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Z Master 7500-D Series Service Manual

March 2018 - Digital Edition

Table of Contents

CHASSIS

Fuel Tank (Cont.)

Installation

1. Place fuel tank on the machine.

2. Loosely install the fuel tank mount bolt, washers, spacer, and lock nut.

3. Loosely install the two fuel tank clamps and lock nuts.

4. Tighten all three mounting fasteners.

5. Install the supply, return and vent lines to the fuel tank.

6. Install the left or right tank cover,

see “Left Tank Cover Installation,” chapter 5, page 5-18

see “Right

Tank Cover Installation,” chapter 5, page 5-20.

Summary of Contents for Z Master 74060

Page 1: ...L C EP r o d u c t s S e r v i c eMa n u a l ZMa s t e r 7 5 0 0 DS e r i e s I s s u e d Ma r c h2 0 1 8...

Page 2: ...able of Contents lists the systems and the related topics covered in this manual We are hopeful that service technicians will find this manual a valuable addition to service shops Any questions or com...

Page 3: ...n is used to identify Critical Torque and Fluid Capacity Specifications that are specific to this product and differ from the General Torque Specifications chart given in the Specifications section of...

Page 4: ...Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents Safety 1 1 Specifications 2 1 Troubleshooting 3 1 Engine 4 1 Chassis 5 1 Deck 6 1 Drive 7 1 Electrical 8 1 TABLE OF C...

Page 5: ...1 1 Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents SAFETY Safety Table of Contents Icons 1 2 Think Safety First 1 2 Additional Safety 1 5...

Page 6: ...ion while the unit is running or shortly after it has been running Avoid fires and explosions Use extreme care in handling fuel It is flammable and its vapors are explosive Extinguish all cigarettes c...

Page 7: ...ping under pressure can have sufficient force to penetrate the skin and cause serious injury Seek medical attention right away if hydraulic fluid gets in the skin Personal Protective Equipment Use app...

Page 8: ...s gasoline kerosene grease and oil The numerical rating for class B extinguishers indicates the approximate number of square feet of fire it can extinguish Geometric symbol red square Class C fires in...

Page 9: ...when operating snow products Ensure the area is cleared of any objects that could become entangled or thrown Turf Products Aerator s could puncture underground cables or irrigation systems Walk Power...

Page 10: ...ONS Specifications Table of Contents General Specifications 2 2 Torque Specifications 2 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 5 Standard Torque for Dry Zinc Plated an...

Page 11: ...CCA Hydraulic Drive System Transmission Kanzaki KPS 18T Transmission Lubricant Prem Trans Hyd Tractor Fluid 108 1184 5 gal 108 1183 55 gal Alternate Mobil 424 Max Ground Speed 12 5 mph Forward 7 0 mph...

Page 12: ...l Capacity 12 gal Battery 12V Goup 26 540 CCA Hydraulic Drive System Transmission Kanzaki KPS 18T Transmission Lubricant Prem Trans Hyd Tractor Fluid 108 1184 5 gal 108 1183 55 gal Alternate Mobil 424...

Page 13: ...r presence of a prevailing 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 s...

Page 14: ...8 24 UNF 16 2 16 2 22 3 30 3 41 4 43 5 58 7 17 2 18 2 24 3 35 4 47 5 50 6 68 8 7 16 14 UNC 7 16 20 UNF 27 3 27 3 37 4 50 5 68 7 70 7 95 9 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 1 2 20 UNF 30...

Page 15: ...10 93 10 126 14 M16 X 2 0 166 17 255 23 229 23 310 31 M20 X 2 5 325 33 440 45 450 46 610 62 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are...

Page 16: ...n lb No 10 12 16 38 7 in lb No 12 11 14 85 15 in lb SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Cutting Screws Zinc Plated Steel Thread Cutting Screws Zinc Plated Steel Hole size mate...

Page 17: ...64 0 203125 5 159 45 64 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 44...

Page 18: ...Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons...

Page 19: ...3 1 Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents TROUBLESHOOTING Troubleshooting Table of Contents General Troubleshooting Table 3 2...

Page 20: ...tact Clean the connector terminals thoroughly with electrical contact cleaner apply dielectric grease and make the appropriate connections The relay or switch is worn or damaged Test and replace fault...

Page 21: ...e run condition and repair as needed Hydraulic oil leaks from machine Fitting s hose s or tube s is are loose or damaged Tighten Fitting O Ring s or seal s is are missing or damaged Replace o ring Foa...

Page 22: ...tion Parking brake is locked Inspect brake cables mechanism Oil level in hydraulic reservoir is low Refill fill to correct level Transaxles are in bypass mode Turn bypass knob to run Transaxles are wo...

Page 23: ...tal Edition Table of Contents ENGINE Engine Table of Contents Engine Exploded View 1 4 2 Engine Exploded View 2 4 3 Engine Exploded View 3 4 4 Engine Exploded View 4 4 5 Engine Exploded View 5 4 6 Yan...

Page 24: ...ervice Manual March 2018 Digital Edition Table of Contents ENGINE Engine Exploded View 1 A B C D E F G A Air Shield B Cross Channel C RH Bumper Plate D Exhaust Plate E Center Bumper Plate F Power Fram...

