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Toro Z MASTER 2000 Series Service Manual

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Form No. 3460-328 Rev A
2000 Series Z MASTER®Service
Manual
Published: May 2023

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Summary of Contents for Toro Z MASTER 2000 Series

  • Page 1 Form No. 3460-328 Rev A 2000 Series Z MASTER®Service Manual Published: May 2023...
  • Page 2 Revision History Revision History Page 2 2000 Series Z MASTER®Service Manual 3460-328 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 Preface...
  • 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

    General Information ..................8–2 Service and Repairs ..................8–3 Appendix A ......................A–1 Electrical Drawing Abbreviations..............A–2 TORO Engine Schematic................A–3 TORO Engine Powered Schematic...............A–4 Kawasaki Engine Schematic.................A–5 Kawasaki Engine Powered Schematic............A–6 Briggs & Straton Engine Schemaitc ..............A–7 Briggs & Straton Engine Powered Schematic..........A–8 2000 Series Z MASTER®Service Manual...
  • Page 6 Preface Page 6 2000 Series Z MASTER®Service Manual 3460-328 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 3460-328 Rev A...

  • Page 8: Safety Instructions

    Think Safety First Toro Products are evaluated for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control...
  • Page 9 – Use only Toro-specified lithium-ion battery packs designed for your machine. Do not mix batteries of any brand or type in Toro products. – Use only the Toro-specified lithium-ion charger designed to charge your machine. Do not attempt to use any other battery charger.
  • Page 10 Think Safety First (continued) – Always disconnect the batteries at the battery disconnect provided when servicing products with lithium-ion batteries. – Always change out the batteries while servicing the machine with the lithium-ion batteries machine parked near a service door large enough to move the product or battery outside in case of an emergency and keep a fire blanket nearby.
  • Page 11 Think Safety First (continued) – All lifts, hoists, and jacks should be used in accordance with the manufacturer information. – Inspect lifts, hoists, and jacks prior to use. – Do not overload lifts, hoists, and jacks. – Do not work under a suspended load. –...
  • Page 12 Safety: Safety Instructions Page 1–6 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 13 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Torque Specifications ........................... 2–4 Equivalents and Conversions......................2–9 U.S. to Metric Conversions ......................2–10 2000 Series Z MASTER®Service Manual Page 2–1 Specifications and Maintenance 3460-328 Rev A...

  • Page 14: Specifications

    Capacity Battery 12V - 300 CCA Hydraulic Drive System Transmission ZT-3400 Transmission 1.9 L (2 US qt) Toro HYPR-OIL 500 Hydraulic Fluid or Mobil 1 20W-50 Lubricant Max Ground Up to 16.1 km/h (10 mph) Speed Rear Tires 61 x 61 x 61 x 26.7...
  • Page 15 Blade Tip 18,500+ ft/min Speed Cutting 38.1 - 127 mm (1.5 - 5.0 inch) Height 2000 Series Z MASTER®Service Manual Page 2–3 Specifications and Maintenance: Specifications 3460-328 Rev A...

  • Page 16: 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 17 Metric Bolts and Screws g272209 Figure 2 Class 8.8 Class 10.9 2000 Series Z MASTER®Service Manual Page 2–5 Specifications and Maintenance: Torque Specifications 3460-328 Rev A...
  • Page 18 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 19 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 20 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 21 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 22 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 23 Chapter 3 Troubleshooting Table of Contents General Troubleshooting ........................3–3 2000 Series Z MASTER®Service Manual Page 3–1 Troubleshooting 3460-328 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. Move the motion control levers to the neutral lock position (park).
  • Page 26 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. 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. There is a low voltage supply at the Check the coil resistance, battery clutch. charge, charging system, and wiring connections and replace parts if necessary. The coil is damaged. Replace the clutch.
  • Page 28 Troubleshooting: General Troubleshooting Page 3–6 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 29 Chapter 4 Engine Table of Contents General Information ..........................4–2 Service and Repairs ..........................4–3 Engine Replacement.......................... 4–6 Clutch Replacement......................... 4–17 2000 Series Z MASTER®Service Manual Page 4–1 Engine 3460-328 Rev A...

  • Page 30: General Information

    General Information The 2000 series Z MASTER® mowers use a variety of engines. All engines are 4 cycle V-Twins with varying power outputs. 23.5hp, 726cc Kawasaki; 24.5hp, 708cc Toro; 28hp, 810cc Briggs & Stratton. Engine: General Information Page 4–2 2000 Series Z MASTER®Service Manual...

