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Toro Z MASTER 4000 Series Service Manual
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Toro Z MASTER 4000 Series Service Manual

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© 2020—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
4000 Series Z MASTER® Service
Manual
Published: January 2021
Form No. 3442-427 Rev A
Contact us at www.Toro.com.
Original Instructions (EN)
All Rights Reserved

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Summary of Contents for Toro Z MASTER 4000 Series

  • Page 1 Form No. 3442-427 Rev A 4000 Series Z MASTER® Service Manual Published: January 2021 © 2020—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
  • Page 2 Revision History Revision History Page 2 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 3 The Toro Company RLC/SWS Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420 The Toro Company reserves the right to change product specifications or make changes to this manual without notice. 4000 Series Z MASTER® Service Manual Page 3...
  • Page 4 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. components) that may have been removed •...

  • Page 5: Table Of Contents

    Table of Contents Preface ........................ 3 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–7 Chapter 3: Troubleshooting ................3–1 General Troubleshooting ................3–3 Chapter 4: Engine ................... 4–1 General Information ..................
  • Page 6 Preface Page 6 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 4000 Series Z MASTER® Service Manual Page 1–1 Safety 3442-427 Rev A...

  • Page 8: Safety Instructions

    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.
  • Page 9 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…...
  • Page 10 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.
  • Page 11 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–7 Equivalents and Conversions......................2–12 U.S. to Metric Conversions ......................2–13 4000 Series Z MASTER® Service Manual Page 2–1 Specifications and Maintenance 3442-427 Rev A...

  • Page 12: Specifications

    Specifications Model 74000 74002 74004 74050 Engine 24.5 HP Kawasaki 25.5 hp Kawasaki Engine Type Carbureted 4 Cycle Engine Model FX751V FX801V High Idle 3750 ± 50 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR4ES Oil Capacity 2.3 L (2.4 US qt.) w/filter Fuel Capacity 37.8 L (10 gallons)
  • Page 13 Model 74054 74035 74052 74055 Engine 26.5 hp Kohler 25.5 hp Kawasaki 31 hp Kawasaki Command Pro Engine Type Carbureted 4 Cycle EFI 4 Cycle Carbureted 4 Cycle Engine Model FX801V ECV749 FX921V High Idle 3750 ± 50 RPM Low Idle 1550 ±...
  • Page 14 Model 74010 74015 74000TE 74000TA Engine 31 hp Kawasaki 24.5 hp Kawasaki Engine Type Carbureted 4 Cycle Engine Model FX921V FX751 High Idle 3600 ± 100 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR5ES NGK BPR4ES Oil Capacity 2.2 L (2.3 US qt) w/filter 2.3 L (2.4 US qt) w/filter Fuel Capacity...
  • Page 15 Model 74050TA 74054TA 74052TE 74055TE Engine 25.5 hp Kawasaki 31 hp Kawasaki Engine Type Carbureted 4 Cycle Engine Model FX801V FX921V High Idle 3600 ± 100 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR4ES NGK BPR5ES Oil Capacity 2.3 L (2.4 US qt) w/filter 2.2 L (2.3 US qt) w/filter Fuel Capacity...
  • Page 16 Model 74055TA Engine 31 hp Kawasaki Engine Type Carbureted 4 Cycle Engine Model FX921V High Idle 3600 ± 100 RPM Low Idle 1550 ± 100 RPM Spark Plug NGK BPR5ES Oil Capacity 2.2 L (2.3 US qt) w/filter Fuel Capacity 37.8 L (10 gallons) Battery 300 CCA...

  • Page 17: Torque Specifications

    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.
  • Page 18 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–8 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 19 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 5, & 8 Studes & Sems with Studs & Sems with Regular Studs &...
  • Page 20 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Thread Size Class 8.8 Bolts, Screws, Studs with Regular Class 10.9 Bolts, Screws, Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Height Nuts (Class 10 or stronger Nuts) in-lb N •...
  • Page 21 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 ±...
  • Page 22 Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 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...
  • Page 23 U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Measurement 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 Area Square Inches...
  • Page 24 Specifications and Maintenance: Torque Specifications Page 2–14 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 25 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 4000 Series Z MASTER® Service Manual Page 3–1 Troubleshooting 3442-427 Rev A...
  • Page 26 GEARS The Systematic approach to defining, diagnosing and solving problems. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...

