Toro Z 440 Pro Value Series Service Manual Download

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Z Master Z400 Service Manual

MOWER DECKS/PTO

Fig 494

PICT-0122

6. Install the new belt onto the electric PTO clutch (Fig.

494).

Fig 493

PICT-0188

4. Remove the worn/broken belt.

5. Route the new belt through the left side belt guide

(Fig. 493).

7. Route the belt around the idlers as shown (Fig. 495).

Fig 495

fig. 47 G001679

8. Insert a ratchet with a short extension or a breaker

bar into the square hole in the fixed idler arm.

Rotate the ratchet or breaker bar counterclockwise

to move the fixed idler arm until you feel increased

resistance and the spring-loaded idler pulley stops

moving.

Note: Do not increase the belt tension beyond the

point where the fixed idler arm stops.

1. Ratchet with short

2. Square hole

extension or breaker bar

Summary of Contents for Z 440 Pro Value Series

Page 1: ...Z Master Z400 Series Service Manual LCE Products...

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

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

Page 4: ...Steel Fasteners Metric Fasteners Other Torque Specifications Equivalents and Conversions U S to Metric Conversions Chassis Caster Fork Assembly Removal Estate Series with bushing front casters Caster...

Page 5: ...ng the Handle Neutral Setting the Hydraulic Pump Neutral Setting the LH Hydraulic Pump Neutral Setting the RH Hydraulic Pump Neutral Adjusting the Tracking Purging the Hydraulic System Hydraulic Flow...

Page 6: ...Spindle Removal Estate Series Pro 400 Series Mower Spindle Installation Estate Series Pro 400 Series Mower Spindle Disassembly Estate Series Pro 400 Series Mower Spindle Assembly Estate Series Pro 40...

Page 7: ...iv Z Master Z400 Service Manual THIS PAGE INTENTIONALLY LEFT BLANK TABLE OF CONTENTS...

Page 8: ...1 1 Z Master Z400 Service Manual 1 Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 2 3 4 5 6 7 SAFETY INFORMATION...

Page 9: ...dure Avoid unsafe operation Always test the safety interlock system after making adjustments or repairs on the machine Refer to the Electrical section in this manual for more information SAFETY INFORM...

Page 10: ...2 1 Z Master Z400 Service Manual 3 4 5 6 7 SPECIFICATIONS 1 2 Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks...

Page 11: ...2 2 Z Master Z400 Service Manual 2 SPECIFICATIONS Z 400 Estate Series Fig 001 DSC 4765a Fig 002 DSC 4766a Fig 004 DSC 4768a Fig 003 DSC 4767a 19 hp Kawasaki OHV V Twin...

Page 12: ...2 3 Z Master Z400 Service Manual 2 SPECIFICATIONS Z 400 Estate Series Fig 005 DSC 4842a Fig 006 DSC 4843a Fig 008 DSC 4846a Fig 007 DSC 4844a 18 hp Kohler...

Page 13: ...2 4 Z Master Z400 Service Manual 2 SPECIFICATIONS Z 450 Pro Performance Series 20 hp Kohler OHV V Twin Fig 009 DSC 4833a Fig 010 DSC 4834a Fig 012 DSC 4838a Fig 011 DSC 4835a...

Page 14: ...2 5 Z Master Z400 Service Manual 2 SPECIFICATIONS Fig 014 DSC 0436a Fig 013 DSC 0437a Fig 015 DSC 0440a Fig 016 DSC 0435a Z 100 Series 19 hp Kawasaki KAI OHV V Twin...

Page 15: ...2 6 Z Master Z400 Service Manual 2 SPECIFICATIONS Z 450 Pro Performance Series 23 hp Kawasaki OHV V Twin Fig 017 DSC 0444a Fig 018 DSC 0445a Fig 020 DSC 0448a Fig 019 DSC 0442a...

Page 16: ...2 7 Z Master Z400 Service Manual 2 SPECIFICATIONS Z 440 Pro Value Series Fig 021 DSC 0452a Fig 022 DSC 0451a Fig 024 DSC 0450a Fig 023 DSC 0455a 19 hp Kawasaki KAI OHV V Twin...

Page 17: ...48 7 Gauge Deck 889 lbs 407 78kg 51 129 54cm 69 175 26cm 49 7 126 24cm 64 162 56cm 78 198cm 19 HP Kawasaki 44 SFS Deck 941 lbs 426 83kg 52 132 08cm 70 177 8cm 47 119 38cm 61 3 155 7cm 78 198cm 19 HP...

Page 18: ...s Fuel Filter 15 micron replaceable in line filter Fuel System Models with 7 Gauge Deck Models with SFS and TF Decks Hydraulic Pumps HydroGear 10cc BDP 10A with 2300psi shock valve HydroGear 10cc BDP...

Page 19: ...th SFS and TF Decks Rear Drive Tires 4 ply with turf master tread 20 x 10 10 4 ply with turf master tread 23 x 9 5 12 Except as noted Front Caster Tires 4 ply with smooth tread 11 x 4 5 4 ply with smo...

Page 20: ...as bagger attachment point 7 Gauge High Strength 50 000 psi 3515 3 Kg f 59cm steel 5 12 7cm advanced Turbo Force flow system welded construction 3 8 9 5mm steel discharge reinforcement plate doubles a...

