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Toro Z Master Z597 Service Manual
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Toro Z Master Z597 Service Manual

Diesel series
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Summary of Contents for Toro Z Master Z597

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

  • Page 2: About This 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.
  • Page 3 THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 4: Table Of Contents

    Hydraulic Fan Motor Installation ......4-20 Z Master Z597 Diesel Service Manual...
  • Page 5 ....... . . 6-24, 25 Z Master Z597 Diesel Service Manual...
  • Page 6 7-48 Adjusting the Compression Spring ......7-50 Z Master Z597 Diesel Service Manual...
  • Page 7 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. Z Master Z597 Diesel Service Manual...
  • Page 8 Engine ....Electrical ....Mower Decks ... Z Master Z597 Diesel Service Manual...

  • Page 9: Safety Information

    Publications Department are for troubleshooting, service, and repair of the personal injury or even death. 8111 Lyndale Avenue South Z Master Z597 Zero-turn Riding Mower Bloomington, MN 55420 This manual is intended as a service and repair manual only. The safety instructions provided herein...
  • Page 10 Engine ....Electrical ....Mower Decks ... Z Master Z597 Diesel Service Manual...

  • Page 11: Machine Profile Photos

    SPECIFICATIONS MACHINE PROFILE PHOTOS Fig 001 DSC-2789 Fig 003 DSC-2792 Fig 002 Fig 004 DSC-2790 DSC-2794 Z Master Z597 Diesel Service Manual...
  • Page 12 Rear: 26” x 12” – 12 Front: 13” x 6.5” – 6 Tire Pressure Rear: 13 psi (90kPa) Front: 13 psi (90kPa) Attachment Drive 200 ft-lb. electromagnetic clutch (271.16 Nm) Battery BCI Group Size: 26 540 cold cranking amps. Z Master Z597 Diesel Service Manual...
  • Page 13 Discharge Chute 5/16” (.79cm) Rubber Cutting Height 1-1/2” – 5” (3.81 - 12.7cm) Carrier Frame Construction 2” x 2” x 3/16” (5.08 x 5.08 x .476cm) Steel Anti-scalp Rollers Certification ANSI, CARB, EPA, OSHA Z Master Z597 Diesel Service Manual...

  • Page 14: General Specifications

    Check the fluid level while the fluid is warm. The fluid should be between cold and hot. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Fig. 006 above). Z Master Z597 Diesel Service Manual...

  • Page 15: Available Service Manuals / Service Aids

    Briggs & Stratton Daihatsu 3 Cylinder Liquid-Cooled Engine Repair Manual Form # 492-0670 Hydraulic Troubleshooting: Interactive hydraulic troubleshooting and failure analysis on compact disk Form #492-4777 Electrical Troubleshooting: Interactive electrical troubleshooting and wiring diagrams on compact disk Form #492-9143 Z Master Z597 Diesel Service Manual...

  • Page 16: 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.

  • Page 17: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Z Master Z597 Diesel Service Manual...

  • Page 18: Standard Torque For Dry, Zinc, And Steel Fasteners (Metric Fasteners)

    Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Z Master Z597 Diesel Service Manual...

  • Page 19: Other Torque Specifications

    All torque values are based on non- lubricated fasteners. Conversion Factors in-lb X 11.2985 - N-cm N-cm X - 0.08851 = in-lb ft-lb X 1.3558 = N-m N-cm X 0.73776 - ft-lb 2-10 Z Master Z597 Diesel Service Manual...

  • Page 20: Equivalents And Conversions

    23.812 29/64 0.453125 11.509 61/64 0.953125 24.209 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 0.484375 12.303 63/64 0.984375 25.003 0.5000 12.700 1.000 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm Z Master Z597 Diesel Service Manual 2-11...

  • Page 21: U.s. To Metric Conversions

    Foot-pounds Newton-Meters 1.356 Foot-pounds Kilogram-Meters Work 0.1383 Inch-pounds Kilogram-Centimeters 1.152144 Quarts Liters 0.9463 Liquid Volume Gallons Liters 3.785 3.785 Gallons/Minute Liters/Minute Liquid Flows 1. Subtract 32° Fahrenheit Celsius Temperature 2. Multiply by 5/9 2-12 Z Master Z597 Diesel Service Manual...
  • Page 22 Engine ....Electrical ....Mower Decks ... Z Master Z597 Diesel Service Manual...

  • Page 23: Caster Fork Assembly Removal

    2. With a hammer and chisel, remove the top grease cap (Fig. 009). Fig 010 DSC-1532 4. Remove the Belleville washers, caster fork and wheel assembly (Fig. 011). Fig 009 mvc-1531 Fig 011 DSC-1533 Z Master Z597 Diesel Service Manual...

  • Page 24: Replacing The Caster Bearings

    013). the top and bottom end (Fig. 015). Tap the bearing cups in until they seat against the step in the caster hub. Fig 013 DSC-1535 Fig 015 DSC-1537 Z Master Z597 Diesel Service Manual...

  • Page 25: Caster Fork Assembly

    (Fig. 017). 3. Install the Belleville (spring) washers as shown in (Fig. 019). A. Dust Cap B. Locknut C. Spring Washers Fig 017 DSC-1538 Fig 019 washers line art Z Master Z597 Diesel Service Manual...

  • Page 26: Front Wheel Removal And Bearing Replacement

    Replacement passing through the upper bearing (Fig. 021). 1. Raise the front of the unit off the ground. 2. Remove the wheel bolt from the fork (Fig. 023). Fig 021 DSC-1540 Fig 023 DSC-1543 Z Master Z597 Diesel Service Manual...

  • Page 27: Fuel Tank Removal

    Fig. 024. Pump grease into the wheel bearings through the grease fitting located on the rim (Fig. 025). 3. Remove the fuel return line located on the inside of the fuel tank (Fig. 027). Fig 025 DSC-1547 Fig 027 DSC-1549 Z Master Z597 Diesel Service Manual...
  • Page 28 5. Remove the bolt, washer, and nut securing the left 7. Remove the tank from the frame (Fig. 031). rear of the fuel tank bracket to the frame (Fig. 029). Fig 031 DSC-1555 Fig 029 DSC-1552 Z Master Z597 Diesel Service Manual...

