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Toro Z Master Z597, Service Manual

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Z Master Z597

Diesel Series

Service Manual

LCE Products

Summary of Contents for Z Master Z597

Page 1: ...Z Master Z597 Diesel Series Service Manual LCE Products...

Page 2: ...ctrical Troubleshooting Interactive electrical troubleshooting and wiring diagrams on compact disk Form 492 9143 The Z Master 597 model years 2004 and 2005 are covered in this manual The manual may al...

Page 3: ...THIS PAGE INTENTIONALLY LEFT BLANK...

Page 4: ...Fuel Tank Removal Left Side Fuel Tank Installation Hood Assembly Removal Hood Assembly Installation Throttle Control Replacement Installation Brake Lever Removal Brake Lever Installation Brake Band Re...

Page 5: ...ng and Tensioning the Alternator Belt Replacing the Alternator Belt Tensioning the Alternator Belt Servicing the Fuel Filter Draining Water from the Fuel Filter Changing the Fuel Filter Priming the Fu...

Page 6: ...ckshaft and Pulley Assembly Right Hand Mower Idler Assembly Removal Right Hand Mower Idler Assembly Installation Left Hand Mower Idler Assembly Removal Left Hand Mower Idler Assembly Installation Repl...

Page 7: ...iv Z Master Z597 Diesel Service Manual THIS PAGE INTENTIONALLY LEFT BLANK TABLE OF CONTENTS...

Page 8: ...1 1 Z Master Z597 Diesel Service Manual Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 2 3 4 5 6 7 1 SAFETY INFORMATION...

Page 9: ...lock system after making adjustments or repairs on the machine Refer to the Electrical section in this manual for more information SAFETY INFORMATION General Information This symbol means WARNING or P...

Page 10: ...2 1 Z Master Z597 Diesel Service Manual 3 4 5 6 7 1 SPECIFICATIONS 1 2 Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks...

Page 11: ...2 2 Z Master Z597 Diesel Service Manual 2 SPECIFICATIONS MACHINE PROFILE PHOTOS Fig 001 DSC 2789 Fig 002 DSC 2790 Fig 004 DSC 2794 Fig 003 DSC 2792...

Page 12: ...r 76 193cm Z597 72 182 9cm TF Deck 73 6 186 9cm Deflector 88 223 5cm Height 74 188cm ROPS Height Upright 55 140cm ROPS Folded Weight Z597 60 152 4cm TF Deck 1630 lbs 739 36kg Z597 72 182 9cm TF Deck 1...

Page 13: ...er 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 635cm Heat...

Page 14: ...Fig 006 fig 55 m 5615 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 T...

Page 15: ...bel above Fig 008 can be located on the pump housing It identifies the model and configuration of the BDP pump Available Service Manuals Service Aids Hydrostatic Pumps Hydro Gear BDP 10A 16A 21L Servi...

Page 16: ...ure hardness of the surface underneath of the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated...

Page 17: ...h Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts In lb In lb N cm In lb N cm In lb N cm 6 32 UNC 10 2 13 2 147 23 15 2 170 20 23 2 260 20 6 40 UNF 17 2 190 20 25 2 280 20 8 32 UNC 13 2 25 5 282...

Page 18: ...etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Thin height nuts include...

Page 19: ...read Size Recommended Torque Square Head Hex Socket 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lb 145 20 in lb 3 8 16 UNC 35 10 ft lb 18 3 ft lb 1 2 13 UNC 75 15 ft lb 50 10 ft lb Type...

Page 20: ...64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 2...

Page 21: ...s Square Centimeters Hectare 2 59 0 0929 6 452 0 4047 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...

Page 22: ...3 1 Z Master Z597 Diesel Service Manual 2 4 5 6 7 1 CHASSIS Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 1 3...

Page 23: ...t 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 Fig 009 mvc 1531 Fig 011 DSC 1533 4 Remove...

Page 24: ...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 Tap the bearing cup...

Page 25: ...6 DSC 1539 2 Install the upper bearing 3 Install the Belleville spring washers as shown in Fig 019 A Dust Cap B Locknut C Spring Washers Fig 018 DSC 1533 Fig 019 washers line art 1 Install the castor...

Page 26: ...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 Fig 021 DSC 1540 Fig 022 DSC 1541 6 Remove...

