LCE Products Z Master Z597 Diesel Series Service Manual
ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
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TABLE OF CONTENTS Safety Information General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Specifications Machine Profile Photos . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Hydraulic System continued Setting the Hydrostatic Pump Neutral . . . Adjusting the Handle Neutral . . . . . . Setting the LH Hydrostatic Pump Neutral . Setting the RH Hydrostatic Pump Neutral . Adjusting the Tracking . . . . . . . . . Hydraulic Flow Testing Procedure . . . . Cooling Fan Pump Flow Testing Procedure Replacing the Traction Pump Drive Belt . . Pushing the Machine by Hand . . . . . . Changing to Machine Operation . . . . . Hydraulic Schematic . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Mower Decks Electric PTO Clutch Removal . . . . . . . PTO Clutch Installation . . . . . . . . . Mower Deck Removal . . . . . . . . . . Mower Deck Installation . . . . . . . . . Mower Spindle Removal . . . . . . . . . Mower Spindle Disassembly . . . . . . . Mower Spindle Assembly . . . . . . . . . Mower Jackshaft Assembly Removal . . . . Mower Jackshaft Installation . . . . . . . Mower Jackshaft and Pulley Assembly . . . Right Hand Mower Idler Assembly Removal .
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SAFETY INFORMATION Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
SAFETY INFORMATION SAFETY INFORMATION The riding mower and attachment operator's manual General Information symbol means WARNING or SAFETY This INFORMATION PERSONAL SAFETY INSTRUCTION - read the instruction because it has to General Information do with your safety. Failure to comply with instruction result inor This the symbol meansmay WARNING personal injury or evenINSTRUCTION death.
SPECIFICATIONS Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
SPECIFICATIONS MACHINE PROFILE PHOTOS 2 2-2 Fig 001 DSC-2789 Fig 003 DSC-2792 Fig 002 DSC-2790 Fig 004 DSC-2794 Z Master Z597 Diesel Service Manual
SPECIFICATIONS Item Specification Engine Briggs & Stratton® Vanguard™ Daihatsu® 27 Horsepower Diesel Engine RPM setting High RPM Setting (no load) 3850 + 50 (International: 3450 + 50) Low RPM Setting 1750 Fuel Capacity 12 gallons (45.4 liters) Diesel Fuel Length Z597 – 60” (152.4cm) TF Deck - 81.5” (207cm) Z597 – 72” (182.9cm) TF Deck - 84.5” (214.6cm) Width Z597 – 60” (152.4cm) TF Deck - 61.7” (156.7cm) - Deflector 76” (193cm) Z597 – 72” (182.9cm) TF Deck - 73.6” (186.9cm) - Deflector 88” (223.
SPECIFICATIONS 2 Item Specification Mower Deck TURBO FORCE Deck Construction Fabricated, High Strength 7-gauge Steel/with Bull-nose Bumper Deck Depth 5 ½” (13.97cm) Mower Baffles Adjustable Discharge Baffle Spindle Housing 9 3/8” (23.8cm) Diameter Cast Iron Spindle Shaft/Bearings 1” (2.54cm) Shaft / Tapered Roller Blade Tip Speed 18,500+ ft/min (5,638+ m/min) Blades ¼” (.635cm) Heat Treated Steel Discharge Chute 5/16” (.79cm) Rubber Cutting Height 1-1/2” – 5” (3.81 - 12.
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. 2 Fig 006 1. Cap 2. Baffle Fig 005 fig. 55 m-5615 3. Cold fluid level - full 4. Hot fluid level - full fig. 50 decal Hydraulic System Oil Capacity: 4 quarts (3.8 l) Fluid Type: Mobil 1 15W – 50 synthetic motor oil or equivalent synthetic oil Fluid Level: Check the fluid level while the fluid is warm.
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. 007). 2 Fig 007 Fig 008 DSC-2351 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.
SPECIFICATIONS Torque Specifications Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
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 N-cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5
SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size 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.
SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 2 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.
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 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 0.328125 8.
SPECIFICATIONS U.S. to Metric Conversions 2 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.
CHASSIS Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
CHASSIS Caster Fork Assembly Removal 3. Remove the locknut (Fig. 010). 1. Raise the front of the unit off the ground, allowing enough clearance to remove the castor fork from the bottom of the hub. 2. With a hammer and chisel, remove the top grease cap (Fig. 009). 3 Fig 010 DSC-1532 4. Remove the Belleville washers, caster fork and wheel assembly (Fig. 011).
CHASSIS Replacing the Caster Bearings 3. With a driver and hammer, remove both the bottom and top tapered bearing cups (Fig. 014). 1. Remove the top tapered roller bearing (Fig. 012). Fig 014 Fig 012 DSC-1534 2. Remove bottom seal and tapered roller bearing (Fig. 013). Fig 013 4. With a driver and hammer, install new bearing cups. The bearing cups are tapered; make sure the tapered/thicker end of the cup is installed inward for the top and bottom end (Fig. 015).
CHASSIS 5. Pack the upper and lower tapered bearings prior to installation (Fig. 016). Castor Fork Assembly 1. Install the castor fork into the frame (Fig. 018). 3 Fig 016 DSC-1539 Fig 018 6. Install the lower bearing and seal, with the open end of the seal facing up (Fig. 017). DSC-1533 2. Install the upper bearing. 3. Install the Belleville (spring) washers as shown in (Fig. 019). A. Dust Cap B. Locknut C.
CHASSIS 4. Install the locknut and tighten until the spring washers are flat, then back off 1/4 turn to properly set the preload on the bearings (Fig. 020). 6. Remove the grease fitting and install the grease plug. 7. Install the dust cap on the caster hub (Fig. 022). 3 Fig 020 DSC-1532 Fig 022 5. Remove the plug located on the side of the hub on the frame for the castor fork. Install a grease fitting. Pump grease into the housing until grease is passing through the upper bearing (Fig. 021).
CHASSIS 3. Remove bearing spacers and the front caster spacer. Remove the seals located on each side of the wheel and both the tapered bearings (Fig. 024). A. Bearing Spacer B. Bearing Seal C. Taper Bearing D. Caster Spacer E. Retaining wheel nut F. Retaining wheel bolt Fuel Tank Removal Right Side Fuel Tank Removal 1. Disconnect the negative battery cable. Empty the fuel tank. 2. Remove the fuel hose at the bottom of the fuel tank (Fig. 026). A B C C 3 B A D F E Fig 024 DSC-1546 4.
CHASSIS 4. Remove the front bolt, spacer, washer, and nut that secure the fuel tank bracket to the frame (Fig. 028). Fig 028 DSC-1550 5. Remove the bolt, washer, and nut securing the left rear of the fuel tank bracket to the frame (Fig. 029). 6. Remove bolt, washer, and nut securing the right rear of the fuel tank bracket to the frame (Fig. 030). Fig 030 7. Remove the tank from the frame (Fig. 031).
CHASSIS 8. Remove the fuel tank bracket by removing 3 locknuts and springs and 1 bolt (Fig. 032). Right Side Fuel Tank Installation Reverse the order of removal. Note: When tightening the nuts and springs on the fuel tank bracket, Do Not over-tighten the nuts. Tighten the nuts until there are three threads showing on the threaded stud (Fig. 033). A B 3 Fig 032 DSC-1556 D C E Fig 033 A. Tank Stud B. Compression Spring C. Tank mounting Plate 3 thread above nut D. Nut E.
CHASSIS 2. Remove the 4 screws retaining the control panel and control panel shield to the tank (Fig. 034). Fig 034 DSC-1563 3. Carefully remove the control panel and control panel shield by lifting the panel and sliding it to the middle of the unit. 5. Remove the return fuel line, located on the inside of the fuel tank (Fig. 036). Fig 036 DSC-1565 6. Remove the fuel line, located under the front of the fuel tank (Fig. 037). NOTE: It is not necessary to disconnect any cables or wiring. 4.
CHASSIS 7. Remove the front bolt, spacer, washer, and nut that secure the fuel tank bracket to the frame (Fig. 038). 3 Fig 038 9. Remove the bolt, washer, and nut that retain the fuel tank bracket to the frame. They are located under the left rear of the fuel tank (Fig. 040). DSC-1568 Fig 040 8. Remove the bolt, washer, and nut that retain the fuel tank bracket to the frame. They are located under the right rear of the fuel tank (Fig. 039). Fig 039 3-10 DSC-1571 DSC-1573 10.
CHASSIS 11. Remove the fuel tank bracket by removing 3 locknuts, springs, and 1 bolt (Fig. 042). Hood Assembly Removal 1. Unhook the two rubber latches located on the rear of the hood. 2. Remove the two hairpins, clevis pins, and washers located in the front left and right side of the hood (Fig. 044). Fig 042 3 DSC-1576 Left Side Fuel Tank Installation Reverse the order of removal. Note: Fig 044 When tightening the nuts and bolts, Do Not over-tighten the nuts.
CHASSIS Hood Assembly Installation 4. Remove the two locknuts and carriage bolts retaining the throttle cable assembly (Fig. 048). Reverse the order of removal. Throttle Control Replacement 1. Disconnect the negative battery cable. 2. Remove the 4 screws retaining the control panel to the fuel tank (Fig. 046). 3 Fig 048 DSC-1591 5. Disconnect the end of throttle cable at the swivel clamp, located on the throttle linkage at the injector pump (Fig. 049). Fig 046 DSC-1584 3.
CHASSIS 6. Loosen the screw on the throttle casing clamp and remove the throttle cable (Fig. 050). Installation 1. Install the throttle control in the control plate. Install the two carriage bolts and nuts and tighten (Fig. 052). Fig 050 3 DSC-1593 7. Keeping the tie straps in place, slide the throttle cable through the two tie straps to remove it from the machine. One tie strap is located at the radiator fan motor mount, Ref. A, and the other is at the engine removal bracket, Ref. B (Fig. 051).