  • Page 29: Right Side Fuel Tank Installation

    3 thread above nut A. Tank Stud D. Nut B. Compression Spring E. 3 Threads C. Tank mounting Plate Left Side Fuel Tank Removal 1. Disconnect the negative battery cable. Empty the fuel tank. Z Master Z597 Diesel Service Manual...
  • Page 30 (Fig. 037). of the unit. NOTE: It is not necessary to disconnect any cables or wiring. 4. Unplug the 3 connectors that plug into the delay module (Fig. 035). Fig 037 DSC-1566 Fig 035 DSC-1578 Z Master Z597 Diesel Service Manual...
  • Page 31 They are located under 10. Remove the fuel tank from the frame (Fig. 041). the right rear of the fuel tank (Fig. 039). Fig 041 DSC-1575 Fig 039 DSC-1571 3-10 Z Master Z597 Diesel Service Manual...

  • Page 32: Left Side Fuel Tank Installation

    Remove the hood from the frame of the unit (Fig. 045). Fig 043 3 thread above nut Fig 045 DSC-1581 A. Tank Stud D. Nut B. Compression Spring E. 3 Threads C. Tank mounting Plate Z Master Z597 Diesel Service Manual 3-11...

  • Page 33: Hood Assembly Installation

    (Fig. 049). Fig 046 DSC-1584 3. Remove the ball knob located on the throttle control by applying upward pressure under the knob (Fig. 047). Fig 049 DSC-1592 Fig 047 DSC-1586 3-12 Z Master Z597 Diesel Service Manual...

  • Page 34: Installation

    2. Feed the throttle cable through the tie strap on the removal bracket, Ref. B (Fig. 051). radiator fan motor mount (Fig. 053). NOTE: DO NOT cut or remove the tie straps. Fig 053 DSC-1597 Fig 051 DSC-1594 Z Master Z597 Diesel Service Manual 3-13...
  • Page 35 Note: The cable wire should be routed through the swivel clamp, with the swivel clamp washer located under the cable wire (Fig. 055). Fig 057 DSC-1606 Fig 055 DSC-1600 A. Cable wire B. Washer 3-14 Z Master Z597 Diesel Service Manual...
  • Page 36 (Fig. 061). (6.35mm) of the throttle cable wire protrudes through the opposite end of the clamp. Carefully tighten the swivel clamp screw (Fig. 059). Fig 061 DSC-1617 Fig 059 DSC-1614 Z Master Z597 Diesel Service Manual 3-15...
  • Page 37 5. Slide the brake shaft out of the frame pivot bushings (Fig 065). Fig 062 DSC-1618 3. Lift the floor pan assembly to access the brake lever shaft and cotter pin (Fig. 063). Fig 065 DSC-1621 Fig 063 DSC-1619 3-16 Z Master Z597 Diesel Service Manual...

  • Page 38: Brake Lever Installation

    7. Inspect the brake shaft and bushings for excessive wear. Replace any worn or broken components (Fig. 067). Fig 068 DSC-1624 2. Remove the four wheel lug bolts. Fig 067 DSC-1623 A. Brake Lever C. Cotter Pin B. Bushings Z Master Z597 Diesel Service Manual 3-17...

  • Page 39: Brake Band Installation

    1. Install the brake band around the wheel hub (Fig. 1. Raise the rear end of the unit and remove the right 070). and left rear tires. Note: To prevent the unit from rolling, block the two front tires. Fig 070 DSC-1629 3-18 Z Master Z597 Diesel Service Manual...
  • Page 40 3. Remove the cotter pin and clevis pin from the left 5. On the right side, remove the two bolts and nuts side lower brake linkage assembly (Fig. 073). holding the flange bearing (Fig. 075). Fig 073 DSC-1633 Fig 075 DSC-1635 Z Master Z597 Diesel Service Manual 3-19...

  • Page 41: Brake Shaft Installation

    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. 079). Fig 077 DSC-1637 Fig 079 DSC-1640 3-20 Z Master Z597 Diesel Service Manual...
  • Page 42 DSC-1641 brake rod clevis (Fig. 082). A. Brake Lever Arm C. Bolt B. Spacer Fig 082 DSC-1644 5. Install left and right rear tires. Torque wheel mounting bolts to 95 ft-lbs (128.8 Nm). Z Master Z597 Diesel Service Manual 3-21...

  • Page 43: Adjusting The Parking Brake

    1/4 - 5/16” (5 - 8mm) Brake lever - disengaged Spring bracket Spring, 2-3/4” (70mm) Lock nut below trunion Jam nut above trunion roller roller Nut below spring bracket 10. Brake rod Trunion roller 11. Yoke 3-22 Z Master Z597 Diesel Service Manual...

  • Page 44: Deck Lift Lever Removal

    4”x 4” block under each corner of the deck. Lower the mower deck onto the support blocks to remove the weight from the support chains (Fig. 085). Fig 087 DSC-1650 Fig 085 DSC-1648 Z Master Z597 Diesel Service Manual 3-23...
  • Page 45 9. Lift the floor pan assembly to its fully opened position (Fig. 091). 7. Remove hex bolt, nut, and lift lever bushing from the lower deck lift plate mounting location (Fig. 089). Fig 091 DSC-1654 Fig 089 DSC-1652 3-24 Z Master Z597 Diesel Service Manual...
  • Page 46 RH floor pan hinge mounting hardware. Push the RH hinge upward. Re-tighten the RH floor pan hinge mounting hardware (Fig. 095). Fig 093 DSC-1656 Fig 095 DSC-1661 A. RH Floor pan hinge Z Master Z597 Diesel Service Manual 3-25...

  • Page 47: Deck Lift Lever Installation

    15. Carefully slide the lift lever assembly out of its carrier frame pivot (Fig. 097). 2. Install lift lever assembly into front frame pivot location (Fig. 099). Fig 097 DSC-1667 Fig 099 DSC-1670 3-26 Z Master Z597 Diesel Service Manual...
  • Page 48 (outer). From the outside of the frame, install hex bolt, spacer, and flanged lock nut as shown. Tighten bolt (Fig. 103). Fig 101 DSC-1674 A. Bushing Fig 103 DSC-1677 A. Hex Bolt C. Flanged Lock Nut B. Spacer Z Master Z597 Diesel Service Manual 3-27...
  • Page 49 10. Install hex nut on end of deck lift rod. Tighten against deck mount swivel. Repeat procedure for opposite side deck lift rod (Fig. 107). Fig 105 DSC-1681 A. HOC Pin Fig 107 DSC-1683 3-28 Z Master Z597 Diesel Service Manual...

