Form No. 3442-427 Rev A 4000 Series Z MASTER® Service Manual Published: January 2021 © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision History Page 2 4000 Series Z MASTER® Service Manual 3442-427 Rev A
Preface This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. We are hopeful that you will find this manual a valuable addition to your service shop.
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • Installing safety equipment (shields, guards, seat belts, brakes, and R.O.P.S.
Table of Contents Preface ................................................................................................................ 3 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Chapter 2: Specifications and Maintenance .................................................... 2–1 Specifications ..............................
Preface Page 6 4000 Series Z MASTER® Service Manual 3442-427 Rev A
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Think Safety First ...............................................................................................................................
Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could cause serious permanent injury, disability, or death. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions can result in serious injury. CAUTION This safety symbol means caution.
Think Safety First (continued) Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes and clothing. Battery gases can explode. Keep cigarettes, sparks and flames away from the battery. Avoid injury due to inferior parts… Use only original equipment parts to ensure that important safety criteria are met. Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment.
Think Safety First (continued) The proper class of fire extinguisher should be used in case of fire. Class A extinguishers are for ordinary combustible materials such as paper, wood, cardboard, and most plastics. The numerical rating on these types of extinguishers indicates the amount of water it holds and the amount of fire it can extinguish. Geometric symbol (green triangle). Class B fires involve flammable or combustible liquids such as gasoline, kerosene, grease and oil.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Torque Specifications ........................................................................................................................... 2–7 Equivalents and Conversions........................................................................................................... 2–12 U.S.
Specifications Model 74000 Engine 24.5 HP Kawasaki Engine Type Engine Model 74002 74004 74050 25.5 hp Kawasaki Carbureted 4 Cycle FX751V FX801V High Idle 3750 ± 50 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR4ES Oil Capacity 2.3 L (2.4 US qt.) w/filter Fuel Capacity 37.8 L (10 gallons) Battery 300 CCA Hydraulic Drive System Transmission ZT-4400 Transmission Lubricant HYPR-OIL 500 7.57 L (8 US qt.) Max Ground Speed (FWD) 10 MPH Rear Tires 60.9 x 24.1–30.1 cm (24 x 9.
Model Engine Engine Type Engine Model 74054 74035 74052 25.5 hp Kawasaki 26.5 hp Kohler Command Pro 31 hp Kawasaki Carbureted 4 Cycle EFI 4 Cycle Carbureted 4 Cycle FX801V ECV749 FX921V High Idle Low Idle 74055 3750 ± 50 RPM 1550 ± 100 RPM 1800 ± 100 RPM 1550 ± 100 RPM Spark Plug NGK BPR4ES XC12YC NGK BPR5ES Oil Capacity 2.3 L (2.4 US qt) w/filter 1.9 L (64 oz) w/filter 2.2 L (2.3 US qt) w/filter Fuel Capacity 37.
Model Engine 74010 74015 31 hp Kawasaki 74000TA 24.5 hp Kawasaki Engine Type Engine Model 74000TE Carbureted 4 Cycle FX921V FX751 High Idle 3600 ± 100 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR5ES NGK BPR4ES Oil Capacity 2.2 L (2.3 US qt) w/filter 2.3 L (2.4 US qt) w/filter Fuel Capacity 37.8 L (10 gallons) Battery 300 CCA Hydraulic Drive System Transmission ZT-5400 ZT-4400 Transmission Lubricant HYPR-OIL 500 9.46 L (10 US qt) HYPR-OIL 500 7.
Model Engine 74050TA 74054TA 74052TE 25.5 hp Kawasaki 74055TE 31 hp Kawasaki Engine Type Carbureted 4 Cycle Engine Model FX801V FX921V High Idle 3600 ± 100 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR4ES NGK BPR5ES Oil Capacity 2.3 L (2.4 US qt) w/filter 2.2 L (2.3 US qt) w/filter Fuel Capacity 37.8 L (10 gallons) Battery 300 CCA Hydraulic Drive System Transmission ZT-4400 Transmission Lubricant HYPR-OIL 500 7.57 L (8 US qt) Max Ground Speed (FWD) 12 MPH Rear Tires 66 x 25.