Page 21: ...ached with draw latches 14 gauge formed steel covers with access holes to allow greasing of outer spindles without removal Attached with draw latches Plastic HDPE deck covers Attached with swell latch...

Page 22: ...6 DECAL SHALL LOSE NONE OF ITS INITIAL PROPERTIES OR DIMENSIONS WHEN STORED BY TORO FOR ONE YEAR AT TEMPERATURES BELOW 100o F AND OUT OF DIRECT SUNLIGHT DURING STORAGE ADHESIVE SHALL NOT MIGRATE OR LO...

Page 23: ...D Version Toro 2004 200 23 hp Kawasaki 132cm 52 TF Deck Fig 027 107 1686A 4 3 2 1 4 3 2 1 CONFIDENTIAL THIRD ANGLE PROJECTION RELEASE CHANGE AUTHORIZATION NUMBER AUTH C0312 04 DO NOT SCALE DRAWING UNL...

Page 24: ...he BDP pump Available Service Manuals Service Aids Hydrostatic Pumps Hydro Gear BDP 10A 16A 21L Service and Repair Manual Form 492 4789 Wheel Motors Parker Ross Wheel Motor Service Manual Form 492 475...

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

Page 26: ...egular Height Nuts SAE J995 Grade 2 or Stronger Nuts In lb In lb N cm In lb N cm In lb N cm 6 32 UNC 10 2 13 2 147 23 15 2 170 20 23 2 260 20 6 40 UNF 17 2 190 20 25 2 280 20 8 32 UNC 13 2 25 5 282 30...

Page 27: ...Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam...

Page 28: ...Size Recommended Torque Square Head Hex Socket 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lb 145 20 in lb 3 8 16 UNC 35 10 ft lb 18 3 ft lb 1 2 13 UNC 75 15 ft lb 50 10 ft lb Type 1 Ty...

Page 29: ...0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 3...

Page 30: ...quare Centimeters Hectare 2 59 0 0929 6 452 0 4047 Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0 7646 0 02832 16 39 Weight Tons Short Pounds Ounces Metric To...

Page 31: ...2 22 Z Master Z400 Service Manual 2 SPECIFICATIONS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 32: ...3 1 Z Master Z400 Service Manual 2 4 5 6 7 CHASSIS Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 1 3...

Page 33: ...off the ground allowing enough clearance to remove the caster fork from the bottom hub 2 With a hammer and chisel remove the top grease cap Fig 032 Fig 032 PICT 0001 rev Fig 034 PICT 0003 4 Remove the...

Page 34: ...h bushing front casters 1 Drive the upper and lower bushings in until they seat against the step in the housing Fig 037 Fig 037 PICT 0006 rev Fig 039 PICT 0009 3 Install the tall spacer Fig 039 Fig 03...

Page 35: ...s needed with 7 8 ID shims Fig 040 Fig 040 PICT 0010 Fig 042 PICT 0012 6 Install the top grease cap Fig 042 5 Install the E ring Fig 041 Fig 041 PICT 0011 rev Caster Fork Assembly Removal Pro 100 400...

Page 36: ...ers 3 Fig 046 Fig 046 PICT 0208 6 Remove the top tapered roller bearing Fig 047 Fig 047 PICT 0209 CHASSIS Fig 045 PICT 0207 4 Remove the caster fork and wheel assembly from the frame Fig 045 Fig 044 P...

Page 37: ...er tapered bearing cups with the thick edge facing inside Fig 051 Fig 051 PICT 0213 Caster Fork Assembly Installation Fig 049 PICT 0211 8 Remove the lower tapered bearing cup Fig 049 Fig 048 PICT 0210...

Page 38: ...prior to installation Fig 052 Fig 052 PICT 0214 3 Install the lower tapered bearing and lower seal with the open end of the seal facing up Fig 053 Fig 053 PICT 0215 Fig 055 PICT 0207 5 Install the cas...

Page 39: ...057 Fig 057 PICT 0206 9 Replace the grease plug 10 Install the top grease cap Fig 058 PICT 0217 8 Remove the grease plug located on the side of the hub on the frame for the caster fork Install a grea...

Page 40: ...rk Fig 060 4 Remove the spacer nut from one side of the wheel Fig 061 5 Remove the caster axle and second spacer nut from the wheel Fig 062 Fig 060 PICT 0014 Fig 061 PICT 0015 rev Fig 062 PICT 0016 re...

Page 41: ...ICT 0018 rev Caster Fork Wheel and Tire Assembly Fig 064 8 Pack the wheel bearing prior to installation Fig 066 Fig 066 PICT 0019 rev CHASSIS 6 Remove both caster seals from the wheel Fig 063 Fig 063...

Page 42: ...her side of the wheel 12 Install one spacer nut onto the caster axle Fig 069 Fig 068 PICT 0021 rev 10 Install the caster seal Fig 068 Fig 070 PICT 0025 rev 13 Insert caster axle nut assembly into the...

Page 43: ...73 PICT 0028 CHASSIS Fig 071 PICT 0026 rev 14 Bearing pre load is established by the torque of the spacer nuts on the caster axle Set spacer nuts at 80 in lbs 9 0 Nm with a torque wrench Loosen then r...

