Service Manual

ManualsBrandsToro ManualsRiding EquipmentToro 74442

Z Master Z400

Series

Service Manual

LCE Products

Summary of content (190 pages)

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LCE Products Z Master Z400 Series Service Manual
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ABOUT THIS MANUAL 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.
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TABLE OF CONTENTS Safety Information General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Specifications Machine Profile Photos Z 400 Estate Series 19 hp Kawasaki OHV V-Twin . . . . . . . Z 400 Estate Series 18 hp Kohler . . . . . . . . . . . . . . Z 450 Pro Performance Series 20 hp Kohler OHV V-Twin . . . . Z 100 Series 19 hp Kawasaki KAI OHV V-Twin . . . . . . . .
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TABLE OF CONTENTS Chassis continued Parking Brake Handle/Shaft Assembly Removal All models . Parking Brake Handle/Shaft Assembly Installation All models Brake Bar Removal (Estate Series) . . . . . . . . . . . Brake Installation . . . . . . . . . . . . . . . . . . Adjusting the Parking Brake . . . . . . . . . . . . . Brake Band Removal (Pro Series) . . . . . . . . . . . Brake Band Installation . . . . . . . . . . . . . . . Brake Shaft Removal (Pro Series) . . . . . . . . . . . Brake Shaft Installation . . .
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TABLE OF CONTENTS Electrical continued Seat Delay Module . . . . . . . Hour Meter . . . . . . . . . . Electric PTO Clutch . . . . . . . Coil Resistance Measurement . Measuring Clutch Current Draw Solenoid . . . . . . . . . . . Fuse Block . . . . . . . . . . Electrical Schematics 74412 . . . . . . . . . . 74410 . . . . . . . . . . 74411 . . . . . . . . . . 74413 and 74415 . . . . . . 74414 . . . . . . . . . . 74416 and 74417 . . . . . . 74411TE . . . . . . . . . 74416TE . . . .
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SAFETY INFORMATION Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
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SAFETY INFORMATION SAFETY INFORMATION General Information The riding mower and attachment operator's manual contain safety information and operating tips for safe This symbol means WARNING or operating practices.
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SPECIFICATIONS Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
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SPECIFICATIONS Z 400 Estate Series 19 hp Kawasaki OHV V-Twin 2 2-2 Fig 001 DSC-4765a Fig 003 DSC-4767a Fig 002 DSC-4766a Fig 004 DSC-4768a Z Master Z400 Service Manual
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SPECIFICATIONS Z 400 Estate Series 18 hp Kohler 2 Fig 005 DSC-4842a Fig 007 DSC-4844a Fig 006 DSC-4843a Fig 008 DSC-4846a Z Master Z400 Service Manual 2-3
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SPECIFICATIONS Z 450 Pro Performance Series 20 hp Kohler OHV V-Twin 2 2-4 Fig 009 DSC-4833a Fig 011 DSC-4835a Fig 010 DSC-4834a Fig 012 DSC-4838a Z Master Z400 Service Manual
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SPECIFICATIONS Z 100 Series 19 hp Kawasaki KAI OHV V-Twin 2 Fig 013 DSC-0437a Fig 015 DSC-0440a Fig 014 DSC-0436a Fig 016 DSC-0435a Z Master Z400 Service Manual 2-5
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SPECIFICATIONS Z 450 Pro Performance Series 23 hp Kawasaki OHV V-Twin 2 2-6 Fig 017 DSC-0444a Fig 019 DSC-0442a Fig 018 DSC-0445a Fig 020 DSC-0448a Z Master Z400 Service Manual
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SPECIFICATIONS Z 440 Pro Value Series 19 hp Kawasaki KAI OHV V-Twin 2 Fig 021 DSC-0452a Fig 023 DSC-0455a Fig 022 DSC-0451a Fig 024 DSC-0450a Z Master Z400 Service Manual 2-7
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SPECIFICATIONS Engines 2 Output Make High Idle Low Idle Charging Coil 19 HP (14.2kW) Kawasaki OHV V-Twin Forced Air Cooled 3650 + 100 RPM 1500 RPM 13 AMP 18 HP (13.4kW) Kohler OHV Single Forced Air Cooled 3650 + 100 RPM 1500 RPM 13 AMP 19 HP (14.2kW) Kawasaki OHV V-Twin Forced Air Cooled 3650 + 100 RPM 1500 RPM 13 AMP 20 HP (14.9kW) Kohler OHV V-Twin Forced Air Cooled 3650 + 100 RPM 1500 RPM 13 AMP 23 HP (17.
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SPECIFICATIONS Z 400 Series Manual Specifications Frame Assembly Consists of front and rear frames bolted together Front Frame Welded 2 x 2 x .188” structural steel tube, 7 Gauge front cross member Rear Frame Welded tube and fabricated steel Fuel System Tanks Dual fuel tanks containing large fill necks and vented caps. Rotational molded high density polyethylene. Mounted above drive wheels. Capacity 10 gallons (37.
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SPECIFICATIONS Deck Drive Models with 7-Gauge Deck Clutch Type Warner Electromagnetic “Mag-Stop” with Warner Electromagnetic “Mag-Stop” with 120 ft-lbs. (162.7 Nm) rating 175 ft-lbs. (237-3 Nm) rating Deep B-Groove pulley with belt from engine to deck Take-Up 2 Models with SFS and TF Decks Spring Idler system Tires Models with 7-Gauge Deck Models with SFS and TF Decks Rear Drive Tires 4-ply with “turf master” tread 20” x 10” – 10” 4-ply with “turf master” tread 23” x 9.
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SPECIFICATIONS Cutting Decks 48” (121.9cm) & 52” (132.1cm) 7-Gauge Deck Discharge 52” (132.1cm) TF Deck Drawn 12 gauge steel super flow system deck with welded mounting brackets and gage wheel brackets. 1/2” (12.7mm) diameter steel reinforcement rod on left side. 11 gauge steel front reinforcement plate doubles as bagger attachment point 7 Gauge, High Strength 50,000 psi (3515.3 Kg-f / 59cm) steel 5” (12.7cm) advanced Turbo Force flow system, welded construction. 3/8” (9.
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SPECIFICATIONS Cutting Decks cont. 48” (121.9cm) & 52” (132.1cm) 7-Gauge Deck Deck Suspension Deck suspended from machine by four lift chains, and attached to front cross member by flat strut arms and cross brace. The deck is pulled along the ground. Belt Covers Plastic HDPE deck covers. Attached with swell latches. Gage Wheels Three adjustable gage wheels to reduce scalping on the front of deck (one on the left-hand side and two in the center). Wheels have four adjustment positions.
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SPECIFICATIONS Lubrication Fittings 48”/52” (132.1cm/121.9cm) SFS and TF Decks 7-Gauge Decks Front Caster Pivots 2 removable plugs (1 per side) for periodic lubrication Front Caster Wheels n/a 2 fittings (1 per side) Lift Assembly 5 fittings Brake Arms 2 fittings (1 per side) Rear Deck Struts 2 fittings (1 per side) Deck Spindles 2 3 fittings (1 per spindle) Pump Idler Pivot 1 fitting General Specifications Greasing and Lubrication: Grease: No.
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4 3 2 SPECIFICATIONS 1 NOTES: 12. MUST NOT SHOW LOSS OF ADHESION OR LEGIBILITY AFTER 15 MINUTES IMMERSION IN GASOLINE. 11. MUST BE PROVIDED BY A SILKSCREEN VENDOR. 10. MUST BE PROVIDED IN ROLL DISPENSE, SHEET FORM OR SPLIT BACKING. 11 12 1 3 2 10 3 1. 9. MUST HAVE TEDLAR CLEAR OVER LAMINATE FOR ABRASION, GASOLINE RESISTANCE. 8. MUST COMPLY WITH (TURF) ANSI B71.4-1999 WHEN APPLIED TO PAINTED METAL OR POLYETHYLENE FOR A PERIOD OF 24 HOURS. 50 2. 3. 4. 5. 6. 7. 10 8 8 7 9 6 6.
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SPECIFICATIONS Hydraulic System Oil Capacity: 2.1 quarts (2.0 liters) Fluid Type: Mobil 1 Extended Performance 15W-50 Synthetic Fluid Level: Check the fluid level while the fluid is warm. The fluid should be between cold and hot. Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Fig. 000 above).
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SPECIFICATIONS Torque Specifications Fastener Identification 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. 2 These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual.
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SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts (SAE J995 Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) In-lb # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24
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SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size 2 Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m M10 X 1.
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SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts 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 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb 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.
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SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions 1/64 1/32 3/64 2 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.21875 5.556 0.234375 5.953 0.2500 6.350 0.265625 6.747 0.28125 7.144 19/64 0.296875 7.541 0.3125 7.541 21/64 0.
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SPECIFICATIONS U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.9078 0.4536 28.
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CHASSIS Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
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CHASSIS Caster Fork Assembly Removal 4. Remove the caster fork assembly from the front frame (Fig. 034). Estate Series with bushing front casters 1. Raise the front of the unit off the ground, allowing enough clearance to remove the caster fork from the bottom hub. 2. With a hammer and chisel, remove the top grease cap (Fig. 032). 3 Fig 034 PICT-0003 5. Remove the spacer (Fig. 035). Fig 032 PICT-0001 rev 3. Remove the E-ring (Fig. 033).