Page 27: ...etaining wheel bolt Fuel Tank Removal A A B B C C D E F 4 Pack both tapered wheel bearings Reassemble per Fig 024 Pump grease into the wheel bearings through the grease fitting located on the rim Fig...

Page 28: ...rame 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 Fig 029 DSC 1552 6 Remove bolt washer and nut securing the right rea...

Page 29: ...e 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 1...

Page 30: ...ny cables or wiring 4 Unplug the 3 connectors that plug into the delay module Fig 035 Fig 035 DSC 1578 5 Remove the return fuel line located on the inside of the fuel tank Fig 036 Fig 036 DSC 1565 6 R...

Page 31: ...k Fig 039 CHASSIS Fig 039 DSC 1571 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 Fig 040 DSC 1573 10 Rem...

Page 32: ...ads showing on the threaded stud Fig 043 Hood Assembly Removal 3 Lift the hood and remove the stop lanyards located on each side of the hood Remove the hood from the frame of the unit Fig 045 Fig 045...

Page 33: ...wo locknuts and carriage bolts retaining the throttle cable assembly Fig 048 Fig 048 DSC 1591 3 Remove the ball knob located on the throttle control by applying upward pressure under the knob Fig 047...

Page 34: ...en Fig 052 Fig 052 DSC 1596 Fig 050 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 radiato...

Page 35: ...mp injector lines and through the swivel clamp Note The cable wire should be routed through the swivel clamp with the swivel clamp washer located under the cable wire Fig 055 6 Install control panel t...

Page 36: ...e cable housing clamp Fig 060 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...

Page 37: ...clevis pin from the brake rod yoke Fig 062 Brake Lever Removal Fig 062 DSC 1618 3 Lift the floor pan assembly to access the brake lever shaft and cotter pin Fig 063 5 Slide the brake shaft out of the...

Page 38: ...ivot Fig 066 Fig 066 DSC 1622 7 Inspect the brake shaft and bushings for excessive wear Replace any worn or broken components Fig 067 Fig 067 DSC 1623 Fig 068 DSC 1624 1 Raise the left rear tire off t...

Page 39: ...1631 2 Install the 3 bolts brake band retainer brake band and spacers and tighten Fig 071 A B C D 1 Install the brake band around the wheel hub Fig 070 Brake Band Installation Fig 070 DSC 1629 3 Insta...

Page 40: ...072 DSC 1632 3 Remove the cotter pin and clevis pin from the left side lower brake linkage assembly Fig 073 Fig 073 DSC 1633 4 On the right side remove the cotter pin and clevis pin from the lower br...

Page 41: ...1640 1 Install the flange bearing on the right side of the shaft From the outside of the frame align the flange bearing holes with the frame mounting holes Install mounting hardware and tighten Fig 0...

Page 42: ...arm is pointing upward between the mounting hardware Fig 080 Fig 080 DSC 1641 Fig 082 DSC 1644 4 Install clevis spring pin connecting brake rod to brake shaft Rotate clevis spring pin until it clips...

Page 43: ...g brake lever up 6 Measure the distance between the spring bracket and the adjusting nut under spring bracket The measurement should be 1 4 5 16 5 8mm Fig 083 7 If adjustment is necessary loosen the j...

Page 44: ...087 DSC 1650 Fig 085 DSC 1648 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...

Page 45: ...51 7 Remove hex bolt nut and lift lever bushing from the lower deck lift plate mounting location Fig 089 Fig 089 DSC 1652 A A Lift Lever at lowest position 8 Loosen the top hex head flange nut at the...

Page 46: ...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 095 Fig 095 DSC 1661 Fig 093 DSC 1656 11 Remove reta...

Page 47: ...the motion control arm to hold the floor pan assembly in place Fig 096 Fig 096 DSC 1665 15 Carefully slide the lift lever assembly out of its carrier frame pivot Fig 097 Fig 097 DSC 1667 Deck Lift Le...

Page 48: ...r 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 103 Fig 103 DSC 1677...

Page 49: ...h ends of deck lift rod 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...

Page 50: ...r 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 shou...

Page 51: ...olts Fig 111 Fig 111 DSC 1690 Fig 113 DSC 2062 5 Remove the two bolts retaining the lever assembly to the control arm shaft Fig 113 4 Remove pocket Fig 112 6 Disconnect motion control dampener from mo...