Page 44: ...S 3 Remove the wheel from the fork Fig 075 Fig 075 PICT 0220 4 Remove both bearing spacers Fig 076 Fig 076 PICT 0221 rev Fig 078 PICT 0223 rev 6 Remove both bearing seals Fig 078 Fig 077 PICT 0222 rev...

Page 45: ...lt 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 o...

Page 46: ...dle of the unit Note Do not disconnect any cables or wiring 5 Remove the two bolts lock washers and flat washers from the front of the tank Fig 084 Fig 084 PICT 0031 6 Locate and remove the two nuts s...

Page 47: ...tank Fig 087 Fig 087 PICT 0001b Fig 088 PICT 0002b rev Flat side of the check valve faces fuel tank Fig 088 Location Proper Installation Follow the same procedures for the Left Side Fuel Tank Removal...

Page 48: ...he left hand side of the engine Fig 089 Fig 089 PICT 0005b The arrow at the bottom of the valve faces toward the engine Fig 091 Fig 091 PICT 0007b rev CHASSIS Fuel Shut off Valve Purpose Location Prop...

Page 49: ...from the outer bearing of the parking brake shaft Fig 094 CHASSIS 3 Remove the parking brake handle Fig 093 Fig 093 PICT 0035 All Models 1 Release the parking brake forward position 2 Lift the floor...

Page 50: ...rod assembly to the parking brake shaft Fig 097 Fig 097 PICT 0039 Fig 099 PICT 0041 9 Inspect the brake shaft and bushings for excessive wear Replace any worn or broken components Fig 099 Fig 098 PIC...

Page 51: ...me Fig 102 Fig 101 PICT 0043 3 Remove the cotter pin and clevis pin from the brake rod assembly where it attaches to the brake bar Fig 101 1 Disengage the brake 2 Remove the brake return spring Fig 10...

Page 52: ...of all 4 tires 2 Disengage the brake lever lever down Reverse the order of removal Adjusting the Parking Brake 3 Measure the distance vertically between the front of the brake bar and the crown of th...

Page 53: ...he hairpin and cotter pin from the brake linkage Fig 105 Fig 105 Firgure 44 6 Adjust the yoke clockwise to shorten the distance counterclockwise to lengthen distance Fig 105 7 Measure the distance ver...

Page 54: ...Install the 3 bolts brake band retainer brake band and spacers and tighten Fig 109 Fig 109 DSC 1631 rev 1 Raise the rear end of the machine and remove both right and left wheels Note To prevent the un...

Page 55: ...ig 112 PICT 0235 5 On both the right and left side remove two bolts and nuts holding the flange bearings Fig 113 Fig 113 PICT 0236 Fig 111 PICT 0234 3 Remove the left and right clevis spring clips fro...

Page 56: ...All Models Fig 116 PICT 0048 3 With the mower deck in the transport position place a 4 x 4 block under each corner of the deck Lower the mower deck onto the support blocks to remove the weight from th...

Page 57: ...g 119 PICT 0051 7 Remove hex bolt nut and lift lever bushing from the lower deck lift plate mounting location Fig 120 Fig 120 PICT 0053 Fig 118 PICT 0050 5 Remove the hex nut from RH rear deck lift as...

Page 58: ...8 Loosen the top hex head flange nut at the deck lift plate mounting location Pivot the INNER deck lift plate up and back toward the RH motion control lever Fig 121 CHASSIS 11 Remove the bracket that...

Page 59: ...1 Install the bracket that supports the lower RH corner of the panel assembly Fig 128 Fig 128 PICT 0055 Fig 126 PICT 0060 14 Carefully slide the lift lever grip assembly out of its carrier frame pivot...

Page 60: ...or ease of installation make sure deck lift arm plates bushings and hardware are installed on the deck lift lever assembly prior to installation Fig 129 4 Install bolt nut and bushing through the plat...

Page 61: ...eated firmly against the deck lift plates DO NOT over tighten or deck lift plates will deform inward causing HOC pin assembly to bind Fig 136 Fig 136 PICT 0069 B A Fig 134 PICT 0067 7 Align rear deck...

Page 62: ...tightening the spring jam nut Fig 138 Fig 137 PICT 0070 10 Install hex nut on end of deck lift rod Tighten against deck mount swivel Repeat procedure for opposite side deck lift swivel Fig 137 CHASSIS...

Page 63: ...2 Fig 142 PICT 0073 4 Disconnect the motion control dampener from the motion control assembly Fig 143 Fig 143 PICT 0074 Fig 144 PICT 0076 5 Remove the bolt and nut that retaining the ball joint to the...

Page 64: ...uts that retain flange bearing on the inside of the motion control Fig 146 Fig 146 PICT 0079 8 Remove the two bolts and nuts that retain the flange bearing on the outside of the motion control Fig 147...

Page 65: ...3 34 Z Master Z400 Service Manual 3 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 66: ...4 1 Z Master Z400 Service Manual 2 3 5 6 7 HYDRAULIC SYSTEM Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks 4 1...

Page 67: ...installation This procedure shows the LH Hydrostatic Pump being removed Use these same procedures to remove the RH Hydrostatic Pump 1 Disconnect the negative battery cable from the battery 2 Using com...