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CHASSIS 6. Remove the top and bottom bushings (Fig. 036). Fig 036 PICT-0005 rev Caster Fork Assembly Installation 2. Install the caster fork assembly into the front frame (Fig. 038). Fig 038 PICT-0008 Note: Ensure short caster spacer is installed prior to assembling the caster assembly. Estate Series with bushing front casters 1. Drive the upper and lower bushings in until they seat against the step in the housing (Fig. 037). 3. Install the tall spacer (Fig. 039).
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CHASSIS 4. When reinstalling the castor fork assembly on early production Z400 Estates Series check for excessive endplay between the E-ring groove and the top of the spacer. To minimize endplay, adjust as needed with 7/8” ID shims (Fig. 040). 3 6. Install the top grease cap (Fig 042). Fig 042 Fig 040 PICT-0010 PICT-0012 Caster Fork Assembly Removal Pro 100/400 Series with tapered roller front casters 1.
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CHASSIS 3. Loosen and remove the caster nut (Fig. 044). Fig 044 PICT-0206 4. Remove the caster fork and wheel assembly from the frame (Fig. 045) 5. Remove cup washers (3) (Fig. 046). Fig 046 6. Remove the top tapered roller bearing (Fig. 047).
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CHASSIS 7. Remove the lower seal and lower tapered bearing (Fig. 048). 3 9. Remove the upper tapered bearing cup (Fig. 050) Fig 050 Fig 048 PICT-0212 PICT-0210 8. Remove the lower tapered bearing cup (Fig. 049) Caster Fork Assembly Installation Pro 100/400 Series with tapered roller front casters 1. Install the upper and lower tapered bearing cups with the thick edge facing inside (Fig. 051).
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CHASSIS 2. Pack the upper and lower tapered roller bearings prior to installation (Fig. 052). 4. Install the upper tapered bearing (Fig. 054). Fig 054 Fig 052 3. Install the lower tapered bearing and lower seal with the open end of the seal facing up (Fig. 053). 5. Install the caster fork into the frame (Fig. 055).
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CHASSIS 6. Install the three spring washers (Fig. 056). 8. Remove the grease plug located on the side of the hub on the frame for the caster fork. Install a grease fitting, and pump grease into the housing until grease is passing through the upper bearing (Fig. 058). A B C 3 Fig 056 A. Dust cap B. Locknut washers line art C. Spring washers Fig 058 7. Install the locknut and tighten until the spring washers are flat, then back off 1/4 turn to properly set the preload on the bearings (Fig. 057).
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CHASSIS 2. Remove the wheel bolt and nut from the fork (Fig. 059). Fig 059 PICT-0013 3. Remove the wheel from the fork (Fig. 060). Fig 060 4. Remove the spacer nut from one side of the wheel (Fig. 061). Fig 061 5. Remove the caster axle and second spacer nut from the wheel (Fig. 062).
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CHASSIS 6. Remove both caster seals from the wheel (Fig. 063). 3 Fig 063 7. Fill the center of the wheel cavity with grease and work the grease into the race (Fig. 065). PICT-0017 Fig 065 Caster Fork Wheel and Tire Assembly (Fig. 064) H CB A A BC Fig 064 Seal Guard Caster Seal Taper Cone Bearing Caster Axle 3-10 8. Pack the wheel bearing prior to installation (Fig. 066). D E G E F A. B. C. D. PICT-0020 rev E. F. G. H.
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CHASSIS 11. Repeat steps 8-10 for the other side of the wheel. 9. Install the wheel bearing (Fig. 067). 12. Install one spacer nut onto the caster axle (Fig. 069). Fig 067 3 PICT-0022 rev Fig 069 PICT-0024 rev 10. Install the caster seal (Fig. 068). 13. Insert caster axle/nut assembly into the wheel hub and install the second spacer nut (Fig. 070). Fig 068 PICT-0021 rev Fig 070 PICT-0025 rev Note: Spacer nuts should be installed an equal distance onto each end of the caster axle.
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CHASSIS 14. Bearing pre-load is established by the torque of the spacer nuts on the caster axle. Set spacer nuts at 80 in-lbs. (9.0 Nm) with a torque wrench. Loosen, then reset at 20 in-lbs. (2.3 Nm) (Fig. 071). 3 16. Install wheel and tire assembly into caster fork using wheel bolt and nut (Fig. 073). Tighten. Fig 073 Fig 071 PICT-0028 PICT-0026 rev Pro 100/400 Series with tapered roller front casters 15. Install both seal guards onto wheel hub (Fig. 072). 1.
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CHASSIS 3. Remove the wheel from the fork (Fig. 075). Fig 075 5. Remove the front caster spacer (Fig. 077). PICT-0220 4. Remove both bearing spacers (Fig. 076). Fig 076 Z Master Z400 Service Manual PICT-0221 rev Fig 077 PICT-0222 rev 6. Remove both bearing seals (Fig. 078).
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CHASSIS 7. Remove both taper cone bearings (Fig. 079). 10. Pack both tapered wheel bearings. Reassemble per Fig. 000 (above). Note: The axle bolt torque sets the pre-load on the front caster wheel bearings. Tighten the axle bolt to set the bearings then back off 1/4 turn. Pump grease into the wheel bearings through the grease fitting located on the rim (Fig. 081). 3 Fig 079 PICT-0224 rev Caster Fork Wheel and Tire Assembly (Fig. 080).
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CHASSIS 2. Remove the fuel hose clamp from the bottom of the fuel tank (Fig. 082). 4. Carefully remove the control panel by lifting the panel and sliding it toward the middle of the unit. Note: Do not disconnect any cables or wiring. 5. Remove the two bolts, lock washers and flat washers from the front of the tank (Fig. 084). Fig 082 3 PICT-0029 3. Remove the four screws retaining the control panel to the fuel tank (Fig. 083). Fig 084 PICT-0031 6.
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CHASSIS 7. Remove the fuel tank from the frame (Fig. 086). Location There are two fuel check valves. They are located one beneath each fuel tank approx 6” (15.2cm) down line from the tank (Fig. 087). 3 Fig 086 PICT-0033 Left Side Fuel Tank Installation Fig 087 PICT-0001b Reverse the order of removal. Proper Installation Right Side Fuel Tank Removal & Installation Flat side of the check valve faces fuel tank (Fig. 088).
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CHASSIS Fuel Shut-off Valve Pro 400 Series V-Twin Kohler Purpose Fuel shut-off valve is located on the right hand side of the engine behind the seat (Fig. 090). The fuel shut-off valve cuts off fuel flow to the engine for transporting. Location Estate Series Fuel shut-off valve is located on the left hand side of the engine (Fig. 089). 3 Fig 090 PICT-0228 new Proper Installation The arrow at the bottom of the valve faces toward the engine (Fig. 091).
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CHASSIS Parking Brake Handle/Shaft Assembly Removal 4. Remove the bolts from the outer bearing of the parking brake shaft (Fig. 094). All Models 1. Release the parking brake (forward position). 2. Lift the floor pan and remove the panel assembly by removing the four fasteners retaining the panel to the frame (Fig. 092). 3 Fig 094 PICT-0036 5. Remove the bolts from the inner bearing of the parking brake shaft (Fig. 095). Fig 092 PICT-0034 3. Remove the parking brake handle (Fig. 093).
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CHASSIS 6. Remove the E-ring from the outer end of the parking brake shaft (Fig. 096). Fig 096 8. Slide the parking brake shaft assembly out of the frame (Fig. 098). Fig 098 PICT-0038 7. Remove the cotter pin and clevis pin holding the brake rod assembly to the parking brake shaft (Fig. 097). 9. Inspect the brake shaft and bushings for excessive wear. Replace any worn or broken components (Fig. 099). D E A Fig 097 PICT-0039 F B A C Fig 099 A. Side Flange Bearings B. Brake Shaft C.
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CHASSIS Parking Brake Handle/Shaft Assembly Installation 3. Remove the cotter pin and clevis pin from the brake rod assembly where it attaches to the brake bar (Fig. 101). All Models Reverse the order of removal. Brake Bar Removal (Estate Series) 1. Disengage the brake. 2. Remove the brake return spring (Fig. 100). 3 Fig 101 PICT-0043 4. Remove the two bolts and nuts retaining the brake bar to each side of the frame (Fig. 102).
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CHASSIS 5. Remove the brake bar from the machine (Fig. 103). Fig 103 3. Measure the distance vertically between the front of the brake bar and the crown of the tire; the measurement should be 7/8” to 1” (22 to 25mm) (Fig. 104). 3 PICT-0045 Brake Installation Reverse the order of removal Adjusting the Parking Brake Check the parking brake for proper adjustment. 1. Check tire pressure of all 4 tires. 2. Disengage the brake lever (lever down). Fig 104 1. 2. 3. 4.
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CHASSIS 4. If the measurement is not correct, proceed to the following steps. 5. Remove the hairpin and cotter pin from the brake linkage (Fig. 105). Brake Band Removal (Pro Series) Note: Procedure can be used for left hand or right hand. 1. Raise the right rear wheel (Fig. 106). 3 Fig 105 1. Brake linkage 2. Yoke Firgure 44 3. Hair pin and cotter pin 6. Adjust the yoke clockwise to shorten the distance; counterclockwise to lengthen distance (Fig 105). Fig 106 PICT-0229 2.
