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Toro Z Master Z400 Series Service Manual

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  • Page 1 LCE Products Z Master Z400 Series Service Manual...
  • Page 2 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

    TABLE OF CONTENTS Safety Information General Information ........Think Safety First .
  • Page 5 TABLE OF CONTENTS Chassis continued Parking Brake Handle/Shaft Assembly Removal All models ....3-18 Parking Brake Handle/Shaft Assembly Installation All models ....3-20 Brake Bar Removal (Estate Series) .
  • Page 6 TABLE OF CONTENTS Electrical continued Seat Delay Module ........Hour Meter .
  • Page 7 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. Z Master Z400 Service Manual...
  • Page 8 SAFETY INFORMATION Safety Information ..Specifications ... Chassis ....Hydraulic System .

  • Page 9: Safety Information General Information

    This symbol means WARNING or operating practices. Operator's manuals are available PERSONAL SAFETY INSTRUCTION through the Internet, your Toro parts source, or: Publications Department personal injury or even death. PERSONAL SAFETY INSTRUCTION through your Toro parts source or:...

  • Page 10: Specifications

    SPECIFICATIONS Safety Information ..Specifications ... Chassis ....Hydraulic System ..Engine .
  • Page 11 SPECIFICATIONS Z 400 Estate Series 19 hp Kawasaki OHV V-Twin Fig 001 Fig 003 DSC-4765a DSC-4767a Fig 002 DSC-4766a Fig 004 DSC-4768a Z Master Z400 Service Manual...
  • Page 12 SPECIFICATIONS Z 400 Estate Series 18 hp Kohler Fig 005 Fig 007 DSC-4842a DSC-4844a Fig 006 DSC-4843a Fig 008 DSC-4846a Z Master Z400 Service Manual...
  • Page 13 SPECIFICATIONS Z 450 Pro Performance Series 20 hp Kohler OHV V-Twin Fig 009 DSC-4833a Fig 011 DSC-4835a Fig 010 DSC-4834a Fig 012 DSC-4838a Z Master Z400 Service Manual...
  • Page 14 SPECIFICATIONS Z 100 Series 19 hp Kawasaki KAI OHV V-Twin Fig 013 DSC-0437a Fig 015 DSC-0440a Fig 014 DSC-0436a Fig 016 DSC-0435a Z Master Z400 Service Manual...
  • Page 15 SPECIFICATIONS Z 450 Pro Performance Series 23 hp Kawasaki OHV V-Twin Fig 017 Fig 019 DSC-0444a DSC-0442a Fig 018 DSC-0445a Fig 020 DSC-0448a Z Master Z400 Service Manual...
  • Page 16 SPECIFICATIONS Z 440 Pro Value Series 19 hp Kawasaki KAI OHV V-Twin Fig 021 DSC-0452a Fig 023 DSC-0455a Fig 022 DSC-0451a Fig 024 DSC-0450a Z Master Z400 Service Manual...
  • Page 17 SPECIFICATIONS Engines Output Make High Idle Low Idle Charging Coil 19 HP (14.2kW) Kawasaki 3650 + 100 RPM 1500 RPM 13 AMP OHV V-Twin Forced Air Cooled 18 HP (13.4kW) Kohler 3650 + 100 RPM 1500 RPM 13 AMP OHV Single Forced Air Cooled 19 HP (14.2kW) Kawasaki 3650 + 100 RPM...

  • Page 18: Z 400 Series Manual Specifications

    SPECIFICATIONS Z 400 Series Manual Specifications Frame Assembly Consists of front and rear frames bolted together Front Frame Welded 2 x 2 x .188” structural steel tube, 7 Gauge front cross member Rear Frame Welded tube and fabricated steel Fuel System Tanks Dual fuel tanks containing large fill necks and vented caps.

  • Page 19: Deck Drive

    SPECIFICATIONS Deck Drive Models with 7-Gauge Deck Models with SFS and TF Decks Clutch Warner Electromagnetic “Mag-Stop” with Warner Electromagnetic “Mag-Stop” with 120 ft-lbs. (162.7 Nm) rating 175 ft-lbs. (237-3 Nm) rating Deep B-Groove pulley with belt from engine to deck Type Take-Up Spring Idler system...

  • Page 20: Cutting Decks

    SPECIFICATIONS Cutting Decks 48” (121.9cm) 44” (111.8cm) 48” (121.9cm) 52” (132.1cm) 112cm (44”) 132cm (52”) & SFS Deck TF Deck TF Deck SFS Deck TF Deck 52” (132.1cm) 7-Gauge Deck Configuration Side Discharge, mid-mounted rotary with three blades. Construction 7-Gauge, Drawn 12 7 Gauge, High Strength Drawn 12...
  • Page 21 SPECIFICATIONS Cutting Decks cont. 48” (121.9cm) 44” (111.8cm) 48” (121.9cm) 52” (132.1cm) 112cm (44”) 132cm (52”) & SFS Deck TF Deck TF Deck SFS Deck TF Deck 52” (132.1cm) 7-Gauge Deck Deck Deck Deck suspended from machine by four lift chains, and attached to rear Suspension suspended wheel supports by two struts.

  • Page 22: Lubrication Fittings

    See operator's manual for additional details. 4. LETTERING COLOR: TORO CORDLESS BLUE NO. 500-97. See operator's manual for 107-1687 3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26 additional details. 2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-4 108-4050 Fig 026 107-1687A 1.
  • Page 23 BLOOMINGTON, MINNESOTA INFORMATION. IT MAY NOT WHOLLY OR PARTLY BE COPIED, DISCLOSED TO OT OR USED FOR ANY PURPOSE WITHOUT WRITTEN PERMISSION FROM TORO. IF CATION OCCURS, THE FOLLOWING NOTICE APPLIES: "© 1998 ALL RIGHTS RESE DO NOT SCALE DRAWING...

  • Page 24: Available Service Manuals / Service Aids

    SPECIFICATIONS Hydraulic System Oil Capacity: 2.1 quarts (2.0 liters) Fluid Type: Mobil 1 Extended Performance 15W-50 Synthetic Fluid Level: 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.

  • Page 25: 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 26: 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 27: Standard Torque For Dry, Zinc, And Steel Fasteners (Metric Fasteners)

    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 28: 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 29: 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 30: U.s. To Metric Conversions

    SPECIFICATIONS U.S. to Metric Conversions To Convert Into Multiply By 1.609 Miles Kilometers 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 31 SPECIFICATIONS THIS PAGE INTENTIONALLY LEFT BLANK. 2-22 Z Master Z400 Service Manual...