Page 68: ...086a 8 With a spring puller remove the extension spring from the idler arm assembly and remove the cog belt Fig 153 Fig 155 PICT 0091a 10 Loosen and remove the two bolts and nuts retaining the hydrost...

Page 69: ...Fig 157 PICT 0093a rev Fig 158 PICT 0093a 1 Place the hydrostatic pump into the frame Fig 158 13 For service work on the pump refer to the Hydro Gear BDP 10A PG 16A 21L Service Manual form 492 4789 Hy...

Page 70: ...a 5 Install the pump suction hydraulic line located on the front of the hydrostatic pump Fig 162 Fig 161 PICT 0083a 4 Install the case drain hydraulic hose and hose clamp located on the top inside of...

Page 71: ...the set screws have a knurled cup point for retention and must not be re used Note Apply a drop of thread locking material to the threads of each set screw 10 Install the pulley 11 Align the outer ed...

Page 72: ...15 Connect the negative battery cable to the battery 16 Check the hydraulic fluid in the reservoir tank Add oil if necessary Air will need to be purged from system Follow the procedures for Purging t...

Page 73: ...ail harness from the main harness Fig 172 Fig 171 PICT 0099a 2 Remove the plastic tie holding the clutch harness to frame Fig 171 4 Loosen the clutch stop rod and pivot away from the clutch Fig 173 Fi...

Page 74: ...eys Fig 175 Reverse the order of replacement HYDRAULIC SYSTEM Idler Arm Removal 2 Remove the belt from the idler sheave Fig 176 Fig 176 PICT 0107a 3 Remove the Idler Arm Fig 177 Fig 177 PICT 0109a Fig...

Page 75: ...ff the ground and support the frame with jackstands Remove the rear wheel Fig 179 Fig 179 PICT 0111a Fig 181 PICT 0010a 4 Loosen and remove nut securing hub to the wheel motor output shaft Fig 181 Not...

Page 76: ...6 Place a drain pan under wheel motor 7 Clean any dirt or debris away from the hydraulic line fittings Remove the hydraulic lines Fig 183 Note Make sure to cap the fittings and hoses to prevent dirt...

Page 77: ...88 PICT 0009a 3 Install and tighten the two hydraulic lines to the wheel motor fittings Fig 188 Fig 187 PICT 0008a 2 Torque the wheel motor bolts to 75 to 85 ft lbs 102 to 115 Nm Fig 187 4 Install the...

Page 78: ...l jumper wire in seat switch harness 2 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the engine remove the key and wait for all movin...

Page 79: ...the head of the adjustment bolt in the appropriate direction until the control lever is centered in neutral lock position Fig 191 Note Keeping rearward pressure on the lower lever will keep the pin at...

Page 80: ...PICT 0014a 1 Start the engine open the throttle 1 2 way and release parking brake Note The motion control lever must be in neutral while making any adjustments 3 Move the motion control lever forward...

Page 81: ...k to neutral The wheel must stop turning or slightly creep in reverse 5 Run the engine at full speed Make sure the wheel remains stopped or slightly creeps in reverse adjust if necessary 6 Tighten the...

Page 82: ...go left turn the knob towards the left side of the machine Fig 000 above 6 Repeat this adjustment until the tracking is correct Fig 200 fig 57 m 6280 2 Stop the machine and set the parking brake 3 Unl...

Page 83: ...0019a Note Cleanliness is a key factor in successful flow testing of the hydraulic system Thoroughly clean all exposed surfaces prior to any type of maintenance Cleaning all parts by using a solvent...

Page 84: ...lines Fig 205 Retighten fittings at the pump Fig 205 PICT 0022a Fig 206 PICT 0023a 4 Connect the hydraulic hose fittings to the hydraulic flow tester and tighten the fittings Fig 206 If the flow test...

Page 85: ...idle and turn the ignition switch to the OFF position 15 Disconnect the hydraulic flow tester from the hydraulic lines 16 Reconnect the hydraulic lines to the wheel motor Tighten the fittings 17 Tigh...

Page 86: ...h rotate the by pass valves counter clockwise 1 turn This allows hydraulic fluid to by pass the pump enabling the wheels to turn Fig 208 Important Do not rotate the by pass valves more than 1 turn or...

Page 87: ...4 22 Z Master Z400 Service Manual 4 HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK...

Page 88: ...5 1 Z Master Z400 Service Manual 2 3 4 6 7 ENGINE Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 1 5...

Page 89: ...ne 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 210 PICT 0003b Fig 212 PICT 0008...

Page 90: ...14 Fig 214 PICT 0010c Fig 215 PICT 0011c 7 Disconnect the pink wire from the green wire connected to the fuel solenoid Fig 215 Fig 216 PICT 0012c 8 Disconnect the white wire from the black wire connec...

Page 91: ...tch harness to frame Fig 219 Fig 219 PICT 0099a Fig 220 PICT 0100a 13 Unplug the clutch pigtail harness from the main harness Fig 220 14 Remove the center bolt and two spring washers holding the elect...

Page 92: ...c 16 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 223 Fig 223 PICT 0016c Fig 225 PICT 0018c 18 Remove...