CHASSIS 3. Route the throttle cable through the tie strap located on the engine lifting bracket (Fig. 054). 3 Fig 054 DSC-1599 4. The throttle cable is then routed around the fuel pump injector lines and through the swivel clamp. 5. Install the throttle cable on the inside of the casing clamp, DO NOT tighten (Fig. 056). Fig 056 DSC-1605 6. Install control panel to the fuel tank mount location (Fig. 057).
CHASSIS 7. Install throttle control knob and position throttle control lever to the idle position (Fig. 058). 9. Tighten the cable housing clamp (Fig. 060). Fig 060 Fig 058 8. Position the throttle cable swivel clamp until 1/4” (6.35mm) of the throttle cable wire protrudes through the opposite end of the clamp. Carefully tighten the swivel clamp screw (Fig. 059). 10. Move the throttle control lever to the Full speed position. Verify injector pump arm contacts the high speed stop screw (Fig. 061).
CHASSIS Brake Lever Removal 4. Remove the brake shaft cotter pin (Fig. 064). 1. Release the parking brake (forward position). 2. Remove the cotter pin and clevis pin from the brake rod yoke (Fig. 062). 3 Fig 064 Fig 062 DSC-1618 DSC-1620 5. Slide the brake shaft out of the frame pivot bushings (Fig 065). 3. Lift the floor pan assembly to access the brake lever shaft and cotter pin (Fig. 063).
CHASSIS 6. Using a hammer and punch, drive both brake lever control bearings from the brake pivot (Fig. 066). Brake Lever Installation Reverse the order of removal Brake Band Removal 1. Raise the left rear tire off the ground (Fig. 068). Fig 066 3 DSC-1622 7. Inspect the brake shaft and bushings for excessive wear. Replace any worn or broken components (Fig. 067). Fig 068 2. Remove the four wheel lug bolts. A B Fig 067 A. Brake Lever B. Bushings DSC-1624 C DSC-1623 C.
CHASSIS 3. Remove bolts, brake band retainer, spacers, and brake band (Fig. 069). A. B. C. D. 2. Install the 3 bolts, brake band retainer, brake band, and spacers and tighten (Fig. 071). 3 Bolts Brake Band Retainer 3 Spacers Brake Band B A C D 3 Fig 071 Fig 069 DSC-1626 DSC-1631 3. Install tire assembly and the 4 wheel bolts. Brake Cross Shaft Removal Brake Band Installation 1. Install the brake band around the wheel hub (Fig. 070). 1.
CHASSIS 2. Remove the clevis spring pin from the brake rod and remove the rod (Fig. 072). 4. On the right side, remove the cotter pin and clevis pin from the lower brake linkage assembly (Fig. 074). Fig 072 Fig 074 DSC-1632 3. Remove the cotter pin and clevis pin from the left side lower brake linkage assembly (Fig. 073). Fig 073 Z Master Z597 Diesel Service Manual DSC-1633 DSC-1634 5. On the right side, remove the two bolts and nuts holding the flange bearing (Fig. 075).
CHASSIS 6. On the left side, remove the two bolts, spacers, and nuts holding the flange bearing (Fig. 076). 8. Inspect brake shaft and flange bushings for excessive wear (Fig. 078). A C B D 3 Fig 076 DSC-1636 7. Remove the brake shaft from the frame (Fig. 077). D Fig 078 A. RH Mounting Bolts B. Brake Shaft C. LH Mounting Bolts E DSC-1638 D. Flange Bearing E. Spacers Brake Shaft Installation 1. Install the flange bearing on the right side of the shaft.
CHASSIS 2. Install the flange bearing over the left side of the brake shaft, flange facing outward. Install mounting bolts from the outside of the flange, through brake retainer spacers, and through the frame. Note: 3. Install clevis pin connecting the lower brake assembly to brake shaft. Install cotter pin into clevis pin (Fig. 081). Repeat procedure for right side. Before tightening the mounting hardware, be sure that the brake lever arm is pointing upward between the mounting hardware (Fig. 080).
CHASSIS Adjusting the Parking Brake 3. If an adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 083). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on the opposite side of the unit. Check the parking brake for proper adjustment. 1. Disengage the brake lever (lever down). 2. Measure the length of the spring. The measurement should be 2-3/4” (70mm) between the washers (Fig. 083). 11 5.
CHASSIS Deck Lift Lever Removal 4. Loosen jam nuts on LH and RH deck lift rods until deck support springs are fully extended (Fig. 086). 1. Park the machine on a level surface, disengage the blade control (PTO), and turn the ignition key to OFF to stop the engine. Remove the ignition key. 2. Remove the lower stop bolt from the deck lift plate (Fig. 084). Fig 086 Fig 084 DSC-1647 DSC-1649 5. Remove hex nut from RH rear deck lift assembly. Repeat procedure for LH rear deck lift assembly (Fig. 087). 3.
CHASSIS 6. Lower lift lever to its lowest position. Rear deck swivel mounts should clear deck lift rods on both sides. The mower deck lift linkage should now be fully unloaded (Fig. 088). 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. 090). A 3 Fig 088 DSC-1651 Fig 090 DSC-1653 A. Lift Lever at lowest position 7.
CHASSIS 10. Remove hex bolt, bushing, and nylock nut connecting the deck lift arm plates to the mower deck rear cross-shaft lift assembly (Fig. 092). 12. When removing the lift lever you may experience interference with the RH floor pan hinge or the front edge of the RH motion control plate, or both (Fig. 094). A Fig 092 B 3 DSC-1655 Fig 094 11. Remove retainer clip from lift lever (Fig. 093). A. RH Floor pan hinge DSC-1657 B. RH Motion control plate 13.
CHASSIS 14. If the lift lever contacts the RH motion control plate, tilt and hold the floor pan assembly slightly forward. Move the RH motion control lever out of the neutral lock position and push it in the full forward position. Using a tie strap or wire, tie the floor pan assembly to the motion control arm to hold the floor pan assembly in place (Fig. 096). Deck Lift Lever Installation 1.
CHASSIS 3. Install retainer clip to lift lever shaft (Fig. 100). 5. Install hex bolt through deck lift plates and rear lift arm cross shaft bushing. Install nylock nut and tighten (Fig. 102). A Fig 100 A B 3 DSC-1672 Fig 102 4. Install bushing into rear lift arm cross shaft (Fig. 101). A. Rear Lift Arm Plates DSC-1675 B. Hex Bolt 6. Rotate deck lift plate (inner) downward until lower mounting holes line up with hole in carrier frame and deck lift plate (outer).
CHASSIS 7. Align rear deck mount swivels with ends of deck lift rod (Fig. 104). 3 Fig 104 9. Install lower “stop” bolt through inner and outer deck lift plates. Install nylock nut and tighten until hex nut and bolt are seated firmly against the deck lift plates. DO NOT over-tighten or deck lift plates will deform inward causing height of cut hitch pin assembly to bind (Fig. 106). DSC-1680 8. Raise lift lever until deck mount swivels rest against deck rod jam nuts.
CHASSIS 11. Raise mower deck to the transport position. Remove support blocks. Check deck level adjustment (refer to the Leveling the Mower procedure, pg 7-46). Readjust compression spring length by turning front nut. Spring should be compressed to a length of 11-1/2” (29.2cm) between washers. Lock the front nut into position by tightening the spring jam nut (Fig. 108). Motion Control Assembly Removal 1. Remove both floor pan assembly hinge bolts (Fig. 109). 3 Fig 109 Fig 108 DSC-1685 DSC-1686 2.
CHASSIS 3. Remove (4) pocket mounting bolts (Fig. 111). 3 Fig 111 5. Remove the two bolts retaining the lever assembly to the control arm shaft (Fig. 113). DSC-1690 Fig 113 4. Remove pocket (Fig. 112). Fig 112 6. Disconnect motion control dampener from motion control assembly (Fig. 114).
CHASSIS 7. Disconnect neutral switch wire harness from neutral switch (Fig. 115). Fig 115 DSC-1693 8. Remove bolt, spacer, and nut that retains the ball joint to the motion control (Fig. 116). Fig 116 Z Master Z597 Diesel Service Manual DSC-2063 9. Remove the cotter pin and clevis pin through the adjustable yoke for the neutral return bolt (Fig. 117). Fig 117 DSC-2064 10. Remove the two bolts and nuts that retain the flange bearing on the inside of the motion control (Fig. 118).
CHASSIS 11. Remove the two bolts and nuts that retain the flange bearing on the outside of the motion control (Fig. 119). Motion Control Assembly Installation Reverse the order of removal 3 Fig 119 DSC-2067 12. Remove the motion control from the frame (Fig. 120).
HYDRAULIC SYSTEM Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
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.
HYDRAULIC SYSTEM 6. Remove the case drain hydraulic hose, located on the left hand side of the hydrostatic pump (Fig. 124). Note: When removing hydraulic hoses from the pump, cap the hose and the fitting on the hydrostatic pump. This is to make sure dirt and debris does not enter these areas. 7. Remove the two hydraulic hoses on the bottom of the hydrostatic pump that go to the hydraulic motor (Fig. 125). Install caps on the hydraulic hoses and fittings.
HYDRAULIC SYSTEM 9. Using a 12-point 3/8” socket, loosen the two set screws located on the hydro pump hub Slide the hydrostatic pump hub and pulley off the hydrostatic pump shaft. Remove the key on the hydrostatic pump shaft (Fig. 127). 11. Cut the two cable ties that hold the fuel line and the wiring harness (Fig. 129). Fig 129 Fig 127 4 DSC-2092 DSC-2089 12. Remove the hydrostatic pump from the frame (Fig. 130). 10.