  • Page 32: Chassis

    CHASSIS Safety Information ..Specifications ... Chassis ....Hydraulic System ..Engine .
  • Page 33 CHASSIS Caster Fork Assembly Removal 4. Remove the caster fork assembly from the front frame (Fig. 034). Estate Series with bushing front casters 1. Raise the front of the unit off the ground, allowing enough clearance to remove the caster fork from the bottom hub.
  • Page 34 CHASSIS 6. Remove the top and bottom bushings (Fig. 036). 2. Install the caster fork assembly into the front frame (Fig. 038). Fig 036 PICT-0005 rev Fig 038 PICT-0008 Note: Ensure short caster spacer is installed prior to assembling the caster assembly. Caster Fork Assembly Installation Estate Series with bushing front casters 3.
  • Page 35 CHASSIS 4. When reinstalling the castor fork assembly on early 6. Install the top grease cap (Fig 042). production Z400 Estates Series check for excessive endplay between the E-ring groove and the top of the spacer. To minimize endplay, adjust as needed with 7/8”...
  • Page 36 CHASSIS 3. Loosen and remove the caster nut (Fig. 044). 5. Remove cup washers (3) (Fig. 046). Fig 046 PICT-0208 Fig 044 PICT-0206 6. Remove the top tapered roller bearing (Fig. 047). 4. Remove the caster fork and wheel assembly from the frame (Fig.
  • Page 37 CHASSIS 7. Remove the lower seal and lower tapered bearing 9. Remove the upper tapered bearing cup (Fig. 050) (Fig. 048). Fig 050 PICT-0212 Fig 048 PICT-0210 Caster Fork Assembly Installation 8. Remove the lower tapered bearing cup (Fig. 049) Pro 100/400 Series with tapered roller front casters 1.
  • Page 38 CHASSIS 2. Pack the upper and lower tapered roller bearings 4. Install the upper tapered bearing (Fig. 054). prior to installation (Fig. 052). Fig 054 PICT-0216 Fig 052 PICT-0214 5. Install the caster fork into the frame (Fig. 055). 3. Install the lower tapered bearing and lower seal with the open end of the seal facing up (Fig.

  • Page 39: Front Wheel Removal And Bearing Replacement Estate Series

    CHASSIS 6. Install the three spring washers (Fig. 056). 8. Remove the grease plug located on the side of the hub on the frame for the caster fork. Install a grease fitting, and pump grease into the housing until grease is passing through the upper bearing (Fig. 058).
  • Page 40 CHASSIS 2. Remove the wheel bolt and nut from the fork (Fig. 4. Remove the spacer nut from one side of the wheel 059). (Fig. 061). Fig 059 PICT-0013 Fig 061 PICT-0015 rev 3. Remove the wheel from the fork (Fig. 060). 5.
  • Page 41 CHASSIS 6. Remove both caster seals from the wheel (Fig. 063). 7. Fill the center of the wheel cavity with grease and work the grease into the race (Fig. 065). Fig 063 PICT-0017 Fig 065 PICT-0020 rev Caster Fork Wheel and Tire Assembly (Fig. 064) 8.
  • Page 42 CHASSIS 9. Install the wheel bearing (Fig. 067). 11. Repeat steps 8-10 for the other side of the wheel. 12. Install one spacer nut onto the caster axle (Fig. 069). Fig 067 PICT-0022 rev Fig 069 PICT-0024 rev 10. Install the caster seal (Fig. 068). 13.

  • Page 43: Pro 100/400 Series With Tapered Roller Front Casters

    CHASSIS 14. Bearing pre-load is established by the torque of the 16. Install wheel and tire assembly into caster fork using spacer nuts on the caster axle. Set spacer nuts at 80 wheel bolt and nut (Fig. 073). Tighten. in-lbs. (9.0 Nm) with a torque wrench. Loosen, then reset at 20 in-lbs.
  • Page 44 CHASSIS 3. Remove the wheel from the fork (Fig. 075). 5. Remove the front caster spacer (Fig. 077). Fig 075 PICT-0220 Fig 077 PICT-0222 rev 4. Remove both bearing spacers (Fig. 076). 6. Remove both bearing seals (Fig. 078). Fig 076 PICT-0221 rev Fig 078 PICT-0223 rev...

  • Page 45: Fuel Tank Removal

    CHASSIS 7. Remove both taper cone bearings (Fig. 079). 10. Pack both tapered wheel bearings. Reassemble per Fig. 000 (above). Note: The axle bolt torque sets the pre-load on the front caster wheel bearings. Tighten the axle bolt to set the bearings then back off 1/4 turn. Pump grease into the wheel bearings through the grease fitting located on the rim (Fig.
  • Page 46 CHASSIS 2. Remove the fuel hose clamp from the bottom of the 4. Carefully remove the control panel by lifting the fuel tank (Fig. 082). panel and sliding it toward the middle of the unit. Note: Do not disconnect any cables or wiring. 5.

  • Page 47: Left Side Fuel Tank Installation

    CHASSIS Location 7. Remove the fuel tank from the frame (Fig. 086). There are two fuel check valves. They are located one beneath each fuel tank approx 6” (15.2cm) down line from the tank (Fig. 087). Fig 086 PICT-0033 Left Side Fuel Tank Installation Fig 087 PICT-0001b Reverse the order of removal.

  • Page 48: Fuel Shut Off Valve

    CHASSIS Fuel Shut-off Valve Pro 400 Series V-Twin Kohler Fuel shut-off valve is located on the right hand side of Purpose the engine behind the seat (Fig. 090). The fuel shut-off valve cuts off fuel flow to the engine for transporting.
  • Page 49 CHASSIS Parking Brake Handle/Shaft 4. Remove the bolts from the outer bearing of the parking brake shaft (Fig. 094). Assembly Removal All Models 1. Release the parking brake (forward position). 2. Lift the floor pan and remove the panel assembly by removing the four fasteners retaining the panel to the frame (Fig.
  • Page 50 CHASSIS 6. Remove the E-ring from the outer end of the parking 8. Slide the parking brake shaft assembly out of the brake shaft (Fig. 096). frame (Fig. 098). Fig 096 PICT-0038 Fig 098 PICT-0040 rev 7. Remove the cotter pin and clevis pin holding the 9.

  • Page 51: Brake Bar Removal (Estate Series)

    CHASSIS Parking Brake Handle/Shaft 3. Remove the cotter pin and clevis pin from the brake rod assembly where it attaches to the brake bar Assembly Installation (Fig. 101). All Models Reverse the order of removal. Brake Bar Removal (Estate Series) 1.

  • Page 52: Brake Installation

    CHASSIS 5. Remove the brake bar from the machine (Fig. 103). 3. Measure the distance vertically between the front of the brake bar and the crown of the tire; the measurement should be 7/8” to 1” (22 to 25mm) (Fig. 104). Fig 103 PICT-0045 Brake Installation...