Page 25: ...eries Service Manual March 2018 Digital Edition Table of Contents ENGINE Engine Engine Exploded View 2 A A B B C D D E E F F Figure 2 A Lock Nut B Flat Washer C Flywheel Housing D Isolator Mount E Thr...

Page 26: ...7500 D Series Service Manual March 2018 Digital Edition Table of Contents ENGINE Engine Exploded View 3 A B C D E F Figure 3 A Air Hose B Yanmar Engine C Iso Mount D Air Cleaner Asm E Snubbing Washer...

Page 27: ...ded View 4 A B C D E C F G H I J K L M N O Figure 4 A Top Cooling Bracket B RH Radiator Support C Elbow Fitting D Cooling Asm E Hose F Upper Radiator Hose G Top Shroud H Bottom Shroud I Bulb Seal J LH...

Page 28: ...Series Service Manual March 2018 Digital Edition Table of Contents ENGINE Engine Exploded View 5 A B C D E F Figure 5 A RH Tank Suction B LH Tank Suction C RH Tank Return D LH Tank Return E Engine Ret...

Page 29: ...gine running hands feet and clothing could get caught in moving parts causing serious personal injury Keep bystanders away from the machine WARNING Hot engine parts can cause severe burns Do not touch...

Page 30: ...ontents ENGINE Yanmar Engine Replacement Cont Removal Cont 4 Remove the rear wheels 5 Remove the two carriage bolts and two button head screws securing the skid plate to the machine Figure 6 6 Remove...

Page 31: ...right side covers see Left Tank Cover Removal chapter 5 page 5 17 and see Right Tank Cover Removal chapter 5 page 5 19 9 Remove the seat see Seat Removal chapter 5 page 5 23 10 Remove the front seat m...

Page 32: ...anmar Engine Replacement Cont Removal Cont 13 Remove the gold bracket on the hydro Figure 9 14 Disconnect the four torque motor hoses from the transmission and cap plug the lines and fittings Figure 1...

Page 33: ...zip ties securing the wire harness to the heat deflector panel 17 Remove the fasteners securing the heat deflector panel Remove the panel 18 Remove the operator s floor pan from the machine 19 Remove...

Page 34: ...ove the six bolts three per side securing the air shield and cross channel to the machine Figure 13 22 Disconnect the global power port and alarm Figure 14 23 Disconnect the wire harness clip retainer...

Page 35: ...tor drain plug Using a clean bucket drain the engine coolant Figure 15 Tech Tip Using an eight point socket will reduce plug damage NOTE Properly dispose of engine coolant Plug can be installed once r...

Page 36: ...val Cont 29 Disconnect the two bolts securing the radiator to the bulk head Figure 16 30 Remove the air intake hose from between the air cleaner and radiator 31 Remove the lower radiator hose from wat...

Page 37: ...ler by loosening the lower transmission cooler line Figure 18 Tech Tip By loosening the top transmission cooler line will allow fluid to drain faster 34 Once draining has completed fully disconnect th...

Page 38: ...ital Edition Table of Contents ENGINE Yanmar Engine Replacement Cont Removal Cont 37 Remove the two lock nuts securing the RH ROPS brace to the ROPS Figure 20 38 Remove the RH ROPS brace from the ROPS...

Page 39: ...gital Edition Table of Contents ENGINE Engine Yanmar Engine Replacement Cont Removal Cont 39 Disconnect the air intake hose from the air cleaner to the engine Figure 22 40 Disconnect the harness plug...

Page 40: ...on Table of Contents ENGINE Yanmar Engine Replacement Cont Removal Cont 41 Disconnect electrical connections Figure 24 42 LH ROPS brace removal repeat steps 35 37 Brace will be removed with power dist...

Page 41: ...018 Digital Edition Table of Contents ENGINE Engine Yanmar Engine Replacement Cont Removal Cont 43 Remove the two chassis grounds from the machine Figure 26 44 Remove the six bolts three per side of t...

Page 42: ...able of Contents ENGINE Yanmar Engine Replacement Cont Removal Cont 45 Remove the three torx screws and lock nuts securing the exhaust plate to the machine Remove the exhaust plate Figure 28 46 Remove...

Page 43: ...t 47 Remove the exhaust tube 48 Disconnect the electrical connections from the fuel pump 49 Disconnect and mark the fuel lines from the front side of the fuel pump and water separator Figure 30 50 Dis...

Page 44: ...nsmission cooler lines from the bulk head plate NOTE Residual hydraulic oil may be in the lines 52 Loosen but do not remove the two RH torque motor hoses and pivot to gain access to the bulk head plat...

Page 45: ...ontents ENGINE Engine Yanmar Engine Replacement Cont Removal Cont 55 Remove the two transmission mount bolts located on the bell housing accessible on bottom of machine Figure 34 56 Remove the two mot...

Page 46: ...ft points raise engine slightly and ensure the engine and transmission are free of the chassis Figure 36 Tech Tip Raising the rear of the engine first and lifting at an angle may assist in removal 58...