HYDRAULIC SYSTEM Hydrostatic Pump Installation Note: Prior to connecting the hydraulic lines, replace the O-Rings with new ones and lightly lubricate with petroleum jelly. 1. Install the hydrostatic pump to the frame. Install and tighten the two bolts and nuts (Fig. 131). Note: Before installing the pulley, replace the set screws. The end of the set screws have a knurled cup point for retention and must not be re-used. 3. Install pulley and hydro pump hub on the hydrostatic pump shaft and key.
HYDRAULIC SYSTEM 5. Install the hydraulic suction line on the top of the hydrostatic pump (Fig. 135). Fig 135 4 DSC-2088 6. Install the two hydraulic hoses that run from the hydraulic wheel motor to the bottom of the hydrostatic pump (Fig. 136). Fig 136 DSC-2098 7. Install the case drain hydraulic line, located on the left hand side of the pump (Fig. 137). Fig 137 DSC-2099 8. Install and tighten the bolt and nut retaining the hydro pump control linkage to the hydro control arm (Fig. 138).
HYDRAULIC SYSTEM 9. Using a 3/8” drive ratchet, insert the wrench into the square hole in the pump belt tensioner arm and relieve the tension to install the hydrostatic pump v-belt (Fig. 139). 11. Install the battery in the unit and connect the positive and negative battery cables. 12. Check the hydraulic fluid in the reservoir tank. Add oil if necessary, refer to Figure 006, page 2-5. Air will need to be purged in the system. Follow the procedures on Purging the Hydraulic System, page 4-13. 13.
HYDRAULIC SYSTEM Wheel Motor Removal 4. Loosen and remove nut securing hub to the wheel motor output shaft (Fig. 144). 1. Disconnect the battery negative cable. 2. Raise the rear wheels of the machine off the ground and support frame with jackstands. Remove the rear wheel (Fig. 142). Fig 144 4 Fig 142 DSC-2102 DSC-2105 5. Remove the 3 bolts securing the brake band to the actuator (Fig. 145). 3. Apply the parking brake and remove the cotter pin from the wheel motor output shaft (Fig. 143).
HYDRAULIC SYSTEM 6. Remove the brake band from the hub (Fig. 146). 8. Clean any dirt or debris away from the hydraulic line fittings. Remove the hydraulic lines. Note: Cap the fittings and hoses to prevent dirt from entering the hydraulic system (Fig. 148). Fig 146 DSC-2107 7. Install a wheel puller on to the hub and remove the hub from the motor output shaft (Fig. 147). Fig 148 DSC-2110 9. Remove the front two wheel motor mounting bolts, lock washers, and nuts (Fig. 149).
HYDRAULIC SYSTEM 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. 150). Wheel Motor 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. Note: There are two different spacers used on the wheel motors (Fig. 152).
HYDRAULIC SYSTEM 1. Install wheel motor in the frame. Loosely install the back two bolts, long spacers, lock washers and nuts (Fig. 153). Fig 153 DSC-2116 2. Align the brake linkage up with the two front bolt holes (Fig. 154). 3. Install the two front bolts, short spacers, lock washers, and nuts through the wheel motor, brake linkage and frame (Fig. 155). Fig 155 DSC-2120 4. Install the two rear bolts and long spacers through the wheel motor and frame. 5. Torque the bolts to 80 to 90 ft-lbs.
HYDRAULIC SYSTEM 6. Install and tighten the hydraulic lines (Fig. 157). Fig 157 8. Install the nut on the wheel motor shaft, DO NOT tighten (Fig. 159). DSC-2123 Fig 159 4 7. Install wheel hub assembly, making sure the woodruff key is in place (Fig. 158). Fig 158 9. Install spacers, brake band retainer, and brake band around the wheel hub and tighten all three retainer bolts (Fig. 160).
HYDRAULIC SYSTEM 10. Install rear wheel and wheel lug nuts and tighten. Purging the Hydraulic System 11. Engage parking brake, torque the wheel hub nut to 125 ft-lbs. (169 Nm) (Fig. 161). Install cotter key through the nut and motor wheel shaft. The hydraulic 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. Note: Re-torque nut at 100 hours, and every 500 hours thereafter.
HYDRAULIC SYSTEM 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. 2. Push down on the pump belt tensioner and remove the drive belt from the pulley on the PTO clutch. Remove the other end of the pump drive belt from the hydraulic pump pulley (Fig. 165). 5. Repeat this procedure on the opposite wheel.
HYDRAULIC SYSTEM 4. Remove the hydraulic pump pulley. Note: It may be necessary to use a puller to remove the pulley (Fig. 167). 5. Disconnect the three hydraulic lines connected to the hydraulic fan pump (Fig. 169). Fig 169 Fig 167 DSC-2362 Note: Cut a piece of cardboard approximately 8” x 18” (20.3 x 45.7cm) to be used as a deflector to channel oil away from the mower drive belt and pulleys located under the hydraulic pump fan (Fig. 168). 6.
HYDRAULIC SYSTEM 7. Remove the hydraulic fan pump from the unit (Fig. 171). Fig 171 4 DSC-2368 Hydraulic Fan Pump Installation 2. Install the three hydraulic lines to the hydraulic fan pump and tighten (Fig. 173). Fig 173 DSC-2366 Note: Prior to connecting the hydraulic lines, replace the O-rings with new ones and lightly lubricate with petroleum jelly. 3. Install the square key in the hydraulic fan pump shaft. Install the fan pump pulley on the shaft.
HYDRAULIC SYSTEM 4. Install pump drive belt around the hydraulic pump pulley. Push down the pump belt tensioner and install the belt around the PTO clutch pulley (Fig. 175). Hydraulic Fan Motor Removal Note: Cleanliness is a key factor in a successful repair of any hydraulic 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.
HYDRAULIC SYSTEM 2. There are 6 bolts and nuts, 3 on each side, retaining the radiator and fan mounting plate assembly to the right and left upper frame assembly. Loosen, DO NOT remove, the two bolts and nuts at the front right and left side; this will allow you to pivot the assembly upward. Remove the rear 4 bolts and nuts (Fig. 178). A A Fig 180 B 4 4. Loosen and remove the clamp on the hydraulic return line located on the left side of the unit (Fig. 180). Fig 178 A. Remove DSC-2371 B.
HYDRAULIC SYSTEM 6. Tilt the fan mounting plate assembly and the radiator up approximately 5” (12.7cm) to get enough clearance to remove the hydraulic motor fan. 8. Loosen and remove the 4 bolts and nuts holding the fan motor mount (Fig. 184). Caution: Do not raise too far, as damage could occur to some of the hydraulic lines and cooling hoses. Use a nylon tie down strap between the fan mounting plate and the center section of the ROPS Bar to hold in place (Fig. 182). Fig 184 DSC-2379 9.
HYDRAULIC SYSTEM 10. With a hex wrench loosen the two set screws on the fan hub and remove the fan (Fig. 186). Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricate with petroleum jelly. 2. Note the location of the hydraulic fittings and install the hydraulic fan motor to the fan motor mount tighten the 4 bolts and nuts (Fig. 188). Fig 186 4 DSC-2382 11.
HYDRAULIC SYSTEM 4. Apply a thread locking compound to the hex set screws and tighten both screws (Fig. 190). 6. Install the 4 bolts and nuts that retain the fan motor mount to the fan mounting plate. Note: Make sure the mounting tab on the fan motor mount is facing toward the left rear of the unit. Before tightening the bolts and nuts, make sure the fan is centered in the middle of the fan shroud. Tighten the bolts and nuts (Fig. 192). A Fig 190 DSC-2396 4 5.
HYDRAULIC SYSTEM 8. Remove the nylon tie strap to lower the fan mounting plate and radiator assembly. Reinstall the 4 bolts and nuts that retain the fan mounting plate to the right and left upper frame and tighten the bolts, including the front two nuts and bolts (Fig. 194). 10. Install clamp, located on the left side of the unit, that retains the hydraulic return line. Tighten the bolt and nut (Fig. 196). Fig 196 4 Fig 194 DSC-2371 9.
HYDRAULIC SYSTEM 12. Install the rear heat shield and tighten the bolts (Fig. 198). Fig 198 DSC-2370 13. Close the engine hood and latch. Start unit up and operate for approximately 5 minutes and check the oil level in the reservoir. 1. Raise the frame and support the machine so drive wheels can rotate freely (Fig. 199). Fig 199 DSC-2352 2. Slide the seat fully forward, unlatch the seat and tilt the seat forward (Fig. 200).
HYDRAULIC SYSTEM 3. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector (Fig. 201). Fig 201 4 3. Unlatch the seat and tilt the seat up. 4. Begin with either the left or right motion control lever. 5. Move lever to the neutral position but not locked (Fig. 202). DSC-2355 Fig 202 Adjusting the Handle Neutral If motion control levers do not align, or move easily into the console notch, adjustment is required.
HYDRAULIC SYSTEM 7. Check where the control lever is relative to notch in console (Fig. 203). It should be centered allowing lever to pivot outward to the neutral lock position. Setting the LH Hydrostatic Pump Neutral 1. Start the engine, open throttle half way and release parking brake. Note: Motion control lever must be in neutral while making any adjustments. 2. Adjust pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or slightly creeping in reverse (Fig. 204).