  • Page 53: Brake Band Removal (Pro Series)

    CHASSIS Brake Band Removal (Pro Series) 4. If the measurement is not correct, proceed to the following steps. Note: Procedure can be used for left hand or right 5. Remove the hairpin and cotter pin from the brake hand. linkage (Fig. 105). 1.

  • Page 54: Brake Band Installation

    CHASSIS 3. Remove bolts, brake band retainer, spacers, and 2. Install the 3 bolts, brake band retainer, brake band, brake band (Fig. 107). and spacers and tighten (Fig. 109). Fig 107 DSC-1626 rev Fig 109 DSC-1631 rev A. 3 Bolts C.
  • Page 55 CHASSIS 2. Remove the cotter pin and clevis pin from the brake 4. Cut the plastic tie that holds the fuel line to the brake rod assembly (Fig. 110). shaft (Fig. 112). Fig 112 PICT-0235 Fig 110 PICT-0231 3. Remove the left and right clevis spring clips from the 5.

  • Page 56: Brake Shaft Installation

    CHASSIS 6. Remove the brake shaft from the unit (Fig. 114). 2. Remove the lower stop bolt from the deck lift plate (Fig. 115). Fig 114 PICT-0237 Fig 115 PICT-0047 7. Inspect the brake shaft and flange bearings for excessive wear. 3.
  • Page 57 CHASSIS 4. Loosen jam nuts on the deck lift rods until the 6. Remove the two 4” x 4” blocks at the rear of the deck support springs are fully extended. Repeat deck, leaving the blocks in place at the front of the procedure for both deck lift rods (Fig.
  • Page 58 CHASSIS 8. Loosen the top hex head flange nut at the deck lift 11. Remove the bracket that supports the lower RH plate mounting location. Pivot the INNER deck lift corner of the panel assembly (Fig. 123). plate up and back toward the RH motion control lever (Fig.

  • Page 59: Deck Lift Lever Installation

    CHASSIS 13. Remove the retainer clip from the lift lever grip 15. Inspect the deck lift lever assembly components for assembly (Fig. 125). wear, especially the bushings (Fig. 127). B C D E Fig 125 PICT-0059 rev Fig 127 PICT-0061 rev A.
  • Page 60 CHASSIS 2. For ease of installation, make sure deck lift arm 4. Install bolt, nut and bushing through the plates into plates, bushings and hardware are installed on the the rear deck lift cross-shaft (Fig. 131). deck lift lever assembly prior to installation (Fig. 129).
  • Page 61 CHASSIS 6. Rotate deck lift plate (inner) downward until lower 8. Raise deck lift lever assembly until deck mount mounting holes line up with hole in carrier frame and swivels rest against deck rod jam nuts. Install HOC deck lift plate (outer). From the outside of the frame pin into deck lift plate HOC holes that correspond to install hex bolt, spacer, and flanged lock nut as the 3”...

  • Page 62: Motion Control Assembly Removal

    CHASSIS 10. Install hex nut on end of deck lift rod. Tighten 12. Install the panel assembly with the four fasteners against deck mount swivel. Repeat procedure for retaining the panel to the frame (Fig. 139). opposite side deck lift swivel (Fig. 137). Fig 139 PICT-0034 Fig 137...
  • Page 63 CHASSIS 2. Remove the two bolts and washers retaining the 4. Disconnect the motion control dampener from the lever assembly to the control arm shaft (Fig. 141). motion control assembly (Fig. 143). Fig 141 PICT-0072 Fig 143 PICT-0074 3. Remove the cotter pin and clevis pin securing the 5.

  • Page 64: Motion Control Assembly Installation

    CHASSIS 6. Disconnect neutral switch wire harness from the 8. Remove the two bolts and nuts that retain the flange neutral switch (Fig. 145). bearing on the outside of the motion control (Fig. 147). Fig 145 PICT-0078 Fig 147 PICT-0080 7.
  • Page 65 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK. 3-34 Z Master Z400 Service Manual...

  • Page 66: Hydraulic System

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

  • Page 67: Hydrostatic Pump Removal

    HYDRAULIC SYSTEM Hydrostatic Pump Removal 4. Drain the hydraulic oil from the hydraulic reservoir tank. Note: Cleanliness is a key factor in a successful 5. Remove the hose clamp from the case drain repair of any hydrostatic system. Thoroughly hydraulic hose, located on the top inside of the clean all exposed surfaces prior to any type hydrostatic pump (Fig.
  • Page 68 HYDRAULIC SYSTEM 7. Remove the two high pressure hydraulic lines, 9. Loosen the two square head set screws located on located at the rear of the hydrostatic pump (Fig. the pump sheave and remove the pulley (Fig. 154). 152). Fig 154 PICT-0090a Fig 152 PICT-0086a...

  • Page 69: Hydrostatic Pump Installation

    HYDRAULIC SYSTEM Hydrostatic Pump Installation 11. Remove the seat retainer rod (Fig. 156). 1. Place the hydrostatic pump into the frame (Fig. 158). Fig 156 PICT-0092a Fig 158 PICT-0093a 12. Remove the hydrostatic pump from the frame (Fig. 157). 2. Install the bolt, washer and nut that retain the tracking link rod to the hydro control arm (Fig.
  • Page 70 HYDRAULIC SYSTEM 3. Loosely install the two bolts and nuts retaining the 5. Install the pump suction hydraulic line located on the hydrostatic pump to the frame (Fig. 160). front of the hydrostatic pump (Fig. 162). Fig 160 PICT-0091a Fig 162 PICT-0084a 4.
  • Page 71 HYDRAULIC SYSTEM 7. Tighten the pump mounting bolts (Fig. 164). 10. Install the pulley. 11. Align the outer edge of the hydrostatic pump pulley using a straight edge, to the outer edge of the existing pump pulley (Fig. 166). Note: Deck drive belt was removed for clarity. Fig 164 PICT-0091a 8.

  • Page 72: Replacing The Pump Drive Belt

    HYDRAULIC SYSTEM 13. Install the cog belt onto the drive pulley. With a 15. Connect the negative battery cable to the battery. spring puller, install the extension spring to the idler arm assembly (Fig. 168). 16. Check the hydraulic fluid in the reservoir tank. Add oil if necessary.
  • Page 73 HYDRAULIC SYSTEM 2. Remove the plastic tie holding the clutch harness to 4. Loosen the clutch stop rod and pivot away from the frame (Fig. 171). clutch (Fig. 173). Fig 173 PICT-0104a Fig 171 PICT-0099a 3. Unplug the clutch pigtail harness from the main 5.

  • Page 74: Installing The Pump Drive Belt

    HYDRAULIC SYSTEM Installing the Pump Drive Belt 3. Remove the Idler Arm (Fig. 177). Reverse the order of replacement. Idler Arm Removal 1. With a spring puller, remove the extension spring from the idler arm assembly and remove the cog belt from the pump drive and idler pulleys (Fig.