Page 52: ...lt Fig 117 10 Remove the two bolts and nuts that retain the flange bearing on the inside of the motion control Fig 118 Fig 117 DSC 2064 Fig 118 DSC 2066 7 Disconnect neutral switch wire harness from n...

Page 53: ...two bolts and nuts that retain the flange bearing on the outside of the motion control Fig 119 12 Remove the motion control from the frame Fig 120 Fig 119 DSC 2067 Fig 120 DSC 2068 Reverse the order...

Page 54: ...4 1 Z Master Z597 Diesel Service Manual 2 3 5 6 7 1 HYDRAULIC SYSTEM Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 4 1...

Page 55: ...nstallation This procedure is showing the LH Hydrostatic Pump being removed Use these same procedures to remove the RH Hydrostatic Pump 1 Disconnect the negative and positive battery cables Remove the...

Page 56: ...t enter these areas Fig 124 DSC 2083 Note Before removing the hydraulic lines from the hydrostatic pump mark or tag one of the hoses to make sure they are reconnected correctly Fig 126 DSC 2088 8 Remo...

Page 57: ...on the hydrostatic pump shaft Fig 127 Fig 127 DSC 2089 10 Loosen and remove the two bolts and nuts retaining the hydrostatic pump to the frame Fig 128 Fig 128 DSC 2091 Fig 130 DSC 2094 12 Remove the h...

Page 58: ...ostatic pump shaft make sure the key is facing up on the shaft Fig 132 Fig 132 DSC 2095 Fig 134 DSC 2089 4 Tighten the two sets screws on the pulley using a 12 point 3 8 9 5mm socket Fig 134 Fig 133 D...

Page 59: ...nd tighten the bolt and nut retaining the hydro pump control linkage to the hydro control arm Fig 138 Fig 137 DSC 2099 7 Install the case drain hydraulic line located on the left hand side of the pump...

Page 60: ...140 Fig 140 DSC 2101 Fig 141 DSC 2071 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 re...

Page 61: ...ith jackstands Remove the rear wheel Fig 142 Fig 142 DSC 2102 Fig 144 DSC 2105 4 Loosen and remove nut securing hub to the wheel motor output shaft Fig 144 Fig 143 DSC 2103 3 Apply the parking brake a...

Page 62: ...hydraulic lines Note Cap the fittings and hoses to prevent dirt from entering the hydraulic system Fig 148 Fig 147 DSC 2108 7 Install a wheel puller on to the hub and remove the hub from the motor out...

Page 63: ...e the back two bolts lock washers spacers and nuts and remove the wheel motor from the frame Fig 151 Wheel Motor Installation Note As a reminder prior to connecting the hydraulic lines the O Rings sho...

Page 64: ...the frame Loosely install the back two bolts long spacers lock washers and nuts Fig 153 3 Install the two front bolts short spacers lock washers and nuts through the wheel motor brake linkage and fra...

Page 65: ...e woodruff key is in place Fig 158 Fig 157 DSC 2123 6 Install and tighten the hydraulic lines Fig 157 Fig 160 DSC 2106 9 Install spacers brake band retainer and brake band around the wheel hub and tig...

Page 66: ...ct the battery negative cable 14 Check the hydraulic fluid in the reservoir tank Add oil if necessary Air will need to be purged in the system Follow the procedures on Purging the Hydraulic System pag...

Page 67: ...dequate 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 Upon removal...

Page 68: ...oard 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 Fig 168 DSC 2363 Fig 170 DSC 23...

Page 69: ...and nuts to the fan pump mounting plate Fig 172 HYDRAULIC SYSTEM Hydraulic Fan Pump Installation Fig 173 DSC 2366 2 Install the three hydraulic lines to the hydraulic fan pump and tighten Fig 173 3 I...

Page 70: ...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...

Page 71: ...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 nu...

Page 72: ...nes 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 182 DSC 2377 7 Place a small oil drain pan on top of...

Page 73: ...allation 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 fitting...

Page 74: ...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 tighten...

Page 75: ...bolts Fig 194 HYDRAULIC SYSTEM 9 Install the two hose clamps the large clamp retaining the inlet cooling hose and the small clamp for the overflow hose to the radiator Secure the throttle cable to the...