Model 74055TA Engine 31 hp Kawasaki Engine Type Carbureted 4 Cycle Engine Model FX921V High Idle 3600 ± 100 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR5ES Oil Capacity 2.2 L (2.3 US qt) w/filter Fuel Capacity 37.8 L (10 gallons) Battery 300 CCA Hydraulic Drive System Transmission ZT-4400 Transmission Lubricant HYPR-OIL 500 7.57 L (8 US qt) Max Ground Speed (FWD) 12 MPH Rear Tires 66 x 30.5–30.5 cm (26 x 12-12 inches) Rear Tire Pressure 13 psi Front Caster Tires 38.1 x 16.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual. These torque specifications for the installation and tightening of fasteners shall apply for all fasteners which do not have a specific requirement identified in the service manual.
Metric Bolts and Screws g272209 Figure 2 1. Class 8.8 Specifications and Maintenance: Torque Specifications 2. Page 2–8 Class 10.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 Fasteners with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studes & Sems with Regular Height Nuts (SAE Grade 2 or Better Nut) in-lb in-lb N • cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 1/4-20 UNC 48 ± 7 53 ± 7 1/4-28 UNF 53 ± 7 5/16-18 UNC 5/16-24 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE Grade 5 or Better Nut) SAE Grade 8 Bolt
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 10 or stronger Nuts) in-lb N • cm in-lb N • cm M5 X 0.8 57 ± 6 644 ± 68 78 ± 8 881 ± 90 M6 X 1.0 96 ± 10 1085 ± 113 133 ± 14 1503 ± 158 ft-lb N • m ft-lb N • m M8 X 1.25 19 ± 2 26 ± 3 28 ± 3 38 ± 4 M10 X 1.5 38 ± 4 52 ± 5 54 ± 6 73 ± 8 M12 X 1.
SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 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 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N • m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N • m M12 X 1.25 Class 8.8 80 ± 10 ft-lb 108 ± 14 N •m M12 X 1.5 Class 8.
Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64 0.078125 1.984 37/64 0.578125 14.684 3/32 0.9375 2.381 19/32 0.59375 15.081 1/8 0.1250 3.175 5/8 0.6250 15.875 9/64 0.140625 3.572 41/64 0.640625 16.272 5/32 0.15625 3.969 21/32 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre Hectare 0.4047 Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Specifications and Maintenance: Torque Specifications Page 2–14 4000 Series Z MASTER® Service Manual 3442-427 Rev A
Chapter 3 Troubleshooting Table of Contents General Troubleshooting .......................................................................................................................
GEARS The Systematic approach to defining, diagnosing and solving problems.
General Troubleshooting Problem The starter does not crank The engine does not start, starts hard, or fails to keep running Engine loses power 4000 Series Z MASTER® Service Manual 3442-427 Rev A Possible Cause Corrective Action The blade control switch (PTO) is engaged. Move the blade-control switch (PTO) to the disengaged position. The parking brake is not engaged. Move the motion control levers to the neutral lock (Park) position. The battery is dead. Charge the battery.
General Troubleshooting (continued) Problem The engine overheats The mower pulls to the left or right (with levers fully forward) The machine does not drive The machine vibrates abnormally The machine produces an uneven cutting height Troubleshooting: General Troubleshooting Possible Cause Corrective Action The engine load is excessive. Reduce the ground speed or raise height-of-cut. The oil level in the crankcase is low. Add oil to the crankcase.
General Troubleshooting (continued) Problem The blades do not rotate The clutch does not engage 4000 Series Z MASTER® Service Manual 3442-427 Rev A Possible Cause Corrective Action The mower deck belt is damaged, worn, loose, or broken. Install a new deck belt. The mower deck belt is off the pulley. Install the mower belt on the deck pulley and check the idler pulley, idler arm, and spring for correct position and function. The idler spring is broken or missing. Replace the spring.
Troubleshooting: General Troubleshooting Page 3–6 4000 Series Z MASTER® Service Manual 3442-427 Rev A
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Kawasaki Engine Replacement .........................................................................................................
General Information The 4000 series Z MASTER® mowers use a variety of engines. All options are V-Twin 4 cycle engines 726cc, 852cc and 999cc Kawasaki carbureted engines and 747cc Kohler EFI engines.
