Toro Z MASTER 2000 Series Service Manual
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Toro Z MASTER 2000 Series Service Manual

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© 2020—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2000 Series Z MASTER® Service
Manual
Published: November 2020
Form No. 3438-778 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 2000 Series

  • Page 1 Form No. 3438-778 Rev A 2000 Series Z MASTER® Service Manual Published: November 2020 © 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 2000 Series Z MASTER® Service Manual 3438-778 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. 2000 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 ................... 2–5 Chapter 3: Troubleshooting ................3–1 General Troubleshooting ................3–3 Chapter 4: Engine ................... 4–1 General Information ..................
  • Page 6 Preface Page 6 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 7 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–2 2000 Series Z MASTER® Service Manual Page 1–1 Safety 3438-778 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 ........................... 2–5 Equivalents and Conversions......................2–10 U.S. to Metric Conversions ......................2–11 2000 Series Z MASTER® Service Manual Page 2–1 Specifications and Maintenance 3438-778 Rev A...

  • Page 12: Specifications

    Battery 12 volt - 300 CCA Hydraulic Drive System Transmission ZT3400 Transmission 4.45 L (150 oz.) Toro® HYPR-OIL™ 500 hydraulic fluid or Mobil 1 15W-50 oil Lubricant Max Ground Speed Up to 10 mph (FWD) Rear Tires 24 x 9.5 - 12...
  • Page 13 12 volt - 300 CCA Hydraulic Drive System Transmission ZT3800 Transmission Lubricant 4.45 L (150 oz.) Toro® HYPR-OIL™ 500 hydraulic fluid or Mobil 1 15W-50 oil Max Ground Speed (FWD) Up to 11 mph Rear Tires 24 x 9.5 – 12 24 x 12 –...
  • Page 14 12 volt - 300 CCA Hydraulic Drive System Transmission ZT3400 ZT3800 Transmission 4.45 L (150 oz.) Toro® HYPR-OIL™ 500 hydraulic fluid or Mobil 1 15W-50 oil Lubricant Max Ground Speed Up to 10 mph (FWD) Rear Tires 24 x 9.5 - 12...

  • Page 15: 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 16 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 Specifications and Maintenance: Torque Specifications Page 2–6 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 17 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 18 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 19 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 20 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 21 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 22 Specifications and Maintenance: Torque Specifications Page 2–12 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 23 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 2000 Series Z MASTER® Service Manual Page 3–1 Troubleshooting 3438-778 Rev A...
  • Page 24 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 25: 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. Set the parking brake. The motion-control levers are not in the Ensure that the motion-control levers Neutral-Lock position.
  • Page 26 General Troubleshooting (continued) Problem Possible Cause Corrective Action The engine overheats The engine load is excessive. Reduce the ground speed. The oil level in the crankcase is low. Add oil to the crankcase. The cooling fins and the air passages Remove the obstruction and thoroughly above the engine are plugged.
  • Page 27 General Troubleshooting (continued) Problem Possible Cause Corrective Action The clutch does not engage 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 Check the coil resistance, battery clutch.
  • Page 28 Troubleshooting: General Troubleshooting Page 3–6 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 29 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 ......................4–9 2000 Series Z MASTER® Service Manual Page 4–1 Engine 3438-778 Rev A...

  • Page 30: General Information

    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. Engine: General Information Page 4–2 2000 Series Z MASTER®...

  • Page 31: Service And Repairs

    Service and Repairs Toro Engine Assembly g337394 Figure 3 Rain Cap Kit Engine Sheave Air Cleaner Asm Clutch Anchor Air Canister Strap PTO Clutch Intake Hose Flat Idler Pulley 2P77F—HD Engine Idler Pivot Bushing Muffler Idler Arm Asm V-Belt 2000 Series Z MASTER® Service Manual Page 4–3...
  • Page 32 Kawasaki Engine Assembly g337393 Figure 4 Kawasaki Engine Clutch Anchor Engine Oil Drain Hose Asm Clutch Exhaust Gasket Flat Idler Pulley Muffler Idler Pivot Bushing Idler Arm Asm Sheave V-Belt Engine: Service and Repairs Page 4–4 2000 Series Z MASTER® Service Manual 3438-778 Rev A...

