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Z Master 500 Gas Series Service Manual

2

SPECIFICATIONS

Kohler Gas Product Shots

 

Fig 009

 

DSC-2870a

 

Fig 010

 

DSC-2869a

 

Fig 012

 

DSC-2874a

 

Fig 011

 

DSC-2875a

Summary of Contents for Z Master 500 Series

Page 1: ...Z Master 500 Series Gasoline Engine Models Service Manual LCE Products...

Page 2: ...ctive electrical troubleshooting and wiring diagrams on compact disk Form 492 9143 Z Master 500 Series gasoline engine machines model years 2004 and 2005 are covered in this manual This manual may als...

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

Page 4: ...Screws Thread Cutting Screws Zinc Plated Steel Wheel Bolts and Lug Nuts Thread Cutting Screws Zinc Plated Steel Equivalents and Conversions US to Metric Conversions CHASSIS Caster Fork Assembly Remov...

Page 5: ...HP Kohler EFI Air Cooled Engine Removal 28 HP Kohler EFI Air Cooled Engine Installation Kohler Electronic Fuel Injection EFI Models EFI Fuel System EFI Electrical System 27 HP Kawasaki Liquid Cooled...

Page 6: ...ch Installation Mower Deck Removal 52 60 72 Mower Deck Installation 52 60 72 Mower Spindle Removal Mower Spindle Installation Mower Spindle Disassembly Mower Spindle Assembly Replacing the Mower Belt...

Page 7: ...iv Z Master 500 Gas Series Service Manual TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 8: ...1 1 Z Master 500 Gas Series Service Manual Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 2 3 4 5 6 7 1 SAFETY INFORMATION...

Page 9: ...criteria are met Avoid injury to bystanders Always clear the area of bystanders before starting or testing powered equipment Avoid injury due to projectiles Always clear the area of sticks rocks or a...

Page 10: ...2 1 Z Master 500 Gas Series Service Manual 3 4 5 6 7 SPECIFICATIONS Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 1 2...

Page 11: ...2 2 Z Master 500 Gas Series Service Manual 2 SPECIFICATIONS Kawasaki Liquid Cooled Product Shots Fig 001 DSC 2861a Fig 002 DSC 2860a Fig 004 DSC 2864a Fig 003 DSC 3792a...

Page 12: ...2 3 Z Master 500 Gas Series Service Manual 2 Fig 006 DSC 2866a Fig 005 DSC 2865b Kohler EFI Product Shots Fig 007 DSC 2867a Fig 008 DSC 2868a SPECIFICATIONS...

Page 13: ...2 4 Z Master 500 Gas Series Service Manual 2 SPECIFICATIONS Kohler Gas Product Shots Fig 009 DSC 2870a Fig 010 DSC 2869a Fig 012 DSC 2874a Fig 011 DSC 2875a...

Page 14: ...2 5 Z Master 500 Gas Series Service Manual 2 Fig 014 DSC 2879a Fig 013 DSC 2877a Kawasaki Gas Product Shots Fig 015 DSC 2880a Fig 016 DSC 2882a SPECIFICATIONS...

Page 15: ...HV V Twin Air Cooled 3750 50 100 RPM 1500 RPM 15 AMP 25 HP 18 6 kW Kawasaki OHV V Twin Air Cooled 3750 50 100 RPM 3000 100 Int l 1500 RPM 13 AMP 27 HP 20 1 kW Kohler OHV V Twin Air Cooled 3750 50 100...

Page 16: ...m 53 7 136cm 68 173cm 79 5 202cm 23 hp Kohler 60 TF Deck 1215 lbs 551kg 53 134cm 72 183cm 61 7 157cm 76 193cm 81 5 207cm 25 hp Kawasaki 60 TF Deck 1215 lbs 551kg 53 134cm 72 183cm 61 7 157cm 76 193cm...

Page 17: ...P PJ Series variable displacement hydrostatic with shock valves Pump Drive Self tensioning belt drive Wheel Motors Twin Parker Ross Torqmotor positive displacement with 1 25 inch heavy duty tapered sh...

Page 18: ...ched to rear wheel supports by two struts Belt Covers 16 gauge formed steel covers Attached with swell latches Gauge Wheels 52 Cutting Deck Five adjustable gauge wheels to reduce scalping three on fro...

Page 19: ...ig 55 m 5615 Hydraulic System Oil Capacity 4 quarts 3 8 l Fluid Type Mobil 1 15w50 synthetic motor oil or equivalent synthetic oil Fluid Level Check the fluid level while the fluid is warm The fluid s...

