Form No. 3438-778 Rev A 2000 Series Z MASTER® Service Manual Published: November 2020 © 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 2000 Series Z MASTER® Service Manual 3438-778 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 2000 Series Z MASTER® Service Manual 3438-778 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 ........................................................................................................................... 2–5 Equivalents and Conversions........................................................................................................... 2–10 U.S.
Specifications Configuration Model 2000 Series 74490 74491 Engine 74492 Toro Engine Type Toro V-Twin 708CC Engine Model LCP77F High Idle 3600 ± 100 RPM Low Idle 1800 ± 150 RPM (Governor Set) Spark Plug Champion: RN9YC/NGK: BPR6ES Oil Capacity 2.4 L (80 oz.) with filter change CARB No EPA Yes Fuel Capacity 26.5 L (7 gallons) Battery 12 volt - 300 CCA Hydraulic Drive System Transmission ZT3400 Transmission Lubricant 4.45 L (150 oz.
Configuration Model 2000 Series 74493 74494 Engine Toro Engine Type Toro V-Twin 708CC Engine Model LCP77F High Idle 3600 ± 100 RPM Low Idle 1800 ± 150 RPM (Governor Set) Spark Plug Champion: RN9YC/NGK: BPR6ES Oil Capacity 2.4 L (80 oz.) with filter change CARB No EPA Yes Fuel Capacity 26.5 L (7 gallons) Battery 12 volt - 300 CCA Hydraulic Drive System Transmission Transmission Lubricant ZT3800 4.45 L (150 oz.
Configuration Model 2000 Series 74495 74496 Engine 74497 Kawasaki Engine Type Kawasaki FX 726CC Engine Model FX730V High Idle 3750 ± 50 RPM Low Idle 1550 (Governor Set) Spark Plug NGK: BPR6ES Oil Capacity 2.1 L (71 oz.) with filter change CARB Yes EPA Yes Fuel Capacity 26.5 L (7 gallons) Battery 12 volt - 300 CCA Hydraulic Drive System Transmission Transmission Lubricant ZT3400 4.45 L (150 oz.
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 2–6 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 2–12 2000 Series Z MASTER® Service Manual 3438-778 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 2000 Series Z MASTER® Service Manual 3438-778 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. Set the parking brake. The motion-control levers are not in the Neutral-Lock position.
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 The blades do not rotate Troubleshooting: General Troubleshooting Possible Cause Corrective Action The engine load is excessive. Reduce the ground speed. The oil level in the crankcase is low. Add oil to the crankcase.
General Troubleshooting (continued) Problem The clutch does not engage 2000 Series Z MASTER® Service Manual 3438-778 Rev A Possible Cause Corrective Action The fuse is blown. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. There is a low voltage supply at the clutch. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary. The coil is damaged.
Troubleshooting: General Troubleshooting Page 3–6 2000 Series Z MASTER® Service Manual 3438-778 Rev A
Chapter 4 Engine Table of Contents General Information .............................................................................................................................. 4–2 Service and Repairs ............................................................................................................................. 4–3 Toro Twin Cylinder Engine Replacement............................................................................................ 4–5 Kawasaki Engine Replacement .............
General Information The 2000 Z MASTER® series of mowers use the 708cc V-Twin as well as the 726cc Kawasaki V-Twin. Either selection is a 4 Cycle, OHV 90º carburetor engine. All engine selections utilize a heavy duty air cleaner.
Service and Repairs Toro Engine Assembly g337394 Figure 3 1. Rain Cap Kit 2. 3. Air Cleaner Asm Air Canister Strap 8. Engine Sheave 9. 10. Clutch Anchor PTO Clutch 4. Intake Hose 11. Flat Idler Pulley 5. 2P77F—HD Engine 12. Idler Pivot Bushing 6. 7. Muffler Key 13. 14.