HYDRAULIC SYSTEM Setting the RH Hydrostatic Pump Neutral 3. Adjust pump rod length by rotating double nuts on rod, in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 206). 1. Loosen the locknuts at the ball joints on pump control rod (Fig. 205). Note: The front nut on the pump rod has left-hand threads. Fig 206 4 Fig 205 DSC-2569 2. Start the engine, open the engine throttle half way and release the parking brake.
HYDRAULIC SYSTEM 7. After both pump neutrals are set, shut off the machine. 8. Remove jumper wire from the harness connector and plug the connector into the seat switch. 1. Push both control levers forward the same distance (Fig. 209). Test operate the machine in an open, flat area. 9. Lower the seat into position. 10. Remove the jack stands. Adjusting the Tracking The left-hand pump has a knob for adjusting the tracking (Fig. 208). Fig 209 DSC-2571 2. Check to see if the machine pulls to one side.
HYDRAULIC SYSTEM 4. To make the machine go right, turn the knob towards the right side of the machine (Fig. 210). Hydraulic Flow Testing Procedure Note: Cleanliness is a key factor in successful flow testing of the hydraulic 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.
HYDRAULIC SYSTEM 2. Clean any dirt or debris away from the hydraulic line fittings. Remove the hydraulic lines. 4. Check the hydraulic reservoir and fill as needed with Mobil 1, 15w-50 oil. Note: Cap the fittings to prevent dirt from entering the hydraulic system (Fig. 212). 5. Disconnect the electric PTO clutch from the wiring harness to prevent accidental engagement of the mower deck (Fig. 214). Fig 212 DSC-2110 Fig 214 3.
HYDRAULIC SYSTEM 7. Verify the restrictor valve on the hydraulic flow tester is in the fully “Opened” position. 8. Start the machine. Run the unit for approximately 5 minutes to warm the oil in the hydrostatic system. 9. Release the parking brake and bring both levers to the inside neutral position. Set the engine throttle to full RPM. Cooling Fan Pump Flow Testing Procedure 1. Raise the seat and disconnect the seat switch plug from the harness. Temporary install a jumper lead into the harness. 2.
HYDRAULIC SYSTEM 5. Remove the hydraulic pressure and return lines at the fan hydraulic motor. Connect the flow meter as shown (Fig. 217). CASE DRAIN TO COOLER Note: If using a directional flow tester, be sure to correctly connect hoses. FAN MOTOR 9. Remove the flow tester from the machine. Reconnect the hydraulic lines to the fan motor. RESUME LINE FROM PUMP RETURN TO PUMP If flow drops more than 1 gpm (3.8 lpm), replace the pump.
HYDRAULIC SYSTEM 2. Using a 3/8” drive ratchet, pull the spring loaded idler toward the right side of the unit and remove the traction belt from the engine and hydro pump pulleys (Fig. 218). 4. Install the 3/8” drive ratchet, pull the spring loaded idler toward the right side of the unit and release the pressure on the spring. 5. Install the front engine panels. Pushing the Machine by Hand Important: Always push the machine by hand. Never tow the machine because hydraulic system damage may occur. 1.
HYDRAULIC SYSTEM Changing to Machine Operation Rotate the by-pass valves clockwise 1 turn to operate the machine (Fig. 221). Note: Do not over-tighten the by-pass valves. Note: The machine will not drive unless the by-pass valves are turned in.
HYDRAULIC SYSTEM HYDRAULIC DIAGRAM 4 4-34 Z Master Z597 Diesel Service Manual
ENGINE Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
ENGINE Engine Removal 4. Remove the hood lanyard from the right and left radiator support bolts (Fig. 224) 1. Disconnect the negative, then the positive battery cable and remove the battery from the unit. 2. Unlatch and open the engine hood. Loosen and remove the rear heat shield from the frame (Fig. 222). Fig 224 DSC-2410 5. Remove the left and right hair pins, the clevis pins and remove the hood (Fig. 225) Fig 222 5 DSC-2370 3. Remove the two knobs located on the engine access panel.
ENGINE DANGER! Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns. 7. At the left rear of machine, remove the tie strap and the clamp holding the engine inlet cooling hose and the overflow hose to the radiator (Fig. 227). • Do not remove radiator cap or open drain petcock when the engine is hot.
ENGINE 5 9. Located on the right side of the fan mounting plate assembly is an access hole to remove the hose clamp for the engine outlet hose, located at the radiator (Fig. 229). Remove the clamp and lower the hose to drain any coolant that is left in the hose. 11. Remove the case drain hydraulic line at the tee fitting, located at the left front corner of the radiator (Fig. 231). A drain pan will be needed to catch any oil from the hydraulic line. Cap the fittings to prevent contamination.
ENGINE 13. Remove the tie strap holding the radiator overflow hose, located at the radiator cap (Fig. 233). 15. Remove the radiator and frame assembly (Fig. 235). Fig 235 Fig 233 DSC-2435 DSC-2434 14. Remove the six bolts, three on each side, retaining the radiator and fan mounting plate assembly to the right and left upper frame (Fig. 234). 16. Install a 3/8” ratchet wrench in the spring loaded idler arm and pull down to remove the pump drive belt from the engine and hydro pump pulleys (Fig. 236).
ENGINE 17. Loosen the hose clamp on the air intake hose and remove the hose from the air filter (Fig. 237). 19. Remove the air cleaner assembly (Fig. 239). Fig 239 Fig 237 DSC-2442 DSC-2440 18. Loosen the outer clamp on the short hose between the intake hood and the air filter. Remove the two bolts and nuts on the air cleaner mount (Fig. 238). 20. Make sure the fuel valve is in the OFF position. Tag or mark the OUT or return fuel line. Loosen the clamps and remove the fuel lines from the engine (Fig.
ENGINE 21. Remove the throttle cable clamp and the throttle casing clamp from the fuel pump injector linkage (Fig. 241). 23. Remove the following wires from the engine: • Dark Blue wire to the oil pressure sending unit (E) • Dark Green wire to the fuel solenoid (F) (Fig. 243). A F B E Fig 241 DSC-2444 Fig 243 A. Throttle Casing Clamp B. Throttle Cable Clamp DSC-2446 24. Remove the bolt that holds the wire clamp located on top of the alternator (Fig. 244). 22.
ENGINE 25. Disconnect the red wire located on top of the alternator and unplug the wiring harness located at the back of the alternator (Fig. 245). 27. Remove the Orange/Black wire and the Red wire to the starter motor. 29. Unplug the jack and plug to the electric PTO clutch. 30. Located below the starter motor are two ground wires bolted to a bracket attached to the engine block. Remove the bolt and nut (Fig. 247). B A Fig 245 DSC-2546 A. Red lead to alternator B.
ENGINE 32. Pull the spring loaded idler down and remove the fan drive belt (Fig. 249). 34. Remove both mower drive belts; refer to Replacing Mower Drive Belts, page 7-41. 35. Located on the left rear side of the engine is a ball joint assembly, between the frame and the engine flywheel cover. Remove the nut holding the assembly to the frame (Fig. 251). Fig 249 DSC-2453 33. Remove the bolt and nut holding the clutch/brake strap and rotate the strap up and out of the way (Fig. 250).
ENGINE 37. Remove the bolt holding the ball joint link to the left front engine bracket (Fig. 253). 39. Repeat the procedure on the right hand engine mount. Note: Before removing the rear engine mount, install engine hoist to the lifting brackets located on top of the engine (Fig. 255). Raise until there is NO slack in the lift chain. Fig 253 DSC-2460 38. On the left side of the engine, remove the bolt, nut and washers from the left hand engine mount (Fig. 254). Fig 255 DSC-2469 40.
ENGINE 41. Carefully lift the engine with the hoist. As the engine is being lifted out, turn it slightly to gain clearance between the engine drive pulley, pump idler pulley, and the RH pump pulley. Also, you may have to turn the engine so the muffler clears the right rear radiator support bracket (Fig. 257). Fig 257 2. Carefully lower the engine into the frame of the unit.
ENGINE 4. Install the right hand engine mount bolt. Note the sequence of the washers from the bottom up: bolt, large washer, and then the small thick washer through the isolator; then a small washer and nut (Fig. 260). Do not tighten the bolt and nut. E A B C F D Fig 260 A. Bolt B. Large washer C. Small thick washer 5 6. Before tightening the bolts and nuts on the engine mounts, check the alignment of the engine drive pulley to the right side pump pulley (Fig. 261).
ENGINE 8. Install the front ball joint link assembly between the frame and the engine bracket (Fig. 262). Follow the hardware sequence in the diagram (Fig. 263). Fig 262 9. Install the rear ball joint assembly between the flywheel cover and the frame (Fig. 264). Follow the hardware sequence in the diagram (Fig. 265). DSC-2484 Fig 264 B B A A DSC-2457 A D E C F E C A G D F G F F H Fig 263 A. B. C. D. Washer Screw HH Ball joint assembly Nut - jam E. F. G. H.
ENGINE 10. Install both the mower drive belts; refer to Replacing Mower Drive Belts, page 7-41. 12. Pull the spring loaded idler down and install the fan drive belt (Fig. 268). 11. Install the bolt, spacer, washers, and nuts holding the clutch/brake strap to the frame (Fig. 266). Follow the hardware sequence in the diagram (Fig. 267). Fig 268 Fig 266 DSC-2488 DSC-2489 13. Secure the two ground wires to the bracket located below the starter motor on the engine (Fig. 269).
ENGINE 14. Connect the electric PTO clutch (Fig. 270). Fig 270 16. Install the bolt holding the bottom of the alternator to the bracket. Install the bolt through the adjusting strap to the alternator (Fig. 272). DSC-2490 Fig 272 15. Install the Orange/Black wire to the starter motor (Fig. 271). DSC-2495 17. Install the alternator belt and follow the instructions for Tensioning the Alternator Belt, page 5-31. 18.