Page 20: ...r information Hydrostatic Pumps Model and Serial Number The label above Fig 020 is located on the pump housing It identifies the model and configuration of the BDP pump Available Service Manuals Hydro...

Page 21: ...ature 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 lubricate...

Page 22: ...ith Regular 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 2...

Page 23: ...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 nuts Thre...

Page 24: ...hread 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...

Page 25: ...7 859 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 32 0 78125...

Page 26: ...ers Square 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 Metr...

Page 27: ...2 18 Z Master 500 Gas Series Service Manual 2 SPECIFICATIONS THIS PAGE INTENTIONALLY LEFT BLANK...

Page 28: ...3 1 Z Master 500 Gas Series Service Manual 2 4 5 6 7 CHASSIS Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 3 1...

Page 29: ...move the castor fork from the bottom of the hub 2 With a hammer and chisel remove the top grease cap Fig 021 Fig 021 mvc 1531 Fig 023 DSC 1533 4 Remove the Belleville washers and caster fork and wheel...

Page 30: ...aring cups are tapered make sure the tapered thicker end of the cup is installed inward for the top and bottom end Fig 027 Tap the bearing cups in until they seat against the step in the caster hub Fi...

Page 31: ...ring Washers Fig 030 DSC 1533 Fig 031 washers line art 1 Install the castor fork into the frame Fig 030 6 Install the lower bearing and seal with the open end of the seal facing up Fig 029 Fig 029 DSC...

Page 32: ...d install the grease plug 7 Install the grease cap on the caster hub Fig 034 Fig 036 DSC 1546 3 Remove bearing spacers and the front caster spacer Remove the seals located on each side of the wheel an...

Page 33: ...2 Remove the fuel hose clamp at the bottom of the fuel tank Fig 038 Fig 037 DSC 1547 Left Side Fuel Tank Removal 3 Remove the 4 screws retaining the control panel and control panel shield to the tank...

Page 34: ...fuel tank remove the nut spring and washer from the fuel tank stud Fig 042 Fig 042 DSC 3098 CHASSIS Note Rear tire removed for clarity 8 Remove the fuel tank from the frame Fig 043 Fig 043 DSC 3099 L...

Page 35: ...e hood and remove the stop lanyards located on each side of the hood Remove the hood from the frame of the unit Fig 045 Fig 045 DSC 1581 Hood Assembly Installation Reverse the order of removal Fig 044...

Page 36: ...Remove the brake shaft cotter pin Fig 048 Fig 049 DSC 1621 6 Using a hammer and punch drive both brake lever control bearings from the brake pivot Fig 050 Fig 050 DSC 1622 7 Inspect the brake shaft an...

Page 37: ...nd Fig 052 Reverse the order of removal Brake Band Removal 2 Remove the four wheel lug bolts 3 Remove bolts brake band retainer spacers and brake band Fig 053 Fig 053 DSC 1626 A B C D 1 Install the br...

Page 38: ...1 Raise the rear end of the unit and remove the right and left rear tires Note To prevent the unit from rolling block the two front tires Brake Shaft Removal Fig 056 DSC 3100 3 On the right side remov...

Page 39: ...he right side remove the two bolts and nuts holding the flange bearing Fig 058 Fig 059 DSC 3105 Fig 058 DSC 3104 7 Inspect the brake shaft and flange bearings for excessive wear Fig 061 Fig 061 DSC 31...

Page 40: ...correct measurement is obtained Tighten the two nuts together and repeat on the opposite side of the unit 4 Turn the nuts clockwise to shorten the spring length and counterclockwise to lengthen the sp...

Page 41: ...ft assembly Fig 066 Fig 066 DSC 1650 Fig 064 DSC 1648 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...

Page 42: ...ead 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 069 Fig 069 DSC 1653 9 Lift the floor pan assembly to its ful...

Page 43: ...e tighten the RH floor pan hinge mounting hardware Fig 074 Fig 074 DSC 1661 Fig 072 DSC 1656 11 Remove retainer clip from lift lever grip assembly Fig 072 14 If the lift lever grip assembly contacts t...

Page 44: ...For ease of installation make sure deck lift arm plates bushing and hardware are installed on the lift lever grip assembly prior to installation Fig 077 Fig 077 DSC 1668 E A D C B A Plate D Bolt B Nu...

Page 45: ...ith hole in carrier frame and deck lift plate outer From the outside of the frame install hex bolt spacer and flanged lock nut as shown Tighten bolt Fig 082 Fig 082 DSC 1677 Fig 080 DSC 1674 4 Install...