Kawasaki Engine Assembly g337393 Figure 4 1. Kawasaki Engine 7. Clutch Anchor 2. Engine Oil Drain Hose Asm 8. Clutch 3. Exhaust Gasket 9. Flat Idler Pulley 4. Muffler 10. Idler Pivot Bushing 5. Key 11. Idler Arm Asm 6. Sheave 12.
Toro Twin Cylinder Engine Replacement Toro Twin Cylinder 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. Close the fuel supply valve. 4. Remove the engine guard. 5. Remove the mower belt. Mower Belt Replacement (page 6–6) 6.
Toro Twin Cylinder Engine Removal (continued) g335899 Figure 7 10. Disconnect the fuel supply line at the fuel filter. g335900 Figure 8 11. Disconnect the throttle cable. Throttle Cable Assembly Replacement (page 5–20) 12. Disconnect the choke cable. Choke Control Assembly Replacement (page 5–22) 13. Disconnect the clutch wire from the clutch. 14. Remove the clutch mounting bolt and washers. Slip the clutch off of the crankshaft.
Toro Twin Cylinder Engine Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Install the muffler and 2 new exhaust gaskets. 3. Install the muffler nuts. Torque the muffler nuts to 16–18 N • m (12 ± 14 ft-lb). 4. Lower the engine onto the frame. 5. Align the four holes of the engine base to the frame. Install the rear mounting bolts and Belleville washers loosely. 6. Install the 2 front bolts and Belleville washers through the clutch anchor and into the engine base. 7.
Toro Twin Cylinder Engine Installation (continued) g335899 Figure 10 17. Connect the red (B+) wire to the starter. g335895 Figure 11 18. Connect the chassis wire harness to the main engine wire harness.
Toro Twin Cylinder Engine Installation (continued) g335893 Figure 12 19. Connect the fuel supply line to the fuel filter. 20. Install the engine guard. 21. Open the fuel supply valve. 22. Fill the crankcase with approved oil and verify proper oil level. 23. Connect the battery by installing the positive cable first, then the negative cable to the battery. 24. Verify proper function of the unit. Note: Verify engine speed is set to 3600 ± 50 RPM (or 3000 ± 50 RPM for TE models).
Kawasaki Engine Removal (continued) g335893 Figure 13 8. Disconnect the red (B+) wire from the starter. g335895 Figure 14 9. Disconnect the black engine ground wire.
Kawasaki Engine Removal (continued) g335899 Figure 15 10. Disconnect the fuel supply line at the fuel filter. g337830 Figure 16 11. Disconnect the throttle cable. Throttle Cable Assembly Replacement (page 5–20) 12. Disconnect the choke cable. Choke Control Assembly Replacement (page 5–22) 13. Disconnect the clutch wire from the clutch. 14. Remove the clutch mounting bolt and washers. Slip the clutch off of the crankshaft.
Kawasaki Engine Installation 1. Prepare the frame and secure any fuel lines or wire harness components. 2. Install the muffler and new exhaust gaskets. Torque the muffler mounting bolts or nuts to 16-19 N • m (13 ft-lb). 3. Install the oil drain hose assembly. Torque oil drain hose (at engine block) to 31-40 N • m (26 ± 3 ft-lb). 4. Lower the engine onto the frame. 5. Align the four holes of the engine base to the frame. Install the 2 rear mounting bolts and Belleville washers loosely. 6.
Chapter 5 Chassis Table of Contents General Information .............................................................................................................................. 5–2 Service and Repairs ............................................................................................................................. 5–3 Caster Fork and Bearing Replacement .............................................................................................. 5–9 Caster Wheel Replacement ..............
General Information The 2000 Z MASTER® series of mowers use a one-piece fully welded frame. All models use a foldable ROPS system.
Service and Repairs Chassis Assembly 1 g335781 Figure 17 1. Tapered ROPS Asm 4. Suspension 60 inch Frame 2. Front Plate 5. Light Bracket 3. Push-In Bumper 6.