  • Page 31: Chapter 4: Engine

    Service and Repairs Engine Assembly 1 (Kawasaki) g423561 Figure 3 Engine Oil Drain Hose Assembly Clutch Anchor Kawasaki Engine Idler Pulley Exhaust Gasket Pivot Idler Bushing Muffler Extension Spring Idler Arm Assembly Idler Pulley Sheave Clutch V-Belt 2000 Series Z MASTER®Service Manual Page 4–3 Engine: Service and Repairs 3460-328 Rev A...
  • Page 32 Engine Assembly 2 (Briggs) g423119 Figure 4 Vanguard Engine Idler Pulley Muffler Pivot Idler Bushing Extension Spring Sheave Idler Arm Assembly Clutch Idler Pulley Clutch Anchor V-Belt Engine: Service and Repairs Page 4–4 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 33 Engine Assembly 3 (Toro) g423120 Figure 5 Rain Cap Kit Clutch Anchor Air Cleaner Assembly Idler Bushing Intake Hose Extension Spring Engine Idler Arm Assembly Muffler Idler Pulley Sheave V-Belt Clutch 2000 Series Z MASTER®Service Manual Page 4–5 Engine: Service and Repairs...

  • Page 34: Engine Replacement

    Engine Replacement 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 35 Engine Removal (continued) 6. Using a T40 torx driver, remove the 2 (5/16 inch) screws securing the upper portion of the rear guard assembly. Remove the rear guard assembly. g420408 Figure 8 7. Using a 1/4 inch socket, disconnect the 2 (#8) bolts securing the throttle and choke cables to the engine.
  • Page 36 Engine Removal (continued) g420418 Figure 10 9. Disconnect the engine harness from the main harness. g420392 Figure 11 10. Remove the fuel clamp securing the fuel line to the fuel pump. Remove the fuel line from the fuel pump. g420399 Figure 12 11.
  • Page 37 Engine Removal (continued) 12. Disconnect the vent hose at the engine. Note: Cap off the fuel lines. 13. Remove the (10 mm) nut securing the positive connector to the starter. g420393 Figure 13 14. Using a 1/2 inch socket, remove the 5/16 inch bolt securing the engine ground to the engine crankcase.
  • Page 38 Engine Removal (continued) g420404 Figure 15 16. Remove the deck belt. Refer to Deck Belt Removal (page 5–7). 17. Remove the hydrostatic drive belt. Refer to Hydrostatic Drive Belt Removal (page 7–10). 18. Remove the clutch. Refer to Clutch Removal (page 4–17).
  • Page 39 Engine Installation (continued) 2. Using a 9/16 inch socket, install the 4 (3/8 inch) bolts to secure the engine to the chassis. Torque to 41 ± 4 N•m (30 ± 3 ft-lb). g420390 Figure 17 For securing, refer to the torque sequence below. g431179 Figure 18 3.
  • Page 40 Engine Installation (continued) g420391 Figure 19 7. Install the (10 mm) nut to secure the positive connector to the starter. g420393 Figure 20 8. Connect the vent hose to the engine. Engine: Service and Repairs Page 4–12 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 41 Engine Installation (continued) g420401 Figure 21 9. Install a zip tie to secure the evaporative emissions line to the engine. 10. Install the fuel line to the fuel pump. Install the fuel clamp to secure the fuel line to the fuel pump. g420399 Figure 22 11.
  • Page 42 Engine Installation (continued) g420392 Figure 23 12. Hook the throttle and choke cables at the governor control plate assembly. g420418 Figure 24 13. Using a 1/4 inch socket, install the 2 (#8) bolts to secure the throttle and choke cables to the engine. Engine: Service and Repairs Page 4–14 2000 Series Z MASTER®Service Manual...
  • Page 43 Engine Installation (continued) g420419 Figure 25 14. Install the rear guard assembly. Using a T40 torx driver and a 1/2 inch wrench, install the 2 (5/16 inch) screws to secure the upper portion of the rear guard assembly. g420408 Figure 26 15.
  • Page 44 Engine Installation (continued) g420406 Figure 27 g420407 Figure 28 16. Install muffler guard. Using a T40 torx driver and a 1/2 inch wrench, install the top 2 (5/16 inch) screws/nuts securing the muffler guard to the rear guard assembly. Engine: Service and Repairs Page 4–16 2000 Series Z MASTER®Service Manual 3460-328 Rev A...

  • Page 45: Clutch Replacement

    Engine Installation (continued) g420405 Figure 29 17. Using a 1/2 inch wrench, install the 2 (5/16 inch) nuts to secure the lower portion of the muffler guard to the chassis. 18. Connect the battery by installing the positive cable first, then the negative cable to the battery.
  • Page 46 Clutch Removal (continued) 7. Using a 5/8 inch socket, remove the (7/16 inch) clutch bolt securing the clutch to the engine. g420384 Figure 31 8. Remove the clutch assembly and the engine sheave. g429401 Figure 32 Clutch Installation 1. Install the engine sheave and clutch assembly Note: The clutch must be oriented correctly upon installation.
  • Page 47 Clutch Installation (continued) 2. Using a 5/8 inch socket, install the (7/16 inch) clutch bolt to secure the clutch to the engine. Torque to 75 ± 8 N•m (55 ± 6 ft-lb). g420384 Figure 33 3. Secure the wire harness into the mounting clip. Connect the wire harness to the clutch.
  • Page 48 Engine: Service and Repairs Page 4–20 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 49 Chapter 5 Deck Table of Contents General Information ..........................5–2 Service and Repairs ..........................5–3 Deck Belt Replacement........................5–7 Deck Replacement........................... 5–10 Deck Lift Assembly Replacement..................... 5–12 Spindle Replacement........................5–13 2000 Series Z MASTER®Service Manual Page 5–1 Deck 3460-328 Rev A...