Page 93: ...Fig 227 Fig 227 PICT 0020c 1 Lower the engine to the frame Fig 228 Fig 228 PICT 0021c Fig 229 PICT 0022c 2 Install the five engine mounting bolts a Install the clutch stop rod in the right rear engin...

Page 94: ...locking compound to the clutch retainer bolt Fig 232 Fig 232 PICT 0026c Fig 233 PICT 0027c 5 Install the hydro pump drive pulley and the electric PTO clutch with the bolt and spring washers Torque the...

Page 95: ...ten the stop rod mounting bolt Fig 235 PICT 0104a 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 2...

Page 96: ...line to the fuel pump Fig 238 12 Reconnect the white wire to the black wire that connects to the engine magneto Fig 239 13 Reconnect the pink wire to the green wire that connects to the fuel solenoid...

Page 97: ...ss Fig 242 Fig 242 PICT 0008c 17 Reconnecting the choke cable 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 244 PIC...

Page 98: ...open position left tighten the cable clamp Fig 246 ENGINE 18 Reconnect the throttle cable a Reconnect the z bend of the throttle cable to the throttle linkage Fig 247 Fig 247 PICT 0034c b Position th...

Page 99: ...0267 4 Remove the 4 bolts and nuts that hold the tailpipe guard to the right hand guard strap Fig 251 19 Connect the battery negative cable Fig 249 PICT 0036c c Pull the cable housing until the thrott...

Page 100: ...e Fig 252 6 Remove the right hand muffler guard and guard strap Fig 253 Fig 253 PICT 0275 7 Remove the two sets of fasteners holding the hydraulic oil tank to the guard strap and fuel tank support Fig...

Page 101: ...he choke cable Fig 257 Fig 257 PICT 0279 11 Loosen the right clamp and disconnect the throttle cable Fig 258 Fig 258 PICT 0280 Fig 259 PICT 0281 12 Turn the fuel shut off valve to the Off position Fig...

Page 102: ...arter solenoid Fig 261 Fig 261 PICT 0283 15 Remove the blue wire located on the starter solenoid Fig 262 Fig 262 PICT 0284 Fig 263 PICT 0285 16 Unplug the engine wiring harness Fig 263 Fig 260 PICT 02...

Page 103: ...O clutch Fig 266 Fig 266 PICT 0015c Fig 267 PICT 0016c 21 With a spring puller remove the extension spring from the idler arm assembly Remove the cog belt from the pump drive and idler pulleys Fig 267...

Page 104: ...4 engine mounting bolts Fig 270 Note The left rear engine mounting bolt has 3 ground wires attached Fig 270 PICT 0287 Fig 271 PICT 0290 25 Connect chains to the two lift points on the engine and rais...

Page 105: ...Note The 3 ground wires attach to the left rear engine mounting bolt 2 Apply anti seize compound to the engine shaft Fig 272 Fig 272 PICT 0025c 3 Apply a thread locking compound to the clutch retainer...

Page 106: ...spring onto the idler arm assembly Fig 276 Fig 276 PICT 0016c 7 Install the electric PTO clutch Fig 277 Fig 277 PICT 0015c Fig 279 PICT 0027c 9 Torque the center bolt to 55 ft lbs 74 6 Nm Fig 279 Fig...

Page 107: ...Install the mower drive belt onto the electric PTO clutch Refer to Replacing the Mower Deck Drive Belt page 7 24 12 Plug in the engine wiring harness Fig 281 Fig 281 PICT 0285 Fig 283 PICT 0283 14 Con...

Page 108: ...Reconnect the z bend of the throttle cable to the throttle linkage the hole furthest from the pivot point Pull the cable housing until the throttle linkage is in the full throttle position Tighten the...

Page 109: ...e to the choke linkage The choke linkage should be in the full open position right Tighten the cable clamp Fig 289 Fig 289 PICT 0297 Fig 291 PICT 0272 20 Install the hydraulic oil tank to the guard st...

Page 110: ...stall the tailpipe guard to the right hand guard strap using two bolts and nuts on the right hand side of the machine Fig 293 Fig 293 PICT 0267 24 Install the rear wheels Lower the rear of the machine...

Page 111: ...ands Remove both rear wheels 3 Remove the 6 bolts washers and nuts holding the rear bumper to the frame Fig 295 Remove the rear bumper Fig 295 PICT 0321 4 Loosen the rear cable clamp and disconnect th...

Page 112: ...0327 8 Disconnect the three ground wires located at the right hand engine lift point Fig 300 Reinstall the engine lift bracket Fig 300 PICT 0328 Fig 302 PICT 0330 10 Remove the fuel hose clamp on the...

Page 113: ...located on the starter solenoid Fig 304 Fig 304 PICT 0332 Fig 306 PICT 0100a 15 Unplug the clutch pigtail harness from the main harness Fig 306 Fig 305 PICT 0099a 13 Remove the mower drive belt from...

Page 114: ...ankshaft Fig 307 Fig 307 PICT 0014c 17 Remove the electric PTO clutch Fig 308 Fig 308 PICT 0015c Fig 310 PICT 0017c 19 Remove the drive belt from the engine pulley Fig 310 Fig 309 PICT 0016c 18 With a...

Page 115: ...and washers Fig 312 Fig 312 PICT 0334 Fig 314 PICT 0025c 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 2 App...