Page 76: ...nd check the oil level in the reservoir Note Adjust handle neutral before setting pump neutral See Adjusting the Handle Neutral page 4 24 This adjustment must be made with drive wheels turning Fig 199...

Page 77: ...instructions 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...

Page 78: ...ust if necessary HYDRAULIC SYSTEM 8 If adjustment is needed loosen the nut and jam nut against the yoke Fig 202 9 Apply slight rearward pressure on the motion control lever turn the head of the adjust...

Page 79: ...nd threads 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 Fig 2...

Page 80: ...djust the handle neutral and hydraulic pump neutral before adjusting the tracking Refer to Adjusting the Handle Neutral on page 4 24 and Setting the Hydrostatic Pump Neutral on page 4 23 1 Push both c...

Page 81: ...lean 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...

Page 82: ...ings Fig 213 The flow tester shown is bidirectional so it does not matter in which order the hoses are connected to the flow tester If using a directional flow tester be sure to correctly connect hose...

Page 83: ...ump maximum allowable flow droop is 2 0 gpm 7 5 lpm Any droop greater than 2 0 gpm 7 5 lpm is considered unacceptable and the pump should be repaired replaced barring any other potential causes 13 Ret...

Page 84: ...otor Connect the flow meter as shown Fig 217 Note If using a directional flow tester be sure to correctly connect hoses 8 With the engine running at full rpm carefully close the restrictor valve until...

Page 85: ...he 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 Dise...

Page 86: ...ULIC SYSTEM 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 i...

Page 87: ...4 34 Z Master Z597 Diesel Service Manual 4 HYDRAULIC SYSTEM HYDRAULIC DIAGRAM...

Page 88: ...5 1 Z Master Z597 Diesel Service Manual 2 3 4 6 7 1 ENGINE Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 1 5...

Page 89: ...remove the rear heat shield from the frame Fig 222 Fig 222 DSC 2370 3 Remove the two knobs located on the engine access panel Remove the engine belt shield and the engine access panel Fig 223 Fig 223...

Page 90: ...n petcock Do not touch radiator and surrounding parts that are hot 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...

Page 91: ...be needed to catch any oil from the hydraulic line Cap the fittings to prevent contamination Fig 231 DSC 2429 Fig 232 DSC 2433 12 Loosen and remove the tank return hydraulic hose from the radiator Thi...

Page 92: ...bolts three on each side retaining the radiator and fan mounting plate assembly to the right and left upper frame Fig 234 Fig 234 DSC 2371 15 Remove the radiator and frame assembly Fig 235 Fig 235 DS...

Page 93: ...mount Fig 238 Fig 238 DSC 2441 19 Remove the air cleaner assembly Fig 239 Fig 239 DSC 2442 Fig 240 DSC 2443 20 Make sure the fuel valve is in the OFF position Tag or mark the OUT or return fuel line L...

Page 94: ...ap A Yellow Red wire to the temperature sender B Black Green wire to the temperature switch C Fig 242 Fig 242 DSC 2445 23 Remove the following wires from the engine Dark Blue wire to the oil pressure...

Page 95: ...otor 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 Fig...

Page 96: ...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...

Page 97: ...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 Fi...

Page 98: ...rs the right rear radiator support bracket and to clear the engine drive pulley pump idler pulley and the RH pump pulley 3 Install the bolt and nut on the engine rear mount do not tighten Fig 259 Fig...

Page 99: ...nuts once alignment has been achieved Fig 260 engine mount assembly c 4 Install the right hand engine mount bolt Note the sequence of the washers from the bottom up bolt large washer and then the sma...

Page 100: ...65 rear Fig 264 DSC 2457 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 ENGINE A Washer E Link ball joint B...

Page 101: ...and install the fan drive belt Fig 268 10 Install both the mower drive belts refer to Replacing Mower Drive Belts page 7 41 11 Install the bolt spacer washers and nuts holding the clutch brake strap...

Page 102: ...structions for Tensioning the Alternator Belt page 5 31 18 Connect the Red wire to the top of the alternator and plug the wiring harness into the back of the alternator 19 Install the bolt through the...

Page 103: ...es to the injector pump Make sure you install the tagged or marked fuel line to the Out or return connector Fig 276 20 Install the following wires to the engine Dark Blue to the oil pressure sending u...