Page 47: ...the front half of the drive shaft onto the rear shaft splined 3 Collapse the two halves of drive shaft together and secure to the transmission assembly NOTE Once the drive shaft is cleared during ins...

Page 48: ...n the two transmission mount bolts 9 Connect fuel pump harness 10 Connect two fuel lines to fuel pump and water separator 11 Connect the two fuel lines and return to the fuel tank on each side 12 Inst...

Page 49: ...draulic Hoses at Bulk Head RH Torque Motor Hoses NOTE The tightening sequence is necessary to avoid binding Tech Tip Verify line routing to avoid unwanted contact 21 Install the RH ROPS brace onto the...

Page 50: ...es to avoid unwanted contact 31 Attach torque motor hydraulic lines to transmission Torque to 67 7 ft lbs 90 9 Nm 32 Install the air intake hose from the radiator bracket to the air cleaner 33 Place t...

Page 51: ...mar Engine Replacement Cont Installation Cont 34 Install the rear bumper 35 Install the motion control linkage to the transmission and secure with washer and e clip Figure 41 36 Install the gold brack...

Page 52: ...k vent lines through the 3 clamps and install to the opposite ROPS tube 41 Connect the global power port and alarm 42 Install the two clip retainers to the cross channel 43 Install the heat deflector...

Page 53: ...Installation chapter 5 page 5 20 51 Install the operator s floor pan onto the machine 52 Refill radiator with proper coolant as outlined in the operator s manual 53 Connect the positive terminal firs...

Page 54: ...loded View 5 5 7 Chassis Exploded View 6 5 8 Caster Fork Assembly and Bearing 5 9 Removal 5 9 Installation 5 12 Caster Wheel Assembly Replacement 5 14 Disassembly 5 14 Assembly 5 15 Installation 5 16...

Page 55: ...ontrol Damper 5 29 Removal 5 29 Installation 5 30 Adjusting the Motion Control Damper 5 31 Motion Control Assembly 5 32 Removal 5 32 Installation 5 34 Adjusting the Motion Control Neutral Lock Pivot 5...

Page 56: ...M O O O O H J I F P L Q Figure 1 A RH Motion Control Lever B NI HF Nut C HH Screw D RH Steering Handle Asm E RH Motion Control and Bushing Asm F Leaf Spring G Flat Washer H Spring Washer I HF Nut J Ja...

Page 57: ...f Contents CHASSIS Chassis Exploded View 2 A B C D C E E F F G G H H I J J Figure 2 A Brake Lever Grip B Side Flange Bearing C Upper Brake Link D Brake Shaft Asm E Turnbuckle Asm F Brake Bellcrank wit...

Page 58: ...vice Manual March 2018 Digital Edition Table of Contents CHASSIS Chassis Chassis Exploded View 3 A B C D E E F Figure 3 A Suspension Seat B Seat Latch Plate C Seat Plate Frame D Tilt Seat Support Plat...

Page 59: ...ual March 2018 Digital Edition Table of Contents CHASSIS Chassis Exploded View 4 A B B B B C C D E E F G H I Figure 4 A Hood Asm B Flat Washer C Hair Cotter Pin D Hood Prop E Torx Screw F Flat Washer...

Page 60: ...rch 2018 Digital Edition Table of Contents CHASSIS Chassis Chassis Exploded View 5 A B C D E F G H Figure 5 A Grease Cap B NI Lock Nut C Bellville Washer D Flat Washer E Cone Taper Roller Bearing F Gr...

Page 61: ...ital Edition Table of Contents CHASSIS Chassis Exploded View 6 A B C D E F G H I J K Figure 6 A HH Screw B Flat Washer C Plain Washer D Rubber Washer E Spacer Tube F RH Fuel Tank Asm G Clamp H HH Scre...

Page 62: ...engine wait for all moving parts to stop and remove the key 2 Raise and support the unit so that the front wheels are off the ground and secure with jack stands 3 Remove the caster cap Figure 7 4 Sup...

Page 63: ...e the six spring washers and one large flat washer from the caster fork shaft NOTE Take note of the washer orientation 6 Remove the front caster fork from the frame Inspect the caster fork shaft for w...

Page 64: ...dition Table of Contents CHASSIS Chassis Caster Fork Assembly and Bearing Cont Removal Cont 8 Remove the upper and lower taper bearings from the frame Figure 10 Inspect bearing races for damage and ex...

Page 65: ...nd Bearing Cont Installation 1 Clean the surface inside the axle bearing area 2 Manually grease all bearings 3 Set the lower bearing into place Figure 11 A B C D D E F G H Figure 11 A Wheel and Tire A...

Page 66: ...k 6 Insert one flat washer and six spring washers Figure 12 Spring washer orientation is two curved down two curved up two curved down 7 Install lock nut 8 Manually rotate caster fork two rotations to...

Page 67: ...he front wheels are off the ground 3 Remove the caster wheel from the caster fork 4 Remove the seal guards from the wheel hub 5 Remove one of the spacer nuts from the axle assembly NOTE Thread locking...