  • Page 33: Toro Twin Cylinder Engine Replacement

    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.
  • Page 34 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)
  • Page 35 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).
  • Page 36 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. Engine: Service and Repairs Page 4–8 2000 Series Z MASTER® Service Manual...

  • Page 37: Kawasaki Engine Replacement

    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.
  • Page 38 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. Engine: Service and Repairs Page 4–10 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 39 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.
  • Page 40 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 •...
  • Page 41 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 ......................5–10 Left Console Replacement....................... 5–11 Right Console Replacement ......................5–13 Seat Replacement ........................... 5–15 Fuel Tank Replacement ........................

  • Page 42: General Information

    General Information The 2000 Z MASTER® series of mowers use a one-piece fully welded frame. All models use a foldable ROPS system. Chassis: General Information Page 5–2 2000 Series Z MASTER® Service Manual 3438-778 Rev A...

  • Page 43: Service And Repairs

    Service and Repairs Chassis Assembly 1 g335781 Figure 17 Tapered ROPS Asm Suspension 60 inch Frame Front Plate Light Bracket Push-In Bumper Light Flush Mount 2000 Series Z MASTER® Service Manual Page 5–3 Chassis: Service and Repairs 3438-778 Rev A...
  • Page 44 Chassis Assembly 2 g335763 Figure 18 Control Panel Asm RH Console Support Choke Control Cable Rear Guard Asm Ball Knob Muffler Guard Throttle Control Cable RH Pod Support Bracket Truss Screw Rear Weight RH Guard Bracket LH Guard Bracket Rear Upper Trim RH Motion Control Cover Truss Screw LH Console Bracket...
  • Page 45 Chassis Assembly 3 g335767 Figure 19 Fuel Hose Asm Fuel Tank Fuel Cap Vent Hose Asm 2000 Series Z MASTER® Service Manual Page 5–5 Chassis: Service and Repairs 3438-778 Rev A...
  • Page 46 Chassis Assembly 4 g335769 Figure 20 Suspension Seat Asm Seat Pan and Latch Asm Seat Pivot Pin Seat Bumper Rubber Seat Guard Tank Retainer Plate Chassis: Service and Repairs Page 5–6 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 47 Chassis Assembly 5 g337405 Figure 21 Floor Mat Fixed Seat Adj Mounting Platform Front Subframe Trailing Arm Cam Lock Asm Seat Plate Trailing Arm Tube Rubber Flap RH Trailing Arm Bracket Backer Plate Bumper Rear Subframe Pivot Rod Lower Mount Bracket LH Trailing Arm Bracket Tank Bracket LH Upper Shock Mount Bracket...
  • Page 48 Chassis Assembly 6 g335890 Figure 22 Grease Cap Front Caster Asm Chassis: Service and Repairs Page 5–8 2000 Series Z MASTER® Service Manual 3438-778 Rev A...

  • Page 49: Caster Fork And Bearing Replacement

    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.

  • Page 50: Caster Wheel Replacement

    Caster Wheel Replacement Caster Wheel Disassembly g336095 Figure 23 Lock Nut Caster Fork Wheel Assembly Screw 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 51: Left Console Replacement

    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.
  • Page 52 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.

  • Page 53: 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 54 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.

  • Page 55: Seat Replacement

    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.

  • Page 56: Fuel Tank Replacement

    Seat Removal (continued) g336087 Figure 31 Bolt 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.
  • Page 57 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.
  • Page 58 Fuel Tank Removal (continued) g336088 Figure 34 Vent Hose Assembly Fuel Shut-Off Valve Fuel Supply Line 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.