  • Page 27: General Troubleshooting

    General Troubleshooting Problem Possible Cause Corrective Action The starter does not crank The blade control switch (PTO) is Move the blade-control switch (PTO) to engaged. the disengaged position. The parking brake is not engaged. Move the motion control levers to the neutral lock (Park) position.
  • Page 28 General Troubleshooting (continued) Problem Possible Cause Corrective Action The engine overheats The engine load is excessive. Reduce the ground speed or raise height-of-cut. The oil level in the crankcase is low. Add oil to the crankcase. A fuel related issue has resulted in a Diagnose the origin of the lean lean condition.
  • Page 29 General Troubleshooting (continued) Problem Possible Cause Corrective Action The blades do not rotate The mower deck belt is damaged, Install a new deck belt. worn, loose, or broken. The mower deck belt is off the pulley. Install the mower belt on the deck pulley and check the idler pulley, idler arm, and spring for correct position and function.
  • Page 30 Troubleshooting: General Troubleshooting Page 3–6 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 31 Chapter 4 Engine Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 Kawasaki Engine Replacement ......................4–5 4000 Series Z MASTER® Service Manual Page 4–1 Engine 3442-427 Rev A...

  • Page 32: General Information

    General Information The 4000 series Z MASTER® mowers use a variety of engines. All options are V-Twin 4 cycle engines 726cc, 852cc and 999cc Kawasaki carbureted engines and 747cc Kohler EFI engines. Engine: General Information Page 4–2 4000 Series Z MASTER® Service Manual 3442-427 Rev A...

  • Page 33: Service And Repairs

    Service and Repairs Engine Assembly 1 g338383 Figure 3 Kawasaki Engine Clutch Exhaust Gasket Clutch Anchor Engine Oil Drain Hose Asm Flat Idler Pulley Muffler Idler Arm Asm Transmission Pulley 4000 Series Z MASTER® Service Manual Page 4–3 Engine: Service and Repairs 3442-427 Rev A...
  • Page 34 Engine Assembly 2 g338446 Figure 4 Kohler Engine Clutch Anchor Oil Drain Hose Asm Clutch Kohler EFI Muffler Flat Idler Pulley Transmission Pulley Idler Arm Asm Engine: Service and Repairs Page 4–4 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 35 Kawasaki Engine Replacement Kawasaki Engine Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.
  • Page 36 Kawasaki Engine Removal (continued) 8. Disconnect the choke cable. Choke Cable Assembly Replacement (page 5–16) 9. Remove the deck belt. Deck Belt Replacement (page 6–4) 10. Remove the hydrostatic drive belt from the engine pulley. Hydrostatic Drive Belt Replacement (page 7–5) 11.
  • Page 37 Kawasaki Engine Removal (continued) g346048 Figure 9 15. Remove the vent line from the air cleaner, if applicable. 16. Disconnect the clutch wire from the clutch. 17. Remove the clutch mounting 7/16 inch bolt, 2 belleville washers, and flat washer. Slip the clutch off of the crankshaft. Note: Before removing the clutch, note the orientation of the clutch wire and the clutch.
  • Page 38 Kawasaki Engine Installation (continued) g346048 Figure 10 10. Connect the black engine ground wire. 11. Connect the red (B+) wire to the starter g346047 Figure 11 12. Connect the chassis wire harness to the main engine harness. Engine: Service and Repairs Page 4–8 4000 Series Z MASTER®...
  • Page 39 Kawasaki Engine Installation (continued) g346046 Figure 12 13. Install the hydrostatic drive belt to the engine pulley. Hydrostatic Drive Belt Replacement (page 7–5) 14. Install the deck belt. Deck Belt Replacement (page 6–4) 15. Connect the choke cable. Choke Cable Assembly Replacement (page 5–16) 16.
  • Page 40 Kawasaki Engine Installation (continued) g346044 Figure 14 19. Open the fuel supply valve. 20. Install the battery onto the machine. Hook the rubber strap securing the battery to the battery tray. 21. Connect the battery by installing the positive cable first, then the negative cable to the battery.
  • Page 41 Chapter 5 Chassis Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 Right Console Replacement ......................5–11 Left Console Replacement....................... 5–13 Throttle Cable Assembly Replacement .................... 5–15 Choke Cable Assembly Replacement....................5–16 Seat Replacement ........................... 5–17 MYRIDE® Replacement ........................5–20 Fuel Tank Replacement ........................