Page 46: ...tighten or deck lift plates will deform inward causing HOC pin assembly to bind Fig 085 Fig 085 DSC 1682 10 Install Hex nut on end of deck lift rod Tighten against deck mount swivel Repeat procedure f...

Page 47: ...88 Motion Control Assembly Removal Fig 088 DSC 1686 2 Remove floor pan assembly Fig 089 Fig 089 DSC 1689 12 Untie the floor pan assembly and lower Return motion control lever to its neutral locked pos...

Page 48: ...ssembly to the control arm shaft Fig 092 6 Disconnect Motion Control Dampener from motion control assembly Fig 093 Fig 093 DSC 1695 7 Disconnect neutral switch wire harness from neutral switch Fig 094...

Page 49: ...and nuts that retain the flange bearing on the inside of the motion control Fig 097 Fig 096 DSC 2064 Fig 097 DSC 2066 11 Remove the two bolts and nuts that retain the flange bearing on the outside of...

Page 50: ...4 1 Z Master 500 Gas Series Service Manual 2 3 5 6 7 HYDRAULIC SYSTEM Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 1 4...

Page 51: ...g installation lightly lubricate all seals O rings and gaskets with clean petroleum jelly prior to installation This procedure shows the LH Hydrostatic Pump being removed Use these same procedures to...

Page 52: ...move the two high pressure hydraulic lines located at the bottom of the hydrostatic pump Fig 104 Note Cap the hose and the fitting to prevent entry of dirt and debris Mark or tag one of the hoses to e...

Page 53: ...mp suction hydraulic line located on top of the hydrostatic pump that comes from the hydraulic filter Fig 110 Fig 109 DSC 3000 Note As a reminder prior to connecting the hydraulic lines the O rings sh...

Page 54: ...ulic lines located at the bottom of the hydrostatic pump Fig 112 Fig 112 DSC 2996 6 Install the key in the hydrostatic pump shaft Note Before installing the pulley replace the set screws The end of th...

Page 55: ...g 115 Tighten the two set screws once alignment is achieved 9 Install the seat prop rod to the frame Fig 117 Fig 116 DSC 3068 Fig 114 DSC 3066 8 Using a pry bar release the spring tension on the idler...

Page 56: ...stment Follow procedures on Adjusting the Handle Neutral page 4 12 Fig 120 DSC 3071 4 Loosen and remove nut securing hub to the wheel motor output shaft Fig 120 Fig 119 DSC 3070 3 Apply the parking br...

Page 57: ...3 Fig 124 DSC 3075 8 Clean any dirt or debris away from the hydraulic line fittings Remove the hydraulic lines Note Make sure to cap the fittings and hoses to prevent dirt from entering the hydraulic...

Page 58: ...s to remove the spacers Fig 126 Fig 126 DSC 3077 12 For service work on the wheel motor refer to the Parker Ross Service Manual Form 492 4753 Fig 127 DSC 3078 11 Remove the back two bolts lock washers...

Page 59: ...pacer long Fig 130 DSC 3081 2 Align the brake linkage with the two front bolt holes Fig 130 Fig 129 DSC 3080 1 Install wheel motor in the frame Loosely install the back two bolts long spacers lock was...

Page 60: ...134 DSC 3087 6 Install wheel hub assembly making sure the woodruff key is in place Fig 134 Note It is recommended to replace the wheel hub assembly prior to installation Fig 133 DSC 3086 5 Install an...

Page 61: ...ver HYDRAULIC SYSTEM 8 Install spacers brake band retainer and brake band around the wheel hub and tighten all three retainer bolts Fig 136 Fig 136 DSC 3089 10 Check the park brake and adjust park bra...

Page 62: ...to pivot outward to the neutral lock position 9 If adjustment is needed loosen the nut and jam nut against the yoke Fig 138 10 Apply slight rearward pressure on the motion control lever turn the head...

Page 63: ...n the throttle half way and release the park brake Note The motion control lever must be in neutral while making any adjustments 2 Slide the seat fully forward unlatch the seat and tilt the seat forwa...

Page 64: ...42 DSC 3117 2 Adjust the pump rod length by rotating the knob in the appropriate direction until the wheel is still or slightly creeping in reverse Fig 142 1 Loosen the locknuts at the pump ball joint...

Page 65: ...ig 146 DSC 3121 3 Adjust pump rod length by rotating the double nuts in the appropriate direction until wheel is still or slightly creeps in reverse Fig 144 Fig 144 DSC 3120 4 Move the motion control...