  • Page 50: Motion Control Assembly Removal

    Fig 109 DSC-1686 Fig 108 DSC-1685 2. Remove floor pan assembly (Fig. 110). 12. Untie the floor pan assembly and lower. Return motion control lever to its neutral locked position. Fig 110 DSC-1689 Z Master Z597 Diesel Service Manual 3-29...
  • Page 51 (Fig. 113). Fig 111 DSC-1690 Fig 113 DSC-2062 4. Remove pocket (Fig. 112). 6. Disconnect motion control dampener from motion control assembly (Fig. 114). Fig 112 DSC-1691 Fig 114 DSC-1695 3-30 Z Master Z597 Diesel Service Manual...
  • Page 52 8. Remove bolt, spacer, and nut that retains the ball bearing on the inside of the motion control (Fig. 118). joint to the motion control (Fig. 116). Fig 118 DSC-2066 Fig 116 DSC-2063 Z Master Z597 Diesel Service Manual 3-31...

  • Page 53: Motion Control Assembly Installation

    11. Remove the two bolts and nuts that retain the flange bearing on the outside of the motion control (Fig. 119). Reverse the order of removal Fig 119 DSC-2067 12. Remove the motion control from the frame (Fig. 120). Fig 120 DSC-2068 3-32 Z Master Z597 Diesel Service Manual...

  • Page 54: Hydraulic System

    Engine ....Electrical ....Mower Decks ... Z Master Z597 Diesel Service Manual...

  • Page 55: Hydrostatic Pump Removal

    3. Remove the two knobs located on the engine access panel assembly. Remove both engine belt shield and the engine access panel (Fig. 121). Fig 123 DSC-2081 Fig 121 DSC-2071 Z Master Z597 Diesel Service Manual...
  • Page 56 (Fig. 126). Install caps on the hydraulic line and on the fittting. 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 Z Master Z597 Diesel Service Manual...
  • Page 57 10. Loosen and remove the two bolts and nuts retaining the hydrostatic pump to the frame (Fig. 128). Fig 130 DSC-2094 Fig 128 DSC-2091 13. For service work on the hydrostatic pump refer to the Hydro-Gear Service Manual, Form 492-4789. Z Master Z597 Diesel Service Manual...

  • Page 58: Hydrostatic Pump Installation

    4. Tighten the two sets screws on the pulley using a 12- sure the key is facing up on the shaft (Fig. 132). point 3/8” (9.5mm) socket (Fig. 134). Fig 132 DSC-2095 Fig 134 DSC-2089 Z Master Z597 Diesel Service Manual...
  • Page 59 Note: It may be easier to remove the rear tire assembly for installation of the bottom and side hydraulic hoses. Z Master Z597 Diesel Service Manual...
  • Page 60 14. Install the engine belt shield and the engine access panel. Install the two knobs (Fig. 141). Fig 139 DSC-2073 10. Install two cable ties for the fuel line and the wiring harness (Fig. 140). Fig 141 DSC-2071 Fig 140 DSC-2101 Z Master Z597 Diesel Service Manual...

  • Page 61: Wheel Motor Removal

    5. Remove the 3 bolts securing the brake band to the actuator (Fig. 145). Fig 142 DSC-2102 3. Apply the parking brake and remove the cotter pin from the wheel motor output shaft (Fig. 143). Fig 145 DSC-2106 Fig 143 DSC-2103 Z Master Z597 Diesel Service Manual...
  • Page 62 9. Remove the front two wheel motor mounting bolts, lock washers, and nuts (Fig. 149). Fig 147 DSC-2108 Note: The Hub Removal Tool (TOR 4097) can also Fig 149 DSC-2111 be used and is available through your Toro Distributor. Z Master Z597 Diesel Service Manual...

  • Page 63: Wheel Motor Installation

    (Fig. 151). Fig 152 DSC-2117 A. Short Spacer B. Long Spacer Fig 151 DSC-2114 12. For service work on the wheel motor refer to the Parker/Ross Service Manual, Form #492-4753. 4-10 Z Master Z597 Diesel Service Manual...
  • Page 64 4. Install the two rear bolts and long spacers through holes (Fig. 154). the wheel motor and frame. 5. Torque the bolts to 80 to 90 ft-lbs. (108 to 122 Nm) (Fig. 156). Fig 154 DSC-2119 Fig 156 DSC-2122 Z Master Z597 Diesel Service Manual 4-11...
  • Page 65 9. Install spacers, brake band retainer, and brake band woodruff key is in place (Fig. 158). around the wheel hub and tighten all three retainer bolts (Fig. 160). Fig 158 DSC-2125 Fig 160 DSC-2106 4-12 Z Master Z597 Diesel Service Manual...

  • Page 66: Purging The Hydraulic System

    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, page 4-13. Fig 163 DSC-2353 Z Master Z597 Diesel Service Manual 4-13...

  • Page 67: Hydraulic Fan Pump Removal

    O-rings and gaskets with clean petroleum jelly prior to installation. 1. Loosen the 4 bolts on the rear bumper assembly and remove. Note: DO NOT remove the bolts (Fig. 164). Fig 166 DSC-2361 Fig 164 DSC-2359 4-14 Z Master Z597 Diesel Service Manual...
  • Page 68 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 170 DSC-2367 Fig 168 DSC-2363 Z Master Z597 Diesel Service Manual 4-15...

  • Page 69: Hydraulic Fan Pump Installation

    Note: Always use new set screws when installing 1. Install the hydraulic fan pump with four bolts and the pump drive pulley. nuts to the fan pump mounting plate (Fig. 172). Fig 174 DSC-2361 Fig 172 DSC-2367 4-16 Z Master Z597 Diesel Service Manual...

  • Page 70: Hydraulic Fan Motor Removal

    DSC-2369 6. Check the hydraulic fluid in the reservoir tank. Add oil of necessary. Air may need to be purged in the system. Follow the procedures on Purging the Hydraulic System, page 4-13. Z Master Z597 Diesel Service Manual 4-17...
  • Page 71 (Fig. 181). 3. Remove the two knobs located on the engine access panel assembly. Remove the engine belt shield and the engine access panel (Fig. 179). Fig 181 DSC-2374 Fig 179 DSC-2071 4-18 Z Master Z597 Diesel Service Manual...
  • Page 72 Fig 182 DSC-2377 7. Place a small oil drain pan on top of the engine. Loosen and remove the hydraulic lines to the hydraulic fan motor (Fig. 183). Fig 185 DSC-2380 Fig 183 DSC-2378 Z Master Z597 Diesel Service Manual 4-19...