Service and Repairs Engine Assembly 1 1 2 3 4 5 6 7 8 9 g338383 Figure 3 1. Kawasaki Engine 6. Clutch 2. 3. Exhaust Gasket Engine Oil Drain Hose Asm 7. 8. Clutch Anchor Flat Idler Pulley 4. 5. Muffler Transmission Pulley 9.
Engine Assembly 2 1 2 3 4 5 6 7 8 g338446 Figure 4 1. Kohler Engine 5. Clutch Anchor 2. 3. Oil Drain Hose Asm Kohler EFI Muffler 6. 7. Clutch Flat Idler Pulley 4. Transmission Pulley 8.
Kawasaki Engine Replacement Kawasaki Engine 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. Unhook the rubber strap securing the battery to the battery tray. Lift the battery away from the machine. 4. Close the fuel supply valve. 5.
Kawasaki Engine Removal (continued) 8. Disconnect the choke cable. Choke Cable Assembly Replacement (page 5–16) 9. Remove the deck belt. Deck Belt Replacement (page 6–4) 10. Remove the hydrostatic drive belt from the engine pulley. Hydrostatic Drive Belt Replacement (page 7–5) 11. Disconnect the chassis wire harness from the main engine harness. g346046 Figure 7 12. Disconnect the red (B+) wire from the starter. 13. Disconnect the black engine ground wire. g346104 Figure 8 14.
Kawasaki Engine Removal (continued) g346048 Figure 9 15. Remove the vent line from the air cleaner, if applicable. 16. Disconnect the clutch wire from the clutch. 17. Remove the clutch mounting 7/16 inch bolt, 2 belleville washers, and flat washer. Slip the clutch off of the crankshaft. Note: Before removing the clutch, note the orientation of the clutch wire and the clutch. 18. Remove the engine pulley and retain the square key for use in reassembly. 19.
Kawasaki Engine Installation (continued) g346048 Figure 10 10. Connect the black engine ground wire. 11. Connect the red (B+) wire to the starter g346047 Figure 11 12. Connect the chassis wire harness to the main engine harness.
Kawasaki Engine Installation (continued) g346046 Figure 12 13. Install the hydrostatic drive belt to the engine pulley. Hydrostatic Drive Belt Replacement (page 7–5) 14. Install the deck belt. Deck Belt Replacement (page 6–4) 15. Connect the choke cable. Choke Cable Assembly Replacement (page 5–16) 16. Connect the throttle cable. Throttle Cable Assembly Replacement (page 5–15) 17. Install the rear guard asm.
Kawasaki Engine Installation (continued) g346044 Figure 14 19. Open the fuel supply valve. 20. Install the battery onto the machine. Hook the rubber strap securing the battery to the battery tray. 21. Connect the battery by installing the positive cable first, then the negative cable to the battery.
Chapter 5 Chassis Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Right Console Replacement ............................................................................................................ 5–11 Left Console Replacement..........
General Information The 4000 series Z MASTER® mowers use a one-piece, fully welded frame. All models use a foldable ROPS system.
Service and Repairs Chassis Assembly 1 g338832 Figure 15 1. Suspension Seat Asm 4. Rear Retainer Tank Plate 2. 3. Seat Pan Front Retainer Tank Plate 5.
Chassis Assembly 2 g338834 Figure 16 1. Rear Retainer Tank Plate Chassis: Service and Repairs 2.
Chassis Assembly 3 g338879 Figure 17 1. 2. 3. ROPS Asm Fixed Seat Floormat Rubber Push-In Bumper 5. 6. 7. Floor Pan Asm 60 Inch Frame Hydro Plate 4. Toeboard 8.
Chassis Assembly 4 g338890 Figure 18 5. Hydro Plate 1. ROPS Asm 2. Toeboard 6. Light Bracket 3. Bumper 7. Step 4.
Chassis Assembly 5 g341393 Figure 19 1. Fuel Vent Asm 4. Fuel Cap 2. Vent Hose Asm 5. Fuel Tank Assembly 3.
Chassis Assembly 6 g341394 Figure 20 1. 2. 3. RH Handle Asm RH Motion Control Asm RH Brake Rod Asm 8. 9. 10. Brake Link Asm Handle Pivot Brake Lever Asm with Grip 4. 5. 6. 7. Brake Asm Brake Bracket LH Brake Rod Asm Damper 11. 12. 13.