Chassis Assembly 2 g335763 Figure 18 1. Control Panel Asm 11. RH Console Support 2. 3. 4. Choke Control Cable Ball Knob Throttle Control Cable 12. 13. 14. Rear Guard Asm Muffler Guard RH Pod Support Bracket 5. Truss Screw 15. Rear Weight 6. 7. RH Guard Bracket Rear Upper Trim 16. 17. LH Guard Bracket RH Motion Control Cover Truss Screw RH Pod Cover RH Console 18. 19. 20. LH Console Bracket LH Console LH Pod Support Bracket 8. 9. 10.
Chassis Assembly 3 g335767 Figure 19 1. 2. Fuel Hose Asm Fuel Cap 2000 Series Z MASTER® Service Manual 3438-778 Rev A 3. 4.
Chassis Assembly 4 g335769 Figure 20 1. Suspension Seat Asm 4. Seat Pan and Latch Asm 2. Seat Pivot Pin 5. Seat Bumper 3. Rubber Seat Guard 6.
Chassis Assembly 5 g337405 Figure 21 1. 2. Fixed Seat Adj Mounting Platform 11. 12. Floor Mat Front Subframe 3. Cam Lock Asm 13. Trailing Arm 4. Seat Plate 14. Trailing Arm Tube 5. Rubber Flap 15. RH Trailing Arm Bracket 6. Backer Plate 16. Bumper 7. 8. Rear Subframe Lower Mount Bracket 17. 18. Pivot Rod LH Trailing Arm Bracket 9. LH Upper Shock Mount Bracket 19. Tank Bracket Shock Spring 20. Lower Front Shock Bracket 10.
Chassis Assembly 6 g335890 Figure 22 1. Grease Cap Chassis: Service and Repairs 2.
Caster Fork and Bearing Replacement Caster Fork and Bearing 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. Raise and support the unit so that the front wheels are off the ground. 3. Remove the caster cap. 4. Support the underside of the caster wheel and remove the fastener screw securing the caster bearing assembly. 5. Remove the caster fork from the front axle.
Caster Wheel Replacement Caster Wheel Disassembly g336095 Figure 23 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. Raise and support the unit so that the front wheels are off the ground. 3. Remove the caster wheel from the caster fork. 4. Remove the seal guards from the wheel hub. 5.
Caster Wheel Assembly (continued) 7. Apply thread locker to the second spacer nut and thread onto the axle. 8. Torque 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.
Left Console Removal (continued) g336093 Figure 25 8. Lift the console upward off of the machine. 9. Install the fuel cap. Left Console Installation 1. Remove the fuel cap from the gas tank. 2. Lower the console into place, ensuring that it seats properly on the support. 3. Install the keeper line into the fuel cap, and reinstall the fuel cap. 4. Install the 2 bolts and nuts through the support bracket. 5. Install the 2 (T25) screws through the console bracket. g336092 Figure 26 6.
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 shoulder bolt (T30) at the front of the console. g336084 Figure 27 4. Remove the 2 bolts on the front of the console. 5.
Right Console Removal (continued) g336085 Figure 28 Right Console Installation 1. Lower the console into place, while moving the control panel assembly through the opening in the console and into position. Ensure that the console seats properly on the supports. Note: Before securing the control panel to the console, ensure that all cables and electrical connections are seated firmly in place on the underside of the control panel assembly. g336086 Figure 29 2.
Right Console Installation (continued) g336084 Figure 30 5. Install the 2 bolts and nuts on the front console. 6. Install the shoulder bolt (T30) at the front of the console. 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. Seat Replacement Seat 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.
Seat Removal (continued) g336087 Figure 31 1. Bolt 2. Seat Pivot 6. Unlatch the seat, then move the seat rearward, out of the way of the motion control box. Lift the seat off of the machine. Seat Installation 1. Place the seat on top of the fuel tank retainer plate. 2. Move the seat forward, aligning the holes in the seat pan with the holes in the motion control box. Note: Make sure the flange bushing is present in each side of the seat pan. 3.
Fuel Tank Removal (continued) g336089 Figure 32 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. Close the fuel supply valve. g336090 Figure 33 4. Remove the right and left side consoles. Right Console Replacement (page 5–13) Left Console Replacement (page 5–11) 5.
