ROPS (Roll Over Protection System) Installation (continued)
3. Install the upper ROPS assembly onto the machine.
4. While supporting the upper ROPS assembly, install the RH shoulder bolt
securing the upper ROPS assembly to the lower ROPS assembly.
Note:
May need assistance to support the upper ROPS assembly.
5. Install the LH shoulder bolt securing the upper ROPS assembly to the lower
ROPS assembly.
6. Raise the upper ROPS assembly, secure with the ROPS fold pins and hair
pins.
7. Install the fuel tank.
Fuel Tank Replacement (page 5–24)
8. Connect the battery by installing the positive cable first, then the negative
cable to the battery.
Caster Fork and Bearing Replacement
Caster Fork and Bearing Removal
1. Park the machine on a level surface and disengage the PTO. Stop the
engine, wait for all moving parts to stop and remove the key. Engage the
parking brake.
2. Disconnect the battery by removing the negative cable first, then the positive
cable from the battery.
3. Raise and support the machine so that the front wheels are off the ground.
4. Remove the caster cap.
5. Support the underside of the caster wheel and remove the fastener screw
securing the caster bearing assembly.
6. Remove the caster fork from the front axle. Inspect the caster fork shaft
for wear or damage.
7. Remove the upper and lower bearings from the axle and inspect the inside of
the axle bearing area for damage and excessive wear.
Caster Fork and Bearing Installation
1. Clean the surface inside the axle bearing area.
2. Install a new lower bearing from the bottom side into the axle, making sure it
is fully seated. Press evenly on the inner and outer race to seat the bearing.
3. Install spring washer on the top side of the axle, followed by a new upper
bearing, ensuring that the bearing is properly seated (the upper bearing
should be floating in the housing and does not need to be pressed in place).
Note:
The bearings are sealed and do not require grease/lubrication.
4. Install the flat washer on top of the bearing.
5. Install the fastener screw and tighten to the caster shaft. The spring washers
will provide the appropriate preload to the bearings.
6. Lower the unit and verify proper function.
Note:
The caster wheel is not serviceable and should be replaced as a
complete assembly.
7. Connect the battery by installing the positive cable first, then the negative
cable to the battery.
Chassis: Service and Repairs
Page 5–28
4000 Series Z MASTER® Service Manual
3442-427 Rev A
Summary of Contents for Z Master 4000 Series
Page 2: ...Revision History Revision History Page 2 4000 Series Z MASTER Service Manual 3442 427 Rev A...
Page 6: ...Preface Page 6 4000 Series Z MASTER Service Manual 3442 427 Rev A...
Page 108: ...Electrical Service and Repairs Page 8 14 4000 Series Z MASTER Service Manual 3442 427 Rev A...
Page 111: ...Drawing Rev A Sheet 1 3442 427 Rev A Page A 3 Electrical Schematic g342795...
Page 112: ...Page A 4 3442 427 Rev A Drawing Rev Sheet Electrical PTO Engaged Schematic g346038...
Page 113: ...Drawing Rev Sheet 3442 427 Rev A Page A 5 Electrical Run Position g346039...
Page 114: ...Page A 6 3442 427 Rev A Drawing Rev Sheet Electrical Start Position g346040...