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CHASSIS 3. Remove bolts, brake band retainer, spacers, and brake band (Fig. 107). B A 2. Install the 3 bolts, brake band retainer, brake band, and spacers and tighten (Fig. 109). C D Fig 107 A. 3 Bolts B. Brake Band Retainer DSC-1626 rev C. 3 Spacers D. Brake Band Fig 109 DSC-1631 rev 3. Install wheel assembly and 4 wheel lug nuts. Brake Band Installation 1. Install the brake band around the wheel hub (Fig. 108). Brake Shaft Removal (Pro Series) 1.
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CHASSIS 2. Remove the cotter pin and clevis pin from the brake rod assembly (Fig. 110). 3 Fig 110 PICT-0231 4. Cut the plastic tie that holds the fuel line to the brake shaft (Fig. 112). Fig 112 PICT-0235 3. Remove the left and right clevis spring clips from the brake shaft (Fig. 111). 5. On both the right and left side, remove two bolts and nuts holding the flange bearings (Fig. 113).
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CHASSIS 6. Remove the brake shaft from the unit (Fig. 114). Fig 114 2. Remove the lower stop bolt from the deck lift plate (Fig. 115). PICT-0237 Fig 115 7. Inspect the brake shaft and flange bearings for excessive wear. Brake Shaft Installation PICT-0047 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 remove the weight from the support chains (Fig. 116). Reverse the order of removal.
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CHASSIS 4. Loosen jam nuts on the deck lift rods until the deck support springs are fully extended. Repeat procedure for both deck lift rods (Fig. 117). 6. Remove the two 4” x 4” blocks at the rear of the deck, leaving the blocks in place at the front of the mower deck. The mower deck linkage should now be fully unloaded (Fig. 119). 3 Fig 117 PICT-0049 Fig 119 PICT-0051 5. Remove the hex nut from RH rear deck lift assembly. Repeat procedure for LH rear deck lift assembly (Fig. 118). 7.
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CHASSIS 8. Loosen the top hex head 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. 121). 11. Remove the bracket that supports the lower RH corner of the panel assembly (Fig. 123). Fig 123 Fig 121 PICT-0055 PICT-0054 rev 9. Lift the floor pan assembly to its fully opened position. 12.
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CHASSIS 13. Remove the retainer clip from the lift lever grip assembly (Fig. 125). 15. Inspect the deck lift lever assembly components for wear, especially the bushings (Fig. 127). A 3 Fig 125 BC D E PICT-0059 rev 14. Carefully slide the lift lever grip assembly out of its carrier frame pivot (Fig. 126). Fig 127 A. Lift Handle Assembly B. Nuts C. Bolts F PICT-0061 rev D. Plates E. Bushings F. Retainer Clip Deck Lift Lever Installation 1.
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CHASSIS 2. For ease of installation, make sure deck lift arm plates, bushings and hardware are installed on the deck lift lever assembly prior to installation (Fig. 129). 4. Install bolt, nut and bushing through the plates into the rear deck lift cross-shaft (Fig. 131). Fig 131 Fig 129 PICT-0062 rev 3. Install lift lever assembly into front frame pivot location (Fig. 130). 5. Install the retainer clip on the deck lift lever assembly shaft (Fig. 132).
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CHASSIS 6. Rotate deck lift plate (inner) downward until lower mounting holes line up with 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. 133). A 8. Raise deck lift lever assembly until deck mount swivels rest against deck rod jam nuts. Install HOC pin into deck lift plate HOC holes that correspond to the 3” (7.62cm) HOC position (Fig. 135). A B B C 3 Fig 135 Fig 133 A. Hex bolt B.
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CHASSIS 10. Install hex nut on end of deck lift rod. Tighten against deck mount swivel. Repeat procedure for opposite side deck lift swivel (Fig. 137). 12. Install the panel assembly with the four fasteners retaining the panel to the frame (Fig. 139). Fig 139 Fig 137 PICT-0034 PICT-0070 14. Lower the floor pan assembly. 11. Raise mower deck to the transport position. Remove the support blocks. Check the deck level adjustment (refer to Mower Deck Leveling page x-xx).
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CHASSIS 2. Remove the two bolts and washers retaining the lever assembly to the control arm shaft (Fig. 141). 3 Fig 141 PICT-0072 3. Remove the cotter pin and clevis pin securing the adjustable yoke of the neutral return bolt (Fig. 142). Fig 142 3-32 PICT-0073 4. Disconnect the motion control dampener from the motion control assembly (Fig. 143). Fig 143 PICT-0074 5. Remove the bolt and nut that retaining the ball joint to the motion control shaft (Fig. 144).
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CHASSIS 6. Disconnect neutral switch wire harness from the neutral switch (Fig. 145). Fig 145 8. Remove the two bolts and nuts that retain the flange bearing on the outside of the motion control (Fig. 147). 3 PICT-0078 Fig 147 7. Remove the two bolts and nuts that retain flange bearing on the inside of the motion control (Fig. 146). Fig 146 PICT-0079 PICT-0080 9. Remove the motion control assembly from the frame (Fig. 148).
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CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
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HYDRAULIC SYSTEM Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks . . . . . . . . . . .
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HYDRAULIC SYSTEM Hydrostatic Pump Removal 4. Drain the hydraulic oil from the hydraulic reservoir tank. Note: Cleanliness is a key factor in a successful repair of any hydrostatic system. Thoroughly clean all exposed surfaces prior to any type of 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.
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HYDRAULIC SYSTEM 7. Remove the two high pressure hydraulic lines, located at the rear of the hydrostatic pump (Fig. 152). 9. Loosen the two square head set screws located on the pump sheave and remove the pulley (Fig. 154). Fig 154 Fig 152 8. With a spring puller, remove the extension spring from the idler arm assembly and remove the cog belt (Fig. 153). 10. Loosen and remove the two bolts and nuts retaining the hydrostatic pump to the frame (Fig. 155).
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HYDRAULIC SYSTEM Hydrostatic Pump Installation 11. Remove the seat retainer rod (Fig. 156). 1. Place the hydrostatic pump into the frame (Fig. 158). Fig 156 PICT-0092a Fig 158 4 PICT-0093a 12. Remove the hydrostatic pump from the frame (Fig. 157). 2. Install the bolt, washer and nut that retain the tracking link rod to the hydro control arm (Fig. 159). Tighten hardware. Fig 157 PICT-0093a rev 13.
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HYDRAULIC SYSTEM 3. Loosely install the two bolts and nuts retaining the hydrostatic pump to the frame (Fig. 160). Fig 160 PICT-0091a 4. Install the case drain hydraulic hose and hose clamp located on the top inside of the hydrostatic pump (Fig. 161). 5. Install the pump suction hydraulic line located on the front of the hydrostatic pump (Fig. 162). Fig 162 6. Install the two high pressure hydraulic lines located at the rear of the hydrostatic pump (Fig. 163).
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HYDRAULIC SYSTEM 7. Tighten the pump mounting bolts (Fig. 164). 10. Install the pulley. 11. Align the outer edge of the hydrostatic pump pulley using a straight edge, to the outer edge of the existing pump pulley (Fig. 166). Note: Deck drive belt was removed for clarity. B A Fig 164 4 PICT-0091a 8. Install the key in the hydrostatic pump shaft. 9. Apply some anti-seize compound to the shaft (Fig. 165). Note: Before installing the pulley replace the set screws.
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HYDRAULIC SYSTEM 13. Install the cog belt onto the drive pulley. With a spring puller, install the extension spring to the idler arm assembly (Fig. 168). 15. Connect the negative battery cable to the battery. 16. Check the hydraulic fluid in the reservoir tank. Add oil if necessary. Air will need to be purged from system. Follow the procedures for Purging the Hydraulic System, page x-xx. 17. Check the neutral adjustment. Follow procedures for Adjusting the Handle Neutral, page x-xx.
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HYDRAULIC SYSTEM 2. Remove the plastic tie holding the clutch harness to frame (Fig. 171). Fig 171 4 PICT-0099a 3. Unplug the clutch pigtail harness from the main harness (Fig. 172). Fig 172 4-8 PICT-0100a 4. Loosen the clutch stop rod and pivot away from the clutch (Fig. 173). Fig 173 PICT-0104a 5. Remove the belt from the clutch drive pulley (Fig. 174).
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HYDRAULIC SYSTEM Installing the Pump Drive Belt 3. Remove the Idler Arm (Fig. 177). Reverse the order of replacement. Idler Arm Removal 1. With a spring puller, remove the extension spring from the idler arm assembly and remove the cog belt from the pump drive and idler pulleys (Fig. 175). Fig 177 PICT-0109a 4. Inspect the idler arm and bushings for excessive wear. Replace any worn or broken components (Fig. 178). Fig 175 4 A PICT-0097a B 2. Remove the belt from the idler sheave (Fig. 176).
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HYDRAULIC SYSTEM Idler Arm Installation 3. Remove the cotter pin from the wheel motor output shaft (Fig. 180). Reverse the order of removal Wheel Motor Removal This procedure is the same for both the right and left wheel motors. 1. Disconnect the battery negative cable. 2. Raise the rear wheels of the machine off the ground and support the frame with jackstands. Remove the rear wheel (Fig. 179). Fig 180 4 PICT-0001a 4. Loosen and remove nut securing hub to the wheel motor output shaft (Fig. 181).