Page 104: ...e hose between the engine and air filter Tighten the hose clamps Fig 279 Fig 279 DSC 2440 Fig 281 DSC 2435 28 Install the radiator and frame assembly to the right and left upper frame Fig 281 Fig 280...

Page 105: ...tall the tank return hydraulic hose to the radiator The line is located at the left rear corner of the radiator Fig 284 29 Install the six bolts three located on each side retaining the radiator and f...

Page 106: ...the hose clamp Fig 288 Fig 288 DSC 2425 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...

Page 107: ...ystem may need air purged from the hydraulic system refer to Purging the Hydraulic System page 4 13 Top up coolant and hydraulic fluid as needed 42 Install the engine access panel with two knobs Fig 2...

Page 108: ...s can cause severe burns Do not remove radiator cap or open drain petcock when the engine is hot Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch w...

Page 109: ...2411 Fig 297 DSC 2370 Fig 299 DSC 2410 4 Slide the hood lanyard off the right and left radiator support bolts Fig 299 Fig 298 DSC 2071 3 Remove the two knobs located on the engine access panel Remove...

Page 110: ...ing 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 Fig 30...

Page 111: ...d 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 DSC 2652 Fig...

Page 112: ...tor to the fan mounting plate assembly Fig 310 Radiator Installation Fig 310 DSC 2659 2 Install the 3 bolts and washers located under the fan mounting plate assembly in the front Fig 311 DO NOT TIGHTE...

Page 113: ...Fig 315 Fig 315 DSC 2434 Fig 313 DSC 2656 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 b...

Page 114: ...reservoir tank to make sure the fluid level is at the cold level mark 12 Connect the negative battery cable Start the unit up and operate for about 5 minutes Observe all the cooling and hydraulic line...

Page 115: ...ng brake 2 With the engine cool check the overflow bottle level The fluid needs to be up to the raised indicator line on the outside of overflow bottle Fig 322 Fig 322 fig 47 m 7402 3 If the coolant l...

Page 116: ...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...

Page 117: ...ts to stop before leaving the operator position 3 Tilt the seat forward and remove the front engine panel Fig 326 Replacing the Alternator Belt Fig 326 DSC 2071 4 Remove the hydrostatic pump drive bel...

Page 118: ...n in the belt between the engine and the alternator Fig 328 3 Tighten the alternator bolts 4 Check the deflection in the belt again and adjust the belt if needed Fig 330 Fig 331 DSC 2587 5 If the defl...

Page 119: ...moving parts to stop before leaving the operating position 3 Disconnect the negative battery cable 4 Allow the machine to cool down 5 Place a drain pan under the fuel filter and loosen the drain plug...

Page 120: ...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 Close the f...

Page 121: ...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 Priming the Fuel System The primer pump is the gold metal butt...

Page 122: ...6 1 Z Master 597 Diesel Series Service Manual 7 5 4 3 2 ELECTRICAL Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 6 1...

Page 123: ...CAL SYSTEM There are 4 relays 1 Start Relay 2 Glow Plug Relay 3 Oil Pressure Relay 4 Alternator Relay 1 Start Relay Once the safety connections are met the relay will activate completing the circuit t...

Page 124: ...isconnect 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...

Page 125: ...ectric clutch and it engages When the switch is pushed in to OFF position current flows through the PTO switch to the Park Brake switch as part of the circuit used to ensure safe starting Fig 346 DSC...

Page 126: ...ch if your test results do not correspond with those given in Fig 347 7 Mount the PTO switch back into the control panel and reinstall the wiring harness Fig 348 Violet Orange Gray Gray Gray Orange Or...

Page 127: ...s to the neutral safety switches remove the front pocket There are 2 neutral switches One for the right motion control handle and one for the left motion control handle Fig 351 Used to ensure the moti...

Page 128: ...t the switch from the wiring harness 2 Using a VOM or test light check first to ensure there is no continuity between the terminals plunger out 3 With the plunger pushed in there should be continuity...

Page 129: ...e 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 cur...

Page 130: ...he seat Purpose SEAT SWITCH How It Works 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 s...

Page 131: ...ig 358 Fig 358 DSC 2534 Fig 359 DSC 2532 The seat delay module circuit board is made up of several different electrical components such as a transient voltage suppressor capacitor transistors carbon f...