  • Page 42: General Information

    General Information The 4000 series Z MASTER® mowers use a one-piece, fully welded frame. All models use a foldable ROPS system. Chassis: General Information Page 5–2 4000 Series Z MASTER® Service Manual 3442-427 Rev A...

  • Page 43: Service And Repairs

    Service and Repairs Chassis Assembly 1 g338832 Figure 15 Rear Retainer Tank Plate Suspension Seat Asm Seat Pan Backer Plate Front Retainer Tank Plate 4000 Series Z MASTER® Service Manual Page 5–3 Chassis: Service and Repairs 3442-427 Rev A...
  • Page 44 Chassis Assembly 2 g338834 Figure 16 Rear Retainer Tank Plate Front Retainer Tank Plate Chassis: Service and Repairs Page 5–4 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 45 Chassis Assembly 3 g338879 Figure 17 ROPS Asm Floor Pan Asm Fixed Seat Floormat 60 Inch Frame Rubber Push-In Bumper Hydro Plate Toeboard Step 4000 Series Z MASTER® Service Manual Page 5–5 Chassis: Service and Repairs 3442-427 Rev A...
  • Page 46 Chassis Assembly 4 g338890 Figure 18 ROPS Asm Hydro Plate Toeboard Light Bracket Bumper Step 60 Inch Frame Chassis: Service and Repairs Page 5–6 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 47 Chassis Assembly 5 g341393 Figure 19 Fuel Vent Asm Fuel Cap Vent Hose Asm Fuel Tank Assembly Fuel Hose Asm 4000 Series Z MASTER® Service Manual Page 5–7 Chassis: Service and Repairs 3442-427 Rev A...
  • Page 48 Chassis Assembly 6 g341394 Figure 20 RH Handle Asm Brake Link Asm RH Motion Control Asm Handle Pivot RH Brake Rod Asm Brake Lever Asm with Grip Brake Asm LH Handle Asm Brake Bracket Switch Plate LH Brake Rod Asm LH Motion Control Asm Damper Chassis: Service and Repairs...
  • Page 49 Chassis Assembly 7 g341395 Figure 21 Seat Asm Subframe Asm Cam Lock Asm Floor Pan Seat Pan Isolator Cam Lock Knob Bearing Bracket Shock/Spring Asm Badge Plate Mounting Bracket Lower Shock Mount Floor Mat Backer Plate Trailing Arm Front Shock Asm 4000 Series Z MASTER®...
  • Page 50 Chassis Assembly 8 g342075 Figure 22 RH Cup Holder Rear Guard Asm RH Side Pod LH Rear Guard RH Console RH Cover Asm Choke Control Cable Cup Holder RH Rear Guard Asm LH Console Top Rear Guard LH Front Plate Cover Throttle Control Cable LH Cover Asm RH Front Plate Cover...

  • Page 51: Right Console Replacement

    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.
  • Page 52 Right Console Removal (continued) 9. Disconnect the wiring harness from the PTO switch. g346222 Figure 25 10. Pinch together the 2 tabs on the PTO switch. Pushing from the bottom side up, remove the PTO switch from the RH side pod. 11.

  • Page 53: Left Console Replacement

    Right Console Installation (continued) 6. Install the hourmeter onto the RH side pod. 7. Connect the wiring harness from the hourmeter. 8. Install the light switch, if applicable. 9. Install the choke cable onto the machine. Choke Cable Assembly Replacement (page 5–16) 10.
  • Page 54 Left Console Removal (continued) g346223 Figure 28 4. Disconnect the wiring harness from the USB charger. 5. Remove the 2 (5/16 inch) lock nuts and carriage bolts securing the LH console to the chassis. 6. Lift the LH console away from the machine. Left Console Installation 1.