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HYDRAULIC SYSTEM 5. Install a wheel hub puller to the wheel hub. Place an impact wrench onto the puller and remove the wheel hub (Fig. 182). Fig 182 8. Remove the wheel motor bolts, lock washers, spacers and nuts (Fig. 184). Fig 184 PICT-0005a PICT-0003a Note: Toro Wheel Hub Puller, P/N TOR 4097, is available through SPX (formerly OTC) 1-800-533-0492. 4 9. Remove the wheel motor (Fig. 185). 6. Place a drain pan under wheel motor. 7. Clean any dirt or debris away from the hydraulic line fittings.
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HYDRAULIC SYSTEM Wheel Motor Installation 3. Install and tighten the two hydraulic lines to the wheel motor fittings (Fig. 188) Note: As a reminder, prior to connecting the hydraulic lines, the O-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 1. Install wheel motor using the 4 bolts, spacers, lock washers and nuts. Install spacer between the frame and the motor housing. (Fig. 186). Fig 188 4 PICT-0009a 4.
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HYDRAULIC SYSTEM 5. Check the alignment between the cotter pin hole on the motor shaft and the castle nut openings. Adjust the castle nut as needed for cotter pin installation. 6. Install the cotter pin in the castle nut (Fig. 190). Adjusting the Handle Neutral If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. Note: Motion control levers must be installed correctly.
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HYDRAULIC SYSTEM 7. Pull lever back until the clevis pin (on arm below pivot shaft) just begins to contact the end of the slot (just beginning to put pressure on the spring) (Fig. 192). 10. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in neutral lock position (Fig. 191).
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HYDRAULIC SYSTEM 2. Slide the seat fully forward, unlatch the seat and tilt the seat forward. 3. Disconnect the electrical connector at the seat switch located between the two hydraulic pumps. Temporarily install a jumper wire across the terminals in the wiring harness connector (Fig. 194). 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. 195).
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HYDRAULIC SYSTEM Setting the RH Hydraulic Pump Neutral 3. Adjust the pump rod length by rotating double nuts on the rod, in the appropriate direction, until the wheel is still or slightly creeps in reverse (Fig. 197). 1. Loosen the locknuts at the ball joints on the pump control rod (Fig. 196). Fig 197 4 Fig 196 PICT-0016a rev PICT-0016a rev 2. Start the engine, open throttle 1/2 way and release parking brake. Note: The motion control lever must be in neutral while making any adjustments.
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HYDRAULIC SYSTEM Adjusting the Tracking 2. Stop the machine and set the parking brake. The left hand pump has a knob for adjusting the tracking (Fig. 198). 3. Unlatch the seat and tilt the seat forward to access the tracking knob. Note: Determine the left and right sides of the machine from normal operating position. 4. To make the machine go right, turn the knob towards the right side of the machine (Fig. 200). Fig 198 PICT-0015a 1. Push both control levers forward the same distance (Fig. 199).
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HYDRAULIC SYSTEM Purging the Hydraulic System The traction system is self bleeding; however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system. 1. Raise the machine so the wheels are off the ground and supported with jack stands (Fig. 201). 3. When the wheel begins to spin on its own, keep it engaged until the wheel drives smoothly (minimum 2 minutes). 4. Check the hydraulic fluid level and add fluid as required to maintain proper level. 5.
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HYDRAULIC SYSTEM 1. Lift the back of the machine so the rear tires (left and right) are off the ground. Place jack stands under the rear frame to support the unit. Remove the rear wheel from side of machine being flow tested; in this case, the left rear wheel is removed (Fig. 203). 3. Loosen hydraulic lines at the pump to obtain enough clearance to connect flow tester to the hydrostatic high pressure lines (Fig. 205). Retighten fittings at the pump.
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HYDRAULIC SYSTEM 5. Check the hydraulic reservoir and fill as needed with Mobil 1 Extended Performance, 15w50 oil. 6. Disconnect the electric PTO clutch from the wiring harness to prevent accidental engagement of the mower deck. 7. Disconnect the seat switch from the harness. Temporarily install a jumper wire across the harness (Fig. 207). Move the seat back to the operating position. 11. Stroke the left hand hydrostatic lever fully forward.
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HYDRAULIC SYSTEM Pushing the Machine by Hand Changing to Machine Operation Important: Always push the machine by hand. Never tow the machine because hydraulic damage may occur. 1. Rotate the by-pass valves clockwise 1 turn to operate the machine (Fig. 209). 1. Disengage the power take off (PTO) and turn the ignition key to OFF. Move the levers to the neutral position and apply the parking brake. Note: Do not over-tighten the by-pass valves.
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HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK.
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ENGINE Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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ENGINE Kawasaki FH580V 19 hp Engine Removal 4. Disconnect the oil pressure switch harness (Fig. 212). 1. Remove the battery negative cable from the battery. 2. Disconnect the choke cable by removing the top clamp (Fig. 210). Note: Rear Bumper removed for clarity. Fig 212 PICT-0008c 5. Remove the positive (red) wire from the starter (Fig. 213). Fig 210 5 PICT-0003b 3. Disconnect the throttle cable by removing the bottom clamp (Fig. 211).
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ENGINE 6. Remove the (violet) wire from the voltage rectifier/ regulator (Fig. 214). Fig 214 PICT-0010c 7. Disconnect the pink wire from the green wire connected to the fuel solenoid (Fig. 215). 8. Disconnect the white wire from the black wire connected to the engine magneto (Fig. 216). Fig 216 PICT-0012c 9. Turn the fuel shot-off valve to the “on” position (Fig. 217).
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ENGINE 10. Remove the fuel line clamp holding the fuel line to the fuel pump. Remove the fuel line from the fuel pump (Fig. 218). 13. Unplug the clutch pigtail harness from the main harness (Fig. 220). Fig 220 Fig 218 11. Remove the Mower Deck Drive Belt. Refer to Replacing the Mower Deck Drive Belt on page x-xx. 5 PICT-0100a PICT-0013c 14. Remove the center bolt and two spring washers holding the electric PTO clutch (Fig. 221). 12. Remove the plastic tie holding the clutch harness to frame (Fig.
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ENGINE 15. Remove the electric PTO clutch (Fig. 222). Fig 222 PICT-0015c 16. With a spring puller, remove the extension spring from the idler arm assembly and remove the cog belt from the pump drive and idler pulleys (Fig. 223). 17. Remove the drive belt from the pulley (Fig. 224). Fig 224 PICT-0017c 18. Remove the pulley (Fig. 225).
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ENGINE 19. Remove the five engine mounting bolts (Fig. 226). Note: The left rear mounting bolt has 4 ground wires attached. Fig 226 PICT-0019c 20. Connect a lift chain to the lift points on the engine. Raise the engine from the frame (Fig. 227). Kawasaki FH580V 19 hp Engine Installation 1. Lower the engine to the frame (Fig. 228). Fig 228 PICT-0021c 2. Install the five engine mounting bolts. a. Install the clutch stop rod in the right rear engine mounting bolt hole (Fig. 229). Do not tighten.
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ENGINE b. Install the four ground wires in the left rearmost mounting bolt hole (Fig. 230). Fig 230 PICT-0019c 3. Apply anti-seize compound to the engine shaft (Fig. 231). 4. Apply a thread-locking compound to the clutch retainer bolt (Fig. 232). Fig 232 PICT-0026c 5. Install the hydro pump drive pulley and the electric PTO clutch with the bolt and spring washers. Torque the bolt to 55 ft-lbs. (74.6 Nm) (Fig. 233).
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ENGINE 6. Install the hydro pump drive belt (Fig. 234). 8. Install the mower drive belt. Refer to Replacing the Mower Deck Drive Belt on page 7-24. 9. Plug the clutch pigtail harness into the main harness (Fig. 236). Fig 234 PICT-0106a rev 7. Align the clutch stop rod with the slot of the electric PTO clutch (Fig. 235). Rotate the clutch stop rod into the slot on the clutch. Tighten the stop rod mounting bolt. Fig 236 PICT-0100a 10. Replace the plastic tie holding the clutch harness to frame (Fig.
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ENGINE 11. Install the fuel line clamp that holds the fuel line to the fuel pump. Reinstall the fuel line to the fuel pump (Fig. 238). 13. Reconnect the pink wire to the green wire that connects to the fuel solenoid (Fig. 240). Fig 240 Fig 238 PICT-0011c PICT-0013c 12. Reconnect the white wire to the black wire that connects to the engine magneto (Fig. 239). 14. Reconnect the (violet) wire to the voltage rectifier/ regulator (Fig. 241).
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ENGINE 16. Reconnect the oil pressure switch harness (Fig. 242). 17. Reconnecting the choke cable: a. Reconnect the z-bend of the choke cable to the choke linkage (Fig. 244). Note: The air cleaner cover has been removed for clarity. Fig 242 PICT-0008c 15. Reconnect the positive (red) wire to the starter (Fig. 243).
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ENGINE b. With the choke knob in the full down position (Fig. 245) and the choke linkage in the full open position (left), tighten the cable clamp (Fig. 246). Fig 245 18. Reconnect the throttle cable: a. Reconnect the z-bend of the throttle cable to the throttle linkage (Fig. 247). PICT-0031c Fig 247 PICT-0034c b. Position the throttle control lever so that there is approximately 1/2” (12.7mm) between the lever and the full throttle position of the throttle slot (Fig. 248).