Chassis Assembly 7 g341395 Figure 21 1. 2. 3. 4. Seat Asm Cam Lock Asm Seat Pan Cam Lock Knob 9. 10. 11. 12. Subframe Asm Floor Pan Isolator Bearing Bracket 5. Shock/Spring Asm 13. Badge Plate 6. Mounting Bracket 14. Lower Shock Mount 7. 8. Floor Mat Trailing Arm 15. 16.
Chassis Assembly 8 g342075 Figure 22 1. RH Cup Holder 10. Rear Guard Asm 2. 3. 4. RH Side Pod RH Console Choke Control Cable 11. 12. 13. LH Rear Guard RH Cover Asm Cup Holder 5. 6. RH Rear Guard Asm Top Rear Guard 14. 15. LH Console LH Front Plate Cover 7. 8. 9. Throttle Control Cable RH Front Plate Cover Muffler Guard 16. 17.
Right Console Replacement Right Console 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. Remove the 4 (1/4-20 inch) torx screws securing the RH side pod to the RH console. Remove the RH side pod from the RH console. g346220 Figure 23 4. Remove the throttle cable from the machine.
Right Console Removal (continued) 9. Disconnect the wiring harness from the PTO switch. g346222 Figure 25 10. Pinch together the 2 tabs on the PTO switch. Pushing from the bottom side up, remove the PTO switch from the RH side pod. 11. Pinch together the 2 tabs on the ignition switch. Pushing from the bottom side up, remove the ignition switch from the RH side pod. 12. Remove the 2 (5/16 inch) lock nuts and carriage bolts securing the RH console to the chassis. 13.
Right Console Installation (continued) 6. Install the hourmeter onto the RH side pod. 7. Connect the wiring harness from the hourmeter. 8. Install the light switch, if applicable. 9. Install the choke cable onto the machine. Choke Cable Assembly Replacement (page 5–16) 10. Install the throttle cable onto the machine. Throttle Cable Assembly Replacement (page 5–15) 11. Install the RH side pod onto the RH console. Install the 4 (1/4-20 inch) torx screws securing the RH side pod to the RH console.
Left Console Removal (continued) g346223 Figure 28 4. Disconnect the wiring harness from the USB charger. 5. Remove the 2 (5/16 inch) lock nuts and carriage bolts securing the LH console to the chassis. 6. Lift the LH console away from the machine. Left Console Installation 1. Install the LH console onto the machine. 2. Install and tighten the 2 (5/16 inch) lock nuts and carriage bolts securing the LH console to the chassis. 3. Connect the wiring harness to the USB charger. 4.
Throttle Cable Assembly Replacement Throttle Cable Assembly Unit 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. Remove the 4 (1/4-20 inch) torx screws securing the RH side pod to the RH console. Remove the RH side pod from the RH console. Note: In image below, 3 screws are shown.
Throttle Cable Assembly Unit Installation (continued) g346220 Figure 31 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. Choke Cable Assembly Replacement Choke Cable Assembly Unit 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.
Choke Cable Assembly Engine Removal Note the position of the throttle clamp on the engine plate. 1. Remove the cable clamp screw securing the cable to the engine plate. Remove the clamp from the engine plate. 2. Disconnect the choke cable. 3. Feed the cable through the retainers and out of the pod. Choke Cable Assembly Engine Installation 1. Feed the cable through the retainers. 2. Connect the choke cable. 3. Install the clamp to the engine plate.
Seat Removal (continued) g348057 Figure 34 4. Remove the 2 (5/16 inch) torx screws securing the front tank retainer plate to the seat pan. g346224 Figure 35 5. Remove the 2 (5/16 inch) torx screws securing the front of the seat pan to the chassis. 6. With assistance, slide the seat pan/seat assembly forward and tip upwards to gain access to the seat switch. Disconnect the seat switch from the seat.
Seat Removal (continued) g346225 Figure 36 7. With assistance, lift the seat pan/seat assembly away from the machine. 8. Remove the 4 (5/16 inch) locks securing the seat pan to the seat assembly. Seat Installation 1. Install and tighten the 4 (5/16 inch) lock nuts securing the seat pan to the seat assembly. 2. With assistance, install the seat pan/seat assembly into the machine. 3. Connect the seat switch to the seat.