Fuel Tank Removal (continued) g336088 Figure 34 1. Vent Hose Assembly 2. Fuel Supply Line 3. Fuel Shut-Off Valve 9. Lift the fuel tank assembly from the machine by sliding the tank rearward and up, away from the frame. Fuel Tank Installation 1. Position the fuel tank assembly onto the frame with the vent ports toward the rear of the machine. 2. Connect the 2 vent lines to the fuel tank. 3. Connect the fuel supply line to the fuel tank and route the fuel line in the detents molded into the tank.
Fuel Tank Installation (continued) 7. Open the fuel supply valve. g336052 Figure 36 8. Connect the battery by installing the positive cable first, then the negative cable to the battery. 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. Fold the ROPS assembly into the upright position and lock in place.
ROPS (Roll Over Protection System) Removal (continued) 4. Lift the ROPS assembly off of the machine. ROPS (Roll Over Protection System) Installation 1. Lift the ROPS assembly into position on the rear side of the mounting support. 2. Install the 4 mounting bolts. Note: Orientation of the ROPS hardware is critical. Make sure that the bolts are orientated g336054 Figure 38 3. Torque the ROPS connecting hardware to 122–135 N •m (95 ± 5 ft-lb). 4. Install the right and left consoles.
Throttle Cable Assembly Removal (continued) g336055 Figure 39 5. Remove the 2 bolts and nuts securing the throttle control assembly to the control panel assembly. 6. Loosen the clamp securing the throttle cable to the throttle plate. g336056 Figure 40 7. Remove the throttle cable from the throttle plate, noting the position of the cable in the plate. 8. Pull the throttle cable assembly through the console and out of the machine. Throttle Cable Assembly Installation 1.
Throttle Cable Assembly Installation (continued) g336057 Figure 41 2. Attach the throttle cable assembly to the control panel assembly using 2 bolts and nuts. 3. Install the knob on the throttle lever. 4. Install the control panel assembly into the console. 5. Move the throttle control lever to the slow idle position. 6. Place the Z-bend of the throttle cable in the throttle plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8.
Choke Control Assembly Installation (continued) 2. Thread the jam nut over the choke cable up to the control panel assembly. g336058 Figure 42 3. Attach the choke cable assembly to the control panel with the jam nut. 4. Install the control panel assembly into the console. 5. Move the choke control lever to the open position (down). 6. Place the Z-bend of the choke cable in the choke plate on the engine in the position previously noted. 7. Place the cable under the cable clamp. 8.
Park Brake Handle Assembly Removal (continued) g336059 Figure 43 1. Locking Cotter Pin 2. Bolt 3. Flange Nut 6. Remove the bolt and flange nut from the park brake lever assembly. Park Brake Handle Assembly Installation 1. Connect the upper brake linkage to the brake shaft. 2. With the park brake handle hardware orientated as shown, install the bolt and flange nut. g336059 Figure 44 1. Locking Cotter Pin 2. Bolt 3. Flange Nut 3.
Park Brake Handle Assembly Installation (continued) g336060 Figure 45 4. Secure with a locking cotter pin. 5. Cycle the park brake lever to ensure that it locks in the engaged position. 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. Adjusting the Park Brake 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.
Adjusting the Park Brake (continued) 6. Check both spring lengths, if adjustment is necessary, turn the top nut clockwise to shorten and counterclockwise to lengthen. The spring length should measure 44 mm (1.75 inch). g336039 Figure 47 1. Flange Nut 2. Compression Spring 3. Lower Brake Linkage 7. Re-check the spring length to ensure both springs are tensioned equally. 8. Disengage the parking brake by pushing the park brake handle all the way forward and down. 9.
Motion Control Damper Removal (continued) g336040 Figure 48 1. Bolts 2. Motion Control Damper 3. Remove the motion control damper from the machine. Motion Control Damper Installation 1. Position the motion control damper on the outside of the frame mounting tab. g336041 Figure 49 2. Torque the rear mounting bolt to 237-305 N • m (200 ± 25 in-lb).