Page 116: ...g 317 PICT 0016c 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 316 PICT 0017c 4 Install the dri...

Page 117: ...ectric PTO clutch to the engine crankshaft Fig 320 Fig 320 PICT 0014c Fig 322 PICT 0100a 10 Plug the clutch pigtail harness into the main harness Fig 322 Fig 321 PICT 0027c 9 Torque the center bolt to...

Page 118: ...Replacing the Mower Deck Drive Belt page 7 24 13 Plug in the engine wiring harness Fig 323 ENGINE Fig 323 PICT 0283 14 Connect the red wires to the starter solenoid Fig 324 15 Connect the fuel hose cl...

Page 119: ...nstall the engine lift bracket Fig 327 PICT 0328 Fig 329 PICT 0325 19 Connect the green oil sending wire to the oil pressure switch Fig 329 Fig 328 PICT 0327 18 Plug in the magneto and charging circui...

Page 120: ...approximately 1 2 12 7mm between the lever and the full throttle position of the throttle slot Fig 332 Fig 333 PICT 0343 rev b Reconnect the z bend of the throttle cable to the throttle linkage the l...

Page 121: ...attery negative cable from the battery 2 Raise the rear wheels of the machine off the ground and support frame with jack stands Remove both rear wheels 3 Remove the four bolts and nuts that hold the t...

Page 122: ...Remove the muffler guard assembly Fig 338 Fig 338 PICT 0400 ENGINE Fig 340 PICT 0402 8 Remove the bottom cable clamp and disconnect the throttle cable Fig 340 Fig 339 PICT 0401 7 Remove the top cable...

Page 123: ...g 342 Fig 342 PICT 0405 Fig 344 PICT 0407 12 Remove the fuel hose clamp on the fuel hose located at the fuel pump Fig 344 Fig 343 PICT 0406 11 Turn the fuel shut off valve to the off position Fig 343...

Page 124: ...ire from the black wire magneto Fig 346 Fig 346 PICT 0409 ENGINE Fig 348 PICT 0375 16 With a spring puller remove the extension spring from the mower deck Fig 348 Fig 347 PICT 0413 15 Remove the red w...

Page 125: ...ankshaft Fig 350 Fig 350 PICT 0014c Fig 352 PICT 0016c 20 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 126: ...nd raise the engine from the frame Fig 356 Fig 355 PICT 0416 23 Remove the 4 engine mounting bolts washers and nuts Fig 355 Z 100 Series FH580V KAI 19 hp Kawasaki Install 1 Lower the engine onto the f...

Page 127: ...nstall the engine pulley spacer and key Fig 358 Fig 358 PICT 0414 Fig 360 PICT 0016c 5 Install the cog belt onto the pump drive and idler pulleys With a spring puller install the extension spring onto...

Page 128: ...362 PICT 0026c Fig 364 PICT 0027c 9 Torque the center bolt to 55 ft lbs 74 6 Nm Fig 364 Fig 363 PICT 0014 8 Install the clutch retainer bolt and two spring washers that hold the electric PTO clutch t...

Page 129: ...ig 368 PICT 0408 13 Connect the violet wire to the B side of the regulator Fig 368 Fig 367 PICT 0409 12 Connect the pink wire to the green wire fuel shut off solenoid and the white wire to the black w...

Page 130: ...7mm between the lever and the full throttle position of the throttle slot Fig 372 Fig 371 PICT 0404 16 Connect the green oil sending wire to the oil pressure switch Fig 371 1 2 b Reconnect the z bend...

Page 131: ...l the muffler guard assembly using 9 sets of fasteners Fig 376 Fig 375 PICT 0421 b Reconnect the z bend of the choke cable to the choke linkage The choke linkage should be in the full open position fa...

Page 132: ...guard to the right hand guard strap and rear muffler guard Fig 378 Fig 378 PICT 0397 23 Install the rear wheels Lower the machine to the ground 24 Connect the battery negative cable Fig 379 PICT 0422...

Page 133: ...5 46 Z Master Z400 Service Manual 5 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK...

Page 134: ...6 1 Z Master Z400 Service Manual 2 3 4 5 7 1 6 Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO ELECTRICAL...

Page 135: ...nding the engine ignition system Fig 380 PICT 0189 The relays are located under the panel assembly Fig 380 A relay is an electrically actuated switch 1 Coil Terminals 85 and 86 are connected to a coil...

Page 136: ...eter ohms setting leads to relay terminals 30 and 87 Ground terminal 86 and apply 12 VDC to 85 The relay should make and break continuity between terminals 30 and 87 when 12 VDC is applied and removed...

Page 137: ...harness from the PTO switch 4 Press in the locking tabs on each side of the switch and pull the switch out of the control panel 5 Verify that there is continuity between the appropriate terminals in t...

Page 138: ...itch back into the control panel and reinstall the wiring harness Fig 386 Violet Orange Gray Gray Gray Orange Orange Fig 386 PTO clutch switch The ignition switch makes the proper connections for the...

Page 139: ...I A XY START Continuity B I S Fig 389 PICT 0192 To gain access to the neutral safety switches remove the panel assembly There are 2 neutral switches One for the right motion control handle and one fo...