  • Page 55: Throttle Cable Assembly Replacement

    Throttle Cable Assembly Replacement Throttle Cable Assembly Unit Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.

  • Page 56: Choke Cable Assembly Replacement

    Throttle Cable Assembly Unit Installation (continued) g346220 Figure 31 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. Choke Cable Assembly Replacement Choke Cable Assembly Unit Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key.

  • Page 57: Seat Replacement

    Choke Cable Assembly Engine Removal Note the position of the throttle clamp on the engine plate. 1. Remove the cable clamp screw securing the cable to the engine plate. Remove the clamp from the engine plate. 2. Disconnect the choke cable. 3.
  • Page 58 Seat Removal (continued) g348057 Figure 34 4. Remove the 2 (5/16 inch) torx screws securing the front tank retainer plate to the seat pan. g346224 Figure 35 5. Remove the 2 (5/16 inch) torx screws securing the front of the seat pan to the chassis.
  • Page 59 Seat Removal (continued) g346225 Figure 36 7. With assistance, lift the seat pan/seat assembly away from the machine. 8. Remove the 4 (5/16 inch) locks securing the seat pan to the seat assembly. Seat Installation 1. Install and tighten the 4 (5/16 inch) lock nuts securing the seat pan to the seat assembly.

  • Page 60: Myride® Replacement

    Seat Installation (continued) g346224 Figure 38 6. Install the 2 (5/16 inch) torx screws securing the rear seat pan to the chassis. g348057 Figure 39 7. Connect the battery by installing the positive cable first, then the negative cable to the battery. MYRIDE®...
  • Page 61 MYRIDE® Removal (continued) 6. Loosen (do not remove) the 2 (3/8 inch) lock nuts securing the lower mount of the rear shock to the ROPS. g348060 Figure 40 7. Loosen (do not remove) the 1/2 inch lock nut securing the front shock upper mount to the MYRIDE platform.
  • Page 62 MYRIDE® Removal (continued) g348084 Figure 42 11. Remove the ½ inch carriage bolt from the shock mount while supporting the front MYRIDE subframe. Reinstall the ½ inch carriage bolt with the MYRIDE subframe resting against the shock and tighten. g346226 Figure 43 12.
  • Page 63 MYRIDE® Installation (continued) 4. Install the 4 (5/16 inch) lock nuts securing the 2 (1 shown below) bearing brackets to the chassis. g348084 Figure 44 5. Close the 2 plastic clamps securing the fuel and vent lines. g348062 Figure 45 6.

  • Page 64: Fuel Tank Replacement

    MYRIDE® Installation (continued) g348060 Figure 46 8. With assistance, tip the seat forward and connect the seat switch. 9. Install the 4 (5/16 inch) lock nuts and carriage bolts securing the rear seat pan to the MYRIDE platform. 10. Connect the battery by installing the positive cable first, then the negative cable to the battery.

  • Page 65: Park Brake Handle Assembly Replacement

    Fuel Tank Installation (continued) 2. Install the vent line to the air filter. 3. Close the 4 plastic clamps securing the vent line. 4. Install the rear tank retainer plate to the chassis. 5. Install the fuel tank vent line to the fuel tank. Plug the fuel line, fuel outlet, and vent fitting.

  • Page 66: Rops (Roll Over Protection System) Replacement

    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.
  • Page 67 ROPS (Roll Over Protection System) Removal (continued) g346263 Figure 48 10. Lift the lower tubes away from the chassis. ROPS (Roll Over Protection System) Installation 1. Install the lower tubes onto the chassis. 2. Install the 4 (½ inch, 2 per side) bolts and lock nuts securing the lower tubes to the chassis.

  • Page 68: Caster Fork And Bearing Replacement

    ROPS (Roll Over Protection System) Installation (continued) 3. Install the upper ROPS assembly onto the machine. 4. While supporting the upper ROPS assembly, install the RH shoulder bolt securing the upper ROPS assembly to the lower ROPS assembly. Note: May need assistance to support the upper ROPS assembly. 5.