Motion Control Damper Installation (continued) 3. Torque the front mounting bolt to 108-135 N• m (90 ± 10 in-lb). Motion Control Assembly Replacement Motion Control Assembly Removal g336042 Figure 50 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. 2. Raise and support the unit so that the drive wheels are off the ground. Note: The console may be removed for easier access.
Motion Control Assembly Removal (continued) g337843 Figure 51 7. Disconnect the motion control assembly from the frame. g336044 Figure 52 8. 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. Adjust the neutral setting. 9. Lower the unit and verify proper function. 10. Adjust the tracking if necessary.
Adjusting the Motion Control Handle Position (continued) g336046 Figure 54 4. Align the levers front to back and secure the bolts. 5. Move the levers into the park position. 6. Verify proper function of the unit. Note: Motion control levers may be adjusted up or down for operator comfort by utilizing the additional mounting holes on the motion control assembly. The motion control levers should always be mounted on the inside of the motion control assembly. MYRIDE® Replacement MYRIDE® Removal 1.
MYRIDE® Removal (continued) g336047 Figure 55 5. Remove the shoulder bolt securing the front shock to the upper shock mount. 6. Place shoulder bolt back in upper mount and finger tighten with the lock nut. g336048 Figure 56 7. Attach the seat and sub-frame assembly to the overhead lift using three lift points.
MYRIDE® Removal (continued) g336049 Figure 57 8. Remove the 2 shoulder bolts securing the trailing arm to the lower ROPS tubes. 9. Using an overhead lift, raise the seat up about 30 cm (12 inches). 10. Disconnect the seat switch. 11. Lift the seat and sub-frame assembly up and away from the machine. MYRIDE® Installation 1. With the seat and sub-frame assembly attached to the overhead lift, lower the seat into the machine, leaving room under the seat. 2. Connect the seat switch. 3.
MYRIDE® Installation (continued) g336047 Figure 59 6. Lower the seat and sub-frame all the way onto the machine. 7. Disconnect the seat and sub-frame from the overhead lift. 8. Secure the front shock with a shoulder bolt. Note: Thread should be on the LH side of the machine (from operator’s position). g336051 Figure 60 9. Disconnect the seat and sub-frame from the overhead lift. 10. Install the 2 nuts securing the lower shock mounts to the ROPS tubes. Torque to 122 N • m (90 ± 9 ft-lb). 11.
Chapter 6 Deck Table of Contents General Information .............................................................................................................................. 6–2 Service and Repairs ............................................................................................................................. 6–3 Mower Belt Replacement ................................................................................................................... 6–6 Mower Deck Replacement ...........
General Information The 2000 Z MASTER® series of mowers use a TURBO FORCE® deck platform. All decks are 5 inch deep and constructed of 7ga sides and a 10ga top plate. The spindles are constructed with an 8 inch housing and 1 inch spindle shaft.
Service and Repairs 48 Inch Deck g337546 Figure 61 2000 Series Z MASTER® Service Manual 3438-778 Rev A Page 6–3 Deck: Service and Repairs
52 Inch Deck g337549 Figure 62 Deck: Service and Repairs Page 6–4 2000 Series Z MASTER® Service Manual 3438-778 Rev A
60 Inch Deck g337550 Figure 63 2000 Series Z MASTER® Service Manual 3438-778 Rev A Page 6–5 Deck: Service and Repairs
Mower Belt Replacement Mower 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. Lower the mower deck to the 76 mm (3 inch) height-of-cut position. 4. Remove the mower belt covers. 5. Remove the spring tension from the idler pulley. 6.
Mower Deck Removal (continued) • Raise the deck to the transport position. • Slowly loosen the adjusting screw on the lift assist spring until the screw can be removed. Save the screw for re-installation. 9. Remove the 2 bolts and nuts on each side of the machine. 10. Slide the deck out toward the right side of the machine. Mower Deck Installation 1. Place the deck on the ground on the right side of the machine. 2. Slide the deck into position under the machine. 3.