Page 66: ...rmal operating position 4 To make the machine go right turn the knob towards the right side of the machine Fig 147 1 Pull the spring loaded idler down and remove traction belt from the engine and hydr...

Page 67: ...maintenance Cleaning all parts by using a solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign material and chemicals Protect all exp...

Page 68: ...ll as needed with Mobil 1 15w50 oil 5 Disconnect the electric PTO clutch from the wiring harness to prevent accidental engagement of the mower deck 6 Disconnect the seat switch from the harness Tempor...

Page 69: ...the OFF position 14 Disconnect the hydraulic flow tester from the hydraulic lines 15 Re connect the hydraulic lines to the wheel motor Tighten fittings 16 Check the hydraulic reservoir and fill as ne...

Page 70: ...ging to Machine Operation 1 Rotate the bypass valves clockwise 1 turn to operate the machine Fig 157 Note Do not over tighten the by pass valves Fig 157 DSC 3130 Note The machine will not drive unless...

Page 71: ...4 22 Z Master 500 Gas Series Service Manual 4 HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK...

Page 72: ...2 3 4 6 7 ENGINE Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 1 5...

Page 73: ...op of the air cleaner bracket Fig 158 Fig 158 DSC 2956 3 Remove the air cleaner hose on the engine Fig 159 Fig 159 DSC 2957 Fig 161 DSC 2959 5 Loosen the clamps and remove the throttle and choke cable...

Page 74: ...162 DSC 2961 7 Turn the fuel shut off valve OFF Remove the fuel line hose clamp at the engine and remove the fuel line Fig 163 Fig 163 DSC 2962 Fig 165 DSC 2964 9 Remove two red cables from the start...

Page 75: ...lts spring washers and nuts Note The front left engine mount has two ground cables Fig 169 Fig 168 DSC 2966 12 Unplug the electric PTO clutch harness from the clutch Remove the tie strap holding the c...

Page 76: ...69 15 Connect lift chains straps to the engine lift brackets Raise the engine from the frame of the unit Fig 170 Kohler Air Cooled Engine Installation 3 Install the mower drive belt around the electri...

Page 77: ...l hydrostatic pump drive belt using a pry bar to relieve the tension on the spring loaded idler pulley Fig 175 9 Install the throttle and choke cables to the throttle linkage Position the throttle lev...

Page 78: ...bly bracket and install the air cleaner end cap Fig 179 Fig 179 DSC 2958 Fig 181 DSC 2957 13 Install the hose to the engine and tighten the hose clamp Fig 181 Fig 180 DSC 2956 12 Install the bolt spac...

Page 79: ...rom the battery 2 Remove the air cleaner cover Fig 182 Note This engine has a standard air cleaner cover If engine is equipped with a heavy duty air cleaner assembly remove the complete air cleaner as...

Page 80: ...the engine starter Fig 186 9 Disconnect three wires going from the main harness to the engine Fig 187 Violet wire to the Regulator Rectifier White wire to the Engine Magneto wire Pink wire to the Fue...

Page 81: ...nt engine mount bolt Fig 190 Fig 189 DSC 2982 11 With a pry bar relieve tension on the spring loaded idler and remove the pump drive belt Fig 189 Kawasaki Air Cooled Engine Installation 13 Connect a l...

Page 82: ...electric PTO clutch harness into the clutch Fig 193 Secure the clutch wire to the PTO stop rod with a tie strap Fig 193 DSC 2977 Fig 195 DSC 2978 6 Install the red heavy gauge wire from the solenoid...

Page 83: ...he engine oil filter Fig 197 Fig 196 DSC 2985 Fig 198 DSC 2975 7 Install the fuel line to the engine and tighten the hose clamp Turn the fuel shut off valve ON Fig 196 9 Connect the throttle and choke...

Page 84: ...Fig 200 Note This unit has a standard air cleaner assembly 28 HP Kohler EFI Air Cooled Engine Removal Note If welding on an EFI equipped machine be sure to disconnect the negative ground cable on the...

Page 85: ...aner bracket Fig 203 Fig 203 DSC 2885 5 Remove the fuel line clamp located on the engine fuel rail and remove hose Fig 204 Fig 204 DSC 2886 Fig 206 DSC 2888 7 Remove the throttle cable from the engine...

Page 86: ...9 Unplug the electric clutch harness from the electric clutch Fig 208 Fig 208 DSC 2891 Fig 210 DSC 2892 11 Remove the mower deck drive belt Note Refer to Mower Deck Removal page 7 8 12 Using a pry bar...