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ENGINE c. Pull the cable housing until the throttle linkage is in the full throttle position. Tighten the cable clamp (Fig. 249). Fig 249 PICT-0036c 19. Connect the battery negative cable. 5 3. Remove the eight bolts, washers and nuts that hold the notched weight onto the rear of the machine. Remove the notched weight from the rear of the machine (Fig. 250). Fig 250 PICT-0265 4. Remove the 4 bolts and nuts that hold the tailpipe guard to the right hand guard strap (Fig. 251).
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ENGINE 5. Remove the three sets of fasteners holding the right hand muffler guard and guard strap to the frame (Fig. 252). Fig 252 PICT-0269 6. Remove the right hand muffler guard and guard strap (Fig. 253). 7. Remove the two sets of fasteners holding the hydraulic oil tank to the guard strap and fuel tank support (Fig. 254). Fig 254 PICT-0272 8. Remove the two sets of fasteners holding the left hand guard strap and muffler guard to the frame (Fig. 255).
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ENGINE 9. Remove the left hand guard strap and muffler guard (Fig. 256). Fig 256 PICT-0274 10. Loosen the left clamp and disconnect the choke cable (Fig. 257). 11. Loosen the right clamp and disconnect the throttle cable (Fig. 258). Fig 258 PICT-0280 12. Turn the fuel shut-off valve to the “Off” position (Fig. 259).
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ENGINE 13. Remove the fuel hose clamp, then the fuel hose located at the fuel pump (Fig. 260). Fig 260 PICT-0282 14. Remove the red wires located on the starter solenoid (Fig. 261). 15. Remove the blue wire located on the starter solenoid (Fig. 262). Fig 262 PICT-0284 16. Unplug the engine wiring harness (Fig. 263).
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ENGINE 17. Remove the mower drive belt from the electric PTO clutch, refer to Replacing the Mower Deck Drive Belt page x-xx. 20. Remove the electric PTO clutch (Fig. 266). 18. Unplug the clutch pigtail harness from the main harness (Fig. 264). Fig 266 Fig 264 5 PICT-0100a PICT-0015c 21. With a spring puller, remove the extension spring from the idler arm assembly. Remove the cog belt from the pump drive and idler pulleys (Fig. 267). 19.
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ENGINE 22. Remove the drive belt from the engine pulley (Fig. 268). Fig 268 24. Remove the 4 engine mounting bolts (Fig. 270). Note: The left rear engine mounting bolt has 3 ground wires attached. PICT-0017c Fig 270 PICT-0287 23. Remove the engine pulley (Fig. 269). 25. Connect chains to the two lift points on the engine and raise the engine from the frame (Fig. 271).
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ENGINE Kohler V-Twin 20 hp Engine Install 4. Install the engine pulley (Fig. 274). 1. Lower the engine onto the frame. Install 4 bolts and spring washers through the frame and into the base of the engine. Tighten the bolts (Fig. 000). 0287 left Note: The 3 ground wires attach to the left rear engine mounting bolt. 2. Apply anti-seize compound to the engine shaft (Fig. 272). Fig 274 PICT-0018c 5. Install the drive belt onto the engine pulley (Fig. 275). Fig 272 5 PICT-0025c 3.
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ENGINE 6. Install the cog belt onto the pump drive and idler pulleys. With a spring puller, install the extension spring onto the idler arm assembly (Fig. 276). Fig 276 PICT-0016c 8. Install the center bolt and two spring washers that hold the electric PTO clutch to the engine crankshaft (Fig. 278). Fig 278 PICT-0014c 9. Torque the center bolt to 55 ft-lbs. (74.6 Nm) (Fig. 279). 7. Install the electric PTO clutch (Fig. 277).
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ENGINE 10. Plug the clutch pigtail harness into the main harness (Fig. 280). 13. Connect the blue wire onto the starter solenoid (Fig. 282). Fig 280 Fig 282 PICT-0100a 11. Install the mower drive belt onto the electric PTO clutch. Refer to Replacing the Mower Deck Drive Belt page 7-24. PICT-0284 14. Connect the red wires onto the starter solenoid (Fig. 283). 12. Plug in the engine wiring harness (Fig. 281).
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ENGINE 17. Reconnect the throttle cable: a. Position the throttle control lever so that there is approximately 1/2” (12.7mm) between the lever and the full throttle position of the throttle slot (Fig. 286). 1/2 ” 15. Connect the fuel hose clamp onto the fuel hose at the fuel pump (Fig. 284). Fig 284 PICT-0282 16. Turn the fuel shut-off valve to the “on” position (Fig. 285). Fig 286 PICT-0293 b.
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ENGINE 18. Reconnecting the choke cable: a. Push the choke knob into the full down position (Fig. 288). 19. Install the left hand guard strap and muffler guard to the frame using the two sets of fasteners (Fig. 290). Fig 290 Fig 288 5 PICT-0296 b. Reconnect the z-bend of the choke cable to the choke linkage. The choke linkage should be in the full open position (right). Tighten the cable clamp (Fig. 289). 20.
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ENGINE 21. Install the right hand muffler guard and strap guard using three sets of fasteners (Fig. 292). Fig 292 23. Install the notched weight onto the rear of the machine using eight bolts, washers and nuts (Fig. 294). PICT-0269 Fig 294 22. Install the tailpipe guard to the right hand guard strap using two bolts and nuts on the right hand side of the machine (Fig. 293). PICT-0265 24. Install the rear wheels. Lower the rear of the machine. 25. Reconnect the battery negative cable.
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ENGINE Kohler 18 hp Single Cylinder Removal 5. Remove the front cable clamp and disconnect the throttle cable (Fig. 297). 1. Remove the battery negative cable from the battery. 2. Raise the rear wheels of the machine off the ground and support the frame with jack stands. Remove both rear wheels. 3. Remove the 6 bolts, washers and nuts holding the rear bumper to the frame (Fig. 295). Remove the rear bumper. Fig 297 PICT-0324 6. Remove the green oil sending wire from the oil pressure switch (Fig. 298).
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ENGINE 7. Unplug the magneto and charging circuit wire harness (Fig. 299). Fig 299 PICT-0327 8. Disconnect the three ground wires located at the right hand engine lift point (Fig. 300). Reinstall the engine lift bracket. 9. Turn the fuel shut-off valve to the “off” position (Fig. 301). Fig 301 PICT-0329 10. Remove the fuel hose clamp on the fuel hose located at the fuel pump (Fig. 302).
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ENGINE 11. Remove the red wires located on the starter solenoid (Fig. 303). 13. Remove the mower drive belt from the electric PTO clutch. Refer to Replacing the Mower Deck Drive Belt page x-xx. 14. Remove the plastic tie holding the clutch harness to frame (Fig. 305). Fig 303 PICT-0331 12. Remove the blue wire located on the starter solenoid (Fig. 304). Fig 305 PICT-0099a 15. Unplug the clutch pigtail harness from the main harness (Fig. 306).
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ENGINE 16. Remove the center bolt and two spring washers holding the electric PTO clutch to the engine crankshaft (Fig. 307). Fig 307 PICT-0014c 17. Remove the electric PTO clutch (Fig. 308). 18. With a spring puller, remove the extension spring from the idler arm assembly and remove the cog belt from the pump drive and idler pulleys (Fig. 309). Fig 309 PICT-0016c 19. Remove the drive belt from the engine pulley (Fig. 310).
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ENGINE 20. Remove the engine pulley (Fig. 311). Fig 311 22. Connect chains to the two lift points on the engine and raise the engine from the frame (Fig. 313). PICT-0018c Fig 313 21. Remove the 4 engine mounting bolts and washers (Fig. 312). PICT-0341 Kohler 18 hp Single Cylinder Install 1. Lower the engine onto the frame. Install 4 bolts and spring washers through the frame and into the base of the engine. Tighten the bolts. 5 2. Apply anti-seize compound to the engine crankshaft (Fig. 314).
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ENGINE 3. Install the engine pulley (Fig. 315). Fig 315 5. Install the cog belt onto the pump drive and idler pulleys. With a spring puller, install the extension spring onto the idler arm assembly (Fig. 317). PICT-0018c Fig 317 4. Install the drive belt onto the engine pulley (Fig. 316). PICT-0016c 6. Install the electric PTO clutch (Fig. 318).
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ENGINE 7. Apply a thread locking compound to the clutch retainer bolt (Fig. 319). 9. Torque the center bolt to 55 ft-lbs. (Fig. 321). Fig 321 Fig 319 PICT-0027c PICT-0026c 8. Install the center bolt and two spring washers that hold the electric PTO clutch to the engine crankshaft (Fig. 320). 10. Plug the clutch pigtail harness into the main harness (Fig. 322).
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ENGINE 11. Replace the plastic tie holding the clutch harness to frame. 15. Connect the fuel hose clamp onto the fuel hose located at the fuel pump (Fig. 325). 12. Install the mower drive belt onto the electric PTO clutch. Refer to Replacing the Mower Deck Drive Belt page 7-24. 13. Plug in the engine wiring harness (Fig. 323). Fig 325 Fig 323 PICT-0283 PICT-0330 16. Turn the fuel shut-off valve to the “On” position (Fig. 326). 5 14. Connect the red wires to the starter solenoid (Fig. 324).