Seat Installation (continued) g346224 Figure 38 6. Install the 2 (5/16 inch) torx screws securing the rear seat pan to the chassis. g348057 Figure 39 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. MYRIDE® Replacement MYRIDE® 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.
MYRIDE® Removal (continued) 6. Loosen (do not remove) the 2 (3/8 inch) lock nuts securing the lower mount of the rear shock to the ROPS. g348060 Figure 40 7. Loosen (do not remove) the 1/2 inch lock nut securing the front shock upper mount to the MYRIDE platform. 8. Remove the floor pan. 9. Open the 2 plastic clamps securing the fuel and vent lines. g348062 Figure 41 10. Remove the 4 (5/16 inch) lock nuts securing the 2 (1 shown below) bearing brackets to the chassis.
MYRIDE® Removal (continued) g348084 Figure 42 11. Remove the ½ inch carriage bolt from the shock mount while supporting the front MYRIDE subframe. Reinstall the ½ inch carriage bolt with the MYRIDE subframe resting against the shock and tighten. g346226 Figure 43 12. Lower the ROPS to the full-down position. 13. Fully remove the 2 (3/8 inch) locks nuts securing the lower front rear shocks to the ROPS (previously loosened). 14.
MYRIDE® Installation (continued) 4. Install the 4 (5/16 inch) lock nuts securing the 2 (1 shown below) bearing brackets to the chassis. g348084 Figure 44 5. Close the 2 plastic clamps securing the fuel and vent lines. g348062 Figure 45 6. Install the floor pan. 7. Tighten the 2 (3/8 inch) lock nuts securing the lower front rear shocks to the ROPS.
MYRIDE® Installation (continued) g348060 Figure 46 8. With assistance, tip the seat forward and connect the seat switch. 9. Install the 4 (5/16 inch) lock nuts and carriage bolts securing the rear seat pan to the MYRIDE platform. 10. Connect the battery by installing the positive cable first, then the negative cable to the battery. Fuel Tank Replacement Fuel Tank 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.
Fuel Tank Installation (continued) 2. Install the vent line to the air filter. 3. Close the 4 plastic clamps securing the vent line. 4. Install the rear tank retainer plate to the chassis. 5. Install the fuel tank vent line to the fuel tank. Plug the fuel line, fuel outlet, and vent fitting. 6. Install the fuel line to the fuel tank fitting, secure with the spring clamp. 7. Install the retainers the wiring harness and the vent line to the rear tank retainer plate. 8.
ROPS (Roll Over Protection System) Replacement ROPS (Roll Over Protection System) 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. Remove the fuel tank. Fuel Tank Replacement (page 5–24) 4. Remove the hair pins and ROPS fold pins. 5.
ROPS (Roll Over Protection System) Removal (continued) g346263 Figure 48 10. Lift the lower tubes away from the chassis. ROPS (Roll Over Protection System) Installation 1. Install the lower tubes onto the chassis. 2. Install the 4 (½ inch, 2 per side) bolts and lock nuts securing the lower tubes to the chassis. g346263 Figure 49 CAUTION Upper ROPS assembly is heavy, assistance or support is needed for removal. Personal injury or damage may occur.
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.
Caster Wheel Rebuild Caster Wheel Disassembly g336095 Figure 50 1. 2. Caster Fork Screw 3. Seal Guard 4. 5. Lock Nut Wheel Assembly 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.
Caster Wheel Assembly (continued) 8. Torque the nut to 101–110 N•m (78 ± 3 in-lb) to seat the bearings, loosen, then torque to 27–35 N•m (23 ± 3 in-lb). Note: Make sure that the axle does not extend beyond the nut on either side of the wheel assembly. 9. Install the seal guards onto the wheel hub and assemble the wheel onto the caster fork. 10. Lower the unit and verify proper function. Note: To prevent seal and bearing damage, check the bearing adjustment often.
Motion Control Assembly Removal (continued) g337843 Figure 51 9. Disconnect the motion control assembly from the frame. g336044 Figure 52 10. Lower the motion control assembly through the frame toward the center of the machine, remove the assembly. Motion Control Assembly Installation 1. Position the motion control assembly in place with the linkage extending toward the transmission. 2. Secure the motion control assembly to the frame. 3. Connect the motion control linkage to the transmission. 4.