Page 68: ...e wheel 7 Apply thread locker to the second spacer nut and thread onto the axle 8 Torque nut to 78 3 in lbs 101 110 Nm to seat the bearings Loosen then torque to 23 3 in lbs 27 35 Nm NOTE Make sure th...

Page 69: ...he caster wheel 5 Fill the center of the wheel hub with high temperature grease 6 Position the caster axle through the bearing and seal assembly 7 Install a spacer nut onto both ends of the caster axl...

Page 70: ...king brake Stop the engine wait for all moving parts to stop and remove the key 2 Remove the four screws located on the outside of the left tank cover 3 Remove the two screws and washers located on th...

Page 71: ...Tank Cover Cont Installation 1 With hood raised install the tank cover 2 Place the left tank cover on the machine 3 Insert the two washers and two screws loosely on the inside of the machine 4 Insert...

Page 72: ...e machine 3 Disconnect the negative terminal first then the positive terminal on the battery 4 Disconnect all electrical connections to the control panel Remove the control panel Figure 13 5 Raise the...

Page 73: ...for the control panel Figure 14 3 Align fuel line routing with right tank cover Figure 15 4 Thread harness through the right tank cover while placing on the machine 5 Insert the two washers and two s...

Page 74: ...captured with a lock nut 5 Remove the fuel tank mount bolt washers and spacer located in cup holder on left side and in the control cavity on the right side Bolt is captured by a lock nut 6 Remove the...

Page 75: ...install the fuel tank mount bolt washers spacer and lock nut 3 Loosely install the two fuel tank clamps and lock nuts 4 Tighten all three mounting fasteners 5 Install the supply return and vent lines...

Page 76: ...itch from the bottom of the seat Free seat switch harness from the seat frame 5 Remove the two front nuts securing the seat frame to the seat isolator Do not remove the back nuts in this step 6 Drop t...

Page 77: ...seat on the machine 2 With the seat latched in the down position install the two back nuts securing the seat frame to the seat isolator 3 Tilt the seat forward 4 Install the two front nuts securing th...

Page 78: ...operator s seat see Seat Removal chapter 5 page 5 23 3 Mark the location of the motion control plate with tape to assure proper alignment upon installation Figure 16 4 Remove the four screws two on ea...

Page 79: ...head screw driver remove the remaining harness clip NOTE The clips are intended for a one time use and will need to be replaced 10 Remove the two lock nuts securing the hydraulic fluid tank to the fr...

Page 80: ...ce the seat mount on the machine 3 Install vent line retaining clips in appropriate mount location 4 Install the four screws located in the corners of the seat mount 5 Place the U bolt into the correc...

Page 81: ...nt 8 Place the left and right motion control covers on the machine NOTE Make sure to align the covers with tape marks placed during the removal process 9 Secure the motion control covers with four scr...

Page 82: ...age the PTO and engage the parking brake Stop the engine wait for all moving parts to stop and remove the key 2 Remove the nut securing the damper ball joint to the frame Figure 19 NOTE You will need...

Page 83: ...per Cont Installation 1 Install the damper with ball joint end that has the Belleville washer into the frame Torque the lock nut to 200 in lbs 22 6 Nm Figure 21 2 Install the other end of the damper t...

Page 84: ...g the Motion Control Damper NOTE The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance Figure 22 A B C D E Figure 22 A Torque the lock nut to 200 in lbs...

Page 85: ...all moving parts to stop and remove the key 2 Remove the two screws retaining the LH motion control cover assembly 3 Remove the two bolts and nuts retaining the LH steering handle assembly to the LH l...

Page 86: ...emove the pivot hub from the LH motion control Figure 25 10 Remove the wire harness anchor from the LH motion control 11 Remove the neutral switch from the LH motion control 12 Remove the carriage bol...

Page 87: ...lock nut from the damper motion control to the LH motion control assembly 13 Secure the front pump linkage assembly to the LH motion control assembly with a bolt washer and nut NOTE The washer must b...

Page 88: ...ot NOTE The flanged nut can be adjusted to obtain a more desired motion control lever resistance when moving it to the neutral lock position Figure 26 1 Loosen the jam nut 2 Tighten or loosen the flan...

Page 89: ...to stop and remove the key 2 Slide the operator s seat all the forward and flip upwards 3 Remove the hood from the machine see Engine Cover Removal chapter 5 page 5 40 4 Cut the three zip ties securin...

Page 90: ...nt Removal Cont 6 Disconnect the vent lines from the upper ROPS tube on both sides of the machine Figure 28 7 Lay the ROPS down 8 Remove the two carriage bolts one on each side NOTE Will need assistan...

Page 91: ...Contents CHASSIS Roll Over Protection System ROPS Cont Removal Cont 11 Remove the four upper bolts securing the lower ROPS tubes Figure 30 12 Remove the four lower bolts securing the lower ROPS tubes...

Page 92: ...n each side in the hole for the lower ROPS NOTE Will need assistance to continue 5 Lift the ROPS onto the machine in the down position 6 Install the two carriage bolts one on each side 7 Lift the ROPS...