  • Page 73: Hydraulic Fan Motor Installation

    (Fig. 187). is recessed approximately 1/2” (12.7mm) from the outside of the fan hub (Fig. 189). 1/2 inch (12.7mm) Fig 187 DSC-2383 A. Mounting tab B. Case drain fitting Fig 189 DSC-2391 4-20 Z Master Z597 Diesel Service Manual...
  • Page 74 5. Install the fan motor mount to the fan mounting plate (Fig. 191). Fig 192 DSC-2404 A. Mounting tab 7. Install the hydraulic lines to the hydraulic fan motor and tighten (Fig. 193). Fig 191 DSC-2380 Fig 193 DSC-2378 Z Master Z597 Diesel Service Manual 4-21...
  • Page 75 Secure the throttle cable to the clamp with a tie strap (Fig. 195). Fig 197 DSC-2071 Fig 195 DSC-2405 4-22 Z Master Z597 Diesel Service Manual...

  • Page 76: Setting The Hydrostatic Pump Neutral

    Setting the Hydrostatic Pump Neutral 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 200 DSC-2357 Z Master Z597 Diesel Service Manual 4-23...

  • Page 77: Adjusting The Handle Neutral

    (Fig. 202). 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. 4-24 Z Master Z597 Diesel Service Manual...

  • Page 78: Setting The Lh Hydrostatic Pump Neutral

    4. Open engine throttle to Fast. Make sure wheel 10. Tighten the nut and jam nut (Fig. 202). remains stopped or slightly creeps in reverse; adjust if necessary. 11. Repeat on the opposite side of the machine. Z Master Z597 Diesel Service Manual 4-25...

  • Page 79: Setting The Rh Hydrostatic Pump Neutral

    6. Tighten the locknuts at the ball joints (Fig. 207). Note: Motion control lever must be in neutral while making any adjustments. Fig 207 DSC-2569 4-26 Z Master Z597 Diesel Service Manual...

  • Page 80: Adjusting The Tracking

    Fig 208 DSC-2568 Adjust 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. Z Master Z597 Diesel Service Manual 4-27...

  • Page 81: Hydraulic Flow Testing Procedure

    5. To make the machine go left, turn the knob towards the left side of the machine (Fig. 210 above). 6. Repeat adjustments until the tracking is correct. Fig 211 DSC-2573 4-28 Z Master Z597 Diesel Service Manual...
  • Page 82 If using a directional flow tester, be sure to correctly connect hoses. Fig 215 DSC-2355 Fig 213 DSC-2576 Z Master Z597 Diesel Service Manual 4-29...

  • Page 83: Cooling Fan Pump Flow Testing Procedure

    “Hot” level mark; refer to Figure 006, page 2-5. 17. Reinstall the left rear tire and lower the unit to the ground. Remove the temporary jumper cable and reconnect the seat switch. Reconnect the electric PTO clutch. 4-30 Z Master Z597 Diesel Service Manual...

  • Page 84: Replacing The Traction Pump Drive Belt

    Run the machine at full speed. The gauge should read approximately 3 to 4 gpm (11 to 15 lpm) under no restriction. Record the flow reading. Z Master Z597 Diesel Service Manual 4-31...

  • Page 85: Pushing The Machine By Hand

    1 turn to prevent the valves from coming Fig 219 DSC-000 out of the body and causing fluid to run out. 1. Spring loaded idler pulley 3. Disengage the parking brake before pushing. 2. Pump drive belt 4-32 Z Master Z597 Diesel Service Manual...

  • Page 86: 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. Fig 221 DSC-2795 Z Master Z597 Diesel Service Manual 4-33...
  • Page 87 HYDRAULIC SYSTEM 4-34 Z Master Z597 Diesel Service Manual...

  • Page 88: Engine

    Engine ....Electrical ....Mower Decks ... Z Master Z597 Diesel Service Manual...

  • Page 89: Engine Removal

    (Fig. 225) 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 225 DSC-2411 Fig 223 DSC-2071 Z Master Z597 Diesel Service Manual...
  • Page 90 8. At the right rear of machine, loosen and remove the hose clamp on the engine inlet cooling hose at the radiator (Fig. 228). Lower the hose and drain any coolant that is left in the hose. Fig 226 DSC-2413 Fig 228 DSC-2425 Z Master Z597 Diesel Service Manual...
  • Page 91 Loosen and remove the hydraulic lines to the corner of the radiator (Fig. 232). Cap the fittings to hydraulic fan motor (Fig. 230). Cap the fittings to prevent contamination. protect from any dirt or debris. Fig 232 DSC-2433 Fig 230 DSC-2378 Z Master Z597 Diesel Service Manual...
  • Page 92 14. Remove the six bolts, three on each side, retaining belt from the engine and hydro pump pulleys (Fig. the radiator and fan mounting plate assembly to the 236). right and left upper frame (Fig. 234). Fig 236 DSC-2439 Fig 234 DSC-2371 Z Master Z597 Diesel Service Manual...
  • Page 93 Remove the two clamps and remove the fuel lines from the engine bolts and nuts on the air cleaner mount (Fig. 238). (Fig. 240). Fig 238 DSC-2441 Fig 240 DSC-2443 Z Master Z597 Diesel Service Manual...
  • Page 94 22. Remove the following wires from the engine: • Pink/Black wire to the glow plug strap (A) • Yellow/Red wire to the temperature sender (B) • Black/Green wire to the temperature switch (C) (Fig. 242). Fig 244 DSC-2447 Fig 242 DSC-2445 Z Master Z597 Diesel Service Manual...
  • Page 95 Remove the bolt located at the bottom of the alternator and remove the 31. Loosen the 4 bolts to the rear bumper assembly and alternator (Fig. 246). remove (Fig. 248). Fig 246 DSC-2448 Fig 248 DSC-2452 Z Master Z597 Diesel Service Manual...
  • Page 96 Fig 251 DSC-2457 (Fig. 250). 36. Remove the bolt holding the ball joint link to the flywheel cover (Fig. 252). Fig 250 DSC-2455 Fig 252 DSC-2458 Z Master Z597 Diesel Service Manual...
  • Page 97 (Fig. Fig 255 DSC-2469 254). 40. Remove the bolt, washer and nut on the engine rear mount (Fig. 256). Fig 254 DSC-2468 Fig 256 DSC-2470 5-10 Z Master Z597 Diesel Service Manual...