Motion Control Assembly Installation (continued) g337846 Figure 53 5. Connect the motion control damper to the motion control assembly and torque the bolt to 108-135 N•m (90 ± 10 in-lb). 6. Install the motion control cover to the frame, secure with the 2 screws. 7. Connect the motion control handle to the motion control assembly. 8. Install the side console. Right Console Replacement (page 5–11) Left Console Replacement (page 5–13) 9.
Chapter 6 Deck Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Deck Belt Replacement...................................................................................................................... 6–4 Mower Deck Replacement ..........
General Information The 4000 series Z MASTER® mowers use a TURBO FORCE® deck platform. All decks are 5.5 inch deep and constructed of 7ga steel. The spindles are of aluminum construction and utilize a blade driver.
Service and Repairs Deck Assembly g342236 Figure 54 1. 2. HOC Pin Lift Link 3. Lever Grip 10. 4. Magnetic Retention Tag 11. Deck Chain Asm 5. Transport Lock Plate 12. Extension Spring 6. Flange Bushing 13. Front Deck Lift Shaft Asm 7. Deck Lift Gusset 4000 Series Z MASTER® Service Manual 3442-427 Rev A 8. 9.
Deck Belt Replacement Deck Belt 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. Remove the LH and RH belt guards from the deck. 4. Remove the floor pan from the chassis. 5. Remove the 3/8 inch lock nut securing the belt guides to the idler arm asm.
Mower Deck Removal (continued) g348085 Figure 55 6. Slowly loosen and remove the lift assist spring screw. g348207 Figure 56 7. Remove the 2 (3/8 inch) lock nuts and carriage bolts securing the deck strut to the frame.
Mower Deck Removal (continued) g348210 Figure 57 8. Remove the 4 (3/8 inch) shoulder bolts (1 per deck corner) securing the deck lift chains to the deck lift assembly. 9. Place the deck lift into the transport position. 10. Slide the deck out the RH side of the machine. Mower Deck Installation 1. Place the deck lift into the transport position. 2. Slide the deck under the machine through the RH side. 3. Place the deck on the same blocks that were used in the removal section. g348085 Figure 58 4.
Mower Deck Installation (continued) g348210 Figure 59 7. Install the lift assist spring screw. g348207 Figure 60 8. Install the deck belt. Deck Belt Replacement (page 6–4) 9. Connect the battery by installing the positive cable first, then the negative cable to the battery. Mower Deck Replacement (with Deck Lift) Mower Deck Removal (with Deck Lift) 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.
Mower Deck Removal (with Deck Lift) (continued) g348210 Figure 61 5. Remove the 4 (3/8 inch) shoulder bolts (1 per deck corner) securing the deck lift chains to the deck lift assembly. 6. Raise the deck lift into the transport position. 7. Slide the deck out the RH side of the machine. Mower Deck Installation (with Deck Lift) 1. Slide the deck under the machine through the RH side. 2. Lower the deck lift until the lift chains can be attached to the deck. 3.
Electric Mower Deck Lift Replacement Electric Mower Deck Lift 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. Remove the height-of-cut pin. Lower the deck until it’s on the floor and there is slack in the chains. 3. Remove the ½ lock nut and bolt securing the deck lift to the deck lift actuator. Note: May need to raise deck lift actuator slightly for removal.
Electric Mower Deck Lift Installation (continued) 2. Connect the harness plug to the deck lift to the wiring harness. g348235 Figure 65 3. Swing the actuator up and install the ½ inch lock nut and bolt securing the deck lift to the deck lift actuator. g346264 Figure 66 4. Raise the deck until there is tension in the chains. Install the height-of-cut pin.
Aluminum Spindle Rebuild Aluminum Spindle Disassembly g352924 Figure 67 1. 2. Hex Nut Washer 6. 7. Bottom Guard Spindle Shaft 3. 4. Blade Drive Sheave Top Bearing Guard 8. 9. Blade Hex Bushing 5. Spindle Asm 10. Screw 1. Park the machine on a level surface, disengage the PTO and set the parking brake. Stop the engine, wait for all moving parts to stop and remove the key. 2. Remove the deck belt. Deck Belt Replacement (page 6–4) 3.