Page 132: ...s up on the engine CONTINUOUS TONE The engine is overheating In either case when the alarm sounds while operating the unit it should be shut down immediately Purpose DUAL TONE ALARM 4 Follow the proce...

Page 133: ...running Oil pressure opens the switch contacts taking the wire to the switch off of ground When the oil pressure drops the contacts in the switch close and grounds the audible alarm to pulse tone For...

Page 134: ...ition START position the glow plug controller is continuously on until the ignition switch moves back to the RUN position Fig 365 DSC 2541 The glow plug controller is located under the seat behind the...

Page 135: ...tinuous mode as the machine is being started 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 t...

Page 136: ...69 DSC 2547 It is not practical to test the sender in a shop environ ment 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...

Page 137: ...disconnect the switch lead If the alarm stops the pressure switch is bad The switch can also be tested with an ohmmeter There should be continuity between the wire terminal and ground with the engine...

Page 138: ...located on the left side of the operator on the control panel Fig 373 Fig 373 DSC 2550 Time efficient shop testing is not possible See information under Temperature Sender Testing page 6 15 Fig 374 D...

Page 139: ...tch is in the RUN position Fig 377 DSC 2560 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...

Page 140: ...inals of the battery This is accomplished by placing a resistor in parallel with the meter movement 1 Remove the control panel from the tank by removing 4 screws 2 With a Volt ohm meter place the nega...

Page 141: ...the Power Take Off PTO pulley Purpose ELECTRIC PTO CLUTCH Location The PTO clutch is composed of three major components the field the clutch plate and the friction plate The clutch plate always turns...

Page 142: ...ing Clutch Current Draw Fig 381 diag 3 7 6 Connect the negative meter lead to the clutch harness terminal 3 Fig 381 8 Turn the ignition switch to the RUN position Turn the PTO switch to the ON positio...

Page 143: ...e fuel filter sensor is located under the seat on the left side of the unit The fuel filter sensor is located under the fuel filter Fig 383 How It Works Fig 384 DSC 2566 The fuel filter sensor is a fl...

Page 144: ...of the sensor raise the float upwards you should have continuity Fig 386 Fig 386 fuel filter sensor raised ELECTRICAL Fig 385 fuel filter sensor down Meter reads OPEN Float in down position 2 Set the...

Page 145: ...6 24 Z Master 597 Diesel Series Service Manual 6 ELECTRICAL...

Page 146: ...6 25 Z Master 597 Diesel Series Service Manual 6 ELECTRICAL _ _...

Page 147: ...6 26 Z Master 597 Diesel Series Service Manual 6 THIS PAGE INTENTIONALLY LEFT BLANK ELECTRICAL...

Page 148: ...7 1 Z Master 597 Diesel Series Service Manual 6 5 4 3 2 MOWER DECKS Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 7 1...

Page 149: ...Fig 387 Fig 387 DSC 2595 2 Pull the spring loaded idler down and remove the fan drive belt Fig 388 Fig 388 DSC 2596 Fig 390 DSC 2598 4 Remove the bolt spacer washer and nut retaining the extension sp...

Page 150: ...2 long 3 8 drive extension into the square hole of the idler bracket Use a 3 8 drive ratchet on the extension and pull back to relieve spring tension on the idler bracket Remove the mower drive belt f...

Page 151: ...back on the ratchet to relieve tension on the belt Slip the belt off the idler pulley and the PTO clutch Fig 395 Fig 395 DSC 2607 10 Using an air impact wrench loosen the center bolt retaining the pu...

Page 152: ...ize compound to the crankshaft Fig 399 Fig 399 DSC 2616 2 Install the PTO clutch on the crankshaft Fig 400 Fig 400 DSC 2617 Fig 402 DSC 2619 4 Install drive pulley make sure the square key is in the p...

Page 153: ...04 DSC 2621 Fig 406 DSC 2650 8 On the left side insert a 3 8 drive ratchet with a 12 extension in the square hole in the idler bracket Fig 406 Pull back to relieve the tension on the idler arm Fig 405...

Page 154: ...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 Fig 408 DSC 2604 Fig 410 DSC 2598 11 Install bolt spacer...

Page 155: ...13 Pull the spring loaded idler down and install the fan drive belt Fig 412 Fig 412 DSC 2596 Fig 414 DSC 2596 2 Pull the spring loaded idler down and remove the fan drive belt Fig 414 Fig 413 DSC 2595...

