Fig. 388). 9. Raise the deck to transport position.
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MOWER DECKS/PTO 13. Turn the right front wheel so the caster fork is angled forward. This will allow more clearance to slide the mower deck from under the frame (Fig. 389). Mower Deck Installation (52, 60, 72”) 1. Slide the mower deck under the unit. 2. Install a 4 x 4 block of wood under the left side of the mower deck (Fig. 391). Fig 389 DSC-2637 14. Slide the mower out the right side of the unit (Fig. 390). Fig 391 DSC-2635 3. Install the strut pin through the strut assembly.
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MOWER DECKS/PTO 4. Install the rear and front chains to the mower deck (Fig. 393). Fig 393 11. Install the belt around the electric PTO clutch pulley (Fig. 394). DSC-2640 Fig 394 DSC-3139 Note: Clutch guard removed for clarity. 5. Remove the hitch pin on the lift handle and raise the mower in the transport position. 6. Install a 4 x 4 wood block under the right side of the mower deck. 12.
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MOWER DECKS/PTO 13. Route the belt around all of the mower deck pulleys and install the belt around the right side mower spindle pulley (Fig. 396). 14. Install a 1/2” socket ratchet and extension, in the square hole in the idler plate (Fig. 398). Fig 398 Fig 396 DSC-3147 DSC-3146 Important: Check the amount of twist in the belt between the pulleys. Make sure it is only what is specified in Fig. 397 below. 15.
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MOWER DECKS/PTO 16. Tighten the pivot bolt on the idler plate once the adjustment is achieved (Fig. 400). Fig 400 DSC-3149 17. Install the right belt cover on the mower deck. 5. Lift the floor pan and remove the right side mower belt cover (Fig. 401). Fig 401 DSC-3136 6. Loosen the two nuts located on the idler plate to relieve tension on the belt (Fig. 402). Mower Spindle Removal This applies to removing any of the three mower spindles. This procedure shows removing the right side spindle. 1.
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MOWER DECKS/PTO 7. Slip the mower drive belt off the left mower spindle pulley (Fig. 403). 9. Raise the mower deck to the transport position. 10. Remove the mower blade from the spindle assembly. 11. Remove the 6 bolts and nuts from the spindle assembly. Remove the spindle assembly (Fig. 405). Fig 403 DSC-3138 8. Remove three bolts retaining the pulley to the pulley hub (Fig. 404). Fig 405 DSC-2666 Mower Spindle Installation Reverse the order of mower spindle removal.
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MOWER DECKS/PTO Mower Spindle Disassembly 3. Remove the bearing shield (Fig. 408). 1. Remove the nut and washer (Fig. 406). Fig 408 Fig 406 DSC-2671 DSC-2669 4. Remove the spindle housing from the spindle shaft assembly (Fig. 409). 2. Remove the pulley hub and square key (Fig. 407).
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MOWER DECKS/PTO 5. Remove the seal spacer from the top of the spindle housing (Fig. 410). Fig 410 DSC-2673 6. Remove the seal spacer from the bottom of the spindle housing (Fig. 411). Fig 411 Z Master 500 Gas Series Service Manual DSC-2674 7. Remove the top oil seal from the spindle housing (Fig. 412). Fig 412 DSC-2675 8. Remove the tapered roller bearing from the top of the spindle housing (Fig. 413).
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MOWER DECKS/PTO 9. Remove the spindle spacer (Fig. 414). Fig 414 11. Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing (Fig. 416). Note the orientation of the lower oil seal. The open end of the seal faces outwards to help relieve pressure from over-greasing the spindle assembly. DSC-2677 10. Remove the split ring (Fig. 415). Fig 416 DSC-2679 12. Remove the tapered roller bearing from the bottom of the spindle assembly (Fig. 417).
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MOWER DECKS/PTO 13. Using a hammer and a driver with a square edge, drive both the top and bottom bearing races out of the spindle housing (Fig. 418). 15. This view shows the 2 bearing races and the large spacer in the spindle housing (Fig. 420). Note the internal snap ring in the housing, it is not necessary to remove when installing new bearing races and the spacer. A B Fig 418 A DSC-2681 Fig 420 14. Remove the large spacer in the spindle housing (Fig. 419). A. Bearing race DSC-2684 B.