ENGINE 20. Install the following wires to the engine: • Dark Blue to the oil pressure sending unit (E) • Dark Green to the fuel solenoid (F) (Fig. 274). 22. Install the throttle cable; follow instructions under Throttle Control Installation page 3-13. 23. Install the two fuel lines to the injector pump. Make sure you install the tagged or marked fuel line to the Out or return connector (Fig. 276). F UT O E Fig 274 DSC-2446 Fig 276 5 21.
ENGINE 25. Tighten the hose clamps and the two bolts and nuts on the air cleaner mount (Fig. 278). Fig 278 27. Insert a 3/8” ratchet wrench into the spring loaded idler arm. Pull down to install the pump drive belt from the engine to the hydro pump pulleys (Fig. 280). DSC-2441 Fig 280 26. Install the air intake hose between the engine and air filter. Tighten the hose clamps (Fig. 279). DSC-2439 28. Install the radiator and frame assembly to the right and left upper frame (Fig. 281).
ENGINE 29. Install the six bolts, three located on each side, retaining the radiator and fan mounting plate assembly to the right and left upper frame (Fig. 282). Fig 282 DSC-2371 30. Install the radiator overflow hose, located at the radiator cap. Install a tie strap to hold it in place (Fig. 283). 31. Install the tank return hydraulic hose to the radiator. The line is located at the left rear corner of the radiator (Fig. 284). Fig 284 DSC-2433 32.
ENGINE 33. Install the three hydraulic lines to the hydraulic fan motor (Fig. 286). Fig 286 DSC-2500 34. On the right side of the radiator, install the hose for the engine outlet to the radiator. Install the clamp and tighten the clamp through the access hole in the fan mounting plate (Fig. 287). 35. Install the engine inlet hose to the radiator and tighten the hose clamp (Fig. 288) Fig 288 DSC-2425 36.
ENGINE 37. Install coolant in the radiator (Fig. 290), and the overflow bottle (Fig. 291). Fill to the line indicator of the overflow bottle. Refer to Checking the Radiator Coolant, page 5-28. 40. Prime the fuel system; refer to Priming the Fuel System, page 5-34. Start the unit up and run for approximately 5 minutes. 41. Check for any leaks in the hydraulic fluid lines, fuel lines, and the coolant lines.
ENGINE Slip the hood lanyards on the radiator support bolts (Fig. 296). 44. Install the rear heat shield (Fig. 294). Fig 294 DSC-2370 Fig 296 45. Install the engine hood assembly with clevis pins, washers and hairpins (Fig. 295). DSC-2410 Cooling System Removing the Radiator DANGER! Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns.
ENGINE 2. Unlatch and open the engine hood. Loosen and remove the rear heat shield from the frame (Fig. 297). 4. Slide the hood lanyard off the right and left radiator support bolts (Fig. 299). Fig 299 Fig 297 DSC-2410 DSC-2370 3. Remove the two knobs located on the engine access panel. Remove the engine belt shield and the engine access panel (Fig. 298). 5. Remove the right and left hair pins off the clevis pins and remove the hood assembly (Fig. 300).
ENGINE 6. With a drain funnel and pan, open the radiator petcock, located at the lower right hand corner of the radiator, and drain the coolant out of the radiator (Fig. 301). Fig 301 8. Located on the right side of the fan mounting plate is an access hole to remove the hose clamp for the engine outlet hose, located at the radiator (Fig. 303). Remove the clamp and lower the hose to drain any coolant that is left in the hose. DSC-2413 Fig 303 7.
ENGINE 10. Loosen and remove the tank return hydraulic hose from the radiator. This line is located at the left rear corner of the radiator (Fig. 305). Cap the hydraulic fittings to prevent contamination. Fig 305 5 12. Remove 6 bolts and washers located under the fan mounting plate assembly. 3 bolts are located in the front of the fan mounting plate (Fig. 307) and 3 are located in the rear (Fig. 308). These 6 bolts retain the radiator to the fan mounting plate.
ENGINE 13. Remove the radiator from the fan mounting plate (Fig. 309). Fig 309 DSC-2659 Radiator Installation 2. Install the 3 bolts and washers located under the fan mounting plate assembly in the front (Fig. 311). DO NOT TIGHTEN. Fig 311 DSC-2658 Install the 3 bolts and washers under the fan mounting plate assembly and in the rear (Fig. 312) DO NOT TIGHTEN. 1. Install the radiator to the fan mounting plate assembly (Fig. 310).
ENGINE 3. Before tightening the bolts and washers, check to make sure there is clearance between the fan blades and the engine cooling shroud and then tighten all 6 bolts. 6. Install the radiator overflow hose and tie strap the hose next to the radiator cap (Fig. 315). 4. Install the two hydraulic case drain lines to the T-fitting, located under the front left corner of the radiator (Fig. 313). Fig 315 Fig 313 5 DSC-2656 DSC-2434 7.
ENGINE 8. Install the engine inlet house and tighten the clamp (Fig. 317). Fig 317 DSC-2425 9. Close the radiator petcock. 10. Fill the radiator with 50/50 mix of extended life antifreeze/Dex-Cool and water. 14. Install the right and left hair pins to the clevis pins that hold the engine hood assembly (Fig. 318). Fig 318 DSC-2411 15. Slide the right and left hood lanyards on the radiator support bolts (Fig. 319). Check the antifreeze overflow bottle and make sure it is up to indicator line.
ENGINE 16. Install the engine belt shield and the engine access panel assembly with two knobs (Fig. 320). Checking the Radiator Coolant Check the cooling system level daily. Fluid Type: 50/50 mix of extended life antifreeze/DexCool and water. Cooling system capacity: 128 ounces (3.8l) Note: Do not open the radiator cap. Doing this may induce air into the cooling system. 1. Position the machine on a level surface, stop the engine, and set the parking brake. 2.
ENGINE Replacing the Fan Pump Drive Belt Check the fan pump drive belt for wear after every 50 hours of operation. 1. Loosen the bolts and remove the rear engine panel (Fig. 323). 3. Install the new belt around the engine and hydro pump pulley. 4. Pull the spring loaded idler down and align the belt. Release the pressure on the spring loaded idler (Fig. 325). Fig 325 Fig 323 DSC-2580 2. Pull the spring loaded idler down and remove the fan pump drive belt from the engine and pump pulley (Fig. 324).
ENGINE Replacing the Alternator Belt 5. Loosen the two bolts (top and bottom) holding the alternator (Fig. 327). 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 operator position. 3. Tilt the seat forward and remove the front engine panel (Fig. 326) Fig 327 DSC-2584 6. Remove the belt from the pulleys and alternator. 7.
ENGINE Tensioning the Alternator Belt 1. Place a wood tool handle between the alternator and cylinder block to use as a lever (Fig. 329). 5. If the deflection is correct, torque the upper bolt to 170 in-lbs. (19 Nm) and the bottom bolt to 40 ft-lbs. (54 Nm) (Fig. 331). Fig 331 Fig 329 DSC-2587 DSC-2585 2. Adjust the alternator to the outside until there is 3/8 to 1/2 inch (10 to 13mm) deflection in the belt between the engine and the alternator (Fig. 328). 6.
ENGINE Servicing the Fuel Filter 6. Let the water drain. If necessary, operate the priming pump to drain water, but only until fuel flows from the filter (Fig. 334). Draining Water from the Fuel Filter If the Water in Fuel Light comes on stop the engine and drain the water from the fuel filter. 1. Disengage the PTO, move the motion control levers to the neutral locked postion and set the parking brake. 2.
ENGINE Changing the Fuel Filter 5. Disconnect the sensor wire (Fig. 336). Replace the fuel filter after every 800 operating hours or yearly, whichever occurs first. Never reinstall a dirty filter once it is removed. 1. Allow the machine to cool down. 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 operator position. 4.
ENGINE 7. Remove the filter. Priming the Fuel System 8. Install a new filter by hand until the gasket contacts the housing, then tighten an extra 1/3 of a turn. The primer pump is the gold metal button on top of the fuel filter (Fig. 339). 9. Install the drain plug with new O-ring and connect the sensor wire. 10. Bleed the air from the fuel line by priming the fuel system. Refer to Priming the Fuel System, page 5-34. 11. Open the fuel shut-off valve (Fig. 338).
ELECTRICAL Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
ELECTRICAL ELECTRICAL SYSTEM Location General The alternator and the oil pressure relays are located behind the engine access panel on the left side (Fig. 341). Note: Interactive Electrical Troubleshooting CD, Form 492-9143 is also available. When turning the ignition switch clockwise to the RUN position, the glow plug indicator light will come on. After the glow plug indicator light goes out, turn the key to the START position and start the mower. The “Low Oil Pressure” alarm will sound a “pulse tone”.
ELECTRICAL Testing How It Works A relay is an electrically actuated switch. 85 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning it into a 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. The switch is spring loaded so that 30 and 87a are connected when the coil is not energized.
ELECTRICAL 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 345). Location The PTO switch is located on the control panel, on the left side of the operator (Fig. 346). Fig 345 xl relay Fig 346 DSC-2519 PTO SWITCH Purpose How It Works The PTO (Power Take Off) switch is typically used to activate the Electric PTO Clutch and to function as part of the safety interlock system. Contacts inside the switch electrically connect various terminals in both “On” and “Off” position.
ELECTRICAL 5. Verify that there is continuity between the appropriate terminals in the ON and OFF positions (Fig. 347). OFF (IN) Y Cont. Cont. Y Cont. Y Location N The ignition switch is located on the control panel, to the left side of the operator (Fig. 349). Cont. N Open Open N Continuity? Y = Yes N = No N Open Open not used Purpose The ignition switch provides the proper switching for the starter, accessories, and safety circuits.