Page 87: ...213 One bolt goes into the side of the engine block and the other is the engine mounting bolt and nut Fig 212 DSC 2895 Fig 214 DSC 2903 14 Remove the blue wire from the starter solenoid Fig 212 16 Di...

Page 88: ...ve the red retainer clip Fig 216 Fig 216 DSC 2907 Next remove the multi pin connector from the ECU Fig 217 Fig 217 DSC 2908 Fig 218 DSC 2910 19 Remove the wire clip located on the side of the ECU that...

Page 89: ...es 21 Unplug the left and center relay from their connectors Remove 2 bolts and nuts retaining the connectors to the frame Fig 220 Fig 220 DSC 2912 Fig 222 DSC 2916 23 Remove the remaining 3 bolts was...

Page 90: ...e rear engine mount Tighten the bolts 2 Connect the two tan wires one from the engine harness and the other from the main harness Fig 223 28 HP Kohler EFI Air Cooled Engine Installation 3 Install the...

Page 91: ...ector Fig 229 Fig 228 DSC 2908 7 Install the wire connector to the bottom of the ECU Fig 228 5 Install the clamp holding the test plug connector to the side of the ECU control Fig 226 Fig 226 DSC 2910...

Page 92: ...0 Fig 230 DSC 2904 9 Connect the engine harness connector to the main harness Fig 231 Fig 231 DSC 2903 Fig 233 DSC 2895 11 Install the blue wire to the starter solenoid terminal Fig 233 Fig 232 DSC 29...

Page 93: ...Fig 236 DSC 2891 14 Install the mower deck drive belt around the electric PTO clutch Refer to Replacing the Mower Belt page 7 24 15 Install the PTO clutch harness to the PTO clutch Fig 236 12 Install...

Page 94: ...l lever in the full speed position Tighten throttle housing clamp Fig 238 Fig 238 DSC 2888 18 Fasten the throttle cable to the engine lift bracket using a tie strap Fig 239 Fig 239 DSC 2919 Fig 241 DS...

Page 95: ...2948 For engine specific service or diagnostics procedures consult the engine manufacture s service manual The following are the locations of components which are EFI related but mounted to the unit...

Page 96: ...flow fuel valve is located under the seat mounted to the frame Fig 246 Fig 246 DSC 2952 Fig 248 DSC 2953 2 The Transient Voltage Supression TVS diode is located on the left side of the engine next to...

Page 97: ...ood assembly Fig 251 Fig 250 DSC 2800 Fig 249 DSC 2955 1 Disconnect the negative and then the positive battery cable and remove the battery from the unit 2 Unlatch and open the engine hood Remove the...

Page 98: ...e drain port located on the engine block next to the engine oil filter Fig 255 5 Remove the air deflector Fig 253 Fig 254 DSC 2805 6 Using a pry bar relieve the idler pulley spring tension and remove...

Page 99: ...plate Fig 260 Fig 260 DSC 2810 ENGINE Fig 259 DSC 2812 11 Unplug the wire connector for the cooling fan Fig 259 Fig 258 DSC 2809 10 Remove the radiator outlet hose located on the left rear of the radi...

Page 100: ...ig 261 DSC 2813 Fig 263 DSC 2815 15 Remove the hose clamp from the air cleaner assembly Fig 263 Fig 262 DSC 2814 14 Remove the fan mounting plate and radiator Fig 262 16 Remove two bolts washers and n...

Page 101: ...nplug the two relays from the relay connectors Remove the two bolts and nuts retaining the connectors to the right hand side plate Fig 265 Fig 265 DSC 2818 Fig 267 DSC 2819 19 Remove the two bolts and...

Page 102: ...me Fig 270 Fig 270 DSC 2826 23 Loosen the clamps and remove the choke and throttle cables from the engine linkage Fig 271 Fig 271 DSC 2827 A Choke Cable B Throttle Cable A B 24 Release the belt tensio...

Page 103: ...276 Note The other two wiring connectors do not need to be disconnected Fig 276 DSC 2832 ENGINE Fig 275 DSC 3164 28 Remove the 3 red wires from the starter solenoid Fig 275 Fig 274 DSC 3163 27 Unplug...

Page 104: ...ped holes in the engine block 33 Remove the engine from the frame Fig 278 A Hose clamp B Fuel line B A 27 HP Kawasaki Liquid Cooled Engine Installation 1 Lower the engine on to the frame Install 4 bol...

Page 105: ...f the engine Fig 283 Fig 283 DSC 2829 8 Plug the wiring connector to the electric PTO clutch Fig 284 Fig 284 DSC 2828 ENGINE Fig 282 DSC 3163 6 Plug the orange black wire to the starter solenoid Fig 2...