  • Page 69: Caster Wheel Rebuild

    Caster Wheel Rebuild Caster Wheel Disassembly g336095 Figure 50 Caster Fork Lock Nut Screw Wheel Assembly Seal Guard 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.

  • Page 70: Motion Control Assembly Replacement

    Caster Wheel Assembly (continued) 8. Torque the nut to 101–110 N•m (78 ± 3 in-lb) to seat the bearings, loosen, then torque to 27–35 N•m (23 ± 3 in-lb). Note: Make sure that the axle does not extend beyond the nut on either side of the wheel assembly.
  • Page 71 Motion Control Assembly Removal (continued) g337843 Figure 51 9. Disconnect the motion control assembly from the frame. g336044 Figure 52 10. Lower the motion control assembly through the frame toward the center of the machine, remove the assembly. Motion Control Assembly Installation 1.
  • Page 72 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.

  • Page 73: Chapter 6: Deck

    Chapter 6 Deck Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 Deck Belt Replacement........................6–4 Mower Deck Replacement ......................... 6–4 Mower Deck Replacement (with Deck Lift)..................6–7 Electric Mower Deck Lift Replacement....................6–9 Aluminum Spindle Rebuild ....................... 6–11 4000 Series Z MASTER®...

  • Page 74: General Information

    General Information The 4000 series Z MASTER® mowers use a TURBO FORCE® deck platform. All decks are 5.5 inch deep and constructed of 7ga steel. The spindles are of aluminum construction and utilize a blade driver. Deck: General Information Page 6–2 4000 Series Z MASTER®...

  • Page 75: Service And Repairs

    Service and Repairs Deck Assembly g342236 Figure 54 HOC Pin Foot Lift Pedal Lift Link Deck Strut with Bushings Asm Lever Grip Deck Lift Shaft Asm Magnetic Retention Tag Deck Chain Asm Transport Lock Plate Extension Spring Flange Bushing Front Deck Lift Shaft Asm Deck Lift Gusset 4000 Series Z MASTER®...

  • Page 76: Deck Belt Replacement

    Deck Belt Replacement Deck Belt Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.
  • Page 77 Mower Deck Removal (continued) g348085 Figure 55 6. Slowly loosen and remove the lift assist spring screw. g348207 Figure 56 7. Remove the 2 (3/8 inch) lock nuts and carriage bolts securing the deck strut to the frame. 4000 Series Z MASTER® Service Manual Page 6–5 Deck: Service and Repairs 3442-427 Rev A...
  • Page 78 Mower Deck Removal (continued) g348210 Figure 57 8. Remove the 4 (3/8 inch) shoulder bolts (1 per deck corner) securing the deck lift chains to the deck lift assembly. 9. Place the deck lift into the transport position. 10. Slide the deck out the RH side of the machine. Mower Deck Installation 1.

  • Page 79: Mower Deck Replacement (With Deck Lift)

    Mower Deck Installation (continued) g348210 Figure 59 7. Install the lift assist spring screw. g348207 Figure 60 8. Install the deck belt. Deck Belt Replacement (page 6–4) 9. Connect the battery by installing the positive cable first, then the negative cable to the battery.
  • Page 80 Mower Deck Removal (with Deck Lift) (continued) g348210 Figure 61 5. Remove the 4 (3/8 inch) shoulder bolts (1 per deck corner) securing the deck lift chains to the deck lift assembly. 6. Raise the deck lift into the transport position. 7.

  • Page 81: Electric Mower Deck Lift Replacement

    Electric Mower Deck Lift Replacement Electric Mower Deck Lift Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2.
  • Page 82 Electric Mower Deck Lift Installation (continued) 2. Connect the harness plug to the deck lift to the wiring harness. g348235 Figure 65 3. Swing the actuator up and install the ½ inch lock nut and bolt securing the deck lift to the deck lift actuator. g346264 Figure 66 4.