ELECTRICAL How It Works NEUTRAL SAFETY SWITCH 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. 350). 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 outward). Location To gain access to the neutral safety switches, remove the front pocket.
ELECTRICAL Testing PARK BRAKE SWITCH 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. 352). Purpose The purpose of the brake switch is to ensure the machine is in neutral and the parking brake is applied before attempting to start the machine.
ELECTRICAL How It Works 2. Using a multimeter, follow the procedures listed below (Fig. 355). In the start position it is used to ensure the park brake is in the ON position. At the same time it allows current to flow through for 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 to maintain current for the safety circuit (Fig. 354).
ELECTRICAL SEAT SWITCH How It Works Purpose When the seat is vacated, the switch is open and there should be NO continuity between the two terminals. When the seat is occupied, the switch closes and there should be continuity between the two terminals (Fig. 357). 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 disengaged, the engine will shut down.
ELECTRICAL DELAY MODULE How It Works Purpose The seat delay module circuit board is made up of several different electrical components, such as a transient voltage suppressor, capacitor, transistors, carbon film resistors, diodes and a relay. These all work together to supply seat switch temporary voltage to the circuit to keep the engine running in case of short term voltage interruption (Fig. 359).
ELECTRICAL 2. Remove the 4 bolts to the control panel and raise the panel. 3. Connect a VOM positive lead to the blue wire on the module (Fig. 361). Connect the negative lead to the battery negative terminal. DUAL-TONE ALARM Purpose The dual-tone alarm is an audible alarm system to alert the operator of the following: PULSE TONE - Either the engine is low on oil pressure or the alternator is not charging.
ELECTRICAL How It Works Testing 12 VDC is applied to the audible alarm when the ignition key is on. For pulse and continuous tone a ground is needed to activate the audible alarm. Connect a positive leadfrom a 12 volt battery to the + terminal on the back of the audible alarm. Connect the negative lead to the S terminal on the back of the audible alarm. You should have a continuous tone. Move the negative lead to the P terminal of the audible alarm and you should get a pulse tone (Fig. 364).
ELECTRICAL GLOW PLUG CONTROLLER Testing Purpose The glow plug timer (Fig. 366) can be tested as an individual component. Refer to the next page for proper testing procedures. Controls the amount of time that voltage is sent to the glow plugs. The glow plug controller has an internal timer. Location The glow plug controller is located under the seat, behind the battery, fastened to the frame (Fig. 365).
ELECTRICAL Step 1 Testing the “timed” output in the “run” position (Fig. 367). set for K set for K RED RED BLACK BLACK Fig 367 glow plug timer test 2 A. Set VOM to read continuity in K ohms. B. Connect the red lead to referenced terminal “A” of the glow plug timer. C. Connect the negative lead to the negative terminal of the battery. D. Connect a jumper lead from terminal “D” of the timer to the negative terminal of the battery. E.
ELECTRICAL TEMPERATURE SENDER How It Works Purpose When the water temperature increases the internal resistance decreases which will cause the water temperature gauge to increase (Fig. 370). The temperature sender is a temperature-dependent variable resistor. As the coolant temperature increases the internal resistance decreases. This causes a change in voltage applied to the water temperature gauge, which indicates a higher temperature.
ELECTRICAL OIL PRESSURE SWITCH How It Works Purpose The oil pressure switch is a normally closed switch. When the engine is running, oil pressure builds and opens the contact in the switch. If the engine oil pressure drops, the contacts in the switch close, grounding the audible alarm, which alerts the operator to shut the unit down immediately (Fig. 372). When the oil pressure drops, the switch activates an audible alarm which alerts the operator to shut the engine down immediately.
ELECTRICAL WATER TEMPERATURE GAUGE How It Works Purpose When the engine water temperature increases the water sending unit resistance decreases, which cause the needle on the water temperature gauge readings will increase (Fig. 374). The purpose of the water temperature gauge is to monitor the engine coolant temperature. Location The water temperature gauge is located on the left side of the operator on the control panel (Fig. 373).
ELECTRICAL Back side of the Temperature Gauge with terminal and wire locations (Fig. 375). S Terminal - Yellow/Red Wire (to Temperature Sender) G Terminal - Black Wire (Ground) I Terminal - Orange Wire (I Terminal of the Ignition Switch) Location Raise the seat, the hour meter is located on the left side of the operator on the lower portion of the control panel (Fig. 376).
ELECTRICAL Testing How It Works Verify that 12 volts DC is present across the two terminals when the ignition key is in the RUN position. If so, and the meter is not running, replace the meter. If 12 volts is not present, check the connections. The meter is a permanently sealed unit and is not repairable. The meter movement is proportional to the voltage level across the two terminals of the battery. This is accomplished by placing a resistor in parallel with the meter movement.
ELECTRICAL ELECTRIC PTO CLUTCH Testing Purpose 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. The electric clutch controls the engagement and disengagement of the Power Take Off (PTO) pulley. Location Coil Resistance Measurement The electric clutch is located on the PTO end of the crankshaft (Fig. 379). 1.
ELECTRICAL Measuring Clutch Current Draw 7. Connect a short jumper lead from terminal (2) to terminal (4) (Fig. 382). 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. 3. Disconnect the PTO clutch harness from the main harness. 4. Set the multimeter to check amps (10 amp scale). 5. Connect the positive meter lead to terminal (1) of the main harness (Fig. 381). Fig 382 diag 3-7 8.
ELECTRICAL FUEL FILTER SENSOR How It Works Purpose The fuel filter sensor is a float type switch. Water is heavier than fuel and when water accumulates in the base of the sensor, a float raises and closes off a set of contacts. This completes the ground to the indicator light located on the control panel (Fig. 384). The fuel filter water sensor activates when too much water has accumulated in the water separator fuel filter.
ELECTRICAL 2. Set the multimeter to read continuity. Place the meter probes on each wire. With the float at the bottom of the sensor you should have NO Continuity (Fig. 385). Meter reads “OPEN” Float in “down” position Fig 385 fuel filter sensor down 3. With the meter probes still on the wires of the sensor, raise the float upwards, you should have continuity (Fig. 386).
ELECTRICAL 6 6-24 Z Master 597 Diesel Series Service Manual
ELECTRICAL + + _ 6 + _ Z Master 597 Diesel Series Service Manual 6-25
ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK.
MOWER DECKS Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
MOWER DECKS Electric PTO Clutch Removal 3. Remove the bolt and nut retaining the idler pulley to the fan pump tension assembly (Fig. 389). 1. Loosen the 4 bolts holding the rear bumper assembly and remove from the unit (Fig. 387). Fig 389 Fig 387 DSC-2595 2. Pull the spring loaded idler down and remove the fan drive belt (Fig. 388). 7 4. Remove the bolt, spacer, washer, and nut retaining the extension spring to the top of the fan pump tension assembly (Fig. 390).
MOWER DECKS 5. Disconnect the electric clutch harness from the wiring harness (Fig. 391). Fig 391 7. On the left side of the unit is the spring loaded idler pulley for the mower drive belt. Note the square cut hole in the idler bracket (Fig. 393). DSC-2601 Fig 393 6. Remove the bolt, spacer, washers and nut retaining the clutch brake strap to the frame (Fig. 392). DSC-2650 Note: Rear tire removed for clarity. 8. Insert a 12” long 3/8” drive extension into the square hole of the idler bracket.
MOWER DECKS 9. On the right side of the unit is the spring loaded idler pulley for the second mower drive belt. Insert a 3/8” drive ratchet with a 6” extension into the square cut hole in the idler bracket. Pull back on the ratchet to relieve tension on the belt. Slip the belt off the idler pulley and the PTO clutch (Fig. 395). 11. Use a wheel puller to remove the fan pump drive pulley from the PTO clutch (Fig. 397). Fig 397 Fig 395 DSC-2607 DSC-2614 12.
MOWER DECKS PTO Clutch Installation 3. Slide the spacer on the crankshaft (Fig. 401). 1. Apply anti-seize compound to the crankshaft (Fig. 399). Fig 401 Fig 399 DSC-2616 DSC-2618 4. Install drive pulley; make sure the square key is in the pulley (Fig. 402). 2. Install the PTO clutch on the crankshaft (Fig. 400).
MOWER DECKS 5. The retention hardware for the electric clutch is: a bolt, 2 spring washers, and a large washer (Fig. 403). B A Fig 403 A. Bolt C. Large Washer 7. Install the right side mower drive belt. Insert a 3/8” drive ratchet with a 6” extension into the square hole in the idler bracket. Pull back to relieve the tension on the idler arm and slip the belt on the inner sheave of the electric clutch drive pulley (Fig. 405). C DSC-2620 B. 2 Spring Washers 6.
MOWER DECKS Install the mower drive belt onto the outer clutch sheave, then the spring loaded idler pulley (Fig. 407). 10. Connect the PTO clutch harness to the wiring harness (Fig. 409). Fig 409 Fig 407 9. Install bolt spacer, washers, and nut retaining the clutch/brake strap to the frame (Fig. 408). See Fig. 447 (pg 7-17) for hardware assembly sequence. 11. Install bolt, spacer, washer, and nut to retain the extension spring to the top of the fan pump tension assembly (Fig. 410).
MOWER DECKS 12. Install the idler pulley to the fan pump tension assembly with a bolt and nut (Fig. 411). Mower Deck Removal 1. Loosen the 4 bolts holding the rear bumper assembly and remove from the unit (Fig. 413). Fig 411 DSC-2597 Fig 413 DSC-2595 13. Pull the spring loaded idler down and install the fan drive belt (Fig. 412). 2. Pull the spring loaded idler down and remove the fan drive belt (Fig. 414). 7 Fig 412 DSC-2596 Fig 414 DSC-2596 14.
