Toro Z Master 500 Series Service Manual
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Toro Z Master 500 Series Service Manual

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  • Page 1 LCE Products Z Master 500 Series Gasoline Engine Models Service Manual...
  • Page 2 Interactive electrical troubleshooting and wiring diagrams on compact disk Form #492-9143 Z Master 500 Series gasoline engine machines, model years 2004 and 2005 are covered in this manual. This manual may also be specified for use on later model products.
  • Page 3 THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION General Information ....... . . Think Safety First .
  • Page 5 TABLE OF CONTENTS CHASSIS cont. Motion Control Assembly Removal ......3-20 Motion Control Assembly Installation .
  • Page 6 TABLE OF CONTENTS ELECTRICAL cont. Kawasaki A/C (Air Cooled) Wiring Diagram ......6-20 Kawasaki L/C (Liquid Cooled) Wiring Diagram ..... . . 6-21 MOWER DECKS/PTO Electric PTO Clutch Removal...
  • Page 7 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. Z Master 500 Gas Series Service Manual...
  • Page 8 SAFETY INFORMATION Safety Information ..Specifications ... Chassis ....Hydraulic System .

  • Page 9: General Information

    PERSONAL SAFETY INSTRUCTION - read the instruction because it has to operating practices. Operator’s manuals are available through your Toro parts source or: - read the instruction because it has to do with your safety. Failure to comply through your Toro parts source or: do with your safety.

  • Page 10: Specifications

    SPECIFICATIONS Safety Information ..Specifications ... Chassis ....Hydraulic System ..Engine .

  • Page 11: Kawasaki Liquid Cooled Product Shots

    SPECIFICATIONS Kawasaki Liquid Cooled Product Shots Fig 001 DSC-2861a Fig 003 DSC-3792a Fig 002 DSC-2860a Fig 004 DSC-2864a Z Master 500 Gas Series Service Manual...

  • Page 12: Kohler Efi Product Shots

    SPECIFICATIONS Kohler EFI Product Shots Fig 005 DSC-2865b Fig 007 DSC-2867a Fig 006 DSC-2866a Fig 008 DSC-2868a Z Master 500 Gas Series Service Manual...

  • Page 13: Kohler Gas Product Shots

    SPECIFICATIONS Kohler Gas Product Shots Fig 009 DSC-2870a Fig 011 DSC-2875a Fig 010 DSC-2869a Fig 012 DSC-2874a Z Master 500 Gas Series Service Manual...

  • Page 14: Kawasaki Gas Product Shots

    SPECIFICATIONS Kawasaki Gas Product Shots Fig 013 DSC-2877a Fig 015 DSC-2880a Fig 014 DSC-2879a Fig 016 DSC-2882a Z Master 500 Gas Series Service Manual...

  • Page 15: Engines

    SPECIFICATIONS Engines Output Make High Idle Low Idle Charging Coil 20 HP (14.9kW) Kohler 3750 +50/-100 RPM 1500 RPM 15 AMP OHV V-Twin Air Cooled 23 HP (17.2 kW) Kohler 3750 +50/-100 RPM 1500 RPM 15 AMP OHV V-Twin Air Cooled 25 HP (18.6 kW) Kawasaki 3750 +50/-100 RPM...

  • Page 16: Dimensions And Weight

    SPECIFICATIONS Dimensions and Weight ROPS Height Width Model Weight Folded Upright Deck Deflector Length 23 hp Kohler/52” TF Deck 1140 lbs 53” 72” 53.7” 68” 79.5” (517kg) (134cm) (183cm) (136cm) (173cm) (202cm) 23 hp Kohler/60” TF Deck 1215 lbs 53” 72”...

  • Page 17: Traction System

    SPECIFICATIONS Traction System Hydraulic Pumps Twin Hydro-Gear BDP/PJ Series variable displacement hydrostatic with shock valves Pump Drive Self-tensioning belt drive Wheel Motors Twin Parker-Ross Torqmotor™ positive displacement with 1.25 inch heavy duty tapered shafts Ground Speeds Infinitely variable: Forward: 0 - 10 mph (16.1 km/hr) Reverse: 0 - 6.3 mph (10.1 km/hr) Release Valves Contained in pumps.

  • Page 18: Cutting Decks

    SPECIFICATIONS Cutting Decks Configuration Side discharge, mid-mounted rotary with three blades. Construction 7 gauge, high strength 50,000 psi steel, 5-1/2” deep, advanced, super flow system, welded construction. 3/8” steel discharge reinforcement plate doubles as bagger attachment point. Discharge Right hand as viewed from operator seat. Rubber chute, spring biased down toward operating position.

  • Page 19: General Specifications

    SPECIFICATIONS General Specifications Greasing and Lubrication: Grease: No. 2 general purpose lithium base or molybdenum grease. Where to Add Grease: See Check Service Reference Aid decal below (Fig. 017). Fig 018 fig. 55 m-5615 1. Cap 3. Cold fluid level - full 2.

  • Page 20: Model And Serial Number Locations

    SPECIFICATIONS Model and Serial Number Location The unit model and serial number plate is located on the right hand side of the unit, below the right side motion control lever (Fig. 019). Fig 019 DSC-2351 Fig 020 configuration Engine Model and Serial Number Consult the appropriate engine manufacture’s service literature for the Identification: location and translation of the engine model and serial number information.

  • Page 21: 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 22: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, &...
  • Page 23 SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Regular Height Nuts Regular Height Nuts ( (Class 8 or Strong Nuts) Class 10 or Strong Nuts) M5 X 0.8 57 ±...

  • Page 24: Other Torque Specifications

    SPECIFICATIONS Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 - 20 UNF 65 ± 10 ft-lb 88 ± 14 N-m Grade 5 1/4 - 20 UNC 140 ±...

  • Page 25: Equivalents And Conversions

    SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32...
  • Page 26 SPECIFICATIONS U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Feet Centimeters 30.48 Measurement Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Area...
  • Page 27 SPECIFICATIONS THIS PAGE INTENTIONALLY LEFT BLANK. 2-18 Z Master 500 Gas Series Service Manual...