Mower Spindle Disassembly (continued) g336156 Figure 65 1. Bearing and Spacer Assembly 6. Belleville Washer 2. Taptite Screw 7. Blade Bolt 3. Bearing Shield 8. Washer 4. Spindle Shaft 9. Locknut 5. Pulley 3. 4. 5. 6. Remove the pulley. Remove the shaft from the spindle housing. Remove the bearing shield . Remove the bearing and the bearing spacer from the top of the spindle housing. 7. Flip over the spindle housing and remove the lower bearing. 8.
Mower Spindle Assembly (continued) Note: Brush grease completely around the outer seal of the bearing before installing the bearing seal. 8. Install the pulley to the spindle shaft. 9. Install the washer and nut. Torque the top nut to 136-149 N • m (105 ± 5 ft-lb). Mower Spindle Installation Note: Verify that the underside of the deck is clean before proceeding with the spindle installation. 1. Position the spindle against the deck and align the mounting holes. 2. Install 6 spindle mounting screws.
Leveling the Mower Deck (continued) 6. Measure between the outside cutting edges (blade tips) and the flat surface. If all measurements are not within 5 mm (3/16 inch), an adjustment is required and this procedure should be continued. 7. Rotate the blades so that they are perpendicular to the rear of the deck. Ensure the front blade tip is lower than the rear blade tip as indicated in the Block Height and Rake Table (step 12). g336158 Figure 67 1. Blades Front to Rear 2. Blade Tip 3.
Leveling the Mower Deck (continued) g336159 Figure 68 1. Block 7.3 cm (2.87 inch) 2. Welds Block Height and Rake Table Deck Size Block Height Rake All Mower Deck 7.3 cm (2.87 inch) 4.8 - 6.4 mm (3/16 - 1/4 inch) 13. Rotate the blades side-to-side so that they are parallel to the rear of the deck. 14. Loosen the leveling adjustment lock nuts on all 4 corners so that the deck is sitting squarely on the blocks. 15.
Deck: Service and Repairs Page 6–12 2000 Series Z MASTER® Service Manual 3438-778 Rev A
Chapter 7 Drive System Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Using the Drive Wheel Release Valves (Bypass Valves) ....................................................................
General Information The 2000 Z MASTER® series of mowers use ZT3400 and ZT3800 transaxles. Either transaxle is fully serviceable via spin on filter and remote reservoir.
Service and Repairs Drive System Assembly 1 g335888 Figure 69 1. Hydraulic Tank 6. Hydro Spacer 2. Hydraulic Hose 7. RH Transaxle Asm 3. Hydraulic Hose 8. Spacer Shaft 4. 5. Handle Knob Hydro Bypass Arm 9.
Drive System Assembly 2 g335889 Figure 70 8. Adjustable Yoke 9. Upper Brake Linkage 1. RH Control Handle Asm 2. RH Motion Control Asm 3. 4. 5. Brake Bracket Brake Shaft Spherical Bearing 10. 11. 12. Brake Lever LH Control Handle Asm LH Motion Control Asm 6. Damper 13. Lower Brake Linkage 7.
Using the Drive Wheel Release Valves (Bypass Valves) The drive wheel release valves are located on the left and right sides underneath the engine block. 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 park brake. 2. Locate the bypass levers behind the seat near the drive wheels, on the left and right side of the frame. 3.
Adjusting the Motion Control Linkage (Neutral Setting) (continued) g336201 Figure 72 1. Nut 1. Prior to starting the engine, push the deck lift pedal and remove the height-of-cut pin. Lower the deck to the ground. 2. Raise the rear of the machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. 3. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat.
Adjusting the Motion Control Linkage (Neutral Setting) (continued) 14. Raise the mower deck and install the height-of-cut pin. 15. Check for proper operation and ensure that the machine does not creep in neutral with the park brake disengaged. Tracking Adjustment 1. Disengage the PTO switch. 2. Drive to an open, flat area and move the motion control levers to the neutral-lock position. 3. Move the throttle midway between the FAST and SLOW positions. 4.