Page 106: ...ve belt around the electric PTO clutch follow the procedures for Replacing the Mower Belt page 7 24 10 Install the choke cable to the engine linkage make sure the choke knob is pushed all the way in b...

Page 107: ...ig 291 DSC 2825 Fig 292 DSC 2818 14 Install the two bolts and nuts retaining the top and bottom strap guard located on the right side Fig 289 Install the corresponding bolts and nuts on the left side...

Page 108: ...ir cleaner cover off until after you fill the coolant reservoir bottle 19 Install the hose clamp on the air cleaner assembly shown with air filter cover on Fig 294 Fig 294 DSC 2815 Fig 293 DSC 2817 EN...

Page 109: ...99 Fig 299 DSC 2809 25 Install the radiator inlet hose and clamp located on the right side of the radiator Fig 300 Fig 300 DSC 2808 ENGINE Fig 298 DSC 2812 23 Connect the wiring for the cooling fan Fi...

Page 110: ...303 Fill to the line indicator of the overflow bottle Fig 301 DSC 2853 26 Install the overflow hose next to the radiator cap with a tie strap Fig 301 28 Install the air filter and air cleaner cover 29...

Page 111: ...34 Install the battery and connect the positive and then the negative battery cable 35 Test operate engine adjust choke and throttle cables as required Check engine low and high idle are to specificat...

Page 112: ...ht and left hair pins located on the hood Remove the hood assembly Fig 309 Fig 309 DSC 2800 3 Remove four bolts washers and nuts retaining the rear engine shield Remove the engine shield Fig 310 Fig 3...

Page 113: ...emove the radiator outlet hose located on the left rear of the radiator Fig 316 Fig 316 DSC 2809 ENGINE Fig 314 DSC 2807 7 Remove the tie strap around the overflow hose located next to the radiator ca...

Page 114: ...r retaining the radiator to the fan mounting plate Remove all 6 bolts and washers Remove the radiator Fig 317 Fig 320 DSC 2849 13 Remove the fan assembly through the front opening of the radiator supp...

Page 115: ...5 44 Z Master 500 Gas Series Service Manual 5 ENGINE THIS PAGE INTENTIONALLY LEFT BLANK...

Page 116: ...2 3 4 5 7 ELECTRICAL Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 1 6...

Page 117: ...on energizing the cooling fan Liquid cooled machines only 4 Fuel Pump Relay Kohler EFI engine Activates when the ignition switch is in the run position providing 12VDC to the fuel pump fuel injectors...

Page 118: ...ng it into an electromagnet 2 Switch Terminals 30 87 and 87a are actually part of a single pole double throw SPDT switch Terminal 30 is the common lead The switch is spring loaded so that terminals 30...

Page 119: ...elay should make and break continuity between terminals 30 and 87 when 12 VDC is applied and removed from terminal 85 4 Connect multimeter ohms setting leads to relay terminals 30 and 87a Apply 12VDC...

Page 120: ...y circuit to start the unit 6 Replace the switch if your test results do not correspond with those given in Figure 329 above 7 Mount the PTO switch back into the control panel and reinstall the wiring...

Page 121: ...gnition switch is located on the control panel to the left side of the operator Fig 330 Ignition Switch B Battery voltage in S Starting Circuit I Safety Circuit Gauges and Start Circuit A Alternator C...

Page 122: ...otion control handle and one for the left motion control handle Fig 332 Fig 332 DSC 2524 Fig 333 DSC 2527 This single pole plunger normally open type switch has two terminals When the motion control h...

Page 123: ...rators below the left motion control handle Fig 334 Fig 334 DSC 2525 1 Disconnect the switch from the wiring harness Fig 335 DSC 2528 In the start position it is used to ensure the park brake is ON At...

Page 124: ...With a delay module in the system there will be a slight delay before the engine shuts down after the operator vacates the seat Plunger Not Depressed Plunger Depressed A B Terminals Closed Circuit Con...

Page 125: ...he seat is occupied the switch closes and there should be continuity between the two terminals Deluxe suspension seat switch shown Fig 339 Fig 339 DSC 2556 1 Disconnect the switch from the wiring harn...

Page 126: ...3157 1 Raise the seat and disconnect the seat switch Install a jumper wire in place of the seat switch Fig 343 Fig 342 DSC 2532 The seat delay module circuit board is made up with several different el...

Page 127: ...hould read approximately 12 volts DC 5 Lift off the seat or disconnect one of the seat jumper wire leads The meter should hold around 12 volts and then read 0 volts DC after approximately 1 to 3 secon...