Page 156: ...2651 6 Insert a 3 8 drive ratchet with a 12 long 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 l...

Page 157: ...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 Fig 419 DSC 2607 8 Lift...

Page 158: ...wer drive belts from the jackshaft sheave Fig 424 Fig 424 DSC 2630 Fig 426 DSC 2631 14 Remove the front and rear lift chains from the right side of the mower deck Fig 426 Fig 425 DSC 2623 13 Raise the...

Page 159: ...he tension of the lift assist springs Use the hitch pin above the lift handle to lock the handle in the down position Fig 430 Fig 429 DSC 2635 17 Raise the deck to transport position Install a 4 x 4 w...

Page 160: ...aster fork is angled forward This will allow more clearance to slide the mower deck from under the frame Fig 431 Fig 431 DSC 2637 22 Slide the mower deck out the right side of the unit Fig 432 Fig 434...

Page 161: ...he mower deck 7 Lower the mower deck down on the wood block 8 Install the strut pin in the strut assembly Install and tighten the bolt and nut 9 Install the rear and front lift chains to the mower dec...

Page 162: ...stall the tension spring on the idler arm Fig 439 Fig 439 DSC 2645 Fig 441 DSC 2646 Fig 440 fig 74 m 7404 15 Install the right side belt cover Fig 440 MOWER DECKS 16 Install the RH drive belt over the...

Page 163: ...DSC 2648 Fig 445 DSC 2651 21 Pull back to relieve idler spring tension Install the mower drive belt on the spring loaded idler pulley and the outer sheave of PTO pulley Release the idler arm slowly Fi...

Page 164: ...the clutch brake strap to the frame Fig 446 Fig 446 DSC 2488 Follow the hardware sequence in the diagram Fig 447 Fig 447 deck belt drive a Fig 449 DSC 2596 24 Pull the spring loaded idler down and in...

Page 165: ...450 DSC 2595 Fig 451 DSC 2625 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...

Page 166: ...ide belt cover Fig 452 Fig 452 DSC 2626 7 Remove the tension spring on the idler arm Fig 453 Fig 453 DSC 2628 Fig 455 DSC 2662 9 Remove three bolts retaining the pulley to the pulley hub Fig 455 Fig 4...

Page 167: ...rt position 11 Remove the mower blade from the spindle assembly 12 Remove the 6 bolts and nuts from the spindle assembly Remove the spindle assembly Fig 456 Note Early production units did not have nu...

Page 168: ...housing from the spindle shaft assembly Fig 460 Fig 459 DSC 2671 3 Remove the bearing shield Fig 459 MOWER DECKS 5 Remove the seal spacer from the top of the spindle housing Fig 461 Fig 461 DSC 2673 6...

Page 169: ...acer Fig 465 Fig 465 DSC 2677 10 Remove the split ring Fig 466 Fig 466 DSC 2678 MOWER DECKS Fig 464 DSC 2676 8 Remove the tapered roller bearing from the top of the spindle housing Fig 464 Fig 463 DSC...

Page 170: ...he 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 MOWER DECKS...

Page 171: ...indle housing Fig 473 Note The wider inside diameter of the bearing race should be facing up to accept the tapered bearing Fig 473 DSC 2689 MOWER DECKS A Bearing Race B Spacer Fig 471 DSC 2684 15 This...

Page 172: ...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 Fig 475 DSC 2691 4 Pack the tapered bearin...

Page 173: ...open lip of the seal faces inward Fig 481 DSC 2696 MOWER DECKS 7 Turn the spindle assembly over and install the split ring spacer Fig 478 Fig 478 DSC 2699 Fig 480 DSC 2694 9 Pack the tapered bearing w...

Page 174: ...seal spacer onto the spindle shaft Fig 482 Fig 482 DSC 2702 Fig 484 DSC 2704 13 Install the seal spacer on the top of the spindle housing Fig 484 Fig 483 DSC 2703 12 Lower the spindle housing over th...

Page 175: ...the pulley hub on the spindle shaft Fig 487 15 Install the square key onto the spindle shaft Fig 486 Fig 486 DSC 2706 Fig 488 DSC 2708 17 Install the heavy washer and nut on the top of the spindle sh...

Page 176: ...1 Fig 490 DSC 2625 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 MOWER DECKS 5 Remove the tension spring on...