  • Page 98: Engine Installation

    Fig 257 DSC-2480 Fig 259 DSC-2482 Engine Installation 1. Before installing the engine, make sure the large washer is located on top of the rear engine mount isolator (Fig. 258). Fig 258 DSC-2481 Z Master Z597 Diesel Service Manual 5-11...
  • Page 99 7. Tighten all three engine mount bolts and nuts once alignment has been achieved. 5. Install the left hand engine mount bolt following the same pattern as the right hand engine mount bolt. Do not tighten the bolt and nut. 5-12 Z Master Z597 Diesel Service Manual...
  • Page 100 B. Screw HH F. Washer, large C. Ball joint assembly G. Isolator C. Ball joint assembly G. Isolator D. Nut - jam H. Nut - lock D. Nut - jam H. Nut - lock Z Master Z597 Diesel Service Manual 5-13...
  • Page 101 (Fig. 269). Fig 267 deck belt drive Fig 269 DSC-2451 A. Nut - lock E. Spacer, large B. Washer, large F. Washer, flat C. Spacer G. Screw, HH D. Grommet, brake 5-14 Z Master Z597 Diesel Service Manual...
  • Page 102 19. Install the bolt through the wiring clamp that holds the wiring harness to the top of the alternator (Fig. 273). Fig 271 DSC-2492 Fig 273 DSC-2447 Z Master Z597 Diesel Service Manual 5-15...
  • Page 103 • Pink/Black to the glow plug strap (A) • Yellow/Red to the temperature sender (B) 24. Install the air cleaner assembly (Fig. 277). • Black/Green to the temperature switch (C) (Fig. 275). Fig 277 DSC-2442 Fig 275 DSC-2445 5-16 Z Master Z597 Diesel Service Manual...
  • Page 104 26. Install the air intake hose between the engine and air filter. Tighten the hose clamps (Fig. 279). 28. Install the radiator and frame assembly to the right and left upper frame (Fig. 281). Fig 279 DSC-2440 Fig 281 DSC-2435 Z Master Z597 Diesel Service Manual 5-17...
  • Page 105 32. Install the case drain hydraulic line at the tee radiator cap. Install a tie strap to hold it in place (Fig. fitting, located at the left front corner of the radiator 283). assembly (Fig. 285). Fig 283 DSC-2496 Fig 285 DSC-2429 5-18 Z Master Z597 Diesel Service Manual...
  • Page 106 Install the clamp mounting plate (Fig. 289). and tighten the clamp through the access hole in the fan mounting plate (Fig. 287). Fig 289 DSC-2374 Fig 287 DSC-2428 Z Master Z597 Diesel Service Manual 5-19...
  • Page 107 DSC-2503 38. Check the hydraulic fluid in the reservoir; refer to Figure 006, page 2-5. 39. Install the battery in the unit and connect the positive and negative battery cables. Fig 293 DSC-2452 5-20 Z Master Z597 Diesel Service Manual...

  • Page 108: Cooling System

    • Do not touch radiator and surrounding parts that are hot. Fig 295 DSC-2505 1. Disconnect the battery negative cable. Z Master Z597 Diesel Service Manual 5-21...
  • Page 109 3. Remove the two knobs located on the engine access and remove the hood assembly (Fig. 300). panel. Remove the engine belt shield and the engine access panel (Fig. 298). Fig 300 DSC-2411 Fig 298 DSC-2071 5-22 Z Master Z597 Diesel Service Manual...
  • Page 110 9. Remove the tie strap holding the radiator overflow the hose and drain any coolant that is left in the hose, located at the radiator cap (Fig. 304). hose. Fig 304 DSC-2434 Fig 302 DSC-2425 Z Master Z597 Diesel Service Manual 5-23...
  • Page 111 Cap the hydraulic fittings to prevent contamination. Fig 308 DSC-2657 Fig 306 DSC-2656 5-24 Z Master Z597 Diesel Service Manual...

  • Page 112: Radiator Installation

    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). Fig 312 DSC-2657 Fig 310 DSC-2659 Z Master Z597 Diesel Service Manual 5-25...
  • Page 113 DSC-2656 5. Install and tighten the tank return hydraulic hose assembly to the radiator. This is located at the left rear corner of the radiator (Fig. 314). Fig 316 DSC-2428 Fig 314 DSC-2652 5-26 Z Master Z597 Diesel Service Manual...
  • Page 114 13. Recheck the hydraulic reservoir tank at the hot level mark; add oil if necessary. Also, recheck the coolant level in the overflow bottle. Fig 319 DSC-2410 Z Master Z597 Diesel Service Manual 5-27...

  • Page 115: Checking The Radiator Coolant

    2. Indicator line on side of overflow bottle Fig 321 DSC-2370 3, If the coolant level is low, add a 50/50 mix of extended life antifreeze/Dex-Cool and water to the overflow bottle to the indicator line on the bottle. 5-28 Z Master Z597 Diesel Service Manual...

  • Page 116: Replacing The Fan Pump Drive Belt

    2. Pull the spring loaded idler down and remove the Alternator Belt fan pump drive belt from the engine and pump pulley (Fig. 324). Check the alternator belt for wear after every 50 hours of operation. Fig 324 DSC-2581 Z Master Z597 Diesel Service Manual 5-29...

  • Page 117: Replacing The Alternator Belt

    Replacing the Traction Pump Drive Belt, page 4-31. Fig 328 fig 80 m-7421 1. Alternator 4. Deflection, 3/8 to 1/2 2. Alternator belt inch (10 to 13mm) 3. Handle 5. Top bolt 6. Bottom bolt 5-30 Z Master Z597 Diesel Service Manual...

  • Page 118: Tensioning The Alternator Belt

    (Fig. 328). 3. Tighten the alternator bolts. 4. Check the deflection in the belt again and adjust the belt if needed (Fig. 330). Fig 332 DSC-2071 Fig 330 DSC-2586 Z Master Z597 Diesel Service Manual 5-31...