  • Page 75: Idler Arm Install

    HYDRAULIC SYSTEM Idler Arm Installation 3. Remove the cotter pin from the wheel motor output shaft (Fig. 180). Reverse the order of removal Wheel Motor Removal This procedure is the same for both the right and left wheel motors. 1. Disconnect the battery negative cable. 2.
  • Page 76 (Fig. 182). Fig 184 PICT-0005a Fig 182 PICT-0003a Note: Toro Wheel Hub Puller, P/N TOR 4097, is available through SPX (formerly OTC) 9. Remove the wheel motor (Fig. 185). 1-800-533-0492. 6. Place a drain pan under wheel motor. 7. Clean any dirt or debris away from the hydraulic line fittings.

  • Page 77: Wheel Motor Installation

    HYDRAULIC SYSTEM Wheel Motor Installation 3. Install and tighten the two hydraulic lines to the wheel motor fittings (Fig. 188) 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 78: Adjusting The Handle Neutral

    HYDRAULIC SYSTEM Adjusting the Handle Neutral 5. Check the alignment between the cotter pin hole on the motor shaft and the castle nut openings. Adjust the castle nut as needed for cotter pin installation. If motion control levers do not align, or move easily into the console notch, adjustment is required.

  • Page 79: Setting The Hydraulic Pump Neutral

    HYDRAULIC SYSTEM 7. Pull lever back until the clevis pin (on arm below 10. Apply slight rearward pressure on the motion pivot shaft) just begins to contact the end of the slot control lever, turn the head of the adjustment bolt (just beginning to put pressure on the spring) (Fig.

  • Page 80: Setting The Lh Hydraulic Pump Neutral

    HYDRAULIC SYSTEM 2. Slide the seat fully forward, unlatch the seat and tilt 2. Adjust the pump rod length by rotating the knob in the seat forward. the appropriate direction, until the wheel is still or slightly creeping in reverse (Fig. 195). 3.

  • Page 81: Setting The Rh Hydraulic Pump Neutral

    HYDRAULIC SYSTEM Setting the RH Hydraulic Pump 3. Adjust the pump rod length by rotating double nuts on the rod, in the appropriate direction, until the Neutral wheel is still or slightly creeps in reverse (Fig. 197). 1. Loosen the locknuts at the ball joints on the pump control rod (Fig.

  • Page 82: Adjusting The Tracking

    HYDRAULIC SYSTEM Adjusting the Tracking 2. Stop the machine and set the parking brake. 3. Unlatch the seat and tilt the seat forward to access The left hand pump has a knob for adjusting the tracking the tracking knob. (Fig. 198). Note: Determine the left and right sides of the machine from normal operating position.

  • Page 83: 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 84 HYDRAULIC SYSTEM 1. Lift the back of the machine so the rear tires (left and 3. Loosen hydraulic lines at the pump to obtain enough right) are off the ground. Place jack stands under clearance to connect flow tester to the hydrostatic the rear frame to support the unit.
  • Page 85 HYDRAULIC SYSTEM 5. Check the hydraulic reservoir and fill as needed with 11. Stroke the left hand hydrostatic lever fully forward. Mobil 1 Extended Performance, 15w50 oil. Very slowly, rotate the “T” handle of the adjustable flow tester restrictor valve until the pressure gauge 6.

  • Page 86: Pushing The Machine By Hand

    HYDRAULIC SYSTEM Pushing the Machine by Hand Changing to Machine Operation Important: Always push the machine by hand. 1. Rotate the by-pass valves clockwise 1 turn to Never tow the machine because operate the machine (Fig. 209). hydraulic damage may occur. Note: Do not over-tighten the by-pass valves.
  • Page 87 HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 4-22 Z Master Z400 Service Manual...

  • Page 88: Engine

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

  • Page 89: Kawasaki Fh580V 19 Hp Engine Removal

    ENGINE Kawasaki FH580V 19 hp Engine 4. Disconnect the oil pressure switch harness (Fig. 212). Removal 1. Remove the battery negative cable from the battery. 2. Disconnect the choke cable by removing the top clamp (Fig. 210). Note: Rear Bumper removed for clarity. Fig 212 PICT-0008c 5.
  • Page 90 ENGINE 6. Remove the (violet) wire from the voltage rectifier/ 8. Disconnect the white wire from the black wire regulator (Fig. 214). connected to the engine magneto (Fig. 216). Fig 214 PICT-0010c Fig 216 PICT-0012c 7. Disconnect the pink wire from the green wire 9. Turn the fuel shot-off valve to the “on” position (Fig. connected to the fuel solenoid (Fig.
  • Page 91 ENGINE 10. Remove the fuel line clamp holding the fuel line to 13. Unplug the clutch pigtail harness from the main the fuel pump. Remove the fuel line from the fuel harness (Fig. 220). pump (Fig. 218). Fig 220 PICT-0100a Fig 218 PICT-0013c 14.
  • Page 92 ENGINE 15. Remove the electric PTO clutch (Fig. 222). 17. Remove the drive belt from the pulley (Fig. 224). Fig 222 PICT-0015c Fig 224 PICT-0017c 16. With a spring puller, remove the extension spring 18. Remove the pulley (Fig. 225). from the idler arm assembly and remove the cog belt from the pump drive and idler pulleys (Fig.

  • Page 93: Kawasaki Fh580V 19 Hp Engine Installation

    ENGINE Kawasaki FH580V 19 hp Engine 19. Remove the five engine mounting bolts (Fig. 226). Installation Note: The left rear mounting bolt has 4 ground wires attached. 1. Lower the engine to the frame (Fig. 228). Fig 226 PICT-0019c Fig 228 PICT-0021c 20. Connect a lift chain to the lift points on the engine. 2. Install the five engine mounting bolts.
  • Page 94 ENGINE b. Install the four ground wires in the left rearmost 4. Apply a thread-locking compound to the clutch mounting bolt hole (Fig. 230). retainer bolt (Fig. 232). Fig 230 PICT-0019c Fig 232 PICT-0026c 3. Apply anti-seize compound to the engine shaft (Fig. 5.
  • Page 95 ENGINE 6. Install the hydro pump drive belt (Fig. 234). 8. Install the mower drive belt. Refer to Replacing the Mower Deck Drive Belt on page 7-24. 9. Plug the clutch pigtail harness into the main harness (Fig. 236). Fig 234 PICT-0106a rev 7.
  • Page 96 ENGINE 11. Install the fuel line clamp that holds the fuel line to 13. Reconnect the pink wire to the green wire that the fuel pump. Reinstall the fuel line to the fuel pump connects to the fuel solenoid (Fig. 240). (Fig.
  • Page 97 ENGINE 16. Reconnect the oil pressure switch harness (Fig. 17. Reconnecting the choke cable: 242). a. Reconnect the z-bend of the choke cable to the choke linkage (Fig. 244). Note: The air cleaner cover has been removed for clarity. Fig 242 PICT-0008c 15.
  • Page 98 ENGINE b. With the choke knob in the full down position 18. Reconnect the throttle cable: (Fig. 245) and the choke linkage in the full open position (left), tighten the cable clamp (Fig. 246). a. Reconnect the z-bend of the throttle cable to the throttle linkage (Fig.