  • Page 50: General Information

    General Information The 2000 series Z MASTER® mowers use a TURBO FORCE® deck platform. All decks are 5.5 inches deep, constructed of 7ga steel, and are equipped with anti-scalp rollers. The spindles are of aluminum construction and utilize maintenance free ball bearings. Deck: General Information Page 5–2 2000 Series Z MASTER®Service Manual...

  • Page 51: Service And Repairs

    Service and Repairs Deck Assembly g423560 Figure 34 Link Lift Foot Pedal Lever Grip Deck Strut Assembly w/ Bushing Transport Lock Plate Front Deck Lift Shaft Assembly HOC Pin Assembly Deck Lift Link Magnetic Retention Tag Deck Lift Shaft Assembly Deck Lift Gusset Extension Spring Assembly 2000 Series Z MASTER®Service Manual...
  • Page 52 48 Inch Deck Assembly g423123 Figure 35 Deck Assembly Deck: Service and Repairs Page 5–4 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 53 52 Inch Deck Assembly g423122 Figure 36 Deck Assembly 2000 Series Z MASTER®Service Manual Page 5–5 Deck: Service and Repairs 3460-328 Rev A...
  • Page 54 60 Inch Deck Assembly g423124 Figure 37 Deck Assembly Deck: Service and Repairs Page 5–6 2000 Series Z MASTER®Service Manual 3460-328 Rev A...

  • Page 55: 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 56: Chapter 5: Deck

    Deck Belt Removal (continued) g420389 Figure 40 6. Remove the belt from the center spindle pulley. g420387 Figure 41 7. Using a 1/2 inch wrench and a 9/16 inch socket, remove the (5/16 inch) belt guide shoulder bolt and (3/8 inch) nut from the deck belt tensioner to free the deck belt from the assembly.
  • Page 57 Deck Belt Installation 1. Install the deck belt. Using a 1/2 inch wrench and a 9/16 inch socket, install the (5/16 inch) belt guide shoulder bolt and (3/8 inch) nut to the deck belt tensioner to secure the deck belt to the assembly. g420388 Figure 43 2.

  • Page 58: Deck Replacement

    Deck Belt Installation (continued) 4. Install the left and right deck belt guards. 5. Install the floor pan assembly to the machine. 6. Connect the battery by installing the positive cable first, then the negative cable to the battery. Deck Replacement Deck Removal 1.
  • Page 59 Deck Removal (continued) g422378 Figure 47 8. Using a 9/16 inch wrench, remove the 4 (3/8 inch) shoulder bolts (1 per deck corner) securing the deck lift links to the deck lift assembly. g431181 Figure 48 9. Place the deck lift back into the transport position. Slide the deck out from under the machine.

  • Page 60: Deck Lift Assembly Replacement

    Deck Installation (continued) g431178 Figure 49 5. Raise the deck off of the supporting blocks and secure the height using the height-of-cut pin. 6. Install the deck belt. Refer to Deck Belt Installation (page 5–9). 7. Connect the battery by installing the positive cable first, then the negative cable to the battery.

  • Page 61: Spindle Replacement

    Deck Lift Assembly Removal (continued) 6. Remove the pin clip and clevis pin securing the height-of-cut link to the back deck lift shaft assembly. 7. Using a 1/2 inch wrench, remove the 4 (5/16 inch) nuts and carriage bolts (2 on each side) securing the back deck lift shaft assembly.
  • Page 62 Spindle Removal (continued) 5. Using a 1-1/2 inch and a 15/16 inch wrench, hold the spindle shaft and remove the (5/8 inch) bolt securing the blade to the spindle shaft. Remove the blade. 6. Using a 1-1/2 and 1-1/8 inch wrench, hold the spindle shaft and remove the (3/4 inch) nut securing the blade drive sheave to the spindle.
  • Page 63 Spindle Removal (continued) g422386 Figure 54 Spindle Installation 1. Install the spindle assembly. Using a 1/2 inch socket, install the 6 (5/16 inch) bolts to secure the spindle assembly to the deck. Torque to 16 ± 3 N•m (12 ± 2 ft-lb). g422386 Figure 55 2.
  • Page 64 Spindle Installation (continued) g422372 Figure 56 g429399 Figure 57 3. Install the blades. Using a 1-1/2 and 15/16 inch wrench, hold the spindle shaft and install the (5/8 inch) bolt to secure the blade to the spindle shaft. Torque to 142 ± 7 N•m (105 ± 5 ft-lb). 4.
  • Page 65 Chapter 6 Chassis Table of Contents General Information ..........................6–2 Service and Repairs ..........................6–3 Fuel Tank Replacement ........................6–9 ROPS Assembly Replacement ......................6–12 Seat Replacement ........................... 6–14 MYRIDE® Replacement ........................6–17 Left Hand Pod Replacement ......................6–20 Right Hand Pod Replacement......................6–22 Parking Brake Assembly Replacement ....................