Page 128: ...rease Fig 346 Fig 346 DSC 2549 Time efficient testing is not possible See information under Temperature Sender page 6 14 Back side of the Temperature Gauge with terminal and wire locations Fig 347 S T...

Page 129: ...rature gauge to increase Fig 348 How It Works It is not practical to test the sender in a shop environ ment If the gauge is not reading at all temporarily ground the lead at the sender If the meter re...

Page 130: ...p of an electric winder and a mechanical clock movement When power is applied a coil is energized to wind the movement The movement unwinds in about 2 seconds As it finishes its rotation it re energiz...

Page 131: ...lace the voltmeter Testing ELECTRIC PTO CLUTCH Purpose Location The electric clutch is located on the PTO end of the crankshaft Fig 352 Fig 352 DSC 2552 The PTO clutch is composed of three major compo...

Page 132: ...needs to be replaced If the reading falls between 2 4 ohms measure clutch current draw 1 Disengage the PTO set the parking brake turn the ignition key to OFF and remove the key 2 Loosen 4 bolts and r...

Page 133: ...6 18 Z Master 500 Gas Series Service Manual 6 Kohler EFI Electric Fuel Injection ELECTRICAL...

Page 134: ...TRAL POSITION SHOWN IN OFF POSITION GY S X Y B BN BU IGNITION BROWN WIRE COLOR CODES NEUTRAL SW5 VIO BRAKE SW3 SHOWN WITH PARK BRAKE DISENGAGED P1 A SW6 SEAT SW F1 30A BATTERY GND ORANGE GREEN DELAY M...

Page 135: ...X Y B 1 BN BU OR BN BK IGNITION A B NEUTRAL SW5 VIO BRAKE SW3 SHOWN WITH PARK BRAKE DISENGAGED P1 A SW6 SEAT SW F1 20A GY GN BU BATTERY GND YELLOW WHITE VIOLET TAN RED PINK WIRE COLOR CODES DELAY MOD...

Page 136: ...6 21 Z Master 500 Gas Series Service Manual 6 Kawasaki L C Liquid Cooled ELECTRICAL...

Page 137: ...6 22 Z Master 500 Gas Series Service Manual 6 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK...

Page 138: ...2 3 4 5 6 MOWER DECKS PTO Safety Information Specifications Chassis Hydraulic System Engine Electrical Mower Decks PTO 7 1...

Page 139: ...5 The procedure shows an air cooled unit Fig 355 DSC 3131 On the Kawasaki liquid cooled models remove 6 bolts to access the clutch Fig 356 Fig 356 DSC 3794 Fig 358 DSC 3134 2 Remove the right and left...

Page 140: ...e clutch Fig 359 Fig 359 DSC 3135 4 Lift the floor pan and remove the right side mower belt cover Fig 360 Fig 360 DSC 3136 Fig 362 DSC 3138 6 Slip the mower drive belt off the right mower spindle pull...

Page 141: ...Remove the belt from the electric PTO clutch Fig 363 Fig 363 DSC 3139 8 Remove the electric PTO clutch bolt Fig 364 Fig 364 DSC 3140 Fig 366 DSC 3142 1 Apply anti seize compound to the engine cranksha...

Page 142: ...t Install the bolt and two spring washers to the crankshaft Torque the bolt to 65 ft lbs 88 13 Nm Fig 368 Fig 368 DSC 3143 Fig 370 DSC 3145 5 Check and make sure the mower drive belt is in the groves...

Page 143: ...s only what is specified in Figure 372 Fig 372 fig 70 m 6825 Fig 374 DSC 3148 8 Rotate the mower idler plate toward the front of the mower deck until light contact is made between the rear idler arm a...

Page 144: ...lt cover on the mower deck 12 Install the right and left top strap guards with the clutch guard to the unit Fig 377 Fig 376 DSC 3135 10 Connect the PTO clutch connector to the clutch Fig 376 MOWER DEC...

Page 145: ...381 DSC 3138 3 Slip the mower drive belt off the right mower spindle pulley Fig 381 Fig 380 DSC 3137 2 Loosen the two nuts located on the idler plate to relieve tension on the mower drive belt Fig 38...

Page 146: ...to relieve tension on the lift chains on the right side Fig 383 Fig 383 DSC 2623 Fig 385 DSC 2632 7 Remove the bolt and nut holding the right rear strut pin into the strut assembly Fig 385 Fig 384 DS...

Page 147: ...er deck when sliding it out under the frame Remove the 4 x 4 block of wood from the right side of the deck and allow the deck to rest on the floor 9 Raise the deck to transport position Install a 4 x...