Aluminum Spindle Disassembly (continued) g339541 Figure 68 5. Remove the 6 (3/8 inch) flange lock nuts securing the spindle to the deck (from bottom). g339542 Figure 69 6. Lift spindle assembly from the deck. 7. Remove the housing ring (if applicable). 8. Slide spindle shaft out of spindle housing. 9. Move bearing spacer to the side in order to gain access to the inner race of the bottom bearing.
Aluminum Spindle Disassembly (continued) g339543 Figure 70 10. Gently tap the inner race of the lower bearing to remove from the housing. Alternate in a star pattern to avoid binding when removing. Note: Bearings may be damaged during removal. Replace as needed. g339544 Figure 71 11. Remove the bearing spacer. 12. Rotate the spindle housing. Repeat bearing removal for the opposite side. 13. Inspect spindle housing for internal or external damage.
Aluminum Spindle Disassembly (continued) g347983 Figure 72 Aluminum Spindle Assembly 1. Clean and inspect all surfaces. 2. Using the appropriate sized bearing driver, install the upper bearing until seated. Note: Gently tap driver to avoid damaging the bearing during install. 3. Rotate spindle assembly and install the bearing spacer. 4. Using an appropriate bearing driver, install the remaining bearing until seated. 5. Place the bottom bearing guard onto the spindle shaft. 6.
Chapter 7 Drive System Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Hydrostatic Drive Belt Replacement...................................................................................................
General Information The 4000 series Z MASTER® mowers have ZT4400 and ZT5400 hydrostatic transaxles. Either transaxle is serviceable via internal cartridge filter and remote reservoir.
Service and Repairs Drive Assembly 1 g341074 Figure 73 1. Hydraulic Reservoir Asm 4. V-Belt 2. Hydraulic Hose Asm 5. LH Transaxle Asm 3.
Drive Assembly 2 g341076 Figure 74 1.
Hydrostatic Drive Belt Replacement Hydrostatic Drive Belt 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. Remove the deck belt. Deck Belt Replacement (page 6–4) 4. Using a ½ inch breaker bar, insert into the most accessible square hole of the idler arm. g346265 Figure 75 5.
Hydrostatic Drive Belt Installation (continued) 4. Connect the battery by installing the positive cable first, then the negative cable to the battery. Hydrostatic Drive Transmission Replacement Hydrostatic Drive Transmission 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.
Hydrostatic Drive Transmission Removal (continued) 15. Loosen (do not remove) the 4 (1/2 inch) hydrostatic transaxle mount bolts securing the hydrostatic transaxle to the chassis. 16. While supporting the hydrostatic transaxle being removed, remove the 4 loosened mount bolts from the chassis. Remove the hydrostatic transaxle from the machine. Hydrostatic Drive Transmission Installation 1. Place the hydrostatic transaxle into the machine.
Hydrostatic Drive Transmission Installation (continued) Note: Do not lower and support on the hydro plate. 14. Connect the battery by installing the positive cable first, then the negative cable to the battery.
Chapter 8 Electrical Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Ignition Switch Replacement.............................................................................................................. 8–4 Hourmeter Replacement........
General Information The electrical system operates on 12 VDC. The proper battery size is 300CCA. Before performing any electrical troubleshooting, always: • Verify proper battery voltage (above 12.4V), batteries reading 12.4v or less are considered discharged. • Check that all engine and chassis ground wires are securely connected and not damaged. Use of test lights and continuity testers may result in false readings and lead to an incorrect diagnosis.
Service and Repairs Electrical Assembly g342240 Figure 79 1. Bungee Strap 7. Battery 2. 3. Module Asm Ignition Key 8. 9. Bail Switch USB Power Port 4. Ignition Switch 10. Park Brake Switch 5. Rocker Switch 11. Front Bumper 6.
Ignition Switch Replacement Ignition Switch 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. Remove the 4 (1/4-20 inch) torx screws securing the RH side pod to the RH console. Remove the RH side pod from the RH console. 4. Disconnect the wiring harness from the ignition switch. 5.