  • Page 28: Chassis

    CHASSIS Safety Information ..Specifications ... Chassis ....Hydraulic System ..Engine .

  • Page 29: Caster Fork Assembly Removal

    CHASSIS Caster Fork Assembly Removal 4. Remove the Belleville washers and caster fork and wheel assembly (Fig. 023). 1. Raise the front of the unit off the ground, allowing enough clearance to remove the castor fork from the bottom of the hub. 2.
  • Page 30 CHASSIS 2. Remove bottom seal and tapered roller bearing (Fig. 4. With a driver and hammer, install new tapered 025). bearing cups. The bearing cups are tapered; make sure the tapered/thicker end of the cup is installed inward for the top and bottom end (Fig. 027). Tap the bearing cups in until they seat against the step in the caster hub.

  • Page 31: Caster Fork Assembly

    CHASSIS 6. Install the lower bearing and seal, with the open end 2. Install the upper bearing. of the seal facing up (Fig. 029). 3. Install the Belleville (spring) washers as shown in (Fig. 031). A. Dust Cap B. Locknut C.

  • Page 32: Front Wheel Removal And Bearing Replacement

    CHASSIS Front Wheel Removal and Bearing 5. Remove the plug located on the side of the hub on the frame for the castor fork. Install a grease fitting, Replacement and pump grease into the housing until grease is passing through the upper bearing (Fig. 033). 1.

  • Page 33: Fuel Tank Removal

    CHASSIS 4. Pack both tapered wheel bearings. Reassemble 3. Remove the 4 screws retaining the control panel and per Fig. 036. Pump grease into the wheel bearings control panel shield to the tank (Fig. 039). through the grease fitting located on the rim (Fig. 037).

  • Page 34: Left Side Fuel Tank Installation

    CHASSIS 6. Located under the rear portion of the fuel tank, 8. Remove the fuel tank from the frame (Fig. 043). remove the 2 nuts, springs, and washers from the fuel tank studs (Fig. 041). Fig 043 DSC-3099 Fig 041 DSC-3095 Note: Rear tire removed for clarity.

  • Page 35: Hood Assembly Removal

    CHASSIS Hood Assembly Removal Hood Assembly Installation 1. Unhook the two rubber latches located on the rear of Reverse the order of removal. the hood. 2. Remove the two hairpins, clevis pins, and washers Brake Lever Removal located in the front left and right lower side of the hood (Fig.
  • Page 36 CHASSIS 4. Remove the brake shaft cotter pin (Fig. 048). 6. Using a hammer and punch, drive both brake lever control bearings from the brake pivot (Fig. 050). Fig 048 DSC-1620 Fig 050 DSC-1622 5. Slide the brake shaft out of the frame pivot bushings (Fig 049).

  • Page 37: Brake Lever Installation

    CHASSIS Brake Lever Installation 3. Remove bolts, brake band retainer, spacers, and brake band (Fig. 053). Reverse the order of removal Brake Band Removal 1. Raise the left rear tire off the ground (Fig. 052). Fig 053 DSC-1626 A. 3 Bolts C.

  • Page 38: Brake Shaft Removal

    CHASSIS 2. Install the 3 bolts, brake band retainer, brake band, 2. On the left side of the machine, remove both clevis and spacers and tighten (Fig. 055). spring pins, one from the brake rod and the other from the brake shaft (Fig. 056). Fig 055 DSC-1631 Fig 056...
  • Page 39 CHASSIS 4. On the right side, remove the two bolts and nuts 6. Remove the brake shaft from the left side of the unit holding the flange bearing (Fig. 058). (Fig. 060). Fig 060 DSC-3106 Fig 058 DSC-3104 5. On the left side, remove the two bolts and nuts 7.

  • Page 40: Brake Shaft Installation

    CHASSIS Brake Shaft Installation 3. If an adjustment is necessary, loosen the jam nut below the spring and tighten the nut directly below the yoke (Fig. 062). Turn the nut until the correct Reverse the order of removal. measurement is obtained. Tighten the two nuts together and repeat on the opposite side of the unit.
  • Page 41 CHASSIS 3. With the mower deck in the transport position, place 5. Remove hex nut from RH rear deck lift assembly. a 4”x 4” block under each corner of the deck. Lower Repeat procedure for LH rear deck lift assembly the mower deck onto the support blocks to remove (Fig.
  • Page 42 CHASSIS 7. Remove hex bolt, nut, and lift lever bushing from the 9. Lift the floor pan assembly to its fully opened lower deck lift plate mounting location (Fig. 068). position (Fig. 070). Fig 070 DSC-3112 Fig 068 DSC-1652 8. Loosen the top hex head flange nut at the deck lift 10.
  • Page 43 CHASSIS 11. Remove retainer clip from lift lever grip assembly 13. If the lift lever grip assembly contacts the RH floor (Fig. 072). pan hinge, loosen the RH floor pan hinge mounting hardware. Push the RH hinge upward. Re-tighten the RH floor pan hinge mounting hardware (Fig. 074).

  • Page 44: Deck Lift Lever Installation

    CHASSIS 15. Carefully slide the lift lever grip assembly out of its 2. Install lift lever grip assembly into front frame pivot carrier frame pivot (Fig. 076). location (Fig. 078). Fig 078 DSC-1670 Fig 076 DSC-1667 Deck Lift Lever Installation 3.
  • Page 45 CHASSIS 4. Install bushing into rear lift arm cross shaft (Fig. 6. Rotate deck lift plate (inner) downward until lower 080). 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.
  • Page 46 CHASSIS 8. Raise lift lever grip assembly until deck mount 10. Install Hex nut on end of deck lift rod. Tighten swivels rest against deck rod jam nuts. Install against deck mount swivel. Repeat procedure for HOC pin into deck lift plate height of cut holes that opposite side deck lift rod (Fig.