  • Page 66: General Information

    General Information The 2000 series Z MASTER® mowers use a one-piece, fully welded frame, with an integrated receiver hitch. All models use a square tube foldable Roll Over Protection System (ROPS). Chassis: General Information Page 6–2 2000 Series Z MASTER®Service Manual 3460-328 Rev A...

  • Page 67: Service And Repairs

    Service and Repairs Seat Assembly g423109 Figure 58 Seat Suspension Assembly Plate Backer Seat Pan Firewall Bracket Badge Plate Assembly 2000 Series Z MASTER®Service Manual Page 6–3 Chassis: Service and Repairs 3460-328 Rev A...
  • Page 68 Toro Welded Assembly g423562 Figure 59 Seat Assembly Subframe Assembly Isolator Seat Pan Trailing Arm Cam Lock Assembly Badge Plate Shock/Spring Assembly MYRIDE Floormat Front Shock Assembly Floor Pan Lower Shock Mounting Chassis: Service and Repairs Page 6–4 2000 Series Z MASTER®Service Manual...
  • Page 69 Fuel Tank Assembly 1 (LON) g423107 Figure 60 Fuel Hose Fuel Filler Hose Vent Hose Fuel Filler Neck Fuel Tank Assembly Ratcheting Fuel Cap Rear Tank Retainer 2000 Series Z MASTER®Service Manual Page 6–5 Chassis: Service and Repairs 3460-328 Rev A...
  • Page 70 Fuel Tank Assembly 2 (Kawasaki) g423105 Figure 61 Fuel Hose Assembly Fuel Filler Hose Fuel Vent Assembly Fuel Filler Neck Fuel Tank Assembly Ratcheting Fuel Cap Rear Tank Retainer Chassis: Service and Repairs Page 6–6 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 71 Fuel Tank Assembly 3 (Briggs) g423106 Figure 62 Fuel Hose Assembly Fuel Filler Hose Fuel Hose Fuel Filler Neck Fuel Tank Assembly Ratcheting Fuel Cap Rear Tank Retainer 2000 Series Z MASTER®Service Manual Page 6–7 Chassis: Service and Repairs 3460-328 Rev A...
  • Page 72 Caster Wheel g423111 Figure 63 Front Caster w/ Fork Assembly Chassis: Service and Repairs Page 6–8 2000 Series Z MASTER®Service Manual 3460-328 Rev A...

  • Page 73: Fuel Tank Replacement

    Fuel Tank Replacement Fuel Tank 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 74: Chapter 6: Chassis

    Fuel Tank Removal (continued) g421527 Figure 65 10. Using a 9/16 inch socket, remove the (3/8 inch) bolt and nut securing the rear tank retainer to the chassis. Remove the rear tank retainer. Remove the fuel tank. g421556 Figure 66 Fuel Tank Installation 1.
  • Page 75 Fuel Tank Installation (continued) g421556 Figure 67 2. Using a T40 torx driver, install the 4 (5/16 inch) bolts to secure the badge plate assembly to the chassis. g421527 Figure 68 3. Install the RH pod. Refer to Right Hand Pod Installation (page 6–23).

  • Page 76: Rops Assembly Replacement

    Fuel Tank Installation (continued) g420401 Figure 69 8. Install the seat. Refer to Seat Installation (page 6–16). 9. Connect the battery by installing the positive cable first, then the negative cable to the battery. ROPS Assembly Replacement ROPS 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 77 ROPS Removal (continued) g422383 Figure 70 6. Using a 3/4 inch wrench, remove the 2 (1/2 inch) lower shoulder bolts securing the upper ROPS to the lower ROPS. Remove the upper ROPS (note orientation). 7. Using a T40 torx driver, remove the 2 (5/16) screws securing the lower ROPS to the rear guard assembly.