Page 177: ...for the inner mower drive belt Insert a 3 8 drive ratchet with a 6 long extension into the square hole in the idler bracket Pull back on the idler arm to relieve tension on the belt and slip the belt...

Page 178: ...and left mower drive belts from the jackshaft pulley 13 Remove the two bolts and washers retaining the jackshaft belt guide and the jackshaft assembly to the rear mower bracket Fig 498 Mower Jackshaft...

Page 179: ...Jackshaft Guard Fig 503 DSC 2607 2 Remove the right side mower drive belt by inserting a 3 8 drive ratchet with a 6 long extension into the square cut hole in the idler bracket Pull back to relieve t...

Page 180: ...2719 Fig 507 DSC 2725 6 Remove the belt tensioner spacer washer and bolt to allow for removal of the extension spring Fig 507 Fig 506 DSC 2720 5 Insert the ratchet with a 6 extension into the square...

Page 181: ...508 Fig 508 DSC 2727 8 Remove the RH idler assembly Fig 509 Fig 509 DSC 2730 Fig 510 DSC 2731 9 Inspect the sleeve bearing and bushing for any wear Fig 510 MOWER DECKS Right Hand Mower Idler Assembly...

Page 182: ...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 I...

Page 183: ...the square hole in the idler bracket Fig 518 Fig 518 DSC 2650 Fig 516 DSC 2595 6 Install the rear bumper assembly and tighten the 4 bolts Fig 516 Left Hand Mower Idler Assembly Removal Note Rear tire...

Page 184: ...p bolt spacer and nut Fig 520 Fig 520 DSC 2735 Fig 522 DSC 2741 6 Remove the bolt and nut retaining the idler bracket to the frame Fig 522 Fig 521 DSC 2737 5 Remove the bolt spacer 2 washers and nut o...

Page 185: ...C 2743 Fig 526 DSC 2737 2 Fasten the tension spring to the frame with the bolt spacer 2 washers and a nut Fig 526 Fig 525 DSC 2741 1 Install the left hand idler bracket to the frame with bolt and nut...

Page 186: ...hten the 4 bolts Fig 529 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 e...

Page 187: ...Remove the mower belt from the mower pulleys idler pulleys and the top groove of the triple sheave jackshaft pulley Fig 533 Fig 533 fig 71 m 7419 7 Install the new belt around the mower pulleys idler...

Page 188: ...te 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 ne...

Page 189: ...DSC 2596 4 Pull the spring loaded idler down and remove the fan drive belt Fig 538 MOWER DECKS 6 Remove the bolt spacer washers and nut retaining the clutch brake strap to the frame Fig 540 Fig 540 DS...

Page 190: ...e belt off the idler pulleys and the PTO clutch Fig 543 Fig 542 DSC 2651 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...

Page 191: ...of the jackshaft pulley the adjustable idler pulley and around the inner sheave of the PTO clutch pulley Fig 549 Fig 549 fig 74 m 7404 MOWER DECKS 1 Belt drive 4 Fixed idler pulley 2 Clutch 5 Three s...

Page 192: ...acket Pull back to relieve tension on the idler bracket Install the belt onto the idler pulley Fig 550 MOWER DECKS 1 Belt drive 4 Fixed idler pulley 2 Clutch 5 Three stacked pulleys 3 Spring loaded id...

Page 193: ...ing position 4 Check the tire pressure of all four tires If needed adjust to 13 psi 90 kPa Leveling the Mower 22 Install the mower spindle belt refer to Mower Spindle Belt page 7 39 23 Install the rea...

Page 194: ...to Rear Mower Pitch on page 7 48 Leveling the Mower Side to Side 1 Position the right blade side to side Fig 557 Fig 557 fig 65 m 1078 2 Measure the right blade at the B location Fig 557 from a level...

Page 195: ...et to the same distance 9 Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm Fig 559 fig 67 m 6830 1 Rear chain 5 Adjustment bolt 2 Rear sup...

Page 196: ...e same amount to maintain equal chain tension 7 Loosen the front swivel jam nuts at the front of the right and left swivels approximately 1 2 inch 13mm Fig 562 and Fig 563 4 Front swivel 6 Lift nut 5...

Page 197: ...ning 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...

Page 198: ...Z Master Z597 Diesel Series Service Manual Form No 492 9150...

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