  • Page 83: Aluminum Spindle Rebuild

    Aluminum Spindle Rebuild Aluminum Spindle Disassembly g352924 Figure 67 Hex Nut Bottom Guard Washer Spindle Shaft Blade Drive Sheave Blade Top Bearing Guard Hex Bushing Spindle Asm Screw 1. Park the machine on a level surface, disengage the PTO and set the parking brake.
  • Page 84 Aluminum Spindle Disassembly (continued) g339541 Figure 68 5. Remove the 6 (3/8 inch) flange lock nuts securing the spindle to the deck (from bottom). g339542 Figure 69 6. Lift spindle assembly from the deck. 7. Remove the housing ring (if applicable). 8.
  • Page 85 Aluminum Spindle Disassembly (continued) g339543 Figure 70 10. Gently tap the inner race of the lower bearing to remove from the housing. Alternate in a star pattern to avoid binding when removing. Note: Bearings may be damaged during removal. Replace as needed. g339544 Figure 71 11.
  • Page 86 Aluminum Spindle Disassembly (continued) g347983 Figure 72 Aluminum Spindle Assembly 1. Clean and inspect all surfaces. 2. Using the appropriate sized bearing driver, install the upper bearing until seated. Note: Gently tap driver to avoid damaging the bearing during install. 3.
  • Page 87 Chapter 7 Drive System Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Hydrostatic Drive Belt Replacement....................7–5 Hydrostatic Drive Transmission Replacement..................7–6 4000 Series Z MASTER® Service Manual Page 7–1 Drive System 3442-427 Rev A...

  • Page 88: General Information

    General Information The 4000 series Z MASTER® mowers have ZT4400 and ZT5400 hydrostatic transaxles. Either transaxle is serviceable via internal cartridge filter and remote reservoir. Drive System: General Information Page 7–2 4000 Series Z MASTER® Service Manual 3442-427 Rev A...

  • Page 89: Service And Repairs

    Service and Repairs Drive Assembly 1 g341074 Figure 73 Hydraulic Reservoir Asm V-Belt Hydraulic Hose Asm LH Transaxle Asm RH Transaxle Asm 4000 Series Z MASTER® Service Manual Page 7–3 Drive System: Service and Repairs 3442-427 Rev A...
  • Page 90 Drive Assembly 2 g341076 Figure 74 Wheel and Tire Asm Drive System: Service and Repairs Page 7–4 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 91 Hydrostatic Drive Belt Replacement Hydrostatic Drive Belt Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.
  • Page 92 Hydrostatic Drive Belt Installation (continued) 4. Connect the battery by installing the positive cable first, then the negative cable to the battery. Hydrostatic Drive Transmission Replacement Hydrostatic Drive Transmission Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key.
  • Page 93 Hydrostatic Drive Transmission Removal (continued) 15. Loosen (do not remove) the 4 (1/2 inch) hydrostatic transaxle mount bolts securing the hydrostatic transaxle to the chassis. 16. While supporting the hydrostatic transaxle being removed, remove the 4 loosened mount bolts from the chassis. Remove the hydrostatic transaxle from the machine.
  • Page 94 Hydrostatic Drive Transmission Installation (continued) Note: Do not lower and support on the hydro plate. 14. Connect the battery by installing the positive cable first, then the negative cable to the battery. Drive System: Service and Repairs Page 7–8 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 95 Chapter 8 Electrical Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Ignition Switch Replacement......................8–4 Hourmeter Replacement........................8–5 Left and Right Neutral Switch Replacement ..................8–6 Park Brake Switch Replacement......................8–7 PTO Switch Replacement ........................8–8 Electric PTO Clutch Replacement......................

  • Page 96: General Information

    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.

  • Page 97: Service And Repairs

    Service and Repairs Electrical Assembly g342240 Figure 79 Bungee Strap Battery Module Asm Bail Switch Ignition Key USB Power Port Ignition Switch Park Brake Switch Rocker Switch Front Bumper Wire Harness 4000 Series Z MASTER® Service Manual Page 8–3 Electrical: Service and Repairs 3442-427 Rev A...

  • Page 98: Ignition Switch Replacement

    Ignition Switch Replacement Ignition Switch Removal 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key. Engage the parking brake. 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery.