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MOWER DECKS/PTO 2. Using a press, install the upper bearing race into the spindle housing (Fig. 422). 4. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig. 424). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing. Fig 424 Fig 422 DSC-2689 3. Turn the spindle housing over and install the lower bearing race with a press (Fig. 423). DSC-2691 5. Install the lower seal (Fig. 425).
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MOWER DECKS/PTO 6. Using a seal driver, drive or press the seal on the lower end of the spindle housing until the seal is flush with the outer edge of the housing (Fig. 426). Fig 426 DSC-2693 7. Turn the spindle assembly over and install the split ring spacer (Fig. 427). Fig 427 Z Master 500 Gas Series Service Manual DSC-2699 8. Install the inner spacer to the spindle assembly (Fig. 428). Fig 428 DSC-2700 9. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig. 429).
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MOWER DECKS/PTO 10. Install the seal. Press it flush with the top of the housing (Fig. 430). 12. Lower the spindle housing over the spindle shaft (Fig. 432). Note: The open lip of the seal faces inward. Fig 432 Fig 430 DSC-2696 11. Install the bearing shield and the seal spacer onto the spindle shaft (Fig. 431). 7 13. Install the seal spacer on the top of the spindle housing (Fig. 433).
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MOWER DECKS/PTO 14. Install the bearing shield (Fig. 434). Fig 434 16. Install the pulley hub on the spindle shaft (Fig. 436). DSC-2705 15. Install the square key onto the spindle shaft (Fig. 435). Fig 436 DSC-2707 17. Install the heavy washer and nut on the top of the spindle shaft (Fig. 437). Note: The cup side of the washer should be facing down toward the pulley hub.
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MOWER DECKS/PTO 18. Torque the top nut to 100 to 120 ft. lbs. (Fig. 438). Fig 438 3. Remove the belt covers (Fig. 439). Fig 439 DSC-2709 1. Belt cover fig. 71 m-6824 2. Latch Replacing the Mower Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. 4.
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MOWER DECKS/PTO 5. Install the new mower belt around the mower spindle pulleys, mower idler pulley, into the belt guides, into rear idler arm assembly, and the clutch (Fig. 441). Adjusting the Mower Belt Tension 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower to the transport position.
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MOWER DECKS/PTO 4. Check the belt tension. The spring loaded idler center bolt needs to be near the top alignment hole in left support plate (light contact with the rubber stop) (Fig. 443). Fig 443 1. Center bolt 2. Alignment hole fig. 72 m-4417 3. Left support plate 4. Spring loaded idler 9. Check the distance from the rubber stop and the arm of the spring loaded idler pulley when the idler plate is tightened. Light contact should be made between the idler arm and the rubber stop (Fig. 444).
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MOWER DECKS/PTO 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Fig. 445). Leveling the Mower Setting up the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check the tire pressure of all four tires. If needed, adjust to 13 psi (90 kPa).
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MOWER DECKS/PTO Leveling the Mower Side-to-Side 1. Position the right blade side-to-side (Fig. 447). 3. Record this measurement. This measurement needs to be 3-1/8 to 3-1/4 inches (7.9 to 8.3cm). 4. Position the left blade side-to-side refer to Fig. 447. 5. Measure the left blade at the C location (Fig. 447) from level surface to cutting edge of the blade tips (Fig. 448). 6. Record this measurement. The measurement needs to be 3-1/8 to 3-1/4 inches (7.9 to 8.3cm). 7.
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MOWER DECKS/PTO Adjusting the Front-to-Rear Mower Pitch 1. Position the right blade front-to-rear (Fig. 450). 3. Record the measurement. 4. Measure the right blade at the B location (Fig. 450), from a level surface to the cutting edge of the blade tip (Fig. 451). 5. Record this measurement. 6. The mower blade should be a 1/4 to 3/8 inch (6 to 10mm) lower at position A than at position B (Fig. 450). If it is not correct, proceed to the following steps.
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Z Master 500 Series Gasoline Engine Models Service Manual Form No.
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MOWER DECKS/PTO 8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10mm) lower in front A than in the rear at B (Fig. 453). Fig 453 1. 11-1/2” (29.2cm) between the large washers 2. Front nut 3. Spring jam nut fig. 70 m-6831 4. 5. 6. 7. 8. Front swivel Swivel jam nut Lift nut Front support arm Large washer 9. Tighten both swivel jam nuts against the front swivel to lock the height. 10.