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ENGINE 17. Connect the three ground wires located at the right hand engine lift point (Fig. 327). Reinstall the engine lift bracket. 19. Connect the green oil sending wire to the oil pressure switch (Fig. 329). Fig 329 Fig 327 PICT-0325 PICT-0328 18. Plug in the magneto and charging circuit wire harness (Fig. 328). 20. Reconnecting the choke cable: a. Position the choke knob in the full down position (Fig. 330).
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ENGINE b. Reconnect the z-bend of the choke cable to the choke linkage (the middle hole in the choke plate). The choke linkage should be in the full open position (up). Tighten the cable clamp (Fig. 331). Fig 331 PICT-0342 21. Reconnect the throttle cable: a. Position the throttle control lever so that there is approximately 1/2” (12.7mm) between the lever and the full throttle position of the throttle slot (Fig. 332). b.
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ENGINE Z 100 Series FH580V (KAI) 19 hp Kawasaki Removal 4. Remove the two bolts and nuts holding the hydraulic oil tank to the guard strap and fuel tank support (Fig. 336). 1. Remove the battery negative cable from the battery. 2. Raise the rear wheels of the machine off the ground and support frame with jack stands. Remove both rear wheels. 3. Remove the four bolts and nuts that hold the tailpipe guard to the right hand guard strap and rear muffler guard (Fig. 335). Fig 336 PICT-0398 5.
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ENGINE 6. Remove the 9 sets of fasteners holding the right hand muffler guard and guard strap to the frame. Remove the muffler guard assembly (Fig. 338). 8. Remove the bottom cable clamp and disconnect the throttle cable (Fig. 340). Fig 340 Fig 338 PICT-0402 PICT-0400 7. Remove the top cable clamp and disconnect the choke cable (Fig. 339). 9. Remove the green oil sending wire from the oil pressure switch (Fig. 341).
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ENGINE 10. Unplug the electric PTO clutch plug (Fig. 342). Fig 342 12. Remove the fuel hose clamp on the fuel hose located at the fuel pump (Fig. 344). PICT-0405 Fig 344 11. Turn the fuel shut-off valve to the “off” position (Fig. 343). PICT-0407 13. Unplug the violet wire from the B+ side of the regulator (Fig. 345).
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ENGINE 14. Unplug the pink wire from the green wire (fuel shutoff solenoid) and the white wire from the black wire (magneto) (Fig. 346). 16. With a spring puller, remove the extension spring from the mower deck (Fig. 348). Fig 348 Fig 346 PICT-0375 PICT-0409 15. Remove the red wire located on the starter solenoid (Fig. 347). 17. Remove the belt from the electric PTO clutch (Fig. 349).
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ENGINE 18. Remove the center bolt and two spring washers holding the electric PTO clutch to the engine crankshaft (Fig. 350). Fig 350 PICT-0014c 19. Remove the electric PTO clutch (Fig. 351). 20. With a spring puller, remove the extension spring from the idler arm assembly and remove the cog belt from the pump drive and idler pulleys (Fig. 352). Fig 352 PICT-0016c 21. Remove the drive belt from the engine pulley (Fig. 353).
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ENGINE 22. Remove the engine pulley, spacer and key (Fig. 354). Fig 354 PICT-0414 23. Remove the 4 engine mounting bolts, washers and nuts (Fig. 355). 24. Connect chains to the two lift points on the engine and raise the engine from the frame (Fig. 356). Fig 356 PICT-0419 Z 100 Series FH580V (KAI) 19 hp Kawasaki Install 1. Lower the engine onto the frame. Install the 4 engine mounting bolts, washers and nuts through the frame and engine mounts. Tighten the bolts. 2.
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ENGINE 3. Install the engine pulley, spacer and key (Fig. 358). Fig 358 5. Install the cog belt onto the pump drive and idler pulleys. With a spring puller, install the extension spring onto the idler arm assembly (Fig. 360). PICT-0414 Fig 360 4. Install the drive belt onto the engine pulley (Fig. 359). PICT-0016c 6. Install the electric PTO clutch (Fig. 361).
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ENGINE 7. Apply a thread-locking compound to the clutch retainer bolt (Fig. 362). Fig 362 PICT-0026c 8. Install the clutch retainer bolt and two spring washers that hold the electric PTO clutch to the engine crankshaft (Fig. 363). 9. Torque the center bolt to 55 ft-lbs. (74.6 Nm) (Fig. 364). Fig 364 PICT-0027c 10. Plug the clutch pigtail harness into the main harness (Fig. 365).
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ENGINE 11. Connect the red wire onto the starter solenoid (Fig. 366). Fig 366 PICT-0413 12. Connect the pink wire to the green wire (fuel shut-off solenoid) and the white wire to the black wire (magneto) (Fig. 367). 13. Connect the violet wire to the B+ side of the regulator (Fig. 368). Fig 368 PICT-0408 14. Install the fuel hose clamp onto the fuel hose located at the fuel pump (Fig. 369).
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ENGINE 17. Reconnect the throttle cable: a. Position the throttle control lever so that there is approximately 1/2” (12.7mm) between the lever and the full throttle position of the throttle slot (Fig. 372). 1/2 ” 15. Turn the fuel shut-off valve to the “on” position (Fig. 370). Fig 370 PICT-0406 16. Connect the green oil sending wire to the oil pressure switch (Fig. 371). Fig 372 PICT-0293 b. Reconnect the z-bend of the throttle cable to the throttle linkage (the top hole of the throttle plate).
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ENGINE 18. Reconnecting the choke cable: a. Position the choke knob in the full down position (Fig. 374). 19. Install the muffler guard assembly using 9 sets of fasteners (Fig. 376). Fig 376 Fig 374 5 PICT-0296 b. Reconnect the z-bend of the choke cable to the choke linkage. The choke linkage should be in the full open position (far left). Tighten the cable clamp (Fig. 375). 20. Install the hydraulic oil tank using two bolts and nuts. Secure the tank to the guard strap and fuel tank support (Fig.
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ENGINE 21. Install the four bolts and nuts that hold the tailpipe guard to the right hand guard strap and rear muffler guard (Fig. 378). Fig 378 PICT-0397 22. Install a plastic tie to hold the throttle and choke cable to the right hand guard strap (Fig. 379). 5 Fig 379 PICT-0422 23. Install the rear wheels. Lower the machine to the ground. 24. Connect the battery negative cable.
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ENGINE THIS PAGE INTENTIONALLY LEFT BLANK.
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ELECTRICAL Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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ELECTRICAL General How It Works Note: Interactive Electrical Troubleshooting CD, Form 492-9143 is also available. A relay is an electrically actuated switch. Relays 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning 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.
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ELECTRICAL Testing 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 383). 85 87 87a 30 86 Fig 382 relay pin diagram 1. Disconnect the relay from the harness. 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be from 70 to 90 ohms. There should be continuity between terminals 87a and 30. 3. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to 85.
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ELECTRICAL Location Testing The PTO Switch is located on the control panel on the left side of the operator (Fig. 384). 1. Disengage the PTO, set the parking brake, and turn the ignition to OFF. Remove the key. 2. Remove the 4 screws holding the control panel to the fuel tank. 3. Disconnect the wiring harness from the PTO switch. 4. Press in the locking tabs, on each side of the switch, and pull the switch out of the control panel. 5.
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ELECTRICAL 6. Replace the switch if your test results do not correspond with those given in (Fig. 385). 7. Mount the PTO switch back into the control panel and reinstall the wiring harness (Fig. 386). Ignition Switch Purpose The ignition switch makes the proper connections for the starter, accessories, and safety circuits. Violet Location The ignition switch is located on the control panel, to the left side of the operator (Fig. 387).
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ELECTRICAL How It Works Neutral Safety Switch Detents inside the switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released (Fig. 388). Purpose Used to ensure the motion control handles are in neutral to start the unit. It is activated by moving the motion control handles to the neutral position (handles outward). Location To gain access to the neutral safety switches, remove the panel assembly.
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ELECTRICAL Testing 1. Disconnect the switch from the wiring harness. 2. Using a VOM or test light, check first to ensure there is no continuity between the terminals, plunger out. 3. With the plunger pushed in, there should be continuity between the terminals. Park Brake Switch Purpose Fig 390 PICT-0197 The purpose of the brake switch is to ensure the machine is in neutral and the parking brake is applied before attempting to start the machine.
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ELECTRICAL How It Works 2. Using a multimeter, follow the procedures listed below (Fig. 394). When starting, it functions to ensure the park brake is in the ON position. At the same time it allows current to flow through the remainder of the starting safety circuit. When the park brake is released in the (Off position) it bypasses both neutral switches, permitting the control levers to be used, as long as the operator is in the seat to maintain current for the safety circuit (Fig. 393).
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ELECTRICAL Location Testing The seat switch is mounted to the frame directly under the seat (Fig. 395). 1. Disconnect the switch from the wiring harness. 2. Using a VOM or test light, check first to ensure there is no continuity between either terminal, plunger out. 3. With the plunger pushed in, there should be continuity between the terminals.