Page 93: ...ance before continuing 3 While one person is supporting the hood the other remove the upper cotter pin and washer securing the prop bracket to the machine 4 Remove the prop bracket from the pin 5 Cont...

Page 94: ...on each side of the hood slide the hood to the left on the hinge pins until aligned 2 With one person supporting the hood place the washer and cotter pin onto the hinge pin 3 Install the prop bracket...

Page 95: ...6 7 Deck System Exploded View 6 6 8 Deck System Exploded View 7 6 9 Deck System Exploded View 8 6 10 Deck System Exploded View 9 6 11 Deck System Exploded View 10 96 in Deck 6 12 Deck System Exploded...

Page 96: ...r 7500 D Series Service Manual March 2018 Digital Edition Table of Contents DECK Table of Contents Cont Deck Wings 6 27 Removal 6 27 Installation 6 30 Spindle Assembly Rebuild 6 31 Disassembly 6 31 As...

Page 97: ...6 3 Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents DECK Deck Deck System Exploded View 1 A B C D Figure 1 A RH Wing Shield Asm B V Belt C Pulley Idler D V Idler...

Page 98: ...able of Contents DECK Deck System Exploded View 2 A A B B C C D E F G H I I J K L M Figure 2 A Roll Pin B NI Lock Nut C HH Screw D Driveshaft Asm E Gearbox Asm F V Belt G Pulley H V Idler I Extension...

Page 99: ...l March 2018 Digital Edition Table of Contents DECK Deck Deck System Exploded View 3 A A B B B C D E E E E F F G G Figure 3 A Deck Fold Cylinder Asm B Fitting C Hose Asm D Hose Asm E Locking Cotter Pi...

Page 100: ...March 2018 Digital Edition Table of Contents DECK Deck System Exploded View 4 A A B B B B C D E F F G Figure 4 A Pivot Rod Cover B Torsion Spring C RH Shield Hinge Panel D LH Center Shield E LH Shield...

Page 101: ...System Exploded View 5 A A A B B B B C C D E F G H H I I J J K K L M N Figure 5 A Lock Nut B Thrust Washer C Deck Strut Asm D Panhard Rod Asm E HH Screw F HH Screw G Front Deck Lift H Trunnion I Deck...

Page 102: ...6 8 Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents DECK Deck System Exploded View 6 A B C D Figure 6 A LH Shield Asm B V Belt C Pulley Idler D V Idler...

Page 103: ...aster 7500 D Series Service Manual March 2018 Digital Edition Table of Contents DECK Deck Deck System Exploded View 7 A B C D Figure 7 A RH Wing Deck Asm B Deck Asm C LH Wing Deck Asm D Tunnel Dischar...

Page 104: ...nual March 2018 Digital Edition Table of Contents DECK Deck System Exploded View 8 A B C D C A E F G H I Figure 8 A NI HF Nut B Roll Pin C HH Screw D Driveshaft Asm E Tunnel Discharge Asm F HH Screw G...

Page 105: ...Exploded View 9 A B C D E E F F G H I J K L M N O P Q Figure 9 A RH Belt Cover B Reverse Drive Cover C BB Belt D NI Flange Nut E Dust Shield F V Idler G Gearbox Asm H Pulley I Deck Asm J Blade Screw...

Page 106: ...D Series Service Manual March 2018 Digital Edition Table of Contents DECK Deck System Exploded View 10 96 in Deck A B C A D E Figure 10 A Straight Fitting B Elbow Fitting C Lift and Fold Valve D Lift...

Page 107: ...eries Service Manual March 2018 Digital Edition Table of Contents DECK Deck Deck System Exploded View 11 60 72 in Deck A B C D E Figure 11 A Deck Lift Valve Asm B Elbow Fitting C Straight Fitting D Li...

Page 108: ...Release the pressure from the hydraulic system before servicing any hydraulic related component see Releasing Pressure from the Hydraulic System chapter 7 page 7 6 3 Remove the belt see Belt Removal c...

Page 109: ...96 in Cont Removal Cont 5 Locate and disconnect the three wire connectors located near the hydraulic lines 96 in only Figure 13 6 Raise and secure the rear of the machine using jack stands 7 Remove th...

Page 110: ...e wheel back on the machine Torque to 95 ft lbs 129 Nm 10 Remove the jack stands and lower the machine 11 Before removing the deck drive shaft mark the orientation of the deck drive shaft and gear box...

Page 111: ...of the deck 16 Using assistance remove the jack stands from the rear and slowly tip the front of the machine back until rear bumper makes contact with the ground Secure the front of the machine with a...

Page 112: ...n Table of Contents DECK Deck Replacement 96 in Cont Removal Cont 17 Roll the deck assembly out and away from under the machine 18 Slowly lower the front of the machine back to level ground then secur...

Page 113: ...t the deck drive shaft to the gear box being sure to align the roll pin holes 7 Install the roll pin 8 Install and tighten the two pinch bolts 9 Raise and secure the rear of the machine using jack sta...

Page 114: ...gine wait for all moving parts to stop and remove the key 2 Lower the deck into the full down position NOTE Steps 3 9 are 96 in only 3 Remove the two lock nuts and two carriage bolts securing the inne...