  • Page 78: Seat Replacement

    ROPS Installation (continued) 2. Using a T40 torx driver, install the 2 (5/16 inch) screws to secure the lower ROPS to the rear guard assembly. 3. Install the upper ROPS. Using a 3/4 inch wrench, install the 2 (1/2 inch) lower shoulder bolts to secure the upper ROPS to the lower ROPS.
  • Page 79 Seat Removal (continued) g420411 Figure 74 4. Lift the seat forward and disconnect the seat pressure switch from the wire harness. Tilt the seat back into position. 5. Using a 1/2 inch socket and wrench, remove the 2 (5/16 inch) nuts and shoulder bolts securing the front of the seat to the chassis.
  • Page 80 Seat Removal (continued) g421558 Figure 76 Seat Installation 1. Using a 1/2 inch socket, install the 4 (5/16 inch) nuts to secure the seat assembly to the seat pan. g421558 Figure 77 2. Install the seat assembly. Using a 1/2 inch socket, install the 2 (5/16 inch) nuts and shoulder bolts to secure the front of the seat to the chassis.

  • Page 81: Myride® Replacement

    Seat Installation (continued) g421557 Figure 78 3. Lift the seat forward and connect the wire harness to the seat pressure switch. Tilt the seat back into position. 4. Using a 1/2 inch socket, install the 2 (5/16 inch) nuts and carriage bolts to secure the rear of the seat to the chassis.
  • Page 82 MYRIDE® Removal (continued) g424552 Figure 79 7. Support the front of the MYRIDE® subframe. Using a 3/4 inch wrench, remove the (1/2 inch) lock nut and carriage bolt from the front shock mount. Displace the shock and re-install the carriage bolt and lock nut to use as a lift point.
  • Page 83 MYRIDE® Removal (continued) 11. Using an appropriate lifting device, fully raise the MYRIDE® assembly out of the machine. MYRIDE® Installation 1. Using an appropriate lifting device, install the MYRIDE® assembly into the machine. 2. Raise the ROPS. 3. Using a 1/2 inch socket, install the 4 (5/16 inch) lock nuts and carriage bolts to secure the MYRIDE®...

  • Page 84: Left Hand Pod Replacement

    MYRIDE® Installation (continued) g424554 Figure 83 9. Connect the battery by installing the positive cable first, then the negative cable to the battery. Left Hand Pod Replacement Left Hand Pod 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 85 Left Hand Pod Removal (continued) g432460 Figure 84 9. Using a T40 torx driver, remove the 2 (5/16 inch) bolts securing the LH rear guard to the chassis. Remove the LH rear guard. g421544 Figure 85 10. Remove the LH pod. Left Hand Pod Installation 1.

  • Page 86: Right Hand Pod Replacement

    Left Hand Pod Installation (continued) g421543 Figure 86 3. Using a T30 torx driver, install the 3 (1/4 inch) shoulder bolts securing the LH pod to the chassis. g432460 Figure 87 4. Install the 2 retaining clips to secure the fuel filler neck to the LH steering pod assembly.
  • Page 87 Right Hand Pod Removal (continued) 2. Disconnect the battery by removing the negative cable first, then the positive cable from the battery. 3. Using a 9/16 inch socket, remove the 2 (3/8 inch) bolt securing the RH handle assembly to the motion control assembly. Remove the RH handle assembly. 4.

  • Page 88: Parking Brake Assembly Replacement

    Right Hand Pod Installation (continued) 5. Install the RH handle assembly. Using a 9/16 inch socket, install the 2 (3/8 inch) bolts to secure the RH handle assembly to the motion control assembly. 6. Connect the battery by installing the positive cable first, then the negative cable to the battery.
  • Page 89 Parking Brake Assembly Removal (continued) g421529 Figure 91 11. Remove the cotter pin and clevis pin securing the parking brake upper linkage to the brake shaft. 12. Remove the 2 cotter pins securing the left and right hand lower park brake linkages to the transaxles.
  • Page 90 Parking Brake Assembly Removal (continued) g421531 Figure 93 14. Disconnect the extension spring from the chassis. 15. Using a 1/2 inch socket, remove the 2 (5/16 inch) nuts and carriage bolts securing the park brake shaft to the chassis. g421532 Figure 94 16.
  • Page 91 Parking Brake Assembly Removal (continued) g421533 Figure 95 Parking Brake Assembly Installation 1. Lower the park brake shaft into position and slide it into the LH bushing. 2. Using a 1/2 inch socket, install the 2 (5/16 inch) nuts and carriage bolts to secure the park brake shaft to the chassis.
  • Page 92 Parking Brake Assembly Installation (continued) 5. Install the 2 cotter pins to secure the LH and RH lower park brake linkages to the transaxles. g421548 Figure 97 6. Install the cotter pin and clevis pin to secure the parking brake upper linkage to the brake shaft.

  • Page 93: Throttle Assembly Replacement

    Throttle Assembly Replacement Throttle Assembly 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 94: Caster Wheel Rebuild

    Caster Fork and Bearing Removal (continued) 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.
  • Page 95 Caster Wheel Disassembly (continued) 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 wheel from the caster fork. 5.
  • Page 96 Chassis: Service and Repairs Page 6–32 2000 Series Z MASTER®Service Manual 3460-328 Rev A...