  • Page 99: Kohler V-Twin 20 Hp Engine Removal

    ENGINE c. Pull the cable housing until the throttle linkage 3. Remove the eight bolts, washers and nuts that hold is in the full throttle position. Tighten the cable the notched weight onto the rear of the machine. clamp (Fig. 249). Remove the notched weight from the rear of the machine (Fig.
  • Page 100 ENGINE 5. Remove the three sets of fasteners holding the right 7. Remove the two sets of fasteners holding the hand muffler guard and guard strap to the frame hydraulic oil tank to the guard strap and fuel tank (Fig. 252). support (Fig. 254). Fig 252 PICT-0269 Fig 254 PICT-0272 6. Remove the right hand muffler guard and guard 8.
  • Page 101 ENGINE 9. Remove the left hand guard strap and muffler guard 11. Loosen the right clamp and disconnect the throttle (Fig. 256). cable (Fig. 258). Fig 256 PICT-0274 Fig 258 PICT-0280 10. Loosen the left clamp and disconnect the choke 12. Turn the fuel shut-off valve to the “Off” position (Fig. cable (Fig.
  • Page 102 ENGINE 13. Remove the fuel hose clamp, then the fuel hose 15. Remove the blue wire located on the starter solenoid located at the fuel pump (Fig. 260). (Fig. 262). Fig 260 PICT-0282 Fig 262 PICT-0284 14. Remove the red wires located on the starter solenoid 16.
  • Page 103 ENGINE 17. Remove the mower drive belt from the electric PTO 20. Remove the electric PTO clutch (Fig. 266). clutch, refer to Replacing the Mower Deck Drive Belt page x-xx. 18. Unplug the clutch pigtail harness from the main harness (Fig. 264). Fig 266 PICT-0015c 21.
  • Page 104 ENGINE 22. Remove the drive belt from the engine pulley (Fig. 24. Remove the 4 engine mounting bolts (Fig. 270). 268). Note: The left rear engine mounting bolt has 3 ground wires attached. Fig 268 PICT-0017c Fig 270 PICT-0287 23. Remove the engine pulley (Fig. 269). 25.

  • Page 105: Kohler V-Twin 20 Hp Engine Install

    ENGINE Kohler V-Twin 20 hp Engine Install 4. Install the engine pulley (Fig. 274). 1. Lower the engine onto the frame. Install 4 bolts and spring washers through the frame and into the base of the engine. Tighten the bolts (Fig. 000). 0287 left Note: The 3 ground wires attach to the left rear engine mounting bolt.
  • Page 106 ENGINE 6. Install the cog belt onto the pump drive and idler 8. Install the center bolt and two spring washers that pulleys. With a spring puller, install the extension hold the electric PTO clutch to the engine crankshaft spring onto the idler arm assembly (Fig. 276). (Fig.
  • Page 107 ENGINE 10. Plug the clutch pigtail harness into the main harness 13. Connect the blue wire onto the starter solenoid (Fig. (Fig. 280). 282). Fig 280 PICT-0100a Fig 282 PICT-0284 11. Install the mower drive belt onto the electric PTO 14.
  • Page 108 ENGINE 15. Connect the fuel hose clamp onto the fuel hose at 17. Reconnect the throttle cable: the fuel pump (Fig. 284). a. Position the throttle control lever so that there is approximately 1/2” (12.7mm) between the lever and the full throttle position of the throttle slot (Fig.
  • Page 109 ENGINE 18. Reconnecting the choke cable: 19. Install the left hand guard strap and muffler guard to the frame using the two sets of fasteners (Fig. 290). a. Push the choke knob into the full down position (Fig. 288). Fig 290 PICT-0273 Fig 288 PICT-0296 20. Install the hydraulic oil tank to the guard strap and fuel tank support using the two sets of fasteners b.
  • Page 110 ENGINE 21. Install the right hand muffler guard and strap guard 23. Install the notched weight onto the rear of the using three sets of fasteners (Fig. 292). machine using eight bolts, washers and nuts (Fig. 294). Fig 292 PICT-0269 Fig 294 PICT-0265 22. Install the tailpipe guard to the right hand guard strap using two bolts and nuts on the right hand side of the 24.

  • Page 111: Kohler 18 Hp Single Cylinder Removal

    ENGINE Kohler 18 hp Single Cylinder Removal 5. Remove the front cable clamp and disconnect the throttle cable (Fig. 297). 1. Remove the battery negative cable from the battery. 2. Raise the rear wheels of the machine off the ground and support the frame with jack stands.
  • Page 112 ENGINE 7. Unplug the magneto and charging circuit wire 9. Turn the fuel shut-off valve to the “off” position (Fig. harness (Fig. 299). 301). Fig 299 PICT-0327 Fig 301 PICT-0329 8. Disconnect the three ground wires located at the 10. Remove the fuel hose clamp on the fuel hose right hand engine lift point (Fig.
  • Page 113 ENGINE 11. Remove the red wires located on the starter solenoid 13. Remove the mower drive belt from the electric PTO (Fig. 303). clutch. Refer to Replacing the Mower Deck Drive Belt page x-xx. 14. Remove the plastic tie holding the clutch harness to frame (Fig.
  • Page 114 ENGINE 16. Remove the center bolt and two spring washers 18. With a spring puller, remove the extension spring holding the electric PTO clutch to the engine from the idler arm assembly and remove the cog belt crankshaft (Fig. 307). from the pump drive and idler pulleys (Fig.