Hydrostatic Drive Belt Replacement Hydrostatic Drive Belt Removal 1. 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 unit so that the drive wheels are off the ground. 4. Remove the mower belt from the clutch. Mower Belt Replacement (page 6–6) 5.
Hydrostatic Drive Belt Installation (continued) 8. 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. 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 left and right consoles.
Hydrostatic Drive Transmission Removal (continued) g336197 Figure 75 13. Disconnect the hydraulic fluid hose from the top of the transmission. 14. Remove the bolt that connects the transmission to the cross shaft. 15. Remove the 2 front and rear hydro mounting bolts. g336195 Figure 76 1. Front and Rear Mounting Bolts 2. Cross Shaft 3. Axle Horn Bolts 16. Support the transmission, loosen and remove the two axle horn nuts and bolts. Lower the transmission.
Hydrostatic Drive Transmission Installation (continued) g336198 Figure 77 3. Install the front and rear hydro mounting bolts, washers, and nuts. Do not tighten at this time. Note: The proper torque sequence, as outlined below, is critical in avoiding damage to the hydrostatic transmission and the frame. 4. Tighten the cross shaft bolt and torque to 52-65 N • m (43 ± 5 ft-lb). 5. Tighten the rear hydro mounting bolt. 6. Tighten the 2 axle horn bolts. 7. Tighten the front hydro mounting bolt. 8.
Hydrostatic Drive Transmission Installation (continued) g336199 Figure 78 12. Install the drive belt. Hydrostatic Drive Belt Replacement (page 7–8) 13. Install the mower belt. Mower Belt Replacement (page 6–6) 14. Verify that the wheel hub nut is properly torqued, torque to 325-353 N • m (250 ± 10 ft-lb). 15. Install the drive wheel and torque the lug nuts, torque to 122-135 N • m (95 ± 5 ft-lb). 16. Add hydraulic oil to the reservoir to the FULL COLD line. 17.
Chapter 8 Electrical Table of Contents General Information .............................................................................................................................. 8–2 Service and Repairs ............................................................................................................................. 8–3 Fuse Block and Fuses ....................................................................................................................... 8–5 Key/Ignition Switch ......
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 1 g337720 Figure 79 1. USB Power Port 2. 3. Module Asm Ignition Key 8. Bungee Strap 9. 10. Switch Wire Harness 4. PTO Switch 11. Battery 5. 6. Rocker Switch Ignition Switch 12. 13. Wire Harness Bail Switch 7. USB Kit Wire Harness 14.
Electrical Assembly 2 g337721 Figure 80 1. USB Power Port 7. Bungee Strap 2. 3. Module Asm Ignition Key 8. 9. Switch Wire Harness 4. PTO Switch 10. Battery 5. Ignition Switch 11. Bail Switch 6. USB Kit Wire Harness 12.
Fuse Block and Fuses The fuse block houses the fuses that protect the electrical system from electrical surges. Note: Always use Toro fuses when replacing a damaged or blown fuse. g336412 Figure 81 Fuse Block and Fuses Test 1. Visually inspect the fuses. A failed fuse can be identified by a broken or melted element inside the fuse cover or a damaged spade. g336414 Figure 82 2. Using a digital multi-meter set to the OHM or Continuity setting, check the continuity between the fuse blades.
• 1- PTO Switch • 2- Operator Presence Switch, Safety Interlock Switches • 3- Starting Circuit • 4- Regulator, Charging Circuit • 5- Battery Voltage In g336416 Figure 83 Key/Ignition Switch Test 1. Remove the control panel from the right console. 2. Disconnect the ignition switch from the wire harness. 3. Using a digital multi-meter set to the OHM or Continuity setting, verify that continuity exists between the terminals listed for each switch position. 4.