  • Page 97: Service And Repairs

    Chapter 7 Drive Table of Contents General Information ..........................7–2 Service and Repairs ..........................7–3 LH & RH Motion Control Assembly Replacement................7–6 Hydrostatic Drive Belt Replacement....................7–10 Hydrostatic Transaxle Assembly Replacement ................7–12 2000 Series Z MASTER®Service Manual Page 7–1 Drive 3460-328 Rev A...
  • Page 98 General Information The 2000 series Z MASTER® mowers use the ZT-3400 hydraulic transaxle. The transaxle is serviceable via an external filter and internal reservoir. Drive: General Information Page 7–2 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 99 Service and Repairs Motion Control Assembly g423110 Figure 100 RH Handle Assembly Brake Lever RH Motion Control Assembly Upper Brake Linkage Damper Adjustable Yoke Brake Bracket LH Handle Assembly Extension Spring LH Motion Control Assembly Lower Brake Linkage Brake Shaft 2000 Series Z MASTER®Service Manual Page 7–3 Drive: Service and Repairs...
  • Page 100 Hydrostatic Drive Assembly g423104 Figure 101 RH Transaxle Assembly Bypass Rod Spacer Shaft LH Transaxle Assembly Drive: Service and Repairs Page 7–4 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 101 Drive Wheel Assembly g423112 Figure 102 2000 Series Z MASTER®Service Manual Page 7–5 Drive: Service and Repairs 3460-328 Rev A...
  • Page 102 LH & RH Motion Control Assembly Replacement LH & RH Motion Control Assembly 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 103 LH & RH Motion Control Assembly Removal (continued) g421550 Figure 104 8. Using a 1/2 inch socket, remove the (5/16 inch) bolt securing the LH & RH motion control dampeners to the chassis. g421551 Figure 105 9. Using a 9/16 inch wrench and a 3/4 inch socket, remove the (3/8 inch) lock nut and (1/2 inch) shoulder bolt securing the LH &...
  • Page 104 LH & RH Motion Control Assembly Removal (continued) g421549 Figure 106 LH & RH Control Assembly Installation 1. Install the LH & RH motion control assemblies. Using a 9/16 inch wrench and 3/4 inch socket, install the (3/8 inch) lock nut and (1/2 inch) shoulder bolt to secure the LH &...
  • Page 105 LH & RH Control Assembly Installation (continued) 3. Using a 1/2 inch socket, install the (1/2 inch) nut to secure the LH & RH motion control linkages to the transaxle assembly. Torque to 22 ± 3 N•m (200 ± 25 in-lb). Note: For the LH side: Connect the parking brake linkage to the parking brake handle and install the pin to secure the parking brake linkage to the handle.
  • Page 106 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 107 Hydrostatic Drive Belt Removal (continued) g420402 Figure 111 Hydrostatic Drive Belt Installation 1. Install the hydrostatic belt to the clutch. 2. Using a 1/2 inch breaker bar, rotate counter-clockwise to increase tension on the spring. g420403 Figure 112 3. Install the deck belt. Refer to Deck Belt Installation (page 5–9).
  • Page 108 Hydrostatic Drive Belt Installation (continued) 5. Connect the battery by installing the positive cable first, then the negative cable to the battery. Hydrostatic Transaxle Assembly Replacement Hydrostatic Transaxle Assembly 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 109 Hydrostatic Transaxle Assembly Removal (continued) g422381 Figure 114 8. Release the parking brake. Remove the 2 pins securing the lower parking brake linkages to the hydrostatic transaxle assembly. Remove the lower parking brake linkages. g422382 Figure 115 9. Remove the 2 cotter pins securing the bypass rods to the hydrostatic transaxle assembly.
  • Page 110 Hydrostatic Transaxle Assembly Removal (continued) g422385 Figure 116 11. Using a 1/2 inch socket, loosen the 8 lock nuts (4 per side) securing the hydrostatic transaxle assembly to the chassis. 12. While supporting the hydrostatic transaxle, remove the 4 loosened nuts from the chassis on one side.
  • Page 111 Hydrostatic Transaxle Assembly Installation (continued) g422382 Figure 118 5. Using a 5/8 inch wrench and a 1/2 inch socket, install the 2 (5/16 inch) shoulder bolts and lock nuts to secure the LH & RH motion control steering rods to the hydrostatic transaxle assembly. Torque to 22 ± 3 N•m (200 ± 25 in-lb).
  • Page 112 Hydrostatic Transaxle Assembly Installation (continued) g422387 Figure 119 9. Lower the machine. 10. Connect the battery by installing the positive cable first, then the negative cable to the battery. Drive: Service and Repairs Page 7–16 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 113 Chapter 8 Electrical Table of Contents General Information ..........................8–2 Service and Repairs ..........................8–3 Starter Solenoid Replacement ......................8–6 Starter Solenoid Continuity Tests ....................... 8–8 Control Panel Replacement ....................... 8–9 Main PTO Switch Replacement ....................... 8–14 PTO Clutch Coil Tests ........................8–15 Light Switch Replacement........................