Page 115: ...ted on the wing belt idler assembly Rotate the idler assembly counter clockwise to release tension and remove belt Figure 19 NOTE For center belt use a in drive and rotate clockwise 8 Remove the belt...

Page 116: ...idler assembly clockwise with a in drive 2 Install the left and right belts on the machine rotating the idler assembly counter clockwise with a 3 8 in drive 3 Install the floor pan 4 Install the two l...

Page 117: ...e wait for all moving parts to stop and remove the key 2 Remove all belts see Belt Removal chapter 6 page 6 20 3 Remove the three lock nuts flat washers and isolators from the gear box mount Figure 20...

Page 118: ...ulic lines attached to the lift cylinder WARNING Keep body and hands away from pinhole leaks or nozzles that eject hydraulic fluid under pressure Use paper or cardboard not hands to search for leaks S...

Page 119: ...ulics Deck Fold Cylinder Cont Removal Cont 8 Remove the screws securing deck stop bracket to the machine Figure 21 9 Remove the locking cotter pins two on each cylinder on both ends of the deck fold c...

Page 120: ...ng the deck stop bracket to the machine 4 Verify the hydraulic lines are cleaned from debris attach the hydraulic lines to the lift cylinder 5 Install the center floor pan 6 Install the two lynch pins...

Page 121: ...elease the pressure from the hydraulic system before servicing any hydraulic related component see Releasing Pressure from the Hydraulic System chapter 7 page 7 6 3 Place the deck in the Full Down pos...

Page 122: ...ice Manual March 2018 Digital Edition Table of Contents DECK Deck Wings Cont Removal Cont 7 Remove the locking cotter pin from the outer wing ram lift pin Figure 24 8 Support the wing with a floor jac...

Page 123: ...Deck Deck Wings Cont Removal Cont 9 Remove the front and rear cap screws securing the deck pins Figure 26 TECH TIP Wiggling the deck wing up and down may benefit in pin removal 10 While supporting ro...

Page 124: ...and secure with bolts 3 Install the locking cotter pin to the outer wing ram lift pin 4 Install the two cap screws securing the wing stop bracket 5 Lower the center deck 6 Install the rear tire remov...

Page 125: ...the engine wait for all moving parts to stop and remove the key 2 Remove the belt see Belt Removal chapter 6 page 6 20 3 Remove the blade 4 Remove the fasteners securing the pulley to the spindle hub...

Page 126: ...dition Table of Contents DECK Spindle Assembly Rebuild Cont Disassembly Cont 6 Remove the fasteners securing the spindle to the deck from bottom Figure 29 7 Lift spindle assembly from the deck 8 Remov...

Page 127: ...Assembly Rebuild Cont Disassembly Cont 9 Place the spindle assembly in a bench vice and securely clamp onto the hex shank on the bottom of the spindle shaft Figure 31 10 With spindle assembly firmly...

Page 128: ...Service Manual March 2018 Digital Edition Table of Contents DECK Spindle Assembly Rebuild Cont Disassembly Cont 11 Remove lock nut washer and hub Figure 33 and 34 12 Slide spindle shaft out of spindle...

Page 129: ...ly Cont 13 Move bearing spacer to the side in order to gain access to the inner race of the bottom bearing Figure 35 14 Gently tap inner race of lower bearing to remove from the housing Alternate in a...

Page 130: ...ital Edition Table of Contents DECK Spindle Assembly Rebuild Cont Disassembly Cont 15 Remove bearing spacer 16 Rotate spindle housing and repeat bearing removal for opposite side 17 Inspect spindle ho...

Page 131: ...entation of spindle 6 Place spindle hub washer and new fastener onto threaded end of shaft 7 Torque to 120 5 ft lbs 163 6 Nm 8 Rotate the spindle shaft in housing to verify smooth operation 9 Place th...

Page 132: ...sure from the Hydraulic System 7 6 Release the Hydraulic Pressure from the Traction Circuit 7 6 Release the Hydraulic Pressure from the Lift Circuit 7 6 Drive System 7 7 Removal 7 7 Installation 7 12...

Page 133: ...rive System Exploded View 1 A B C D E F G H I J K L M N O Figure 1 A Hose Asm B Hose Clamp C Hose Clamp D Return Hose E Hydraulic Tank Support Rod F Hydraulic Reservoir Asm G Hydraulic Tank Support Ro...

Page 134: ...7 3 Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents DRIVE Drive Drive System Exploded View 2 A B C C C A Hose Asm B Hose Routed C Hose Routed Figure 2...

Page 135: ...7 4 Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents DRIVE Drive System Exploded View 2 Cont A A Transmission Asm Figure 3...

Page 136: ...0 D Series Service Manual March 2018 Digital Edition Table of Contents DRIVE Drive Wheel Motor Exploded View A B B C D E E E A RH Wheel Motor B Motor Plate C LH Wheel Motor D Hydraulic Hose E Hydrauli...

Page 137: ...p Release the Hydraulic Pressure from the Lift Circuit 1 Fully lower the cutting deck onto solid blocks 2 Turn the key switch to the OFF position and allow the engine to stop 3 After lowering the cutt...