Page 140: ...ine is in neutral and the parking brake is applied before attempting to start the machine Fig 391 DSC 2527 This single pole plunger normally open type switch has two terminals When the motion control...

Page 141: ...e starting safety interlock circuit When the brake is released after starting the other pair of terminals closes bypassing the neutral switches and applying power to the seat switch circuit Plunger No...

Page 142: ...tch shown Fig 396 DSC 2556 When operating the unit on rough terrain if the operator should come off the seat momentarily the seat delay module will temporarily delay the engine shutting down 1 Disconn...

Page 143: ...est the delay module function a Disengage the parking brake b Pull the right and left motion control levers out of the neutral position c Turn the ignition key to the RUN position d The meter should r...

Page 144: ...unit and is not repairable Fig 401 DSC 2560 Since a normal clock might be affected by variations in voltage and current the hour meter is made up of an electric winder and a mechanical clock movement...

Page 145: ...friction plate is drawn into the clutch plate magnetically and the two rotate as one component Fig 402 coil resist measure 1 Disengage the PTO set the parking brake turn the ignition to the off posit...

Page 146: ...the ignition switch to the RUN position Turn the PTO switch to the ON position 8 If the meter reading is 6 5 amps or above the system is functioning properly If the meter reading is below 6 5 amps che...

Page 147: ...is protected because only a small amount of current is needed to activate the coil Fig 405 xl solenoid a The solenoid has two primary parts One is a coil of wire wrapped around an iron core Whenever 1...

Page 148: ...el on the left hand side of the frame Fig 407 House the electrical system fuses Fuse Block Purpose Location A Main circuit 30 amp B Charge circuit 25 amp C Optional head light kit circuit 10 amp The f...

Page 149: ...6 16 Z Master Z400 Service Manual 6 ELECTRICAL 74412 Schematics Wire Diagram Rev A...

Page 150: ...6 17 Z Master Z400 Service Manual 6 74410 ELECTRICAL Schematics Wire Diagram Rev A...

Page 151: ...6 18 Z Master Z400 Service Manual 6 ELECTRICAL 74411 Schematics Wire Diagram Rev A...

Page 152: ...6 19 Z Master Z400 Service Manual 6 ELECTRICAL 74413 and 74415 Schematics Wire Diagram Rev A...

Page 153: ...6 20 Z Master Z400 Service Manual 6 ELECTRICAL 74414 Schematics Wire Diagram Rev A...

Page 154: ...6 21 Z Master Z400 Service Manual 6 ELECTRICAL 74416 and 74417 Schematics Wire Diagram Rev A...

Page 155: ...N SHOWN IN OFF POSITION OR S X Y B R GND GREY WHITE BN BU IGNITION A B ORANGE NEUTRAL SW5 VIO BRAKE SW3 SHOWN WITH PARK BRAKE DISENGAGED P1 A KAWASAKI TWIN AIR COOLED SW6 SEAT SW F1 30A STARTER BATTER...

Page 156: ...N SHOWN IN OFF POSITION OR S X Y B R GND GREY WHITE BN BU IGNITION A B ORANGE NEUTRAL SW5 VIO BRAKE SW3 SHOWN WITH PARK BRAKE DISENGAGED P1 A KAWASAKI TWIN AIR COOLED SW6 SEAT SW F1 30A STARTER BATTER...

Page 157: ...6 24 Z Master Z400 Service Manual 6 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK...

Page 158: ...7 1 Z Master Z400 Service Manual 2 3 4 5 6 MOWER DECKS PTO Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 1 7...

Page 159: ...osen the two nuts located on the idler plate to remove tension on the belt Fig 409 Fig 409 PICT 0121 Fig 411 PICT 0124 5 Raise the mower deck to the transport position Place 4 x 4 wood blocks under th...

Page 160: ...Fig 413 PICT 0128 Fig 415 PICT 0129 12 Slide the mower deck out the right side of the unit Fig 415 Fig 414 PICT 0130 8 Secure the cross brace to the frame so it is out of the way when removing the mow...

Page 161: ...handle to the lowest position and pin in place Fig 416 Mower Deck Installation 5 Install the cross brace to the deck using the hardware as shown Fig 417 Fig 416 PICT 0138 4 Inspect the cross brace bus...

Page 162: ...422 Fig 421 PICT 0147 10 Insert a ratchet with a short extension or a breaker bar into the square hole in the fixed idler arm Rotate the ratchet or breaker bar counterclockwise to move the fixed idle...

Page 163: ...TO 3 Loosen the two nuts located on the idler plate to remove tension on the belt Fig 424 Fig 424 PICT 0302 Fig 426 PICT 0304 5 Raise the mower deck to the transport position Place 4 x 4 wood blocks u...

Page 164: ...CT 0306 Fig 430 PICT 0307 9 Raise the lift lever to the transport position 10 Remove the 4 x 4 wood blocks from under the deck 11 Turn the right front wheel so the castor fork is angled forward This w...

Page 165: ...clearance to slide the mower deck under the frame Fig 432 Fig 432 PICT 0307 Fig 434 PICT 312 rev 4 Install the right and left struts into the strut bases Note When installing the rear push struts you...