Ignition Switch Test (continued) 4. Using a digital multi-meter set to the OHM or Continuity setting, verify that NO continuity exists between the terminals not listed for each switch position. Position Circuit “Make” OFF None RUN B+R+I+A START B+R+I+S Hourmeter Replacement Hourmeter 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.
Hourmeter Installation (continued) g346221 Figure 82 3. Install the RH side pod to the RH console. Install the 4 (1/4-20 inch) torx screws securing the RH side pod to the RH console. 4. Connect the battery by installing the positive cable first, then the negative cable to the battery. Hourmeter Test With the ignition switch in the RUN position and the PTO switch closed (ON), verify battery voltage and ground to the hourmeter.
Left and Right Neutral Switch Removal (continued) 3. Remove the 4 (1/4-20 inch) torx screws securing the side pod to the console. Remove the side pod from the console. 4. Push on the 2 tabs on either side of the neutral switch and push the switch through the mount hole to remove. Left and Right Neutral Switch Installation 1. Install the neutral switch to the mount hole on the machine. 2. Install the side pod onto the console. Install the 4 (1/4-20 inch) torx screws securing the side pod to the console. 3.
Park Brake Switch Installation 1. Install the park brake switch to the park brake switch bracket. 2. Install the park brake switch bracket into the chassis and connect. 3. Install the 2 (5/16 inch) screws securing the park brake switch bracket to the chassis. 4. Install the 2 (5/16 inch) screws securing the park brake switch bracket to the chassis. Park Brake Switch Test The parking brake switch is a single pole plunger type switch (normally open) with two terminals.
PTO Switch Test (continued) g349741 Figure 85 3. Using a digital multi-meter set to the OHM or Continuity setting, verify the following: • Pin 2 and 4 should have continuity (closed) • Pin 6 and 8 should have continuity (closed) • Pin 2 and 1 should NOT have continuity (open) • Pin 6 and 5 should NOT have continuity (open) 4.
Electric PTO Clutch Removal (continued) 3. Raise and support the unit so that the drive wheels are off the ground. 4. Remove the deck belt. Deck Belt Replacement (page 6–4) 5. Disconnect the clutch wire connector from the clutch. g336161 Figure 86 6. Remove the clutch mounting bolt and washers. Slip the clutch off of the crankshaft. Electric PTO Clutch Installation 1. Install the clutch onto the crankshaft verifying that the slot in the clutch aligns with the tab on the clutch anchor 2.
Electric PTO Clutch Installation (continued) 5. Lower the unit and verify proper function. Coil Resistance Measurement Test If the PTO clutch is not engaging or is suspect as a cause of electrical problems, use the following electrical troubleshooting steps. These procedures will help determine if the clutch has failed as a result of or is the cause of an electrical problem. 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.
Measuring Clutch Current Draw Test Note: Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. g336411 Figure 89 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 clutch wire connector. 3. Set the multi-meter to measure amps (10 amp scale). 4. Connect the positive meter lead to the chassis harness terminal 1. 5.
Electric Deck Lift Switch Installation 1. Install the deck lift switch. Plug the 3 terminals into the deck lift switch. 2. Install the 2 Philips head screws securing the deck lift switch to the motion control lever. 3. Connect the battery by installing the positive cable first, then the negative cable to the battery.
Electrical: Service and Repairs Page 8–14 4000 Series Z MASTER® Service Manual 3442-427 Rev A
Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations........................................................................................................A–2 Electrical Schematic...........................................................................................................................A–3 Electrical PTO Engaged Schematic ...................................................................................................A–4 Electrical Run Position ..................
Electrical Drawing Abbreviations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. Abbreviation Color BK Black BR or BN Brown BU Blue GN Green GY Gray OR or OG Orange PK Pink R or RD Red T or TN Tan VIO or VT Violet W or WH White Y or YE Yellow Numerous harness wires include a line with an alternate color. These wires are identified with the wire color followed by a / or _ and then the line color (e.
Electrical Schematic g342795 , Drawing Rev A, Sheet 1 3442-427 Rev A Page A–3
Electrical PTO Engaged Schematic g346038 Page A–4 3442-427 Rev A , Drawing Rev , Sheet
Electrical Run Position g346039 , Drawing Rev , Sheet 3442-427 Rev A Page A–5
Electrical Start Position g346040 Page A–6 3442-427 Rev A , Drawing Rev , Sheet
