Caster Fork And Bearing Replacement - Toro Z MASTER 4000 Series Service Manual

ROPS (Roll Over Protection System) Installation (continued)

Caster Fork and Bearing Replacement

Caster Fork and Bearing Removal
Caster Fork and Bearing Installation
Chassis: Service and Repairs
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. Install the LH shoulder bolt securing the upper ROPS assembly to the lower
ROPS assembly.
6. Raise the upper ROPS assembly, secure with the ROPS fold pins and hair
pins.
7. Install the fuel tank.
8. Connect the battery by installing the positive cable first, then the negative
cable to the battery.
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. Raise and support the machine so that the front wheels are off the ground.
4. Remove the caster cap.
5. Support the underside of the caster wheel and remove the fastener screw
securing the caster bearing assembly.
6. Remove the caster fork from the front axle. Inspect the caster fork shaft
for wear or damage.
7. Remove the upper and lower bearings from the axle and inspect the inside of
the axle bearing area for damage and excessive wear.
1. Clean the surface inside the axle bearing area.
2. Install a new lower bearing from the bottom side into the axle, making sure it
is fully seated. Press evenly on the inner and outer race to seat the bearing.
3. Install spring washer on the top side of the axle, followed by a new upper
bearing, ensuring that the bearing is properly seated (the upper bearing
should be floating in the housing and does not need to be pressed in place).
Note: The bearings are sealed and do not require grease/lubrication.
4. Install the flat washer on top of the bearing.
5. Install the fastener screw and tighten to the caster shaft. The spring washers
will provide the appropriate preload to the bearings.
6. Lower the unit and verify proper function.
Note: The caster wheel is not serviceable and should be replaced as a
complete assembly.
7. Connect the battery by installing the positive cable first, then the negative
cable to the battery.
Fuel Tank Replacement (page 5–24)
Page 5–28 4000 Series Z MASTER® Service Manual
3442-427 Rev A