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ELECTRICAL How It Works 2. Remove the 4 bolts mounting the console panel to the frame. The seat delay module circuit board is made up with several different electronic components such as transient voltage suppressor diodes, capacitor, transistors, carbon film resistors, and a relay. The components work together to allow a short term voltage interruption by the seat switch and supplies temporary voltage to the safety circuit to keep the engine running (Fig. 398). Fig 398 DSC-2532 3.
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ELECTRICAL Hour Meter How It Works Purpose Since a normal clock might be affected by variations in voltage and current, the hour meter is made up 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-energizes the coil so that the cycle can start over (Fig. 401).
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ELECTRICAL Electric PTO Clutch Coil Resistance Measurement Purpose 1. Disengage the PTO, set the parking brake, turn the ignition to the “off” position and remove the ignition key. The electric clutch controls the engagement and disengagement of the Power Take Off (PTO) pulley. 2. Disconnect the clutch harness from the main harness. Location 3. Set the multimeter or volt/ohm meter to check resistance (ohms). The electric clutch is located on the PTO end of the crankshaft. 4.
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ELECTRICAL Measuring Clutch Current Draw 7. Turn the ignition switch to the “RUN” position. Turn the PTO switch to the “ON” position. 1. Disengage the PTO, set the parking brake, turn the ignition key to OFF, and remove the key. 2. Disconnect the PTO clutch harness from the main harness. 3. Set the multimeter to check amps (10 amp scale). 8. If the meter reading is 6.5 amps or above, the system is functioning properly. If the meter reading is below 6.5 amps, check the electrical system for problems (i.e.
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ELECTRICAL How It Works Testing The solenoid has two primary parts. One is a coil of wire wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part is a bar type switch (Fig. 405). 1. Disconnect the solenoid from the wiring harness. 2. With a multimeter (ohms setting), check to ensure that terminals “C” and “D” are open (no continuity) (Figure 20). 3. Apply +12 VDC between terminal “A” and ground terminal “B”.
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ELECTRICAL Fuse Block Purpose House the electrical system fuses. Location Located below the control panel on the left hand side of the frame (Fig. 407). A B C Fig 407 PICT-0202 A. Main circuit (30 amp) B. Charge circuit (25 amp) C. Optional head light kit circuit (10 amp) 6 How It Works The fuse block contains the fuses that protect the system from electrical surges.
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ELECTRICAL 74412 Schematics 6 Wire Diagram (Rev.
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ELECTRICAL 74410 Schematics 6 Wire Diagram (Rev.
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ELECTRICAL 74411 Schematics 6 Wire Diagram (Rev.
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ELECTRICAL 74413 and 74415 Schematics 6 Wire Diagram (Rev.
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ELECTRICAL 74414 Schematics 6 Wire Diagram (Rev.
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ELECTRICAL 74416 and 74417 Schematics 6 Wire Diagram (Rev.
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PTO CLUTCH GND BK BK BN VIO (NEUTRAL) SW5 W SW4 (NEUTRAL) SHOWN WITH PARK BRAKE DISENGAGED SW3 (BRAKE) VIO Y SHOWN WITH LEVER IN NEUTRAL POSITION SHOWN WITH LEVER IN NEUTRAL POSITION Y SHOWN IN OFF POSITION GY BN SW2 (PTO) X I S OR BK P1–B T Y K2 (START RELAY) P2–C SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT TERMINAL VIEW FROM BACK OF SWITCH B A KEY SW Y P1–A DELAY MODULE 100–6186 P1–C PK OFF ON START OR BN HOUR METER GY PK OR BN PK PK 2 5 KAWASAKI TWIN AIR–COOLED X
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GND PTO CLUTCH SW5 (NEUTRAL) W SW4 (NEUTRAL) VIO Y SHOWN WITH LEVER IN NEUTRAL POSITION SHOWN WITH LEVER IN NEUTRAL POSITION VIO I S OR BK P1–B T Y K2 (START RELAY) P2–C SW6 (SEAT SW) SHOWN WITH OPERATOR IN SEAT TERMINAL VIEW FROM BACK OF SWITCH P1–A DELAY MODULE 100–6186 P1–C PK X B A KEY SW Y OR BN HOUR METER GY PK OR BN PK PK F1 30A Y BK K1 (KILL RELAY) BU GN R R B GYW F2 25A VIO A F3 OIL GN GND FUEL PK BK REG VIO T VIO W Y BLUE GREEN GREY ORANGE BU
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MOWER DECKS/PTO Safety Information . . . . . . . . . 1 Specifications . . . . . . . . . . . 2 Chassis . . . . . . . . . . . . . . 3 Hydraulic System . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . 5 Electrical . . . . . . . . . . . . . . 6 Mower Decks/PTO . . . . . . . . .
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MOWER DECKS/PTO Mower Deck Removal 4. Remove the belt from the electric PTO clutch (Fig. 410). Estate Series 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2. Lift the floor pan and remove the right side mower belt cover (Fig. 408). Fig 410 PICT-0122 5. Raise the mower deck to the transport position. Place 4 x 4 wood blocks under the edge of the mower deck. Lower the mower deck to relieve the tension on all four lift chains (Fig. 411).
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MOWER DECKS/PTO 6. Remove the front and rear lift chains from the mower deck (Fig. 412). 8. Secure the cross brace to the frame so it is out of the way when removing the mower deck. 9. Raise the lift lever to the transport position. 10. Remove the 4 x 4 wood blocks from under the deck. 11. Turn the right front wheel so the castor fork is angled forward. This will allow more clearance to slide the mower deck out from under the frame (Fig. 414). Fig 412 PICT-0126 7.
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MOWER DECKS/PTO Mower Deck Installation 5. Install the cross brace to the deck using the hardware as shown (Fig. 417). Estate Series 1. Slide the deck under the unit. B 2. Place 4 x 4 wood blocks under the edge of the mower deck. 3. Position the lift handle to the lowest position and pin in place (Fig. 416). A C Fig 417 A. Bolt B. Bushing D PICT-0143 C. Washer (2) D. Nut 6. Attach the front and rear lift chains to the mower deck (Fig. 418). Fig 416 PICT-0138 4.
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MOWER DECKS/PTO 7. Raise the deck to the transport position. Remove the 4x4 wood blocks. 8. Set the lift handle at the 3” (7.6cm) height-of-cut position. Pin in place (Fig. 419). 10. Insert a ratchet with a short extension or a breaker bar into the square hole in the fixed idler arm. Rotate the ratchet or breaker bar counterclockwise to move the fixed idler arm until you feel increased resistance and the spring-loaded idler pulley stops moving.
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MOWER DECKS/PTO Mower Deck Removal 4. Remove the belt from the electric PTO clutch (Fig. 425). Z 400 Series (48” and 50” Decks) 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2. Lift the floor pan and remove the right side mower belt cover (Fig. 423). Fig 425 PICT-0122 5. Raise the mower deck to the transport position. Place 4 x 4 wood blocks under the edge of the mower deck.
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MOWER DECKS/PTO 6. Remove the front and rear lift chains from the mower deck (Fig. 427). 8. Check the bolt, bushing and strut base for wear (Fig. 429). D C B A Fig 427 A B C Fig 429 PICT-0305 A. Bolt B. Bushing PICT-0312 rev C. Nut D. Strut base 7. Remove the right and left struts from the strut bases (Fig. 428). 9. Raise the lift lever to the transport position. 10. Remove the 4 x 4 wood blocks from under the deck. 11. Turn the right front wheel so the castor fork is angled forward.
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MOWER DECKS/PTO 12. Slide the mower deck out the right side of the unit (Fig. 431). Fig 431 2. Slide the deck under the unit. 3. Place 4 x 4 wood blocks under the edge of the mower deck (Fig. 433). PICT-0308 Fig 433 PICT-0304 Mower Deck Installation 4. Install the right and left struts into the strut bases. Z 400 Series (48” and 50” Decks) 1. Turn the right front wheel so the castor fork is angled forward. This will allow more clearance to slide the mower deck under the frame (Fig. 432).
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MOWER DECKS/PTO 5. Install the front and rear lift chains to the mower deck (Fig. 435). Fig 435 PICT-0305 6. Raise the deck to the transport position. Remove the 4x4 wood blocks. 8. Route the belt around the spindles, idler pulleys and the PTO clutch (Fig. 437). Fig 437 1. Fixed idler arm 4. 2. Square hole 5. 3. Fixed idler pulley 6. fig. 49 G001678 Mower belt Belt guide Spring-loaded idler pulley 7. Set the lift handle at the 3” (7.6cm) height-of-cut position. Pin in place (Fig. 436).
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MOWER DECKS/PTO 9. Insert a ratchet or breaker bar with a short extension into the square hole in the fixed idler arm. Rotate the ratchet or breaker bar counterclockwise to move the fixed idler arm until you feel increased resistance and the spring-loaded idler pulley stops moving. Note: Do not increase the belt tension beyond the point where the fixed idler arm stops. Tighten the nut on the slotted idler plate (Fig. 438). Fig 438 PICT-0315 10. Tighten the pivot bolt (Fig. 439).
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MOWER DECKS/PTO 4. Remove the belt from the electric PTO clutch (Fig. 442). Fig 442 6. Remove the four sets of bolts, spacers and washers holding the front and rear lift chains to the mower deck (Fig. 444). PICT-0122 Fig 444 5. Raise the mower deck to the transport position. Place 4 x 4 wood blocks under the edge of the mower deck. Lower the mower deck to relieve the tension on all four lift chains (Fig. 443). PICT-0377 7. Remove the nut and bolt holding the strut pin to the deck (Fig. 445).