  • Page 115: Kohler 18 Hp Single Cylinder Install

    ENGINE 20. Remove the engine pulley (Fig. 311). 22. Connect chains to the two lift points on the engine and raise the engine from the frame (Fig. 313). Fig 311 PICT-0018c Fig 313 PICT-0341 21. Remove the 4 engine mounting bolts and washers Kohler 18 hp Single Cylinder Install (Fig.
  • Page 116 ENGINE 3. Install the engine pulley (Fig. 315). 5. Install the cog belt onto the pump drive and idler pulleys. With a spring puller, install the extension spring onto the idler arm assembly (Fig. 317). Fig 315 PICT-0018c Fig 317 PICT-0016c 4.
  • Page 117 ENGINE 7. Apply a thread locking compound to the clutch 9. Torque the center bolt to 55 ft-lbs. (Fig. 321). retainer bolt (Fig. 319). Fig 321 PICT-0027c Fig 319 PICT-0026c 10. Plug the clutch pigtail harness into the main harness (Fig.
  • Page 118 ENGINE 11. Replace the plastic tie holding the clutch harness to 15. Connect the fuel hose clamp onto the fuel hose frame. located at the fuel pump (Fig. 325). 12. Install the mower drive belt onto the electric PTO clutch. Refer to Replacing the Mower Deck Drive Belt page 7-24.
  • Page 119 ENGINE 17. Connect the three ground wires located at the right 19. Connect the green oil sending wire to the oil hand engine lift point (Fig. 327). Reinstall the engine pressure switch (Fig. 329). lift bracket. Fig 329 PICT-0325 Fig 327 PICT-0328 20.
  • Page 120 ENGINE b. Reconnect the z-bend of the choke cable to b. Reconnect the z-bend of the throttle cable to the the choke linkage (the middle hole in the choke throttle linkage (the lowermost hole of the throttle plate). The choke linkage should be in the full plate).

  • Page 121: Z 100 Series Fh580V (Kai) 19 Hp Kawasaki Removal

    ENGINE Z 100 Series FH580V (KAI) 19 hp 4. Remove the two bolts and nuts holding the hydraulic oil tank to the guard strap and fuel tank support (Fig. Kawasaki Removal 336). 1. Remove the battery negative cable from the battery. 2.
  • Page 122 ENGINE 6. Remove the 9 sets of fasteners holding the right 8. Remove the bottom cable clamp and disconnect the hand muffler guard and guard strap to the frame. throttle cable (Fig. 340). Remove the muffler guard assembly (Fig. 338). Fig 340 PICT-0402 Fig 338 PICT-0400 9. Remove the green oil sending wire from the oil 7.
  • Page 123 ENGINE 10. Unplug the electric PTO clutch plug (Fig. 342). 12. Remove the fuel hose clamp on the fuel hose located at the fuel pump (Fig. 344). Fig 342 PICT-0405 Fig 344 PICT-0407 11. Turn the fuel shut-off valve to the “off” position (Fig. 343).
  • Page 124 ENGINE 14. Unplug the pink wire from the green wire (fuel shut- 16. With a spring puller, remove the extension spring off solenoid) and the white wire from the black wire from the mower deck (Fig. 348). (magneto) (Fig. 346). Fig 348 PICT-0375 Fig 346...
  • Page 125 ENGINE 18. Remove the center bolt and two spring washers 20. With a spring puller, remove the extension spring holding the electric PTO clutch to the engine from the idler arm assembly and remove the cog belt crankshaft (Fig. 350). from the pump drive and idler pulleys (Fig.

  • Page 126: Z 100 Series Fh580V (Kai) 19 Hp Kawasaki Install

    ENGINE 22. Remove the engine pulley, spacer and key (Fig. 24. Connect chains to the two lift points on the engine 354). and raise the engine from the frame (Fig. 356). Fig 354 PICT-0414 Fig 356 PICT-0419 Z 100 Series FH580V (KAI) 19 hp 23.
  • Page 127 ENGINE 3. Install the engine pulley, spacer and key (Fig. 358). 5. Install the cog belt onto the pump drive and idler pulleys. With a spring puller, install the extension spring onto the idler arm assembly (Fig. 360). Fig 358 PICT-0414 Fig 360 PICT-0016c...
  • Page 128 ENGINE 7. Apply a thread-locking compound to the clutch 9. Torque the center bolt to 55 ft-lbs. (74.6 Nm) (Fig. retainer bolt (Fig. 362). 364). Fig 362 PICT-0026c Fig 364 PICT-0027c 8. Install the clutch retainer bolt and two spring 10.
  • Page 129 ENGINE 11. Connect the red wire onto the starter solenoid (Fig. 13. Connect the violet wire to the B+ side of the 366). regulator (Fig. 368). Fig 366 PICT-0413 Fig 368 PICT-0408 12. Connect the pink wire to the green wire (fuel shut-off 14.
  • Page 130 ENGINE 15. Turn the fuel shut-off valve to the “on” position (Fig. 17. Reconnect the throttle cable: 370). a. Position the throttle control lever so that there is approximately 1/2” (12.7mm) between the lever and the full throttle position of the throttle slot (Fig. 372). Fig 370 PICT-0406 16.
  • Page 131 ENGINE 18. Reconnecting the choke cable: 19. Install the muffler guard assembly using 9 sets of fasteners (Fig. 376). a. Position the choke knob in the full down position (Fig. 374). Fig 376 PICT-0400 Fig 374 PICT-0296 20. Install the hydraulic oil tank using two bolts and nuts. Secure the tank to the guard strap and fuel tank b.
  • Page 132 ENGINE 21. Install the four bolts and nuts that hold the tailpipe guard to the right hand guard strap and rear muffler guard (Fig. 378). Fig 378 PICT-0397 22. Install a plastic tie to hold the throttle and choke cable to the right hand guard strap (Fig. 379). Fig 379 PICT-0422 23.
  • Page 133 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. 5-46 Z Master Z400 Service Manual...

  • Page 134: Electrical

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

  • Page 135: General

    ELECTRICAL General How It Works Note: Interactive Electrical Troubleshooting CD, A relay is an electrically actuated switch. Form 492-9143 is also available. 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning it into an electromagnet.

  • Page 136: Pto Switch

    ELECTRICAL Testing 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 383). Fig 382 relay pin diagram Fig 383 xl relay 1. Disconnect the relay from the harness. PTO Switch 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting).
  • Page 137 ELECTRICAL Location Testing The PTO Switch is located on the control panel on the 1. Disengage the PTO, set the parking brake, and turn left side of the operator (Fig. 384). the ignition to OFF. Remove the key. 2. Remove the 4 screws holding the control panel to the fuel tank.

  • Page 138: Ignition Switch

    ELECTRICAL Ignition Switch 6. Replace the switch if your test results do not correspond with those given in (Fig. 385). Purpose 7. Mount the PTO switch back into the control panel and reinstall the wiring harness (Fig. 386). The ignition switch makes the proper connections for the starter, accessories, and safety circuits.

  • Page 139: Neutral Safety Switch

    ELECTRICAL Neutral Safety 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 Used to ensure the motion control handles are in neutral released (Fig.

  • Page 140: Park Brake Switch

    ELECTRICAL Testing 1. Disconnect the switch from the wiring harness. 2. Using a VOM or test light, check first to ensure there is no continuity between the terminals, plunger out. 3. With the plunger pushed in, there should be continuity between the terminals. Park Brake Switch Purpose Fig 390 PICT-0197 The purpose of the brake switch is to ensure the machine is in neutral and the parking brake is applied before attempting to start the machine.