  • Page 47: Motion Control Assembly Removal

    CHASSIS 12. Untie the floor pan assembly and lower. Return 3. Remove (4) pocket mounting bolts (Fig. 090). motion control lever to its neutral locked position. Motion Control Assembly Removal 1. Remove both floor pan assembly hinge bolts (Fig. 088). Fig 090 DSC-3108 4.
  • Page 48 CHASSIS 5. Remove the two bolts retaining the lever assembly 7. Disconnect neutral switch wire harness from neutral to the control arm shaft (Fig. 092). switch (Fig. 094). Fig 092 DSC-2062 Fig 094 DSC-3110 6. Disconnect Motion Control Dampener from motion 8.

  • Page 49: Motion Control Assembly Installation

    CHASSIS 9. Remove the cotter pin and clevis pin through the 11. Remove the two bolts and nuts that retain the flange adjustable yoke for the neutral return bolt (Fig. 096). bearing on the outside of the motion control (Fig. 098).

  • Page 50: Hydraulic System

    HYDRAULIC SYSTEM Safety Information ..Specifications ... Chassis ....Hydraulic System .

  • Page 51: Hydrostatic Pump Removal

    HYDRAULIC SYSTEM Hydrostatic Pump Removal 4. Lift the engine shield. Using a pry bar, relieve the spring tension on the idler assembly and remove the pump drive belt (Fig. 101). Note: Cleanliness is a key factor in a successful repair of any hydrostatic system. Thoroughly clean all exposed surfaces prior to any type of maintenance.
  • Page 52 HYDRAULIC SYSTEM 6. Remove bolt, washer, and nut located between ball 8. Remove the hose clamp around the case drain joint and control arm that retains the tracking link rod hydraulic hose, located on the left side of the to the hydro control arm (Fig. 103). hydrostatic pump (Fig.

  • Page 53: Hydrostatic Pump Installation

    HYDRAULIC SYSTEM Hydrostatic Pump Installation 10. Loosen and remove the two bolts and nuts retaining the hydrostatic pump to the frame (Fig. 107). Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricated with petroleum jelly.
  • Page 54 HYDRAULIC SYSTEM 3. Install the case drain hose and hose clamp onto the 5. Install the bolt, washer, and nut between the ball pump case drain fitting, located around the left side joint and control arm to secure the tracking link rod of the hydrostatic pump (Fig.
  • Page 55 HYDRAULIC SYSTEM Apply some anti-seize compound to the shaft (Fig. 8. Using a pry bar, release the spring tension on the 114). Install the pulley to the shaft. idler assembly and install the pump drive belt (Fig. 116). Fig 114 DSC-3066 Fig 116 DSC-3068...

  • Page 56: Wheel Motor Removal

    HYDRAULIC SYSTEM 10. Install the battery positive and then the negative 3. Apply the parking brake and remove the cotter pin cable to the battery. from the wheel motor output shaft (Fig. 119). 11. Check the hydraulic fluid in the reservoir tank. Add oil if necessary.
  • Page 57 5. Remove the 3 bolts securing the brake band to the 7. Install wheel puller on to the hub and remove the actuator (Fig. 121). hub from motor output shaft (Fig. 123). Note: Toro Wheel Puller, P/N TOR 4097, is available through SPX (formerly OTC) 1-800-533-0492. Fig 121 DSC-3072...

  • Page 58: Wheel Motor Installation

    HYDRAULIC SYSTEM 9. Remove the front two wheel motor bolts, lock 11. Remove the back two bolts, lock washers, spacers, washers, spacers, and nuts (Fig. 125). and nuts and remove the wheel motor from the frame (Fig. 127). Fig 125 DSC-3076 Fig 127 DSC-3078...
  • Page 59 HYDRAULIC SYSTEM Note: There are two different spacers used on the 2. Align the brake linkage with the two front bolt holes wheel motors (Fig. 128). The short spacers (Fig. 130). are used in the front of the wheel motors(with the brake linkage) and the long spacers are used to retain the back of the wheel motor.
  • Page 60 HYDRAULIC SYSTEM 4. Torque the bolts to 80 to 90 ft-lbs. (108 to 122 Nm) 6. Install wheel hub assembly, making sure the (Fig. 132). woodruff key is in place (Fig. 134). Note: It is recommended to replace the wheel hub assembly prior to installation.

  • Page 61: Adjusting The Handle Neutral

    HYDRAULIC SYSTEM 8. Install spacers, brake band retainer, and brake band 10. Check the park brake and adjust park brake if around the wheel hub and tighten all three retainer necessary. Refer to Adjusting the Parking Brake, bolts (Fig. 136). page xxx.
  • Page 62 HYDRAULIC SYSTEM 5. Move the lever to the neutral position but not locked 7. Check where the control lever is relative to notch in (Fig. 138). console (Fig. 139). It should be centered allowing lever to pivot outward to the neutral lock position. Fig 138 fig.

  • Page 63: Setting The Hydraulic Pump Neutral

    HYDRAULIC SYSTEM Setting the Hydraulic Pump Neutral 3. Disconnect the electrical connector at the switch, located between the frame cross member and the hydraulic tank. Temporarily install a jumper wire Note: Adjust handle neutral before making the across the terminals in the wiring harness connector following adjustment.

  • Page 64: Setting The Lh Hydraulic Pump Neutral

    HYDRAULIC SYSTEM Setting the LH Hydraulic Pump 2. Adjust the pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or Neutral slightly creeping in reverse (Fig. 142). 1. Loosen the locknuts at the pump ball joint on the motion control rod (Fig.

  • Page 65: Adjusting The Tracking

    HYDRAULIC SYSTEM Adjusting the Tracking 3. Adjust pump rod length by rotating the double nuts in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 144). The right hand pump has a knob for adjusting the tracking (Fig.

  • Page 66: Replacing The Pump Drive Belt

    HYDRAULIC SYSTEM Replacing the Pump Drive Belt 2. Stop the machine and set the parking brake. 3. Unlatch the seat and tilt the seat forward to access 1. Pull the spring loaded idler down and remove the tracking knob. traction belt from the engine and hydro pump pulleys (Fig.