  • Page 119: Servicing The Fuel Filter

    8. Bleed the air from the fuel line by priming the fuel system. Refer to Priming the Fuel System, page 5-34. Fig 333 fig 48 m-7409 1. Fuel filter 4. O-ring 2. Sensor wire 5. Metal Primer button 3. Drain plug 5-32 Z Master Z597 Diesel Service Manual...

  • Page 120: Changing The Fuel Filter

    6. Remove the drain plug and discard the O-ring (Fig. 337). Fig 335 DSC-2589 Fig 337 fig 48 m-7409 1. Fuel filter 4. O-ring 2. Sensor wire 5. Metal Primer button 3. Drain plug Z Master Z597 Diesel Service Manual 5-33...

  • Page 121: Priming The Fuel System

    This should take about 10 – 15 pushes on the primer button (Fig. 340). Fig 338 DSC-2591 12. Start the engine and check for leaks. Fig 340 DSC-2588 5-34 Z Master Z597 Diesel Service Manual...
  • Page 122 ELECTRICAL Safety Information ..Specifications ... Chassis ....Hydraulic System ..Engine .

  • Page 123: Electrical System

    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.
  • Page 124 ELECTRICAL How It Works Testing A relay is an electrically actuated switch. 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.
  • Page 125 ELECTRICAL Location 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 345). 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...
  • Page 126 ELECTRICAL IGNITION SWITCH 5. Verify that there is continuity between the appropriate terminals in the ON and OFF positions (Fig. 347). Purpose The ignition switch provides the proper switching for the OFF (IN) ON (OUT) starter, accessories, and safety circuits. Cont.

  • Page 127: Neutral Safety Switch

    ELECTRICAL NEUTRAL SAFETY SWITCH How It Works Detents inside the switch give it 3 positions: OFF, RUN, Purpose and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is Used to ensure the motion control handles are in neutral released (Fig.

  • Page 128: Park Brake Switch

    ELECTRICAL PARK BRAKE SWITCH Testing This single pole plunger (normally open) type switch Purpose has two terminals. When the motion control handles are in the neutral position (handles in the out position), The purpose of the brake switch is to ensure the it pushes on the plunger, closing the contact and machine is in neutral and the parking brake is applied connecting the terminals (Fig.
  • Page 129 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.

  • Page 130: Seat Switch

    ELECTRICAL SEAT SWITCH How It Works When the seat is vacated, the switch is open and there Purpose should be NO continuity between the two terminals. When the seat is occupied, the switch closes and there The switch is in the safety circuit. If the engine is should be continuity between the two terminals (Fig.

  • Page 131: Delay Module

    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, When operating the unit on rough terrain and the carbon film resistors, diodes and a relay. These all work operator comes off the seat, the seat delay module will together to supply seat switch temporary voltage to the temporarily delay the engine shutting down, preventing...

  • Page 132: Dual-Tone Alarm

    ELECTRICAL DUAL-TONE ALARM 2. Remove the 4 bolts to the control panel and raise the panel. Purpose 3. Connect a VOM positive lead to the blue wire on the module (Fig. 361). Connect the negative lead to the The dual-tone alarm is an audible alarm system to alert battery negative terminal.
  • Page 133 ELECTRICAL How It Works Testing 12 VDC is applied to the audible alarm when the ignition Connect a positive leadfrom a 12 volt battery to the key is on. For pulse and continuous tone a ground is + terminal on the back of the audible alarm. Connect needed to activate the audible alarm.

  • Page 134: Glow Plug Controller

    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.
  • Page 135 ELECTRICAL Step 1 Testing the “timed” output in the “run” Step 2 Testing continuous output in the “START” position (Fig. 367). position (Fig. 368). set for K set for K BLACK BLACK Fig 367 glow plug timer test 2 Fig 368 glow plug timer test 3 A.

  • Page 136: Temperature Sender

    ELECTRICAL TEMPERATURE SENDER How It Works When the water temperature increases the internal Purpose 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.

  • Page 137: Oil Pressure Switch

    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 When the oil pressure drops, the switch activates an pressure drops, the contacts in the switch close, audible alarm which alerts the operator to shut the grounding the audible alarm, which alerts the operator to...

  • Page 138: Water Temperature Gauge

    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 The purpose of the water temperature gauge is to increase (Fig.

  • Page 139: Hour Meter

    ELECTRICAL Back side of the Temperature Gauge with terminal and Location wire locations (Fig. 375). Raise the seat, the hour meter is located on the left side S Terminal - Yellow/Red Wire (to Temperature of the operator on the lower portion of the control panel Sender) (Fig.

  • Page 140: Volt Meter Gauge

    ELECTRICAL Testing How It Works The meter movement is proportional to the voltage Verify that 12 volts DC is present across the two level across the two terminals of the battery. This is terminals when the ignition key is in the RUN position. If accomplished by placing a resistor in parallel with the so, and the meter is not running, replace the meter.

  • Page 141: Electric Pto Clutch

    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 The electric clutch controls the engagement and whether the clutch has failed or another electrical disengagement of the Power Take Off (PTO) pulley.

  • Page 142: Measuring Clutch Current Draw

    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.

  • Page 143: Fuel Filter Sensor

    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 The fuel filter water sensor activates when too much of contacts.
  • Page 144 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.
  • Page 145 ELECTRICAL 6-24 Z Master 597 Diesel Series Service Manual...
  • Page 146 ELECTRICAL Z Master 597 Diesel Series Service Manual 6-25...
  • Page 147 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 6-26 Z Master 597 Diesel Series Service Manual...
  • Page 148 MOWER DECKS Safety Information ..Specifications ... Chassis ....Hydraulic System .

  • Page 149: Electric Pto Clutch Removal

    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 assem- bly and remove from the unit (Fig. 387). Fig 389 DSC-2597 Fig 387...
  • Page 150 MOWER DECKS 5. Disconnect the electric clutch harness from the 7. On the left side of the unit is the spring loaded idler wiring harness (Fig. 391). pulley for the mower drive belt. Note the square cut hole in the idler bracket (Fig. 393). Fig 391 DSC-2601 Fig 393...
  • Page 151 MOWER DECKS 9. On the right side of the unit is the spring loaded idler 11. Use a wheel puller to remove the fan pump drive pulley for the second mower drive belt. Insert a 3/8” pulley from the PTO clutch (Fig. 397). drive ratchet with a 6”...