  • Page 141: Seat Switch

    ELECTRICAL How It Works 2. Using a multimeter, follow the procedures listed below (Fig. 394). When starting, it functions to ensure the park brake is in the ON position. At the same time it allows current to flow through the remainder of the starting safety circuit. When the park brake is released in the (Off position) it bypasses both neutral switches, permitting the control levers to be used, as long as the operator is in the seat to maintain current for the safety circuit (Fig.

  • Page 142: Seat Delay Module

    ELECTRICAL Location Testing 1. Disconnect the switch from the wiring harness. The seat switch is mounted to the frame directly under the seat (Fig. 395). 2. Using a VOM or test light, check first to ensure there is no continuity between either terminal, plunger out. 3. With the plunger pushed in, there should be continuity between the terminals.
  • Page 143 ELECTRICAL How It Works 2. Remove the 4 bolts mounting the console panel to the frame. The seat delay module circuit board is made up with 3. Connect a VOM positive lead to the violet wires on several different electronic components such as transient the module.

  • Page 144: Hour Meter

    ELECTRICAL Hour Meter 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. The hour meter keeps track of the actual unit running When power is applied, a coil is energized to wind the hours or the time that the ignition key switch is in the movement.

  • Page 145: Electric Pto Clutch

    ELECTRICAL Electric PTO Clutch Coil Resistance Measurement Purpose 1. Disengage the PTO, set the parking brake, turn the ignition to the “off” position and remove the ignition key. The electric clutch controls the engagement and disengagement of the Power Take Off (PTO) pulley. 2.

  • Page 146: Measuring Clutch Current Draw

    ELECTRICAL Measuring Clutch Current Draw 7. Turn the ignition switch to the “RUN” position. Turn the PTO switch to the “ON” position. 1. Disengage the PTO, set the parking brake, turn the 8. If the meter reading is 6.5 amps or above, the ignition key to OFF, and remove the key.
  • Page 147 ELECTRICAL How It Works Testing 1. Disconnect the solenoid from the wiring harness. The solenoid has two primary parts. One is a coil of wire wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part 2.

  • Page 148: Fuse Block

    ELECTRICAL Fuse Block Purpose House the electrical system fuses. Location Located below the control panel on the left hand side of the frame (Fig. 407). Fig 407 PICT-0202 A. Main circuit (30 amp) B. Charge circuit (25 amp) C. Optional head light kit circuit (10 amp) How It Works The fuse block contains the fuses that protect the system from electrical surges.

  • Page 149: Electrical Schematics

    ELECTRICAL 74412 Schematics Wire Diagram (Rev. A) 6-16 Z Master Z400 Service Manual...
  • Page 150 ELECTRICAL Schematics 74410 Wire Diagram (Rev. A) Z Master Z400 Service Manual 6-17...
  • Page 151 ELECTRICAL 74411 Schematics Wire Diagram (Rev. A) 6-18 Z Master Z400 Service Manual...
  • Page 152 ELECTRICAL 74413 and 74415 Schematics Wire Diagram (Rev. A) Z Master Z400 Service Manual 6-19...
  • Page 153 ELECTRICAL 74414 Schematics Wire Diagram (Rev. A) 6-20 Z Master Z400 Service Manual...
  • Page 154 ELECTRICAL 74416 and 74417 Schematics Wire Diagram (Rev. A) Z Master Z400 Service Manual 6-21...
  • Page 155 ELECTRICAL 74411TE Wiring Diagram 6-22 Z Master Z400 Service Manual...

  • Page 156: 74416Te

    ELECTRICAL 74416TE Wiring Diagram Z Master Z400 Service Manual 6-23...
  • Page 157 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 6-24 Z Master Z400 Service Manual...
  • Page 158 MOWER DECKS/PTO Safety Information ..Specifications ... Chassis ....Hydraulic System .
  • Page 159 MOWER DECKS/PTO Mower Deck Removal 4. Remove the belt from the electric PTO clutch (Fig. 410). Estate Series 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2. Lift the floor pan and remove the right side mower belt cover (Fig. 408). Fig 410 PICT-0122 5.
  • Page 160 MOWER DECKS/PTO 6. Remove the front and rear lift chains from the mower 8. Secure the cross brace to the frame so it is out of deck (Fig. 412). the way when removing the mower deck. 9. Raise the lift lever to the transport position. 10.