  • Page 67: Purging The Hydraulic System

    HYDRAULIC SYSTEM Purging the Hydraulic System 3. When the wheel begins to spin on its own, keep it engaged until the wheel drives smoothly (minimum 2 minutes). The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after 4.
  • Page 68 HYDRAULIC SYSTEM 2. Clean any dirt or debris away from the hydraulic line 4. Check the hydraulic reservoir and fill as needed with fittings. Remove the hydraulic lines. Make sure you Mobil 1, 15w50 oil. mark which hydraulic line goes to which fitting on the wheel motor.

  • Page 69: Pushing The Machine By Hand

    HYDRAULIC SYSTEM Pushing the Machine by Hand 11. With the unit at full engine throttle speed, slowly rotate the “T” handle of the flow tester restrictor valve clockwise until the pressure gauge reads Important: Always push the machine by hand. Never approximately 1000 to 1200 psi (69 to 83 bar).

  • Page 70: Changing To Machine Operation

    HYDRAULIC SYSTEM Changing to Machine Operation 1. Rotate the bypass valves clockwise 1 turn to operate the machine (Fig. 157). Note: Do not over-tighten the by-pass valves. Fig 157 DSC-3130 Note: The machine will not drive unless the by-pass valves are turned in. Z Master 500 Gas Series Service Manual 4-21...
  • Page 71 HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 4-22 Z Master 500 Gas Series Service Manual...

  • Page 72: Engine

    ENGINE Safety Information ..Specifications ... Chassis ....Hydraulic System ..Engine .

  • Page 73: Kohler Air-Cooled Engine Removal

    ENGINE Kohler Air-Cooled Engine Removal 4. Remove the air cleaner end cap and slide the air cleaner assembly out of the bracket (Fig. 160). 1. Remove the battery negative cable from the battery. 2. Remove the bolt, spacer, spring, and nut on the top of the air cleaner bracket (Fig.
  • Page 74 ENGINE 6. Remove the tie strap securing the choke/throttle 8. With a pry bar, relieve spring tension on the idler cables to the bracket located on the valve cover (Fig. assembly and remove pump drive belt (Fig. 164). 162). Fig 164 DSC-2963 Fig 162 DSC-2961...
  • Page 75 ENGINE 10. Remove the blue wire from the starter solenoid (Fig. 12. Unplug the electric PTO clutch harness from the 166). clutch. Remove the tie strap holding the clutch wire to the PTO stop rod (Fig. 168). Fig 166 DSC-2965 Fig 168 DSC-2966 11.

  • Page 76: Kohler Air-Cooled Engine Installation

    ENGINE 15. Connect lift chains/straps to the engine lift brackets. 3. Install the mower drive belt around the electric PTO Raise the engine from the frame of the unit (Fig. clutch; refer to Replacing the Mower Belt page 7-24. 170). 4.
  • Page 77 ENGINE 6. Attach the two red cables to the starter solenoid (Fig. 8. Install the fuel line to the engine and install a hose 174). clamp. Turn the fuel shut off valve to the ON position (Fig. 176). Fig 174 DSC-2964 Fig 176 DSC-2971...
  • Page 78 ENGINE 10. Secure the throttle and choke cables to the bracket 12. Install the bolt, spacer, spring, and nut on the top of located on the engine valve cover with a tie strap the air cleaner bracket and tighten (Fig. 180). (Fig.

  • Page 79: Kawasaki Air-Cooled Engine Removal

    ENGINE Kawasaki Air-Cooled Engine Removal 3. Loosen the throttle and choke cable clamps and disconnect both cables (Fig. 183). 1. Remove the battery negative cable from the battery. 2. Remove the air cleaner cover (Fig. 182). Note: This engine has a standard air cleaner cover. If engine is equipped with a heavy duty air cleaner assembly, remove the complete air cleaner assembly.
  • Page 80 ENGINE 5. Disconnect the electric PTO clutch wire from the 9. Disconnect three wires going from the main harness clutch (Fig. 185). to the engine (Fig. 187). • Violet wire to the Regulator/Rectifier • White wire to the Engine Magneto wire •...

  • Page 81: Kawasaki Air-Cooled Engine Installation

    ENGINE 11. With a pry bar, relieve tension on the spring loaded 13. Connect a lift chain to the lift points on the engine. idler and remove the pump drive belt (Fig. 189). Raise the engine from the frame (Fig. 191). Fig 189 DSC-2982 Fig 191...
  • Page 82 ENGINE Note: The front left engine mounting bolt has two 5. Connect the three wires going from the main ground cables (Fig. 192). Tighten the bolts. harness to the engine (Fig. 194). • Violet wire to the Regulator/Rectifier • White wire to the Engine Magneto wire •...
  • Page 83 ENGINE 7. Install the fuel line to the engine and tighten the hose 9. Connect the throttle and choke cables to the engine clamp. Turn the fuel shut off valve ON (Fig. 196). control linkage. Position the throttle control in the idle position.