Page 166: ...lt around the spindles idler pulleys and the PTO clutch Fig 437 Fig 436 PICT 0313 6 Raise the deck to the transport position Remove the 4x4 wood blocks 7 Set the lift handle at the 3 7 6cm height of c...

Page 167: ...rease the belt tension beyond the point where the fixed idler arm stops Tighten the nut on the slotted idler plate Fig 438 Fig 438 PICT 0315 10 Tighten the pivot bolt Fig 439 Fig 439 PICT 0316 Fig 441...

Page 168: ...k Lower the mower deck to relieve the tension on all four lift chains Fig 443 Note It may be necessary to push down on the lift lever and pin into place to relieve tension on the lift chains Fig 443 P...

Page 169: ...x 4 wood blocks from under the deck 11 Turn the right front wheel so the castor fork is angled forward This will allow more clearance to slide the mower deck from under the frame Fig 447 Fig 447 PICT...

Page 170: ...left strut pins Fig 451 Note The gauge wheels may need to be loosened or removed to install the strut pin Fig 451 PICT 0380 Fig 453 PICT 0396 6 If needed tighten the anti scalp roller bolts 7 Set the...

Page 171: ...on spring to the idler arm assembly Fig 455 Fig 455 PICT 0375 Fig 457 PICT 0374 12 Install the left and right deck belt covers Fig 457 Fig 456 PICT 0377 10 Lower the lift lever 11 Install the lift cha...

Page 172: ...e wheels 3 Disconnect the battery negative cable 4 Lower the mower deck to the lowest position 5 Lift the floor pan and remove the right side mower belt cover Fig 458 Fig 458 PICT 0374 Fig 460 PICT 03...

Page 173: ...0386 Pro 100 Series Reverse the order of mower spindle removal Fig 463 PICT 0387 11 Remove spindle from mower deck Fig 463 Mower Spindle Removal Estate Series and Pro 400 Series This applies to remov...

Page 174: ...wo nuts located on the idler plate to remove tension on the belt Fig 465 Fig 465 PICT 0121 Fig 467 PICT 0152 8 Lock the blade in position with a 4 x 4 wood block and remove the three bolts retaining t...

Page 175: ...Remove the six bolts and nuts from the spindle assembly Fig 469 Fig 469 PICT 0134 Estate Series and Pro 400 Series Reverse the order of mower spindle removal 11 Remove the spindle assembly Mower Spin...

Page 176: ...ve the spindle housing from the spindle shaft assembly Fig 473 Fig 472 PICT 0158 3 Remove the bearing shield and thrust washer Fig 472 5 Remove the ball bearing from the top of the spindle housing Fig...

Page 177: ...d or half the bearing race may be press fit into the spindle housing If a chemical locking compound is used the lower housing may require heat to release the locking compound Estate Series and Pro 400...

Page 178: ...spindle housing Fig 478 Caution DO NOT get chemical locking compound on the inside of the bearing d Install the open end of the bearing to the inside of the housing until the bearing is fully seated...

Page 179: ...he upper ball bearing with the open end of the bearing to the inside of the housing Fig 483 Fig 483 PICT 0180 Fig 485 PICT 0183 rev 8 Install the pulley hub onto the spindle shaft Note The raised cent...

Page 180: ...he washer and the nut onto the spindle shaft Fig 487 Fig 487 PICT 0185 Fig 488 PICT 0187 11 Torque the top nut to 100 to 120 ft lbs 135 6 to 162 7 Nm Fig 488 Fig 489 PICT 0388 rev Z 100 Series 44 Deck...

Page 181: ...vident 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 mower belt covers Fig 491 Fig 491 PICT 0116 3 Loo...

Page 182: ...the idlers as shown Fig 495 Fig 495 fig 47 G001679 8 Insert a ratchet with a short extension or a breaker bar into the square hole in the fixed idler arm Rotate the ratchet or breaker bar counterclock...

Page 183: ...es 1 Disengage the PTO move the motion control levers to the neutral locked posistion and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving th...

Page 184: ...ley 3 Outside pulley Adjusting the Mower Belt Tension 9 Tighten the outer nut on the spring eye bolt Fig 498 Note Check the spring length The spring should measure 9 3 8 1 8 inch 238 3mm with belt ins...

Page 185: ...measure 9 38 1 8 inch 238 3mm with belt installed Adjust it if it does not Fig 500 5 To increase the belt tension rotate the ratchet or breaker bar counterclockwise to move the fixed idler arm until...

Page 186: ...n the same side Refer to Adjusting the Front to Rear Mower Pitch page 7 30 If one front chain is loose raise tighten the front support arm for that chain Refer to Adjusting the Front to Rear Mower Pit...

Page 187: ...lade front to rear Fig 505 Fig 505 fig 58 G001041 2 Measure the right blade at the A location from a flat surface to the cutting edge of the blade tip Fig 505 3 Record this measurement 4 Measure the r...

Page 188: ...mm lower in front at A than in the rear at B Fig 504 9 Tighten both swivel jam nuts against the front swivel to lock the height 10 Check to make sure there is equal tension on the chains and adjust ag...

Page 189: ...7 32 Z Master Z400 Service Manual 7 MOWER DECKS PTO THIS PAGE INTENTIONALLY LEFT BLANK...

Page 190: ...Z Master Z400 Series Service Manual Form No 492 9166...

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