  • Page 114: General Information

    General Information The electrical system operates on 12 VDC. The proper battery size is 300 CCA. 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 115: Service And Repairs

    Service and Repairs Electrical Assembly 1 (LON) g426945 Figure 120 Light Kit Wire Harness Wire Harness Adapter RH Neutral Switch Positive Battery Cable Edge Clip w/ Tie Solenoid Main PTO Switch Battery Light Switch Parking Brake Switch Ignition Switch ZMaster Wire Harness Ignition Key LH Neutral Switch Module Assembly...
  • Page 116 Electrical Assembly 2 (Kawasaki) g426943 Figure 121 Light Kit Wire Harness USB Power Port RH Neutral Switch Parking Brake Switch Edge Clip w/ Tie Battery Main PTO Switch ZMaster Wire Harness Light Switch LH Neutral Switch Ignition Switch Front Bumper Ignition Key Light Flush Mount Module Assembly...
  • Page 117 Electrical Assembly 3 (Briggs) g426944 Figure 122 Light Kit Wire Harness USB Power Port RH Neutral Switch Parking Brake Switch Edge Clip w/ Tie Wire Harness Adapter Main PTO Switch Battery Light Switch Z Master Wire Harness Ignition Switch LH Neutral Switch Ignition Key Front Bumper Module Assembly...

  • Page 118: Starter Solenoid Replacement

    Starter Solenoid Replacement Starter Solenoid 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 119 Starter Solenoid Removal (continued) g420413 Figure 125 Starter Solenoid Installation 1. Install the starter solenoid. Using a T30 torx driver, install the 2 (1/4 inch) bolts to secure the starter solenoid to the chassis. g420413 Figure 126 2. Using a 3/8 inch socket, install the 2 (#10) nuts to connect the 2 wire harness connectors to the starter solenoid.

  • Page 120: Starter Solenoid Continuity Tests

    Starter Solenoid Installation (continued) g420414 Figure 127 3. Using a 1/2 inch socket, install the 2 (5/16 inch) nuts to secure the battery positive and the battery positive starter cable to the starter solenoid. g420412 Figure 128 4. Connect the battery by installing the positive cable first, then the negative cable to the battery.

  • Page 121: Control Panel Replacement

    Coil Continuity 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. Disconnect the solenoid coil wires. 3. Set the multimeter to measure resistance (OHMs setting). 4.
  • Page 122 Control Panel Removal (continued) g421555 Figure 130 5. Disconnect the wire harness from the light switch (note orientation). g421547 Figure 131 6. Disconnect the wire harness from the ignition switch. Electrical: Service and Repairs Page 8–10 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 123 Control Panel Removal (continued) g421542 Figure 132 7. Disconnect the wire harness from the hourmeter. g421541 Figure 133 8. Disconnect the wire harness from the USB power port. g421559 Figure 134 9. Using a 1/4 inch socket, remove the 2 (#8) bolts securing the throttle and choke cables to the engine.
  • Page 124 Control Panel Removal (continued) 11. Remove the control panel. g421536 Figure 135 Control Panel Installation 1. Install the control panel. 2. Hook the throttle and choke cables to the carburetor linkage. 3. Using a 1/4 inch socket, install the 2 (#8) bolts to secure the throttle and choke cables to the engine.
  • Page 125 Control Panel Installation (continued) g421541 Figure 137 6. Connect the wire harness to the ignition switch. g421542 Figure 138 7. Connect the wire harness to the light switch. 8. Connect the wire harness to the main PTO switch. 2000 Series Z MASTER®Service Manual Page 8–13 Electrical: Service and Repairs 3460-328 Rev A...

  • Page 126: Main Pto Switch Replacement

    Control Panel Installation (continued) g421555 Figure 139 9. Using a T30 torx driver, install the 2 (1/4 inch) screws to secure the control panel to the RH cover panel. 10. Connect the battery by installing the positive cable first, then the negative cable to the battery.

  • Page 127: Pto Clutch Coil Tests

    Main PTO Switch Testing g427669 Figure 140 Using a digital multimeter set to the OHM or Continuity setting, verify the following: 1. Switch open (PTO not engaged) • Pin 2 and 4 should NOT have continuity • Pin 2 and 1 should have continuity •...

  • Page 128: Light Switch Replacement

    Clutch Coil Continuity to Ground Test (continued) 4. Connect one multimeter lead to the engine, chassis, or battery ground. Connect the other multimeter lead to each of the clutch connector terminals. • The clutch connector terminals should never have continuity to ground and should be OPEN at all times.