  • Page 84: Hp Kohler Efi Air-Cooled Engine Removal

    ENGINE 11. Install the engine air cleaner cover on the engine 2. Loosen the hose clamp on the air intake hose (Fig. Fig. 200). 201). Note: This unit has a standard air cleaner assembly. Fig 201 DSC-2883 Fig 200 DSC-2973 3.
  • Page 85 ENGINE 4. Remove the air cleaner cap and slide the air cleaner 6. Remove the tie strap securing the throttle cable to assembly out of the air cleaner bracket (Fig. 203). the bracket on the valve cover (Fig. 205). Fig 203 DSC-2885 Fig 205 DSC-2887...
  • Page 86 ENGINE 8. Remove the tie strap securing the fuel pump and 10. Remove the tie strap securing the electric PTO wires electric clutch harness to the AC voltage wires to the electric PTO clutch stop (Fig. 209). coming from the stator (Fig. 207). Fig 209 DSC-2909 Fig 207...
  • Page 87 ENGINE 13. Remove the 3 red wires located at the starter 15. Remove the ground cables located on the lower left solenoid (Fig. 211). side of the base of the engine (Fig. 213). One bolt goes into the side of the engine block and the other is the engine mounting bolt and nut.
  • Page 88 ENGINE 17. Remove the wire clamp bolted to the frame, located Next, remove the multi-pin connector from the ECU on the left side of the engine (Fig. 215). (Fig. 217). Fig 217 DSC-2908 Fig 215 DSC-2904 18. Remove the wire connector located at the bottom of 19.
  • Page 89 ENGINE 20. Remove the two fuse holders, located in front of the 22. Unplug the tan wire connector (Fig. 221). ECU unit (Fig. 219). Fig 221 DSC-2915 Fig 219 hidden fuses 23. Remove the remaining 3 bolts, washer, and nuts 21.

  • Page 90: Hp Kohler Efi Air-Cooled Engine Installation

    ENGINE 28 HP Kohler EFI Air-Cooled Engine 3. Install the two left relays to the frame using two bolts and washers (Fig. 224). Plug the remaining two Installation relays into the harness. 1. Lower the engine to the frame. Install 2 bolts, washers, and nuts on the right side of the engine.
  • Page 91 ENGINE 5. Install the clamp holding the test plug connector to 7. Install the wire connector to the bottom of the ECU the side of the ECU control (Fig. 226). (Fig. 228). Fig 228 DSC-2908 Fig 226 DSC-2910 6. Install a tie strap around the electric PTO harness Install the red retainer clip on the wire connector (Fig.
  • Page 92 ENGINE 8. Install the wire clamp to the frame on the left side of 10. Install the two sets of ground wires on the left side of the engine (Fig. 230). the engine as shown (Fig. 232). Fig 230 DSC-2904 Fig 232 DSC-2901 11.
  • Page 93 ENGINE 12. Install three red wires to the starter solenoid stud 14. Install the mower deck drive belt around the electric (Fig. 234). PTO clutch. Refer to Replacing the Mower Belt page 7-24. 15. Install the PTO clutch harness to the PTO clutch (Fig.
  • Page 94 ENGINE 17. Install the throttle cable to the engine throttle linkage. 19. Install the fuel line to the engine fuel rail. Tighten the Make sure the throttle contacts the stop with the fuel line clamp (Fig. 240). throttle control lever in the full speed position. Tighten throttle housing clamp (Fig.

  • Page 95: Kohler Electronic Fuel Injection (Efi) Models Efi Fuel System

    ENGINE Kohler Electronic Fuel Injection (EFI) 21. Install the air cleaner assembly and air cleaner cap. Install the bolt, spacer, spring and nut to the air filter Models bracket. Tighten the bolt (Fig. 242). EFI Fuel System For engine specific service or diagnostics procedures, consult the engine manufacture’s service manual.

  • Page 96: Efi Electrical System

    ENGINE EFI Electrical System 2. High pressure fuel filter is located under the seat behind the hydraulic reservoir (Fig. 245). 1. The electronic control unit (ECU) is located next to the engine starter, on the left rear side, mounted to the frame (Fig.

  • Page 97: Hp Kawasaki Liquid-Cooled Engine Removal

    ENGINE The purpose of the TVS diode is to protect the ECU 3. Remove the right and left hair pins, washers and unit from any high voltage spikes in the electrical clevis pins securing the hood. Remove the hood system, typically associated with the engagement assembly (Fig.
  • Page 98 ENGINE 5. Remove the air deflector (Fig. 253). 7. Drain the engine coolant through the engine drain port, located on the engine block, next to the engine oil filter (Fig. 255). Fig 253 DSC-2804 Fig 255 DSC-2806 6. Using a pry bar, relieve the idler pulley spring tension and remove the pump drive belt (Fig.
  • Page 99 ENGINE 9. Remove the radiator inlet hose located on the right 11. Unplug the wire connector for the cooling fan (Fig. side of the radiator (Fig. 257). 259). Fig 257 DSC-2808 Fig 259 DSC-2812 10. Remove the radiator outlet hose, located on the left 12.
  • Page 100 ENGINE 13. Remove the 2 bolts, washers, and nuts on the right 15. Remove the hose clamp from the air cleaner and left side of the fan mounting plate (Fig. 261). assembly (Fig. 263). Fig 261 DSC-2813 Fig 263 DSC-2815 14.
  • Page 101 ENGINE 17. Unplug the two relays from the relay connectors. 19. Remove the two bolts and nuts on the right side of Remove the two bolts and nuts retaining the the machine used to hold the top rib to the right side connectors to the right hand side plate (Fig.
  • Page 102 ENGINE 21. Remove the two bolts and nuts retaining the rear 23. Loosen the clamps and remove the choke and radiator mount to the frame (Fig. 269). throttle cables from the engine linkage (Fig. 271). Fig 269 DSC-2824 Fig 271 DSC-2827 A.
  • Page 103 ENGINE 26. Remove the three engine ground cables located on 28. Remove the 3 red wires from the starter solenoid the lower right rear of the engine (Fig. 273). (Fig. 275). Fig 275 DSC-3164 Fig 273 DSC-2829 27. Unplug the orange/black wire to the starter solenoid 29.