  • Page 59: Rops (Roll Over Protection System) Replacement

    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.

  • Page 60: Throttle Cable Assembly Replacement

    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.
  • Page 61 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.

  • Page 62: Choke Control Assembly Replacement

    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.

  • Page 63: Park Brake Handle Assembly Replacement

    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.
  • Page 64 Park Brake Handle Assembly Removal (continued) g336059 Figure 43 Flange Nut Locking Cotter Pin Bolt 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.

  • Page 65: Adjusting The Park Brake

    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.

  • Page 66: Motion Control Damper

    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 Flange Nut Lower Brake Linkage Compression Spring 7.
  • Page 67 Motion Control Damper Removal (continued) g336040 Figure 48 Bolts 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.

  • Page 68: Motion Control Assembly Replacement

    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.
  • Page 69 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.

  • Page 70: Adjusting The Motion Control Handle Position

    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 71: Myride® Replacement

    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.
  • Page 72 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.
  • Page 73 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.
  • Page 74 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).

  • Page 75: Chapter 6: Deck

    Chapter 6 Deck Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 Mower Belt Replacement ........................6–6 Mower Deck Replacement ......................... 6–6 Mower Spindle Replacement ......................6–7 Leveling the Mower Deck........................6–9 2000 Series Z MASTER® Service Manual Page 6–1 Deck 3438-778 Rev A...

  • Page 76: General Information

    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. Deck: General Information Page 6–2 2000 Series Z MASTER®...

  • Page 77: Service And Repairs

    Service and Repairs 48 Inch Deck g337546 Figure 61 2000 Series Z MASTER® Service Manual Page 6–3 Deck: Service and Repairs 3438-778 Rev A...
  • Page 78 52 Inch Deck g337549 Figure 62 Deck: Service and Repairs Page 6–4 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 79 60 Inch Deck g337550 Figure 63 2000 Series Z MASTER® Service Manual Page 6–5 Deck: Service and Repairs 3438-778 Rev A...

  • Page 80: Mower Belt Replacement

    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.

  • Page 81: Mower Spindle Replacement

    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.
  • Page 82 Mower Spindle Disassembly (continued) g336156 Figure 65 Bearing and Spacer Assembly Belleville Washer Taptite Screw Blade Bolt Washer Bearing Shield Locknut Spindle Shaft Pulley 3. Remove the pulley. 4. Remove the shaft from the spindle housing. 5. Remove the bearing shield . 6.

  • Page 83: Leveling The Mower Deck

    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.
  • Page 84 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).
  • Page 85 Leveling the Mower Deck (continued) g336159 Figure 68 Block 7.3 cm (2.87 inch) Welds Block Height and Rake Table Block Height Rake Deck Size 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.
  • Page 86 Deck: Service and Repairs Page 6–12 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 87 Chapter 7 Drive System Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 Using the Drive Wheel Release Valves (Bypass Valves) ..............7–5 Adjusting the Motion Control Linkage (Neutral Setting) ..............7–5 Tracking Adjustment .......................... 7–7 Purging Procedure ..........................7–7 Hydrostatic Drive Belt Replacement....................

  • Page 88: General Information

    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. Drive System: General Information Page 7–2 2000 Series Z MASTER® Service Manual 3438-778 Rev A...

  • Page 89: Service And Repairs

    Service and Repairs Drive System Assembly 1 g335888 Figure 69 Hydraulic Tank Hydro Spacer Hydraulic Hose RH Transaxle Asm Hydraulic Hose Spacer Shaft Handle Knob LH Transaxle Asm Hydro Bypass Arm 2000 Series Z MASTER® Service Manual Page 7–3 Drive System: Service and Repairs 3438-778 Rev A...
  • Page 90 Drive System Assembly 2 g335889 Figure 70 Adjustable Yoke RH Control Handle Asm RH Motion Control Asm Upper Brake Linkage Brake Bracket Brake Lever Brake Shaft LH Control Handle Asm Spherical Bearing LH Motion Control Asm Damper Lower Brake Linkage Flange Pivot Drive System: Service and Repairs Page 7–4...