  • Page 99: Hourmeter Replacement

    Ignition Switch Test (continued) 4. Using a digital multi-meter set to the OHM or Continuity setting, verify that NO continuity exists between the terminals not listed for each switch position. Position Circuit “Make” None B+R+I+A START B+R+I+S Hourmeter Replacement Hourmeter Removal 1.

  • Page 100: Left And Right Neutral Switch Replacement

    Hourmeter Installation (continued) g346221 Figure 82 3. Install the RH side pod to the RH console. Install the 4 (1/4-20 inch) torx screws securing the RH side pod to the RH console. 4. Connect the battery by installing the positive cable first, then the negative cable to the battery.

  • Page 101: Park Brake Switch Replacement

    Left and Right Neutral Switch Removal (continued) 3. Remove the 4 (1/4-20 inch) torx screws securing the side pod to the console. Remove the side pod from the console. 4. Push on the 2 tabs on either side of the neutral switch and push the switch through the mount hole to remove.

  • Page 102: Pto Switch Replacement

    Park Brake Switch Installation 1. Install the park brake switch to the park brake switch bracket. 2. Install the park brake switch bracket into the chassis and connect. 3. Install the 2 (5/16 inch) screws securing the park brake switch bracket to the chassis.

  • Page 103: Electric Pto Clutch Replacement

    PTO Switch Test (continued) g349741 Figure 85 3. Using a digital multi-meter set to the OHM or Continuity setting, verify the following: • Pin 2 and 4 should have continuity (closed) • Pin 6 and 8 should have continuity (closed) •...
  • Page 104 Electric PTO Clutch Removal (continued) 3. Raise and support the unit so that the drive wheels are off the ground. 4. Remove the deck belt. Deck Belt Replacement (page 6–4) 5. Disconnect the clutch wire connector from the clutch. g336161 Figure 86 6.
  • Page 105 Electric PTO Clutch Installation (continued) 5. Lower the unit and verify proper function. Coil Resistance Measurement Test If the PTO clutch is not engaging or is suspect as a cause of electrical problems, use the following electrical troubleshooting steps. These procedures will help determine if the clutch has failed as a result of or is the cause of an electrical problem.

  • Page 106: Electric Deck Lift Switch Replacement

    Measuring Clutch Current Draw Test Note: Do not measure current draw if the clutch has shorted to ground or if the resistance measurement is out of specification. g336411 Figure 89 1. Park the machine on a level surface and disengage the PTO. Stop the engine, wait for all moving parts to stop and remove the key.
  • Page 107 Electric Deck Lift Switch Installation 1. Install the deck lift switch. Plug the 3 terminals into the deck lift switch. 2. Install the 2 Philips head screws securing the deck lift switch to the motion control lever. 3. Connect the battery by installing the positive cable first, then the negative cable to the battery.
  • Page 108 Electrical: Service and Repairs Page 8–14 4000 Series Z MASTER® Service Manual 3442-427 Rev A...
  • Page 109 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 Electrical Schematic...........................A–3 Electrical PTO Engaged Schematic ....................A–4 Electrical Run Position ........................A–5 Electrical Start Position ........................A–6 4000 Series Z MASTER® Service Manual Page A–1 Foldout Drawings 3442-427 Rev A...

  • Page 110: Electrical Drawing Abbreviations

    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 Black BR or BN Brown Blue Green Gray OR or OG Orange Pink R or RD T or TN Violet VIO or VT...

  • Page 111: Electrical Schematic

    Electrical Schematic g342795 , Drawing Rev A, Sheet 1 3442-427 Rev A Page A–3...

  • Page 112: Electrical Pto Engaged Schematic

    Electrical PTO Engaged Schematic g346038 Page A–4 3442-427 Rev A , Drawing Rev , Sheet...

  • Page 113: Electrical Run Position

    Electrical Run Position g346039 , Drawing Rev , Sheet 3442-427 Rev A Page A–5...

  • Page 114: Electrical Start Position

    Electrical Start Position g346040 Page A–6 3442-427 Rev A , Drawing Rev , Sheet...

This manual is also suitable for:

Z master 74000Z master 74002Z master 74004Z master 74050

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