  • Page 104: Hp Kawasaki Liquid-Cooled Engine Installation

    ENGINE 27 HP Kawasaki Liquid-Cooled 30. Turn the fuel shut-off valve to the OFF position. Engine Installation 31. Move the hose clamp and disconnect the fuel line on top of the engine (Fig. 277). 1. Lower the engine on to the frame. Install 4 bolts and spring washers through the frame and into the base of the engine.
  • Page 105 ENGINE 5. Install the 3 red wires to the starter solenoid post 7. Install the 3 ground wires to the lower rear of the and tighten (Fig. 281). engine (Fig. 283). Fig 283 DSC-2829 Fig 281 DSC-3164 6. Plug the orange/black wire to the starter solenoid 8.
  • Page 106 ENGINE 9. Install the mower drive belt around the electric PTO 12. Install the rear support assembly to the frame (Fig. clutch; follow the procedures for Replacing the 287). Mower Belt page 7-24. 10. Install the choke cable to the engine linkage; make sure the choke knob is pushed all the way in before tightening down the clamp (Fig.
  • Page 107 ENGINE 14. Install the two bolts and nuts retaining the top and 16. Install the hose and clamp, located under the coolant bottom strap guard located on the right side (Fig. overflow tank (Fig. 291). 289). Install the corresponding bolts and nuts on the left side.
  • Page 108 ENGINE 18. Install two bolts, washers, and nuts retaining the air 20. Install the fan mounting plate and radiator (Fig. 295). cleaner assembly to the left side radiator brace (Fig. 293). Note: Leave the air filter and air cleaner cover off until after you fill the coolant reservoir bottle.
  • Page 109 ENGINE 22. Install 3 bolts, washers, and nuts to the rear of the 24. Install the radiator outlet hose clamp located on the fan mounting plate (Fig. 297). Tighten all 7 bolts and left rear of the radiator (Fig. 299). nuts.
  • Page 110 ENGINE 26. Install the overflow hose next to the radiator cap with a tie strap (Fig. 301). Fig 303 DSC-2855 Fig 301 DSC-2853 28. Install the air filter and air cleaner cover. 29. With a suitable pry bar, relieve the spring tension on the idler pulley spring and install the hydraulic pump 27.
  • Page 111 ENGINE 30. Install the air deflector (Fig. 305). 32. Install the engine hood assembly with 2 clevis pins, washers, and hair pins (Fig. 307). Fig 305 DSC-2804 Fig 307 DSC-2802 31. Install the engine shield with 4 bolts, washers, and nuts and tighten (Fig.
  • Page 112 ENGINE Cooling Fan Assembly Removal - 4. Remove the crossbar located across the front of the radiator (Fig. 311). 27 HP Kawasaki Liquid-Cooled Engine 1. Disconnect the negative battery cable. 2. Unlatch and open the engine hood. Remove the right and left hair pins located on the hood. Remove the hood assembly (Fig.
  • Page 113 ENGINE 6. Drain the engine coolant through the engine drain 8. Remove the radiator inlet hose, located on the right bolt located on the engine block next to the engine side of the radiator (Fig. 315). oil filter (Fig. 313). Fig 315 DSC-2808 Fig 313...

  • Page 114: Cooling Fan Assembly Installation

    ENGINE 10. There are 6 bolts and washers located under the 12. Before removing the fan assembly, remove two radiator retaining the radiator to the fan mounting clamps located on the upper engine air duct. plate. Remove all 6 bolts and washers. Remove the Remove the engine air intake duct (Fig.
  • Page 115 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. 5-44 Z Master 500 Gas Series Service Manual...
  • Page 116 ELECTRICAL Safety Information ..Specifications ... Chassis ....Hydraulic System ..Engine .

  • Page 117: General

    ELECTRICAL GENERAL Location Note: Interactive Electrical Troubleshooting CD, Air-Cooled Engine Models: Two relays located on the Form #492-9143 is also available. left side of the unit, between the engine and the frame (Fig. 321). RELAYS Purpose There are as many as three relays in a Z500 air-cooled or liquid cooled gas machine depending on model.
  • Page 118 ELECTRICAL Liquid-Cooled Engine Model: Three relays located on 1. Coil: Terminals 85 and 86 are connected to an the right rear radiator support arms, next to the ROPS internal coil. Applying 12 volts to either terminal (Fig. 323). energizes the coil turning it into an electromagnet. 2.

  • Page 119: Pto Switch

    ELECTRICAL Testing 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 327). 1. Disconnect the relay from the harness. 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be from 70 to 90 ohms. There should be continuity between terminals 87a and 30 (Fig.
  • Page 120 ELECTRICAL Location Testing The PTO switch is located in the control panel on the left 1. Disengage the PTO, set the parking brake, and turn side of the operator (Fig. 328). the ignition to the “OFF” position. Remove the key. 2.

  • Page 121: Ignition Switch

    ELECTRICAL IGNITION SWITCH How It Works Purpose Detents inside the switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is The ignition switch provides the proper switching for the released (Fig.

  • Page 122: Neutral Safety Switch

    ELECTRICAL NEUTRAL SAFETY SWITCH This single pole plunger (normally open) type switch has two terminals. When the motion control handles are in the neutral position (handles in the out position), Purpose it pushes on the plunger, closing the contact, and connecting the terminals (Fig.

  • Page 123: Park Brake Switch

    ELECTRICAL PARK BRAKE SWITCH How It Works Purpose In the start position it is used to ensure the park brake is “ON”. At the same time it allows current to flow through for the safety circuit. When the park brake is released in The purpose of the brake switch is to ensure the the “OFF”...

  • Page 124: Seat Switch

    ELECTRICAL SEAT SWITCH 2. Using a multimeter, follow the procedures listed below (Fig. 336). Purpose The switch is in the safety circuit. If the engine is running and the operator vacates the seat with either the PTO engaged or the parking brake off, the engine will shut down.
  • Page 125 ELECTRICAL For all models equipped with a standard seat, the seat (Standard seat switch shown.) (Fig. 340) switch is located between the frame cross-member and the rear of the hydraulic oil tank (Fig. 338). Fig 340 DSC-3154 Fig 338 DSC-3151 Testing How It Works 1.

  • Page 126: Seat Delay Module

    ELECTRICAL SEAT DELAY MODULE How It Works Purpose The seat delay module circuit board is made up with several different electrical components such as transient voltage suppressor, capacitor, transistors, carbon film When operating the unit on rough terrain, if the operator resistors, diodes and a relay.