  • Page 152: Pto Clutch Installation

    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 DSC-2618 Fig 399 DSC-2616 4. Install drive pulley; make sure the square key is in the pulley (Fig.
  • Page 153 MOWER DECKS 5. The retention hardware for the electric clutch is: a 7. Install the right side mower drive belt. Insert a 3/8” bolt, 2 spring washers, and a large washer (Fig. drive ratchet with a 6” extension into the square hole 403).
  • Page 154 MOWER DECKS Install the mower drive belt onto the outer clutch 10. Connect the PTO clutch harness to the wiring sheave, then the spring loaded idler pulley (Fig. harness (Fig. 409). 407). Fig 409 DSC-2601 Fig 407 DSC-2651 11. Install bolt, spacer, washer, and nut to retain the extension spring to the top of the fan pump tension 9.

  • Page 155: Mower Deck Removal

    MOWER DECKS Mower Deck Removal 12. Install the idler pulley to the fan pump tension assembly with a bolt and nut (Fig. 411). 1. Loosen the 4 bolts holding the rear bumper assembly and remove from the unit (Fig. 413). Fig 411 DSC-2597 Fig 413...
  • Page 156 MOWER DECKS 3. Disconnect the PTO clutch harness from the wiring 5. On the left side of the unit is the spring loaded idler harness (Fig. 415). pulley for the mower drive belt. Note the square cut hole in the idler bracket (Fig. 417). Fig 415 DSC-2601 Fig 417...
  • Page 157 MOWER DECKS 7. On the right side of the unit is the spring loaded 9. Remove the right side belt cover (Fig. 421). 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.
  • Page 158 MOWER DECKS 11. Remove the mower spindle belt from the top groove 13. Raise the mower deck to the transport position. of the jackshaft sheave pulley (Fig. 423). Install a 4 x 4 wood block under the right side of the mower deck.
  • Page 159 MOWER DECKS 15. Remove the bolt and nut holding the right rear strut 17. Raise the deck to transport position. Install a 4 x 4 pin from the strut assembly (Fig. 427). 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.

  • Page 160: Mower Deck Installation

    MOWER DECKS Mower Deck Installation 19. Follow steps 8 through 10 on the left side of the mower deck. 1. Slide the mower deck under the unit. 20. Remove the 4 x 4 wood block from under the left side of the mower deck and lower the deck to the 2.
  • Page 161 MOWER DECKS 4. Install the rear and front lift chains to the mower 11. Install the right mower drive belt on the bottom deck (Fig. 435). sheave of the jackshaft pulley (Fig. 436). Fig 435 DSC-2640 Fig 436 DSC-2641 5. Remove the hitch pin on the lift handle and raise the 12 Install the left mower drive belt on the middle sheave mower in the transport position.
  • Page 162 MOWER DECKS 13. Install the mower spindle belt around the idler 15. Install the right side belt cover (Fig. 440). pulleys and the top sheave of the jackshaft pulley (Fig. 438). Fig 440 fig. 74 m-7404 1. Drive belt 4. Adjustable idler pulley Fig 438 DSC-2643 2.
  • Page 163 MOWER DECKS 17. Install the RH drive belt around the fixed idler 18. Install the LH drive belt over the electric PTO clutch sheave. Insert a 3/8” drive ratchet with 6” extension and around the outer drive pulley. into the 3/8” square hole in the idler arm. Pull toward the back of the machine to overcome the idler spring 19.
  • Page 164 MOWER DECKS 22. Install the bolt, spacer, washers, and nut holding the 23. Connect the PTO clutch harness to the wiring clutch/brake strap to the frame (Fig. 446). harness plug (Fig. 448). Fig 446 DSC-2488 Fig 448 DSC-2601 Follow the hardware sequence in the diagram (Fig. 24.

  • Page 165: Mower Spindle Removal

    MOWER DECKS Mower Spindle Removal 25. Install the rear bumper assembly and tighten the 4 bolts (Fig. 450). 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.
  • Page 166 MOWER DECKS 6. Remove the right side belt cover (Fig. 452). 8. Remove the mower spindle drive belt (Fig. 454). Fig 452 DSC-2626 Fig 454 DSC-2661 7. Remove the tension spring on the idler arm (Fig. 9. Remove three bolts retaining the pulley to the pulley 453).

  • Page 167: Mower Spindle Disassembly

    MOWER DECKS Mower Spindle Disassembly 10. Raise the mower deck to the transport position. 11. Remove the mower blade from the spindle 1. Remove the nut and washer (Fig. 457). assembly. 12. Remove the 6 bolts and nuts from the spindle assembly.
  • Page 168 MOWER DECKS 3. Remove the bearing shield (Fig. 459). 5. Remove the seal spacer from the top of the spindle housing (Fig. 461). Fig 459 DSC-2671 Fig 461 DSC-2673 4. Remove the spindle housing from the spindle shaft 6. Remove the seal spacer from the bottom of the assembly (Fig.
  • Page 169 MOWER DECKS 7. Remove the top oil seal from the spindle housing 9. Remove the spacer (Fig. 465). (Fig. 463). Fig 465 DSC-2677 Fig 463 DSC-2675 10. Remove the split ring (Fig. 466). 8. Remove the tapered roller bearing from the top of the spindle housing (Fig.
  • Page 170 MOWER DECKS 11. Turn the spindle housing over and remove the oil 13. Using a hammer and a driver with a square edge, seal from the bottom of the spindle housing (Fig. drive both the top and bottom bearing races out of 467).

  • Page 171: Mower Spindle Assembly

    MOWER DECKS Mower Spindle Assembly 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 1. Install the spacer through the top of the spindle to remove it when installing new bearing races and housing (Fig.
  • Page 172 MOWER DECKS 3. Turn the spindle housing over and install the lower 5. Install the lower seal (Fig. 476). bearing race into the spindle housing (Fig. 474). Note: The open lip of the seal should be facing Note: The wider inside diameter of the bearing race outward.
  • Page 173 MOWER DECKS 7. Turn the spindle assembly over and install the split 9. Pack the tapered bearing with #2 grease and install ring spacer (Fig. 478). the tapered bearing (Fig. 480). Fig 478 DSC-2699 Fig 480 DSC-2694 8. Install the inner spacer to the spindle assembly (Fig. 10.
  • Page 174 MOWER DECKS 11. Install the bearing shield and the seal spacer onto 13. Install the seal spacer on the top of the spindle the spindle shaft (Fig. 482). housing (Fig. 484). Fig 482 DSC-2702 Fig 484 DSC-2704 12. Lower the spindle housing over the spindle shaft 14.
  • Page 175 MOWER DECKS 15. Install the square key onto the spindle shaft (Fig. 17. Install the heavy washer and nut on the top of the 486). spindle shaft (Fig. 488). Note: The cup side of the washer should be facing down toward the pulley hub. Fig 486 DSC-2706 Fig 488...