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MOWER DECKS/PTO 8. Remove the strut pin (Fig. 446). Note: The gauge wheels may need to be loosened or removed to remove the strut pin. 12. Slide the mower deck out the right side of the unit (Fig. 448). Fig 448 Fig 446 PICT-0382 PICT-0380 Mower Deck Installation 9. Raise the lift lever to the transport position. Z 100 Series (44” Deck) 10. Remove the 4 x 4 wood blocks from under the deck. 1. Turn the right front wheel so the castor fork is angled forward.
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MOWER DECKS/PTO 2. Slide the deck under the frame. 3. Place 4 x 4 wood blocks under the edge of the mower deck (Fig. 450). 5. Install the nut and bolt that holds the strut pin to the deck (Fig. 452). Fig 452 Fig 450 PICT-0379 PICT-0394 6. If needed tighten the anti-scalp roller bolts. 4. Install the right and left strut pins (Fig. 451). Note: The gauge wheels may need to be loosened or removed to install the strut pin. 7. Set the lift handle at the 3” (7.6cm) height-of-cut position. Pin in place (Fig.
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MOWER DECKS/PTO 8. Route the belt around the spindles, idler pulleys and the PTO clutch (Fig. 454). Fig 454 10. Lower the lift lever. 11. Install the lift chains with the four sets of bolts, spacers and washers that hold the front and rear lift chains to the mower deck (Fig. 456). 108-4050 9. With a spring puller, install the extension spring to the idler arm assembly (Fig. 455). Fig 456 PICT-0377 12. Install the left and right deck belt covers (Fig. 457).
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MOWER DECKS/PTO Mower Spindle Removal 6. With a spring puller, remove the spring from the idler arm assembly to remove tension on the belt (Fig. 459). Pro 100 Series This applies to removing any of the three mower spindles. This procedure shows removing the right side spindle. 1. Raise the front of the mower. Note: The mower deck was removed for photo clarity. 2. Chock or block the drive wheels. 3. Disconnect the battery negative cable. 4. Lower the mower deck to the lowest position. 5.
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MOWER DECKS/PTO 9. Remove the nut, washer, key, and pulley from the spindle shaft (Fig. 461). Fig 461 11. Remove spindle from mower deck (Fig. 463). Fig 463 PICT-0387 PICT-0385 10. Remove the mower blade. Remove the 4 bolts that mount the spindle to the deck housing (Fig. 462). Mower Spindle Installation Pro 100 Series Reverse the order of mower spindle removal Mower Spindle Removal Estate Series and Pro 400 Series This applies to removing any of the three mower spindles.
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MOWER DECKS/PTO 5. Lift the floor pan and remove the right side mower belt cover (Fig. 464). Fig 464 PICT-0116 6. Loosen the two nuts located on the idler plate to remove tension on the belt (Fig. 465). Fig 465 7. Slip the mower drive belt off the right mower spindle pulley (Fig. 466). Fig 466 8. Lock the blade in position with a 4 x 4 wood block and remove the three bolts retaining the pulley to the pulley hub (Fig. 467).
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MOWER DECKS/PTO 9. Remove the blade (Fig. 468). Mower Spindle Installation Note: Mower deck was removed for photo clarity. Estate Series and Pro 400 Series Reverse the order of mower spindle removal Mower Spindle Disassembly Estate Series and Pro 400 Series 1. Remove the nut and washer (Fig. 470). Fig 468 PICT-0133 10. Remove the six bolts and nuts from the spindle assembly (Fig. 469). Fig 470 PICT-0153 rev 2. Remove the pulley hub and square key (Fig. 471). 7 Fig 469 PICT-0134 11.
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MOWER DECKS/PTO 3. Remove the bearing shield and thrust washer (Fig. 472). Fig 472 PICT-0158 4. Remove the spindle housing from the spindle shaft assembly (Fig. 473). 5. Remove the ball bearing from the top of the spindle housing (Fig. 474). Fig 474 6. Remove the bearing spacer (Fig. 475).
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MOWER DECKS/PTO 7. Remove the ball bearing from the bottom of the spindle housing (Fig. 476) Note: On later production models the bottom ball bearing may be locked into place with a chemical locking compound or half the bearing race may be press-fit into the spindle housing. If a chemical locking compound is used, the lower housing may require heat to release the locking compound. Mower Spindle Assembly Estate Series and Pro 400 Series 1. Install the bottom bearing: For a press-fit bearing: 2.
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MOWER DECKS/PTO For a compound locked bearing: b. Thoroughly clean the spindle housing and the outer race of the bearing. c. 3. Install the bearing shield and thrust washer onto the spindle shaft (Fig. 480). Apply an even coat of chemical locking compound to the outer race and inner spindle housing (Fig. 478). Caution: DO NOT get chemical locking compound on the inside of the bearing. Fig 480 PICT-0173 rev 4. Install the housing (bearing installed) onto the spindle shaft (Fig. 481).
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MOWER DECKS/PTO 5. Install the bearing spacer into the spindle housing opening (Fig. 482). Fig 482 PICT-0176 rev 6. Install the upper ball bearing with the open end of the bearing to the inside of the housing (Fig. 483). 7 Fig 483 7. Install the upper thrust washer and bearing shield onto the spindle shaft (Fig. 484). Fig 484 8. Install the pulley hub onto the spindle shaft. Note: The raised center of the hub faces away from the spindle (Fig. 485).
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MOWER DECKS/PTO 9. Install the key into the spindle shaft (Fig. 486). Fig 486 11. Torque the top nut to 100 to 120 ft-lbs. (135.6 to 162.7 Nm) (Fig. 488). PICT-0184 Fig 488 10. Install the washer and the nut onto the spindle shaft (Fig. 487). PICT-0187 Mower Spindle Disassembly Z 100 Series (44” Deck) 1. Remove the spindle shaft, bearing shield and hardened washer from the spindle housing assembly (Fig. 489).
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MOWER DECKS/PTO 2. Remove the spindle bearings and spacer (Fig. 490) A 2. Lift the floor pan and remove the mower belt covers (Fig. 491). B C B Fig 490 A. Spindle housing B. Bearings (2) PICT-0390 Fig 491 PICT-0116 C. Spacer 3. Loosen the two nuts located on the idler plate to remove tension on the belt (Fig. 492).
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MOWER DECKS/PTO 4. Remove the worn/broken belt. 7. Route the belt around the idlers as shown (Fig. 495). 5. Route the new belt through the left side belt guide (Fig. 493). Fig 495 Fig 493 PICT-0188 6. Install the new belt onto the electric PTO clutch (Fig. 494). 1. Ratchet with short extension or breaker bar fig. 47 G001679 2. Square hole 8. Insert a ratchet with a short extension or a breaker bar into the square hole in the fixed idler arm.
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MOWER DECKS/PTO 9. Tighten the nut on the slotted on the idler plate (Fig. 496). Replacing the Mower Deck Drive Belt Z 100 Series 1. Disengage the PTO, move the motion control levers to the neutral locked posistion, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the belt covers over the outside spindles. 4. Loosen the outer nut on the spring eye bolt (Fig. 498). Fig 496 PICT-0147 10.
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MOWER DECKS/PTO 5. Remove the old belt. Note: Start at the outside pulley and rotate the belt off (Fig. 499). 9. Tighten the outer nut on the spring eye bolt (Fig. 498). Note: Check the spring length. The spring should measure 9-3/8 + 1/8 inch (238 + 3mm) with belt installed. Adjust it if it does not (Fig. 498). 10. Install the belt covers over the outside spindles. Adjusting the Mower Belt Tension Z 100 Series 1.
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MOWER DECKS/PTO 5. Install the belt covers over the outside spindles. 6. Tighten the outer nut on the spring eye bolt (Fig. 500). Note: Check the spring length. The spring should measure 9-38 + 1/8 inch (238 + 3mm) with belt installed. Adjust it if it does not (Fig. 500). 5. To increase the belt tension, rotate the ratchet or breaker bar counterclockwise to move the fixed idler arm until you feel increased resistance and the spring-loaded idler pulley stops moving (Fig. 502).
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MOWER DECKS/PTO Leveling the Mower at 3 Postions Leveling the Mower Side-to-Side Setting Up the Machine 1. Position the right blade side-to-side (Fig. 503). All models 1. Position mower on a 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 leaving the operating position. 4. Check tire pressure of all four tires. If needed, adjust to 13 psi (90kPa).
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MOWER DECKS/PTO 7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Fig. 504). Fig 504 1. 2. 3. 4. Rear chain Rear support arm Bolt Jam nut 8. Loosen the jam nut under the rear support arm and turn the adjustment bolt to get a measurement of 31/8 to 3-1/4 inches (79 - 83mm) (Fig. 504). Note: It is recommended that both sides of the mower are adjusted the same distance. 9.
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MOWER DECKS/PTO 7. Loosen the front swivel jam nuts, at the front of the right and left swivels, approximately 1/2 inch (13mm) (Fig. 504). 8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10mm) lower in front at A than in the rear at B (Fig. 504). 9. Tighten both swivel jam nuts against the front swivel to lock the height. 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 506).
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Z Master Z400 Series Service Manual Form No.