  • Page 127: Temperature Gauge Liquid-Cooled Engine Only

    ELECTRICAL TEMPERATURE GAUGE 2. Remove the 4 bolts to the pocket. Remove the pocket. Liquid-Cooled Engine Only 3. Connect a VOM positive lead to the violet wires on Purpose the module (Fig. 344). Connect the negative lead to the battery negative terminal. The purpose of the temperature gauge is to monitor the engine coolant temperature.
  • Page 128 ELECTRICAL How It Works Testing When the engine coolant temperature increases the Time-efficient testing is not possible. See information sending unit resistance decreases, which causes the under Temperature Sender, page 6-14. needle on the water temperature gauge to increase (Fig. 346).

  • Page 129: Temperature Sender

    ELECTRICAL TEMPERATURE SENDER Testing It is not practical to test the sender in a shop environ- Purpose ment. If the gauge is not reading at all, temporarily ground the lead at the sender. If the meter reads full The temperature sender is a temperature-dependent scale, the ground wire and gauge are OK and the sender variable resistor.

  • Page 130: Voltmeter Gauge

    ELECTRICAL VOLTMETER GAUGE How It Works Purpose 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. This gauge indicates the voltage across the battery. When power is applied, a coil is energized to wind the movement.

  • Page 131: Electric Pto Clutch

    ELECTRICAL Testing Location 1. Remove the control panel from the tank by removing The electric clutch is located on the PTO end of the 4 screws. crankshaft (Fig. 352). 2. With a VOM, place the negative probe to the battery negative cable.

  • Page 132: Coil Resistance Measurement

    ELECTRICAL Testing Measuring Clutch Current Draw If the electric PTO clutch does not engage or is suspect 1. Disengage the PTO, set the parking brake, turn the as the cause of an electrical problem in the PTO circuit, ignition key to OFF, and remove the key. use the following troubleshooting steps to determine whether the clutch has failed or another electrical 2.
  • Page 133 ELECTRICAL Kohler EFI (Electric Fuel Injection) 6-18 Z Master 500 Gas Series Service Manual...
  • Page 134 ELECTRICAL Kohler A/C (Air Cooled) Z Master 500 Gas Series Service Manual 6-19...
  • Page 135 ELECTRICAL Kawasaki A/C (Air Cooled) 6-20 Z Master 500 Gas Series Service Manual...
  • Page 136 ELECTRICAL Kawasaki L/C (Liquid Cooled) Z Master 500 Gas Series Service Manual 6-21...
  • Page 137 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 6-22 Z Master 500 Gas Series Service Manual...

  • Page 138: Mower Decks/Pto

    MOWER DECKS/PTO Safety Information ..Specifications ... Chassis ....Hydraulic System .

  • Page 139: Electric Pto Clutch Removal

    MOWER DECKS/PTO Electric PTO Clutch Removal This procedure is on the Air Cooled Engine Models and follows the same procedure for the Liquid Cooled Engine Model. The electric PTO clutch removal and installation are similar on both the air cooled engine models and the 1.
  • Page 140 MOWER DECKS/PTO 3. Disconnect the electric PTO clutch connector from 5. Loosen the two nuts located on the idler plate to the clutch (Fig. 359). relieve tension on the belt (Fig. 361). Fig 359 DSC-3135 Fig 361 DSC-3137 4. Lift the floor pan and remove the right side mower 6.

  • Page 141: Electric Pto Clutch Installation

    MOWER DECKS/PTO 7. Remove the belt from the electric PTO clutch (Fig. 9. Remove the electric PTO clutch from the engine 363). crankshaft (Fig. 365). Fig 363 DSC-3139 Fig 365 DSC-3141 Electric PTO Clutch Installation 8. Remove the electric PTO clutch bolt (Fig. 364). 1.
  • Page 142 MOWER DECKS/PTO 2. Install the electric PTO clutch to the engine crank- 4. Install the mower drive belt around the electric PTO shaft (Fig. 367). clutch pulley (Fig. 369). Fig 367 DSC-3141 Fig 369 DSC-3144 3. Apply medium strength threadlocking material to the 5.
  • Page 143 MOWER DECKS/PTO 6. Route the belt around all of the mower deck pulleys 7. Install a 1/2” ratchet and extension, into the square and install the belt around the right side mower hole in the idler plate (Fig. 373). spindle pulley (Fig. 371). Fig 373 DSC-3147 Fig 371...
  • Page 144 MOWER DECKS/PTO 9. Tighten the pivot bolt on the idler plate once the 11. Install the right belt cover on the mower deck. adjustment is achieved (Fig. 375). 12. Install the right and left top strap guards, with the clutch guard to the unit (Fig. 377). Fig 375 DSC-3149 Fig 377...

  • Page 145: Mower Deck Removal (52, 60, 72")

    MOWER DECKS/PTO Mower Deck Removal (52, 60, 72”) 3. Slip the mower drive belt off the right mower spindle pulley (Fig. 381). 1. Lift the floor pan and remove the right hand belt cover (Fig. 379). Fig 381 DSC-3138 Fig 379 DSC-3136 4.
  • Page 146 MOWER DECKS/PTO 5. Raise the mower deck to the transport position. 7. Remove the bolt and nut holding the right rear strut Install a 4 x 4 wood block under the right side of the pin into the strut assembly (Fig. 385). mower deck.
  • Page 147 MOWER DECKS/PTO Tie strap the strut assembly up so it will be out of 10. Push the lift handle to the lowest HOC position to the way of the mower deck when sliding it out under overcome the tension of the lift assist springs. Use the frame.

  • Page 148: Mower Deck Installation (52, 60, 72")

    MOWER DECKS/PTO Mower Deck Installation (52, 60, 72”) 13. Turn the right front wheel so the caster fork is angled forward. This will allow more clearance to slide the mower deck from under the frame (Fig. 389). 1. Slide the mower deck under the unit. 2.
  • Page 149 MOWER DECKS/PTO 4. Install the rear and front chains to the mower deck 11. Install the belt around the electric PTO clutch pulley (Fig. 393). (Fig. 394). Fig 393 DSC-2640 Fig 394 DSC-3139 Note: Clutch guard removed for clarity. 5. Remove the hitch pin on the lift handle and raise the mower in the transport position.
  • Page 150 MOWER DECKS/PTO 13. Route the belt around all of the mower deck pulleys 14. Install a 1/2” socket ratchet and extension, in the and install the belt around the right side mower square hole in the idler plate (Fig. 398). spindle pulley (Fig.