  • Page 176: Mower Jackshaft Assembly Removal

    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.
  • Page 177 MOWER DECKS 7. Loosen the 4 bolts holding the rear bumper 9. Insert a 3/8” drive ratchet with a 12” long extension assembly and remove from the unit (Fig. 494). into the square hole of the idler bracket. Pull back on the idler arm to relieve tension on the belt.

  • Page 178: Mower Jackshaft Installation

    MOWER DECKS 11. Lower the mower deck to the lowest cutting position. 15. Remove the jackshaft assembly from the mower deck (Fig. 500). 12. Remove the right 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.

  • Page 179: Mower Jackshaft And Pulley Assembly

    MOWER DECKS Mower Jackshaft and Pulley Right Hand Mower Idler Assembly Assembly Removal The jackshaft housing and bearings are not available 1. Loosen the 4 bolts holding the rear bumper as separate components. Listed below is a view of the assembly and remove from the unit (Fig.
  • Page 180 MOWER DECKS 3. Remove the RH idler pulley (Fig. 504) 5. Insert the ratchet with a 6” extension into the square- cut 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.

  • Page 181: Right Hand Mower Idler Assembly Installation

    MOWER DECKS 7. Remove the RH idler bolt (Fig. 508). 9. Inspect the sleeve bearing and bushing for any wear (Fig. 510). Fig 508 DSC-2727 Fig 510 DSC-2731 8. Remove the RH idler assembly (Fig. 509). Right Hand Mower Idler Assembly Installation 1.
  • Page 182 MOWER DECKS 2. Install the belt tensioner spacer, washer, bolt, and 4. Install the RH idler pulley (Fig. 514). extension spring (Fig. 512). Fig 514 DSC-2716 Fig 512 DSC-2725 5. Insert a ratchet with a 6” extension into the square 3.

  • Page 183: Left Hand Mower Idler Assembly Removal

    MOWER DECKS 6. Install the rear bumper assembly and tighten the 4 2. On the left side of the unit is the spring loaded idler bolts (Fig. 516). pulley for the mower drive belt; note the square hole in the idler bracket (Fig. 518). Fig 516 DSC-2595 Fig 518...
  • Page 184 MOWER DECKS 4. Relieve spring tension with the 3/8” ratchet drive to 6. Remove the bolt and nut retaining the idler bracket allow for removal of the stop bolt, spacer, and nut to the frame (Fig. 522). (Fig. 520). Fig 522 DSC-2741 Fig 520 DSC-2735...

  • Page 185: Left Hand Mower Idler Assembly Installation

    MOWER DECKS 8. Inspect the bushing and sleeve bearing for wear 2. Fasten the tension spring to the frame with the bolt, (Fig. 524). spacer, 2 washers and a nut (Fig. 526). Fig 524 DSC-2743 Fig 526 DSC-2737 Left Hand Mower Idler Assembly 3.

  • Page 186: Replacing The Mower Spindle Belt

    MOWER DECKS Replacing the Mower Spindle Belt 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). Belt squeal/slippage, frayed belt edges, burn marks and cracks are signs of a worn belt.
  • Page 187 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). Fig 531 DSC-2625 Fig 533 fig. 71 m-7419 1.

  • Page 188: Replacing Mower Drive Belts

    MOWER DECKS Replacing Mower Drive Belts 8. Install the tension spring on the idler arm (Fig. 535). 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.
  • Page 189 MOWER DECKS 4. Pull the spring loaded idler down and remove the fan 6. Remove the bolt, spacer, washers, and nut retaining drive belt (Fig. 538). the clutch/brake strap to the frame (Fig. 540). Fig 540 DSC-2604 Fig 538 DSC-2596 5.
  • Page 190 MOWER DECKS 8. Insert a 3/8” drive ratchet with a 12” extension into 10. Raise the floor pan (Fig. 544). 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.
  • Page 191 MOWER DECKS 12. Remove the tension spring (Fig. 546). 14. Remove the drive belts from the jackshaft sheave pulley on the mower deck (Fig. 548). Fig 546 DSC-2628 Fig 548 DSC-2630 13. Remove the mower spindle belt from the top groove of the jackshaft pulley (Fig.
  • Page 192 MOWER DECKS 16. Insert a 3/8” drive ratchet with a 6” extension into 18. Insert a 3/8” drive ratchet with a 12” extension into the square hole in the RH idler bracket. Pull back to the square hole in the LH idler bracket. Pull back to relieve tension on the idler bracket.

  • Page 193: Leveling The Mower

    MOWER DECKS 20. Connect the electric PTO clutch harness to the 22. Install the mower spindle belt; refer to Mower wiring harness (Fig. 554). Spindle Belt, page 7-39. 23. Install the rear bumper and tighten the 4 bolts (Fig. 556). Fig 554 DSC-2601 Fig 556...

  • Page 194: Leveling The Mower Side-To-Side

    MOWER DECKS 5. Lower the mower to the 3 inch (76mm) height-of-cut 2. Measure the right blade at the B location (Fig. 557), position. from a level surface to the cutting edge of the blade tip (Fig. 558). 6. Inspect the four chains. The chains need to have tension.

  • Page 195: Adjusting The Front-To-Rear Mower Pitch

    MOWER DECKS Adjusting the Front-to-Rear Mower 7. If the measurement at positions B or C are not correct, loosen the bolt attaching the rear chain Pitch support arm (Fig. 559). 1. Position the right blade front-to-rear (Fig. 560). Fig 559 fig.
  • Page 196 MOWER DECKS 3. Record the measurement. 8. Adjust the lift nuts on both the left and the right side of the machine (Fig. 562 and Fig. 563) to achieve 4. Measure the right blade at the B location (Fig. 560) 1/4 to 3/8 inch (6 to 10mm) lower in front A than in from a level surface to the cutting edge of the blade the rear at B (Fig.

  • Page 197: Adjusting The Compression Spring

    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.

  • Page 198: Service Manual

    Z Master Z597 Diesel Series Service Manual Form No. 492-9150...

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