  • Page 91: Using The Drive Wheel Release Valves (Bypass Valves)

    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.
  • Page 92 Adjusting the Motion Control Linkage (Neutral Setting) (continued) g336201 Figure 72 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.

  • Page 93: Tracking Adjustment

    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.

  • Page 94: Hydrostatic Drive Belt Replacement

    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.

  • Page 95: Hydrostatic Drive Transmission Replacement

    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.
  • Page 96 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 Front and Rear Mounting Bolts...
  • Page 97 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.
  • Page 98 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 ±...
  • Page 99 Chapter 8 Electrical Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Fuse Block and Fuses ........................8–5 Key/Ignition Switch ..........................8–5 Hourmeter ............................8–6 Operator Presence Switch (Seat Switch) ..................8–7 Neutral Switch - Left and Right ......................8–8 Parking Brake Switch ........................

  • Page 100: 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 101: Service And Repairs

    Service and Repairs Electrical Assembly 1 g337720 Figure 79 USB Power Port Bungee Strap Module Asm Switch Ignition Key Wire Harness PTO Switch Battery Wire Harness Rocker Switch Ignition Switch Bail Switch Battery Tray USB Kit Wire Harness 2000 Series Z MASTER® Service Manual Page 8–3 Electrical: Service and Repairs 3438-778 Rev A...
  • Page 102 Electrical Assembly 2 g337721 Figure 80 USB Power Port Bungee Strap Module Asm Switch Ignition Key Wire Harness PTO Switch Battery Ignition Switch Bail Switch USB Kit Wire Harness Battery Tray Electrical: Service and Repairs Page 8–4 2000 Series Z MASTER® Service Manual 3438-778 Rev A...

  • Page 103: Fuse Block And Fuses

    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.

  • Page 104: Hourmeter

    • 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.

  • Page 105: Operator Presence Switch (Seat Switch)

    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...

  • Page 106: Neutral Switch - Left And Right

    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).

  • Page 107: Starter Solenoid

    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.
  • Page 108 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.

  • Page 109: Electric Pto Clutch

    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: •...
  • Page 110 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...
  • Page 111 Electric PTO Clutch-Coil Resistance Measurement Test (continued) g336410 Figure 94 5. See the PTO Clutch Electrical Specifications chart. Resistance (OHMs) AMP Draw Continuity to Ground Series 2.84 4.23 OPEN 1500 and 2000 3.05 ± 5% 3.93 OPEN 2500 Electric PTO Clutch- PTO Clutch Continuity to Ground Test 1.
  • Page 112 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.

  • Page 113: Tvs Diode

    Electric PTO Clutch- Measuring Clutch Current Draw (continued) PTO Clutch Electrical Specification Chart (continued) Resistance (OHMs) AMP Draw Continuity to Ground Series 2.84 4.23 1500 and 2000 OPEN 3.05 ± 5% 3.93 OPEN 2500 TVS Diode The TVS diode protects the electrical system from current surges caused by PTO engagement and disengagement.
  • Page 114 Electrical: Service and Repairs Page 8–16 2000 Series Z MASTER® Service Manual 3438-778 Rev A...
  • Page 115 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 Electrical Schematic...........................A–3 Kawasaki Engine Electrical Schematic ....................A–4 2000 Series Z MASTER® Service Manual Page A–1 Foldout Drawings 3438-778 Rev A...

  • Page 116: 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 117: Electrical Schematic

    Electrical Schematic g339610 , Drawing Rev A, Sheet 1 3438-778 Rev A Page A–3...

  • Page 118: Kawasaki Engine Electrical Schematic

    Kawasaki Engine Electrical Schematic g339611 Page A–4 3438-778 Rev A , Drawing Rev , Sheet...

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