  • Page 161: Mower Decks

    MOWER DECKS/PTO Mower Deck Installation 5. Install the cross brace to the deck using the hardware as shown (Fig. 417). Estate Series 1. Slide the deck under the unit. 2. Place 4 x 4 wood blocks under the edge of the mower deck.
  • Page 162 MOWER DECKS/PTO 7. Raise the deck to the transport position. Remove 10. Insert a ratchet with a short extension or a breaker the 4x4 wood blocks. bar into the square hole in the fixed idler arm. Rotate the ratchet or breaker bar counterclockwise 8. Set the lift handle at the 3” (7.6cm) height-of-cut to move the fixed idler arm until you feel increased position.
  • Page 163 MOWER DECKS/PTO Mower Deck Removal 4. Remove the belt from the electric PTO clutch (Fig. 425). Z 400 Series (48” and 50” Decks) 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake.
  • Page 164 MOWER DECKS/PTO 6. Remove the front and rear lift chains from the mower 8. Check the bolt, bushing and strut base for wear (Fig. deck (Fig. 427). 429). A B C Fig 429 PICT-0312 rev Fig 427 PICT-0305 A. Bolt C.
  • Page 165 MOWER DECKS/PTO 12. Slide the mower deck out the right side of the unit 2. Slide the deck under the unit. (Fig. 431). 3. Place 4 x 4 wood blocks under the edge of the mower deck (Fig. 433). Fig 431 PICT-0308 Fig 433 PICT-0304...
  • Page 166 MOWER DECKS/PTO 5. Install the front and rear lift chains to the mower 8. Route the belt around the spindles, idler pulleys and deck (Fig. 435). the PTO clutch (Fig. 437). Fig 437 fig. 49 G001678 Fig 435 PICT-0305 1. Fixed idler arm 4.
  • Page 167 MOWER DECKS/PTO Mower Deck Removal 9. Insert a ratchet or breaker bar with a short extension into the square hole in the fixed idler arm. Rotate the ratchet or breaker bar counterclockwise to move the Z 100 Series (44” Deck) fixed idler arm until you feel increased resistance and the spring-loaded idler pulley stops moving. 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking Note: Do not increase the belt tension beyond the brake.
  • Page 168 MOWER DECKS/PTO 4. Remove the belt from the electric PTO clutch (Fig. 6. Remove the four sets of bolts, spacers and washers 442). holding the front and rear lift chains to the mower deck (Fig. 444). Fig 442 PICT-0122 Fig 444 PICT-0377 5.
  • Page 169 MOWER DECKS/PTO 8. Remove the strut pin (Fig. 446). 12. Slide the mower deck out the right side of the unit (Fig. 448). Note: The gauge wheels may need to be loosened or removed to remove the strut pin. Fig 448 PICT-0382 Fig 446 PICT-0380...
  • Page 170 MOWER DECKS/PTO 2. Slide the deck under the frame. 5. Install the nut and bolt that holds the strut pin to the deck (Fig. 452). 3. Place 4 x 4 wood blocks under the edge of the mower deck (Fig. 450). Fig 452 PICT-0379 Fig 450...
  • Page 171 MOWER DECKS/PTO 8. Route the belt around the spindles, idler pulleys and 10. Lower the lift lever. the PTO clutch (Fig. 454). 11. Install the lift chains with the four sets of bolts, spacers and washers that hold the front and rear lift chains to the mower deck (Fig.
  • Page 172 MOWER DECKS/PTO Mower Spindle Removal 6. With a spring puller, remove the spring from the idler arm assembly to remove tension on the belt (Fig. 459). Pro 100 Series This applies to removing any of the three mower spindles. This procedure shows removing the right side spindle.
  • Page 173 MOWER DECKS/PTO 9. Remove the nut, washer, key, and pulley from the 11. Remove spindle from mower deck (Fig. 463). spindle shaft (Fig. 461). Fig 463 PICT-0387 Fig 461 PICT-0385 Mower Spindle Installation 10. Remove the mower blade. Remove the 4 bolts that mount the spindle to the deck housing (Fig.
  • Page 174 MOWER DECKS/PTO 5. Lift the floor pan and remove the right side mower 7. Slip the mower drive belt off the right mower spindle belt cover (Fig. 464). pulley (Fig. 466). Fig 466 PICT-0151 Fig 464 PICT-0116 8. Lock the blade in position with a 4 x 4 wood block 6.
  • Page 175 MOWER DECKS/PTO Mower Spindle Installation 9. Remove the blade (Fig. 468). Note: Mower deck was removed for photo clarity. Estate Series and Pro 400 Series Reverse the order of mower spindle removal Mower Spindle Disassembly Estate Series and Pro 400 Series 1.
  • Page 176 MOWER DECKS/PTO 3. Remove the bearing shield and thrust washer (Fig. 5. Remove the ball bearing from the top of the spindle 472). housing (Fig. 474). Fig 472 PICT-0158 Fig 474 PICT-0160 rev 4. Remove the spindle housing from the spindle shaft 6.
  • Page 177 MOWER DECKS/PTO Mower Spindle Assembly 7. Remove the ball bearing from the bottom of the spindle housing (Fig. 476) Estate Series and Pro 400 Series Note: On later production models the bottom ball bearing may be locked into place with 1.
  • Page 178 MOWER DECKS/PTO For a compound locked bearing: 3. Install the bearing shield and thrust washer onto the spindle shaft (Fig. 480). b. Thoroughly clean the spindle housing and the outer race of the bearing. c. Apply an even coat of chemical locking compound to the outer race and inner spindle housing (Fig.
  • Page 179 MOWER DECKS/PTO 5. Install the bearing spacer into the spindle housing 7. Install the upper thrust washer and bearing shield opening (Fig. 482). onto the spindle shaft (Fig. 484). Fig 482 PICT-0176 rev Fig 484 PICT-0181 rev 6. Install the upper ball bearing with the open end of 8.
  • Page 180 MOWER DECKS/PTO 9. Install the key into the spindle shaft (Fig. 486). 11. Torque the top nut to 100 to 120 ft-lbs. (135.6 to 162.7 Nm) (Fig. 488). Fig 486 PICT-0184 Fig 488 PICT-0187 10. Install the washer and the nut onto the spindle shaft Mower Spindle Disassembly (Fig.
  • Page 181 MOWER DECKS/PTO 2. Remove the spindle bearings and spacer (Fig. 490) 2. Lift the floor pan and remove the mower belt covers (Fig. 491). Fig 490 PICT-0390 Fig 491 PICT-0116 A. Spindle housing C. Spacer B. Bearings (2) 3. Loosen the two nuts located on the idler plate to remove tension on the belt (Fig.
  • Page 182 MOWER DECKS/PTO 4. Remove the worn/broken belt. 7. Route the belt around the idlers as shown (Fig. 495). 5. Route the new belt through the left side belt guide (Fig. 493). Fig 495 fig. 47 G001679 1. Ratchet with short 2. Square hole extension or breaker bar Fig 493 PICT-0188 8.
  • Page 183 MOWER DECKS/PTO Replacing the Mower Deck Drive Belt 9. Tighten the nut on the slotted on the idler plate (Fig. 496). Z 100 Series 1. Disengage the PTO, move the motion control levers to the neutral locked posistion, and set the parking brake.
  • Page 184 MOWER DECKS/PTO 5. Remove the old belt. 9. Tighten the outer nut on the spring eye bolt (Fig. 498). Note: Start at the outside pulley and rotate the belt off (Fig. 499). Note: Check the spring length. The spring should measure 9-3/8 + 1/8 inch (238 + 3mm) with belt installed.
  • Page 185 MOWER DECKS/PTO 5. Install the belt covers over the outside spindles. 5. To increase the belt tension, rotate the ratchet or breaker bar counterclockwise to move the fixed 6. Tighten the outer nut on the spring eye bolt (Fig. idler arm until you feel increased resistance and the 500).

  • Page 186: Leveling The Mower At 3 Positions

    MOWER DECKS/PTO Leveling the Mower at 3 Postions Leveling the Mower Side-to-Side Setting Up the Machine 1. Position the right blade side-to-side (Fig. 503). All models 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 187: Adjusting The Front-To-Rear Mower Pitch

    MOWER DECKS/PTO Adjusting the Front-to-Rear Mower Pitch 7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Fig. 504). 1. Position the right blade front-to-rear (Fig. 505). Fig 504 fig. 57 G001924 Fig 505...

  • Page 188: Adjusting The Compression Spring

    MOWER DECKS/PTO 7. Loosen the front swivel jam nuts, at the front of the 3. Adjust this distance, by loosening the spring jam nut right and left swivels, approximately 1/2 inch (13mm) and turning the nut in front of each spring (Fig. 506). (Fig. 504). Note: Turning the nut clockwise will shorten the spring;...
  • Page 189 MOWER DECKS/PTO THIS PAGE INTENTIONALLY LEFT BLANK. 7-32 Z Master Z400 Service Manual...
  • Page 190 Z Master Z400 Series Service Manual Form No. 492-9166...

This manual is also suitable for:

Z 400 estate seriesZ 450 pro performance seriesZ 100 seriesZ 440 pro value series

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