Page 148: ...ide the mower deck from under the frame Fig 389 Fig 389 DSC 2637 14 Slide the mower out the right side of the unit Fig 390 Fig 390 DSC 2638 Fig 392 DSC 2639 3 Install the strut pin through the strut a...

Page 149: ...down on the wood block 8 Install the strut pin in the strut assembly Install and tighten the bolt and nut 9 Install the rear and front lift chains to the mower 10 Raise the mower deck and remove the...

Page 150: ...cified in Fig 397 below Fig 397 fig 70 m 6825 Fig 399 DSC 3148 15 Rotate the mower idler plate toward the front of the mower deck until light contact is made between the idler arm and the rubber stop...

Page 151: ...oor pan and remove the right side mower belt cover Fig 401 6 Loosen the two nuts located on the idler plate to relieve tension on the belt Fig 402 Fig 402 DSC 3137 This applies to removing any of the...

Page 152: ...DSC 2662 8 Remove three bolts retaining the pulley to the pulley hub Fig 404 Fig 405 DSC 2666 9 Raise the mower deck to the transport position 10 Remove the mower blade from the spindle assembly 11 Re...

Page 153: ...the pulley hub and square key Fig 407 Fig 406 DSC 2669 1 Remove the nut and washer Fig 406 Mower Spindle Disassembly 3 Remove the bearing shield Fig 408 Fig 408 DSC 2671 4 Remove the spindle housing f...

Page 154: ...f the spindle housing Fig 411 Fig 410 DSC 2673 5 Remove the seal spacer from the top of the spindle housing Fig 410 MOWER DECKS PTO 7 Remove the top oil seal from the spindle housing Fig 412 Fig 412 D...

Page 155: ...om the bottom of the spindle assembly Fig 417 Fig 416 DSC 2679 Fig 414 DSC 2677 11 Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing Fig 416 Note the orienta...

Page 156: ...420 DSC 2684 Fig 418 DSC 2681 15 This view shows the 2 bearing races and the large spacer in the spindle housing Fig 420 Note the internal snap ring in the housing it is not necessary to remove when...

Page 157: ...should be facing up to accept the tapered bearing 5 Install the lower seal Fig 425 Note The open lip of the seal should be facing outward Fig 424 DSC 2691 Fig 422 DSC 2689 4 Pack the tapered bearing...

Page 158: ...ntil the seal is flush with the outer edge of the housing Fig 426 Fig 426 DSC 2693 7 Turn the spindle assembly over and install the split ring spacer Fig 427 Fig 427 DSC 2699 Fig 429 DSC 2694 9 Pack t...

Page 159: ...nd the seal spacer onto the spindle shaft Fig 431 13 Install the seal spacer on the top of the spindle housing Fig 433 Fig 432 DSC 2703 Fig 430 DSC 2696 12 Lower the spindle housing over the spindle s...

Page 160: ...15 Install the square key onto the spindle shaft Fig 435 Fig 435 DSC 2706 Fig 437 DSC 2708 17 Install the heavy washer and nut on the top of the spindle shaft Fig 437 Note The cup side of the washer...

Page 161: ...ident 1 Disengage the PTO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving...

Page 162: ...ting the Mower Belt Tension page 7 25 7 Install the belt covers and close the latches Fig 439 Fig 442 fig 72 m 4417 Adjusting the Mower Belt Tension 1 Disengage the PTO move the motion control levers...

Page 163: ...st the tension Fig 440 7 To increase belt tension rotate the mower idler plate until resistance is felt and rotation stops Do not go past when it stops Fig 440 8 Tighten the idler plate bolts Fig 440...

Page 164: ...flat surface 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 moving parts to stop before l...

Page 165: ...me distance 9 Tighten the jam nut under the rear support arm and tighten the bolt securing the chain to the rear support arm Fig 449 fig 67 m 6830 3 Record this measurement This measurement needs to b...

Page 166: ...the measurement 4 Measure the right blade at the B location Fig 450 from a level surface to the cutting edge of the blade tip Fig 451 5 Record this measurement 6 The mower blade should be a 1 4 to 3 8...

Page 167: ...Z Master 500 Series Gasoline Engine Models Service Manual Form No 492 9151...

Page 168: ...ower in front A than in the rear at B Fig 453 Fig 453 fig 70 m 6831 1 11 1 2 29 2cm 4 Front swivel between the large 5 Swivel jam nut washers 6 Lift nut 2 Front nut 7 Front support arm 3 Spring jam nu...

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