MOWER DECKS 3. Disconnect the PTO clutch harness from the wiring harness (Fig. 415). Fig 415 5. On the left side of the unit is the spring loaded idler pulley for the mower drive belt. Note the square cut hole in the idler bracket (Fig. 417). DSC-2601 Fig 417 4. Remove the bolt, spacer, washers and nut retaining the clutch/brake strap to the frame (Fig. 416). DSC-2650 Note: Rear tire removed for clarity. 6.
MOWER DECKS 7. On the right side of the unit is the spring loaded idler pulley for the inner mower drive belt. Insert a 3/8” ratchet drive with a 6” extension into the square hole in the idler bracket. Pull back on the ratchet to relieve tension on the belt. Slip the belt off the idler pulley and the PTO clutch pulley (Fig. 419). 9. Remove the right side belt cover (Fig. 421). Fig 421 Fig 419 DSC-2607 DSC-2626 10. Remove the tension spring on the idler arm (Fig. 422). 8. Lift the floor pan (Fig.
MOWER DECKS 11. Remove the mower spindle belt from the top groove of the jackshaft sheave pulley (Fig. 423). Fig 423 13. 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. 425). DSC-2629 Fig 425 12. Remove both the left and right mower drive belts from the jackshaft sheave (Fig. 424). Fig 424 14.
MOWER DECKS 15. Remove the bolt and nut holding the right rear strut pin from the strut assembly (Fig. 427). Fig 427 17. Raise the deck to transport position. Install a 4 x 4 wood block under the left side of the mower deck. Lower the mower deck until it rests on the block of wood to relieve tension on the lift chains (Fig. 429). DSC-2632 Fig 429 16. Remove the strut pin from the strut assembly and remove the assembly from the mower deck (Fig. 428). 7 Fig 428 18.
MOWER DECKS 19. Follow steps 8 through 10 on the left side of the mower deck. 20. Remove the 4 x 4 wood block from under the left side of the mower deck and lower the deck to the floor. Mower Deck Installation 1. Slide the mower deck under the unit. 2. Install a 4 x 4 wood block under the left side of the mower deck (Fig. 433). 21. 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. 431).
MOWER DECKS 4. Install the rear and front lift chains to the mower deck (Fig. 435). Fig 435 DSC-2640 5. Remove the hitch pin on the lift handle and raise the mower in the transport position. 11. Install the right mower drive belt on the bottom sheave of the jackshaft pulley (Fig. 436). Fig 436 DSC-2641 12 Install the left mower drive belt on the middle sheave of the jackshaft pulley (Fig. 437). 6. Install a 4 x 4 wood block under the right side of the mower deck. 7.
MOWER DECKS 13. Install the mower spindle belt around the idler pulleys and the top sheave of the jackshaft pulley (Fig. 438). 15. Install the right side belt cover (Fig. 440). Fig 440 Fig 438 DSC-2643 1. Drive belt 2. Clutch 3. Spring loaded idler pulley fig. 74 m-7404 4. Adjustable idler pulley 5. Three stacked pulleys 6. Mower belt 14. Install the tension spring on the idler arm (Fig. 439). 16. Install the RH drive belt over the PTO clutch and around the inner drive sheave of the clutch (Fig.
MOWER DECKS 17. Install the RH drive belt around the fixed idler sheave. Insert a 3/8” drive ratchet with 6” extension into the 3/8” square hole in the idler arm. Pull toward the back of the machine to overcome the idler spring tension. Slip the RH drive belt over idler pulley and slowly release the idler arm (Fig. 442). Note: Be sure the belt orientation is correct per Fig. 443. Fig 442 DSC-2648 18. Install the LH drive belt over the electric PTO clutch and around the outer drive pulley. 19.
MOWER DECKS 22. Install the bolt, spacer, washers, and nut holding the clutch/brake strap to the frame (Fig. 446). Fig 446 DSC-2488 Follow the hardware sequence in the diagram (Fig. 447). 23. Connect the PTO clutch harness to the wiring harness plug (Fig. 448). Fig 448 DSC-2601 24. Pull the spring loaded idler down and install the fan drive belt (Fig. 449). G C A D B E F B Fig 447 A. B. C. D. Nut - lock Washer, large Spacer Grommet, brake deck belt drive a Fig 449 DSC-2596 E.
MOWER DECKS 25. Install the rear bumper assembly and tighten the 4 bolts (Fig. 450). Mower Spindle Removal This applies to removing any of the three mower spindles. This procedure shows removing the right side spindle. 1. Use a hoist or the Z Stand to raise the front of the mower deck. 2. Chock or block the drive wheels. 3. Disconnect the battery negative cable. 4. Lower the mower deck to the lowest position. 5. Lift the floor pan (Fig. 451).
MOWER DECKS 8. Remove the mower spindle drive belt (Fig. 454). 6. Remove the right side belt cover (Fig. 452). Fig 452 DSC-2626 7. Remove the tension spring on the idler arm (Fig. 453). Fig 453 Z Master 597 Diesel Series Service Manual DSC-2628 Fig 454 DSC-2661 9. Remove three bolts retaining the pulley to the pulley hub (Fig. 455).
MOWER DECKS 10. Raise the mower deck to the transport position. Mower Spindle Disassembly 11. Remove the mower blade from the spindle assembly. 1. Remove the nut and washer (Fig. 457). 12. Remove the 6 bolts and nuts from the spindle assembly. Remove the spindle assembly (Fig. 456). Note: Early production units did not have nuts on the bolts holding the spindle to the mower deck, It is recommended to install flange nuts to all of the bolts retaining the spindles to the mower deck. Fig 457 DSC-2669 2.
MOWER DECKS 3. Remove the bearing shield (Fig. 459). Fig 459 5. Remove the seal spacer from the top of the spindle housing (Fig. 461). DSC-2671 Fig 461 4. Remove the spindle housing from the spindle shaft assembly (Fig. 460). Fig 460 Z Master 597 Diesel Series Service Manual DSC-2672 DSC-2673 6. Remove the seal spacer from the bottom of the spindle housing (Fig. 462).
MOWER DECKS 7. Remove the top oil seal from the spindle housing (Fig. 463). 9. Remove the spacer (Fig. 465). Fig 465 Fig 463 8. Remove the tapered roller bearing from the top of the spindle housing (Fig. 464). 10. Remove the split ring (Fig. 466).
MOWER DECKS 11. Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing (Fig. 467). 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. 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. 469). Fig 469 Fig 467 DSC-2681 DSC-2679 14. Remove the large spacer in the spindle housing (Fig. 470). 12.
MOWER DECKS 15. This view shows the 2 bearing races and the large spacer in the spindle housing (Fig. 471). Note the internal snap ring in the housing; it is not necessary to remove it when installing new bearing races and the spacer. Mower Spindle Assembly 1. Install the spacer through the top of the spindle housing (Fig. 472). A B A Fig 472 Fig 471 A. Bearing Race B. Spacer DSC-2688 DSC-2684 2. Using a press, install the upper bearing race into the spindle housing (Fig. 473).
MOWER DECKS 3. Turn the spindle housing over and install the lower bearing race into the spindle housing (Fig. 474). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing. 5. Install the lower seal (Fig. 476). Note: The open lip of the seal should be facing outward. Fig 476 Fig 474 DSC-2692 DSC-2690 4. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig. 475). 6.
MOWER DECKS 7. Turn the spindle assembly over and install the split ring spacer (Fig. 478). Fig 478 DSC-2699 8. Install the inner spacer to the spindle assembly (Fig. 479). 9. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig. 480). Fig 480 DSC-2694 10. Install the seal. Press it flush with the top of the housing (Fig. 481). Note: The open lip of the seal faces inward.
MOWER DECKS 11. Install the bearing shield and the seal spacer onto the spindle shaft (Fig. 482). Fig 482 DSC-2702 12. Lower the spindle housing over the spindle shaft (Fig. 483). 13. Install the seal spacer on the top of the spindle housing (Fig. 484). Fig 484 14. Install bearing shield (Fig. 485).
MOWER DECKS 15. Install the square key onto the spindle shaft (Fig. 486). 17. Install the heavy washer and nut on the top of the spindle shaft (Fig. 488). Note: The cup side of the washer should be facing down toward the pulley hub. Fig 486 DSC-2706 16. Install the pulley hub on the spindle shaft (Fig. 487). Fig 488 DSC-2708 18. Torque the top nut to 100 to 120 ft-lbs. (135.58 to 162.7 Nm) (Fig. 489). 7 Fig 487 DSC-2707 Fig 489 DSC-2709 19.
MOWER DECKS Mower Jackshaft Assembly Removal 5. Remove the tension spring on the idler arm (Fig. 492). 1. Raise the rear of the machine and chock or block the front wheels. 2. Disconnect the battery negative cable. 3. Raise the floor pan (Fig. 490). Fig 492 DSC-2628 6. Remove the mower spindle belt from the top sheave of the jackshaft pulley (Fig. 493). Fig 490 DSC-2625 4. Remove the right side belt cover (Fig. 491).
MOWER DECKS 7. Loosen the 4 bolts holding the rear bumper assembly and remove from the unit (Fig. 494). Fig 494 9. Insert a 3/8” drive ratchet with a 12” long extension into the square hole of the idler bracket. Pull back on the idler arm to relieve tension on the belt. Remove the mower drive belt from the spring loaded idler pulley (Fig. 496). DSC-2595 8. On the left side of the unit is the spring loaded idler pulley for the mower drive belt. Note the square cut hole in the idler bracket (Fig. 495).