  • Page 151: Mower Spindle Removal

    MOWER DECKS/PTO 16. Tighten the pivot bolt on the idler plate once the 5. Lift the floor pan and remove the right side mower adjustment is achieved (Fig. 400). belt cover (Fig. 401). Fig 400 DSC-3149 Fig 401 DSC-3136 17. Install the right belt cover on the mower deck. 6.

  • Page 152: Mower Spindle Installation

    MOWER DECKS/PTO 7. Slip the mower drive belt off the left mower spindle 9. Raise the mower deck to the transport position. pulley (Fig. 403). 10. Remove the mower blade from the spindle assembly. 11. Remove the 6 bolts and nuts from the spindle assembly.

  • Page 153: Mower Spindle Disassembly

    MOWER DECKS/PTO Mower Spindle Disassembly 3. Remove the bearing shield (Fig. 408). 1. Remove the nut and washer (Fig. 406). Fig 408 DSC-2671 Fig 406 DSC-2669 4. Remove the spindle housing from the spindle shaft assembly (Fig. 409). 2. Remove the pulley hub and square key (Fig. 407). Fig 409 DSC-2672 Fig 407...
  • Page 154 MOWER DECKS/PTO 5. Remove the seal spacer from the top of the spindle 7. Remove the top oil seal from the spindle housing housing (Fig. 410). (Fig. 412). Fig 410 DSC-2673 Fig 412 DSC-2675 6. Remove the seal spacer from the bottom of the 8.
  • Page 155 MOWER DECKS/PTO 9. Remove the spindle spacer (Fig. 414). 11. Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing (Fig. 416). Note the orientation of the lower oil seal. The open end of the seal faces outwards to help relieve pressure from over-greasing the spindle assembly.

  • Page 156: Mower Spindle Assembly

    MOWER DECKS/PTO 13. Using a hammer and a driver with a square edge, 15. This view shows the 2 bearing races and the large drive both the top and bottom bearing races out of spacer in the spindle housing (Fig. 420). Note the the spindle housing (Fig.
  • Page 157 MOWER DECKS/PTO 2. Using a press, install the upper bearing race into the 4. Pack the tapered bearing with #2 grease and install spindle housing (Fig. 422). the tapered bearing (Fig. 424). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing.
  • Page 158 MOWER DECKS/PTO 6. Using a seal driver, drive or press the seal on the 8. Install the inner spacer to the spindle assembly (Fig. lower end of the spindle housing until the seal is 428). flush with the outer edge of the housing (Fig. 426). Fig 428 DSC-2700 Fig 426...
  • Page 159 MOWER DECKS/PTO 10. Install the seal. Press it flush with the top of the 12. Lower the spindle housing over the spindle shaft housing (Fig. 430). (Fig. 432). Note: The open lip of the seal faces inward. Fig 432 DSC-2703 Fig 430 DSC-2696 13.
  • Page 160 MOWER DECKS/PTO 14. Install the bearing shield (Fig. 434). 16. Install the pulley hub on the spindle shaft (Fig. 436). Fig 436 DSC-2707 Fig 434 DSC-2705 17. Install the heavy washer and nut on the top of the 15. Install the square key onto the spindle shaft (Fig. spindle shaft (Fig.

  • Page 161: Replacing The Mower Belt

    MOWER DECKS/PTO 18. Torque the top nut to 100 to 120 ft. lbs. (Fig. 438). 3. Remove the belt covers (Fig. 439). Fig 439 fig. 71 m-6824 Fig 438 DSC-2709 1. Belt cover 2. Latch Replacing the Mower Belt 4. Loosen the nut securing the idler plate and move Squealing when the belt is rotating, blades slipping when the idler plate to relieve the belt tension on the idler cutting grass, frayed belt edges, burn marks and cracks...

  • Page 162: Adjusting The Mower Belt Tension

    MOWER DECKS/PTO Adjusting the Mower Belt Tension 5. Install the new mower belt around the mower spindle pulleys, mower idler pulley, into the belt guides, into rear idler arm assembly, and the clutch (Fig. 441). 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
  • Page 163 MOWER DECKS/PTO 4. Check the belt tension. The spring loaded idler 9. Check the distance from the rubber stop and the arm center bolt needs to be near the top alignment hole of the spring loaded idler pulley when the idler plate in left support plate (light contact with the rubber is tightened.

  • Page 164: Leveling The Mower

    MOWER DECKS/PTO Leveling the Mower 10. Adjust the belt tension and the idler plate, if necessary, and tighten all hardware securely (Fig. 445). Setting up the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

  • Page 165: Leveling The Mower Side-To-Side

    MOWER DECKS/PTO Leveling the Mower Side-to-Side 3. Record this measurement. This measurement needs to be 3-1/8 to 3-1/4 inches (7.9 to 8.3cm). 1. Position the right blade side-to-side (Fig. 447). 4. Position the left blade side-to-side refer to Fig. 447. 5.

  • Page 166: Adjusting The Front-To-Rear Mower Pitch

    MOWER DECKS/PTO Adjusting the Front-to-Rear Mower 3. Record the measurement. Pitch 4. Measure the right blade at the B location (Fig. 450), from a level surface to the cutting edge of the blade 1. Position the right blade front-to-rear (Fig. 450). tip (Fig.
  • Page 167 Z Master 500 Series Gasoline Engine Models Service Manual Form No. 492-9151...
  • Page 168 MOWER DECKS/PTO 8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10mm) lower in front A than in the rear at B (Fig. 453). Fig 453 fig.

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