Service Manual
Table Of Contents
- Revision History
- Preface
- Chapter 1 : Safety
- Chapter 2 : Specifications and Maintenance
- Chapter 3 : Troubleshooting
- Chapter 4 : Engine
- Chapter 5 : Chassis
- General Information
- Service and Repairs
- Right Console Replacement
- Left Console Replacement
- Throttle Cable Assembly Replacement
- Choke Cable Assembly Replacement
- Seat Replacement
- MYRIDE® Replacement
- Fuel Tank Replacement
- Park Brake Handle Assembly Replacement
- ROPS (Roll Over Protection System) Replacement
- Caster Fork and Bearing Replacement
- Caster Wheel Rebuild
- Motion Control Assembly Replacement
- Chapter 6 : Deck
- Chapter 7 : Drive System
- Chapter 8 : Electrical
- Appendix A: Foldout Drawings
- Electrical Schematic
- Electrical PTO Engaged Schematic
- Electrical Run Position
- Electrical Start Position
CasterWheelAssembly(continued)
8.Torquethenutto101–110N•m(78±3in-lb)toseatthebearings,loosen,
thentorqueto27–35N•m(23±3in-lb).
Note:Makesurethattheaxledoesnotextendbeyondthenutoneither
sideofthewheelassembly.
9.Installthesealguardsontothewheelhubandassemblethewheelonto
thecasterfork.
10.Lowertheunitandverifyproperfunction.
Note:T opreventsealandbearingdamage,checkthebearingadjustment
often.Thetireshouldnotspinfreely(morethanoneortworevolutions)or
haveanysideplay.Ifthewheelspinsfreely,adjustthetorqueonthespacer
nutuntilthereisaslightamountofdrag.Reapplythreadlockingadhesiveto
thespacernut.
11.Connectthebatterybyinstallingthepositivecablerst,thenthenegative
cabletothebattery.
MotionControlAssemblyReplacement
MotionControlAssemblyRemoval
1.ParkthemachineonalevelsurfaceanddisengagethePTO.Stopthe
engine,waitforallmovingpartstostopandremovethekey.Engagethe
parkingbrake.
2.Disconnectthebatterybyremovingthenegativecablerst,thenthepositive
cablefromthebattery.
3.Removethesideconsole.RightConsoleReplacement(page5–11)Left
ConsoleReplacement(page5–13)
4.Raiseandsupporttheunitsothatthedrivewheelsareofftheground.
5.Removethe2boltssecuringthemotioncontrolhandletothemotioncontrol
assembly.
6.Removethe2screwssecuringthemotioncontrolcovertotheframe.
7.Disconnectthemotioncontroldamperfromthemotioncontrolassembly.
8.Disconnectthemotioncontrollinkagefromthetransmission.
Chassis:ServiceandRepairs
Page5–30
4000SeriesZMASTER®ServiceManual
3442-427RevA