Page 138: ...full downward position Stop the engine wait for all moving parts to stop and remove the key 4 Remove the operator s seat see Seat Removal chapter 5 page 5 23 5 Remove the front seat mount see Front S...

Page 139: ...tly tighten to not lose any clamps for re assemble 13 Remove the two nuts securing the hydro tank front mount and remove the front hydro tank mount bracket 14 Slide the hydro tank up and slightly back...

Page 140: ...the roll pin from the deck drive shaft using a drift punch Figure 8 17 Remove the two pinch bolts from the deck drive shaft 18 Slide the deck drive shaft off the gear box 19 Disconnect the two main re...

Page 141: ...ur hoses connected to the wheel motor from the transmission assembly 22 Disconnect the case drain hose 23 Remove the motion control linkage from the transmission 24 Attach a lift chain to the transmis...

Page 142: ...ive System Cont Removal Cont 25 Apply a slight amount of tension on the lift chain with an overhead hoist 26 Remove the seven bolts connecting the transmission assembly to the bell housing 27 Pull tra...

Page 143: ...d on the marked location in removal 6 Apply an anti seize lubricant to the splines of the deck drive shaft 7 Align the mark on the deck drive shaft with the gear box Slide the deck drive shaft on the...

Page 144: ...se the machine and secure with jack stands 4 Remove the rear wheel 5 Release the parking brake 6 Remove cap screw and lock nut on the upper portion of the park brake linkage 7 Place a drain pan under...

Page 145: ...per two motor plate mount bolts 5 Remove the floor jack from under the wheel motor 6 Loosely install the lower two motor plate mount bolts 7 Install the discharge plate mount bolt 8 Torque all four mo...

Page 146: ...m the key switch 2 Check the hydraulic fluid level in the hydraulic reservoir and add correct quantity of fluid if necessary Refer to the operator s manual NOTE A blue wire connects to the starter mot...

Page 147: ...regulations when recycling or disposing the hydraulic fluid and filters 7 Connect all the hydraulic hoses tubes and components that were disconnected while draining the system IMPORTANT Using other hy...

Page 148: ...if necessary See operator s manual for additional information 3 Check the traction control components for proper adjustment binding or damaged parts 4 Prime the hydraulic pumps see Priming the Hydrau...

Page 149: ...ator s manual for additional information 12 Lower the machine to the ground 13 If the transmission or a wheel motor was replaced or rebuilt operate the traction circuit on a level ground so that the t...

Page 150: ...0 37 CID 0 37 CID PORT 1 Suction Screen 100 Mesh Charge Pump Gear Pump 3000 PSI Line Filter Beta 11 200 ISO 16889 43 PSI CHARGE RELIEF 86 15 PSI CHARGE PRESSURE TEST PORT PRESSURE VALVE 313 30 PSI OI...

Page 151: ...n disp 3 040 4000 PSI 0 031 in 17 8 CID TOW VALVE 1 1 CID GEARBOX 1 1 CID PTO CLUTCH PTO PRESSURE TEST PORT 4000 PSI 0 031 in 17 8 CID TOW VALVE 0 37 CID 0 37 CID PORT 1 Suction Screen 100 Mesh Charge...

Page 152: ...g 8 6 Key Ignition Switch 8 7 Ignition Switch Wiring Connections 8 7 Testing 8 7 Control Module 8 8 Testing 8 8 Operator Presence Switch Seat Switch 8 9 Testing 8 9 Neutral Switch Left and Right 8 10...

Page 153: ...Series Service Manual March 2018 Digital Edition Table of Contents ELECTRICAL Table of Contents Cont 37 HP Electrical Wiring Schematic 8 19 60 72 in Electrical Wiring Schematic 8 20 96 in Electrical W...

Page 154: ...ctrical System Exploded View 1 A B C D E F G H I J K L M N O A Ignition Switch Asm B Switch C Sealed PTO Switch D Horizon LDU Module E MCU Module F Yanmar Wire Harness G Engine Controller H 12V Power...

Page 155: ...8 4 Z Master 7500 D Series Service Manual March 2018 Digital Edition Table of Contents ELECTRICAL Electrical System Exploded View 2 A A Figure 2 A Proximity Switch Asm...

Page 156: ...e use of a jumper wire to bypass a safety interlock switch allowing the technician to continue troubleshooting by taking the switch out of the circuit NOTE Jumper wires should be used for troubleshoot...

Page 157: ...n replacing a damaged or blown fuse Testing 1 Visual Inspection The fuses used in this application may be visually inspected A failed fuse can be identified by a broken or melted element inside the fu...

Page 158: ...on Switch Wiring Connections A Accessory B Starting Circuit C Operator Presence Switch Safety Interlock Switches D Battery Voltage In Testing 1 Remove the control panel from the right console 2 Discon...

Page 159: ...of operation when the ignition key is ON and the PTO switch is ON Testing 1 With the ignition switch in the RUN position and the PTO switch closed ON verify battery voltage and ground to the control m...