Hourmeter Test (continued) g336418 Figure 84 Operator Presence Switch (Seat Switch) With the ignition switch in the RUN position, and the operator presence switch closed (operator is in the seat), battery voltage is supplied to the neutral switches. Note: The operator presence switch is part of the seat assembly. g336419 Figure 85 Operator Presence Switch (Seat Switch) Test 1. Disconnect the wire harness from the operator presence switch, located on the bottom of the seat assembly. 2.
Neutral Switch - Left and Right The neutral switch is a single pole plunger type switch (normally open) with two terminals. When the plunger is depressed, the circuit closes and there is continuity between the terminals. Motion control levers in neutral position (OUT), the switch will have continuity (closed). Motion control levers in the operating position (IN), the switch will NOT have continuity (open).
Starter Solenoid The solenoid is a remote switch that connects the battery to the starter motor when the ignition switch is turned to START. The solenoid protects the ignition switch from the high current drawn by the starter motor. g336406 Figure 88 Starter Solenoid Test 1. Disconnect the solenoid from the wiring harness. 2. With a multi-meter set to the OHM or continuity setting, check to ensure that terminals 1 and 2 are open (no continuity). 3. Apply 12 volts (DC) to terminal 3 and ground terminal 4.
g336408 Figure 90 Note: The engine will not crank over when the PTO switch is in the ON position. The PTO switch provides battery voltage from the ignition switch to the parking brake switch and the neutral switches as part of the safety interlock system. PTO Switch Test 1. Remove the control panel from the right console. 2. Disconnect the PTO switch from the wire harness. 3. With the switch in the ON position (button pulled OUT). g336409 Figure 91 4.
PTO Switch Test (continued) • Pin 1 and 4 should NOT have continuity (open) • Pin 2 and 5 should NOT have continuity (open) Electric PTO Clutch The PTO clutch electronically controls the engagement and disengagement of the PTO pulley (deck belt). The PTO clutch is composed of three major components: • Field • Clutch Plate • Friction Plate The clutch plate always turns with the engine (crankshaft). The field is a coil of wire on an iron core which becomes an electromagnet when power is applied.
Electric PTO Clutch Installation (continued) 2. Install the 2 spring washers and clutch bolt. Torque the clutch bolt to 66-83 N • m (55 ± 6 ft-lb). 3. Connect the clutch power wire to the clutch. Note: Verify the wire harness is properly routed to avoid contact with the mower belt or drive belt g336162 Figure 93 4. Connect the battery by installing the positive cable first, then the negative cable to the battery. 5. Lower the unit and verify proper function.
Electric PTO Clutch-Coil Resistance Measurement Test (continued) g336410 Figure 94 5. See the PTO Clutch Electrical Specifications chart. AMP Draw Continuity to Ground Series 2.84 4.23 OPEN 1500 and 2000 3.05 ± 5% 3.93 OPEN 2500 Resistance (OHMs) Electric PTO Clutch- PTO Clutch Continuity to Ground Test 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.
Electric PTO Clutch- PTO Clutch Continuity to Ground Test (continued) g336410 Figure 95 Electric PTO Clutch- Measuring Clutch Current Draw Note: Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. g336411 Figure 96 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.
Electric PTO Clutch- Measuring Clutch Current Draw (continued) PTO Clutch Electrical Specification Chart (continued) AMP Draw Continuity to Ground Series 2.84 4.23 OPEN 1500 and 2000 3.05 ± 5% 3.93 OPEN 2500 Resistance (OHMs) TVS Diode The TVS diode protects the electrical system from current surges caused by PTO engagement and disengagement.
Electrical: Service and Repairs Page 8–16 2000 Series Z MASTER® Service Manual 3438-778 Rev A
Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations........................................................................................................A–2 Electrical Schematic...........................................................................................................................A–3 Kawasaki Engine Electrical Schematic ..............................................................................................
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 g339610 , Drawing Rev A, Sheet 1 3438-778 Rev A Page A–3
Kawasaki Engine Electrical Schematic g339611 Page A–4 3438-778 Rev A , Drawing Rev , Sheet