  • Page 129: Ignition Switch Replacement

    Light Switch Testing g427667 Figure 141 The light switch is a Single Pole Single Throw switch that supplies battery voltage to the front light and any added accessory light. When switched on, the circuit closes, and there is continuity between the terminals. •...

  • Page 130: Hourmeter Replacement

    Ignition Switch Testing g353109 Figure 142 Using a digital multimeter set to the OHM or Continuity setting, verify the following: Position Circuit Continuity None B+R+I+A START B+R+I+S Hourmeter Replacement Hourmeter Removal 1. Connect the battery by installing the positive cable first, then the negative cable to the battery.

  • Page 131: Usb Power Port Replacement

    Hourmeter Testing (continued) g336418 Figure 143 USB Power Port Replacement USB Power Port 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 132 Left and Right Neutral Switch Removal (continued) g421553 Figure 144 Left and Right Neutral Switch Installation 1. Install the neutral safety switches. Connect the wire harness to the LH & RH neutral safety switches. g421553 Figure 145 2. Install the LH and RH pods. Refer to Left Hand Pod Installation (page 6–21) Right Hand Pod Installation (page 6–23).

  • Page 133: Parking Brake Switch Replacement

    Left and Right Neutral Switch Testing g427668 Figure 146 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. This allows battery voltage to flow to the Smart Hour Meter for the safety interlock system.
  • Page 134 Parking Brake Switch Removal (continued) g421531 Figure 147 Parking Brake Switch Installation 1. Install the parking brake switch. Connect the wire harness to the parking brake switch. g421531 Figure 148 2. Connect the wire harness to the seat pressure switch and lower the seat into place.

  • Page 135: Flush Front Light Replacement

    Parking Brake Switch Installation (continued) 4. Connect the battery by installing the positive cable first, then the negative cable to the battery. Parking Brake Switch Testing g427668 Figure 149 The parking brake switch is a single pole plunger type switch (normally open) with two terminals.
  • Page 136 Flush Front Light Removal (continued) g421534 Figure 150 4. Using a 5/16 inch socket, remove the 2 (#10) bolts securing the flush front light to the chassis. g421546 Figure 151 5. Disconnect the main wire harness from the flush front light. Remove the flush front light.

  • Page 137: Electrical Break-Out, Voltage Drop Results

    Flush Front Light Installation 1. Install the flush front light. Connect the main wire harness to the flush front light. 2. Using a 5/16 inch socket, install the 2 (10#) bolts to secure the flush front light to the chassis. 3.
  • Page 138 Electrical Break-Out, Voltage Drop Results (continued) Ignition Switch Pins Key Run Engine Run Wire Color Key Off Key Start Blue/White Orange Pink Smart Hourmeter Pins Wire Engine Run Switch Switch Color Start Open Closed White Black Green Yellow Brown Violet Gray Orange USB Port...
  • Page 139 Electrical Break-Out, Voltage Drop Results (continued) Pink PTO Clutch Pins Wire Color PTO Active PTO Inactive Brown Black TVS Diode Pins Wire Color PTO Active PTO Inactive Black Brown RH Neutral Switch Pins Wire Color Switch Open Switch Closed Pink Green LH Neutral Switch (test with RH switch closed) Pins...
  • Page 140 Electrical: Service and Repairs Page 8–28 2000 Series Z MASTER®Service Manual 3460-328 Rev A...
  • Page 141 Appendix A Foldout Drawings Table of Contents Electrical Drawing Abbreviations......................A–2 TORO Engine Schematic........................A–3 TORO Engine Powered Schematic....................A–4 Kawasaki Engine Schematic......................A–5 Kawasaki Engine Powered Schematic....................A–6 Briggs & Straton Engine Schemaitc ....................A–7 Briggs & Straton Engine Powered Schematic ..................A–8 2000 Series Z MASTER®Service Manual Page A–1...

  • Page 142: 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 143: Toro Engine Schematic

    TORO Engine Schematic g428067 , Drawing Rev A, Sheet 1 3460-328 Rev A Page A–3...

  • Page 144: Toro Engine Powered Schematic

    TORO Engine Powered Schematic g428068 Page A–4 3460-328 Rev A , Drawing Rev , Sheet...

  • Page 145: Kawasaki Engine Schematic

    Kawasaki Engine Schematic g427871 , Drawing Rev , Sheet 3460-328 Rev A Page A–5...

  • Page 146: Kawasaki Engine Powered Schematic

    Kawasaki Engine Powered Schematic g427980 Page A–6 3460-328 Rev A , Drawing Rev , Sheet...

  • Page 147: Briggs & Straton Engine Schemaitc

    Briggs & Straton Engine Schemaitc g427875 , Drawing Rev , Sheet 3460-328 Rev A Page A–7...

  • Page 148: Briggs & Straton Engine Powered Schematic

    Briggs & Straton Engine Powered Schematic g427876 Page A–8 3460-328 Rev A , Drawing Rev , Sheet...

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