Page 160: ...neutral switches NOTE The operator presence switch is part of the seat assembly Testing 1 Disconnect the wire harness from the Operator Presence Switch located on the bottom of the seat assembly 2 Usi...

Page 161: ...ole plunger type switch Figure 8 and 9 normally open with two terminals When the plunger is depressed the circuit closes and there is continuity between the terminals Motion Control Levers in neutral...

Page 162: ...switch Figure 10 and 11 normally open with two terminals When the plunger is depressed parking brake ON the circuit closes and there is continuity between the terminals This allows battery voltage to...

Page 163: ...rrent drawn by the starter motor Testing 1 Disconnect the relay from the wiring harness 2 With a multi meter set to the OHM setting check to ensure that terminals 85 and 86 have approximately 70 85 re...

Page 164: ...esting 1 Remove the control panel from the right console 2 Disconnect the PTO switch from the wire harness 3 With the switch in the OFF position button pushed IN Terminal A and B should NOT have conti...

Page 165: ...ECTRICAL Deck Lift Lower Switch The deck lift lower switch Figure 15 and 16 provides battery power to the solenoid valve directing hydraulic pressure to the lift cylinder Switch Position Connection Ma...

Page 166: ...OFF position Unplug the wire harness electrical connector from the solenoid coil NOTE Before taking the small resistance readings with a digital multimeter short the multimeter test leads together The...

Page 167: ...isconnect the positive cable from the battery Locate and unplug the fusible link connector from the machine wire harness Use a multimeter to ensure that the continuity exists between each terminal pin...

Page 168: ...ble of Contents ELECTRICAL Electrical Deck Limit Switch 96 in Deck Only The deck limit switch prevents the cutting deck from being folded Figure 20 and 21 Testing No testing procedure available If the...

Page 169: ...ion Table of Contents ELECTRICAL TVS Diode The TVS Diode protects the electrical system from current surges caused by PTO engagement and disengagement Figure 22 Testing No testing procedure available...

Page 170: ...CONNECT 65 D GND 66 CHGSW 67 NO CONNECT 68 UB2 69 NO CONNECT 70 GLOW RELAY SAID_RLY 71 NO CONNECT 72 NO CONNECT 73 UB5 74 ANALOG GND A_GND 75 CAN2H 76 CAN1L 77 ANALOG GND A_GND 78 NO CONNECT 79 TFAIR...

Page 171: ...1 CONFIG 12 CAN LO P03 1 N A 2 N A 3 PTO SWITCH IN 4 N A 5 N A 6 N A 7 N A 8 TRANS TEMP 9 N A 10 N A 11 N A 12 N A P14 B P14 A C P18 1 2 3 4 5 6 P16 A GND B ACC PWR C ACC SIGNAL P07 1 3 4 6 8 P07 2 5...

Page 172: ...N A 8 N A 9 N A 10 KEY S 11 N A 12 CAN LO P03 1 N A 2 N A 3 PTO SWITCH IN 4 N A 5 N A 6 N A 7 DECK POS SW 8 TRANS TEMP 9 N A 10 N A 11 N A 12 N A P14 B P14 A C P18 1 2 3 4 5 6 P16 A GND B ACC PWR C AC...

Page 173: ...ump Gear Pump 3000 PSI Line Filter Beta 11 200 ISO 16889 43 PSI CHARGE RELIEF 86 15 PSI CHARGE PRESSURE TEST PORT PRESSURE VALVE 313 30 PSI OIL COOLER 1 0 691 1 1 1 1 025 1 1 025 PORT 2 0 031 in DECK...

Page 174: ...CID GEARBOX 1 1 CID PTO CLUTCH PTO PRESSURE TEST PORT 4000 PSI 0 031 in 17 8 CID TOW VALVE 0 37 CID 0 37 CID PORT 1 Suction Screen 100 Mesh Charge Pump Gear Pump 3000 PSI Line Filter Beta 11 200 ISO 1...

Page 175: ...ELAY SAID_RLY 71 NO CONNECT 72 NO CONNECT 73 UB5 74 ANALOG GND A_GND 75 CAN2H 76 CAN1L 77 ANALOG GND A_GND 78 NO CONNECT 79 TFAIR 80 DPF MIDDLE TEMP TOPFM 81 DPF INLET TEMP TOPFI 82 NO CONNECT 83 NO C...

Page 176: ...7 N A 8 TRANS TEMP 9 N A 10 N A 11 N A 12 N A P14 B P14 A C P18 1 2 3 4 5 6 P16 A GND B ACC PWR C ACC SIGNAL P07 1 3 4 6 8 P07 2 5 7 P06 ENGINE HARNESS CONNECTOR 1 FUSED PWR 2 ACC PWR 3 START 4 SW PW...

Page 177: ...IN 4 N A 5 N A 6 N A 7 DECK POS SW 8 TRANS TEMP 9 N A 10 N A 11 N A 12 N A P14 B P14 A C P18 1 2 3 4 5 6 P16 A GND B ACC PWR C ACC SIGNAL P07 1 3 4 6 8 P07 2 5 7 P06 ENGINE HARNESS CONNECTOR 1 FUSED P...

Page 178: ...L C EP r o d u c t s...

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