MOWER DECKS 11. Lower the mower deck to the lowest cutting position. 12. Remove the right and left mower drive belts from the jackshaft pulley. 15. Remove the jackshaft assembly from the mower deck (Fig. 500). 13. Remove the two bolts and washers retaining the jackshaft belt guide and the jackshaft assembly to the rear mower bracket (Fig. 498). Fig 500 DSC-2713 Mower Jackshaft Installation Fig 498 DSC-2711 14.
MOWER DECKS Mower Jackshaft and Pulley Assembly Right Hand Mower Idler Assembly Removal The jackshaft housing and bearings are not available as separate components. Listed below is a view of the components of the jackshaft and pulley assembly (Fig. 501). 1. Loosen the 4 bolts holding the rear bumper assembly and remove from the unit (Fig. 502). C B A D E F Fig 502 Fig 501 A. Retaining Nut B. Spring Washer C. Bottom Spacer Guard DSC-2595 DSC-2714 D. Jackshaft Assembly E. Jackshaft Pulley F.
MOWER DECKS 3. Remove the RH idler pulley (Fig. 504) Fig 504 5. Insert the ratchet with a 6” extension into the squarecut hole in the idler arm. Pull back on the idler arm to remove tension from the stop spacers and bolt. Remove the stop spacers and bolt and release the idler arm (Fig. 506). DSC-2716 4. Loosen the idler stop flange nut (Fig. 505). Fig 506 DSC-2720 6. Remove the belt tensioner spacer, washer, and bolt to allow for removal of the extension spring (Fig. 507).
MOWER DECKS 9. Inspect the sleeve bearing and bushing for any wear (Fig. 510). 7. Remove the RH idler bolt (Fig. 508). Fig 508 DSC-2727 Fig 510 8. Remove the RH idler assembly (Fig. 509). DSC-2731 Right Hand Mower Idler Assembly Installation 1. Install the right hand idler assembly (Fig. 511).
MOWER DECKS 2. Install the belt tensioner spacer, washer, bolt, and extension spring (Fig. 512). 4. Install the RH idler pulley (Fig. 514). Fig 514 Fig 512 3. Insert the ratchet with 6” extension into the square hole in the idler arm. Pull back on the idler arm and install the idler stop bolt and spacers. Slowly release the idler arm until it contacts the stop bolt and spacers. Install the flange nut to the stop bolt and tighten (Fig. 513). 5.
MOWER DECKS 6. Install the rear bumper assembly and tighten the 4 bolts (Fig. 516). Fig 516 2. On the left side of the unit is the spring loaded idler pulley for the mower drive belt; note the square hole in the idler bracket (Fig. 518). DSC-2595 Fig 518 Left Hand Mower Idler Assembly Removal 1. Loosen the 4 bolts holding the rear bumper assembly and remove from the unit (Fig. 517). DSC-2650 Note: Rear tire removed for clarity. 3.
MOWER DECKS 4. Relieve spring tension with the 3/8” ratchet drive to allow for removal of the stop bolt, spacer, and nut (Fig. 520). 6. Remove the bolt and nut retaining the idler bracket to the frame (Fig. 522). Fig 522 Fig 520 5. Remove the bolt, spacer, 2 washers and nut on the stationary end of the tension spring toward the rear of the machine (Fig. 521). 7. Remove the left hand idler bracket (Fig. 523).
MOWER DECKS 8. Inspect the bushing and sleeve bearing for wear (Fig. 524). Fig 524 DSC-2743 Left Hand Mower Idler Assembly Installation 2. Fasten the tension spring to the frame with the bolt, spacer, 2 washers and a nut (Fig. 526). Fig 526 DSC-2737 3. Relieve the tension on the spring using a 3/8” drive ratchet and 12” extension. Install the stop bolt, spacer, and nut (Fig. 527). 1. Install the left hand idler bracket to the frame with bolt and nut (Fig. 525).
MOWER DECKS 4. Relieve tension on the idler bracket with the 3/8” drive ratchet and 12” extension. Install the left side mower drive belt onto the idler pulley (Fig. 528). Replacing the Mower Spindle Belt Belt squeal/slippage, frayed belt edges, burn marks and cracks are signs of a worn belt. Replace the mower belt if any of theses conditions are evident. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
MOWER DECKS 4. Raise the floor pan (Fig. 531). 6. Remove the mower belt from the mower pulleys, idler pulleys and the top groove of the triple sheave jackshaft pulley (Fig. 533). 4 4 Fig 531 DSC-2625 Fig 533 5. Remove the tension spring on the idler arm (Fig. 532). 1. Triple sheave pulley 2. Mower belt fig. 71 m-7419 3. Mower spindle pulley 4. Mower idler pulleys 7. Install the new belt around the mower pulleys, idler pulleys and the top groove of the triple sheave jackshaft pulley (Fig. 534).
MOWER DECKS 8. Install the tension spring on the idler arm (Fig. 535). Replacing Mower Drive Belts Note: Remove the mower spindle belt first. If any of the primary drive belts need to be replaced, see Replacing the Mower Spindle Belt, page 7-39. 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. Fig 535 DSC-2628 3.
MOWER DECKS 4. Pull the spring loaded idler down and remove the fan drive belt (Fig. 538). 6. Remove the bolt, spacer, washers, and nut retaining the clutch/brake strap to the frame (Fig. 540). Fig 538 Fig 540 DSC-2596 5. Disconnect the PTO clutch harness from the wiring harness (Fig. 539). 7 Fig 539 DSC-2601 DSC-2604 7. There is a 3/8” square hole in the idler arm on the LH side of the machine (Fig. 541). Fig 541 DSC-2650 Note: Rear tire removed for clarity.
MOWER DECKS 8. Insert a 3/8” drive ratchet with a 12” extension into the square hole of the idler bracket and pull back to relieve tension on the idler bracket. Remove the mower drive belt from the spring loaded idler pulley, fixed idler pulley, and the PTO clutch (Fig. 542). 10. Raise the floor pan (Fig. 544). Fig 544 Fig 542 DSC-2651 DSC-2625 11. Remove the right side belt cover (Fig. 545). 9. Insert a 3/8” drive ratchet with a 6” extension into the square hole in the RH idler bracket.
MOWER DECKS 12. Remove the tension spring (Fig. 546). Fig 546 14. Remove the drive belts from the jackshaft sheave pulley on the mower deck (Fig. 548). DSC-2628 Fig 548 13. Remove the mower spindle belt from the top groove of the jackshaft pulley (Fig. 547). 7 Fig 547 15. Install the new right mower drive belt on the bottom sheave of the jackshaft pulley, the adjustable idler pulley, and around the inner sheave of the PTO clutch pulley (Fig. 549). DSC-2629 Fig 549 1. Belt drive 2. Clutch 3.
MOWER DECKS 16. Insert a 3/8” drive ratchet with a 6” extension into the square hole in the RH idler bracket. Pull back to relieve tension on the idler bracket. Install the belt onto the idler pulley (Fig. 550) Fig 550 DSC-2607 17. Install the new left mower drive belt on the middle sheave of the jackshaft pulley, the adjustable idler pulley, and around the outer sheave of the PTO clutch pulley (Fig. 551). 18. Insert a 3/8” drive ratchet with a 12” extension into the square hole in the LH idler bracket.
MOWER DECKS 20. Connect the electric PTO clutch harness to the wiring harness (Fig. 554). 22. Install the mower spindle belt; refer to Mower Spindle Belt, page 7-39. 23. Install the rear bumper and tighten the 4 bolts (Fig. 556). Fig 554 DSC-2601 21. Pull the spring loaded idler bracket down and install the fan pump drive belt (Fig. 555) Fig 556 DSC-2595 Leveling the Mower Setting up the Machine 1. Position mower on a flat surface. 2.
MOWER DECKS 5. Lower the mower to the 3 inch (76mm) height-of-cut position. 6. Inspect the four chains. The chains need to have tension. 2. Measure the right blade at the B location (Fig. 557), from a level surface to the cutting edge of the blade tip (Fig. 558). • If one rear chain is loose, lower (loosen) the front support arm on the same side. Refer to Adjusting the Front-to-Rear Mower Pitch on page 7-48. • If one front chain is loose, raise (tighten) the front support arm for that chain.
MOWER DECKS 7. If the measurement at positions B or C are not correct, loosen the bolt attaching the rear chain support arm (Fig. 559). Adjusting the Front-to-Rear Mower Pitch 1. Position the right blade front-to-rear (Fig. 560). Fig 559 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam nut fig. 67 m-6830 5. Adjustment bolt 6. Front swivel 7. Front support arm Fig 560 fig. 68 m-1078 2. Measure the right blade at the A location (Fig.
MOWER DECKS 3. Record the measurement. 4. Measure the right blade at the B location (Fig. 560) from a level surface to the cutting edge of the blade tip (Fig. 561). 8. Adjust the lift nuts on both the left and the right side of the machine (Fig. 562 and Fig. 563) to achieve 1/4 to 3/8 inch (6 to 10mm) lower in front A than in the rear at B (Fig. 560). 5. Record this measurement. 6. The mower blade should be 1/4 to 3/8 inch (6 to 10mm) lower at position A than at position B (Fig. 560).
MOWER DECKS Adjusting the Compression Spring 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, it needs to be 11-1/2 inches (29.2cm) (Fig. 564). 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 564). Turning the nut clockwise will shorten the spring; counter-clockwise will lengthen the spring. 4. Lock the nut into position by tightening the spring jam nut (Fig. 564). Fig 564 1.
Z Master Z597 Diesel Series Service Manual Form No.
