LCE Products

Z Master Z400
Series
Service Manual
 ABOUT THIS MANUAL
This service manual was written expressly for Toro service technicians. The Toro Company has
made every effort to make the information in this manual complete and correct.

Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents
lists the systems and the related topics covered in this manual.

The following service materials are available in addition to this service manual:

Hydrostatic Pumps: Hydro-Gear BDP-10A/16A/21L - Service and Repair Manual

Form #492-4789
Wheel Motors: Parker/Ross Wheel Motor Service Manual
Form #492-4753
Diesel Engine: Briggs & Stratton Daihatsu 3 Cylinder Liquid-Cooled Engine Repair Manual
Form #492-0670
Hydraulic Troubleshooting: Interactive hydraulic troubleshooting and failure analysis on compact disk
Form #492-4777
Electrical Troubleshooting: Interactive electrical troubleshooting and wiring diagrams on compact disk
Form # 492-9143

The Z Master 597 model years 2004 and 2005 are covered in this manual. The manual may also
be specified for use on later model products.

The hydrostatic drive system is precision machinery. Maintain strict cleanliness control during all
stages of service and repair. Cover or cap all hose ends and fittings whenever they are exposed.
Even a small amount of dirt or other contamination can severely damage the system.

We are hopeful that you will find this manual a valuable addition to your service shop. If you have
any questions or comments regarding this manual, please contact us at the following address:

The Toro Company

LCE Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420

The Toro Company reserves the right to change product specifications or this manual without
notice.

Copyright© All Rights Reserved

©2006 The Toro Company
THIS PAGE INTENTIONALLY LEFT BLANK.
 TABLE OF CONTENTS
Safety Information
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Specifications
Machine Profile Photos
Z 400 Estate Series 19 hp Kawasaki OHV V-Twin . . . . . . . . . . . . . . . . . . . . 2-2
Z 400 Estate Series 18 hp Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Z 450 Pro Performance Series 20 hp Kohler OHV V-Twin . . . . . . . . . . . . . . . . . 2-4
Z 100 Series 19 hp Kawasaki KAI OHV V-Twin . . . . . . . . . . . . . . . . . . . . . 2-5
Z 450 Pro Performance Series 23 hp Kawasaki OHV V-Twin . . . . . . . . . . . . . . . . 2-6
Z 440 Pro Value Series 19 hp Kawasaki KAI OHV V-Twin . . . . . . . . . . . . . . . . . 2-7
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Z 400 Series Manual Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Deck Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Cutting Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Cutting Decks continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Lubrication Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Service Aid Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Available Service Manuals / Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . . . 2-17
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) . . . . . . . . . . . . . . 2-18
Other Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Equivalents and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Chassis
Caster Fork Assembly Removal Estate Series with bushing front casters . . . . . . . . . . . . . 3-2
Caster Fork Assembly Installation Estate Series with bushing front casters . . . . . . . . . . . . 3-3
Caster Fork Assembly Removal Pro 100/400 Series with tapered roller front casters . . . . . . . . 3-4
Caster Fork Assembly Installation Pro 100/400 Series with tapered roller front casters . . . . . . . . 3-6
Front Wheel Removal and Bearing Replacement Estate Series . . . . . . . . . . . . . . . . . 3-8
Pro 100/400 Series with tapered roller front casters . . . . . . . . . . . . . . . . . . . . 3-12
Fuel Tank Removal
Left Side Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Left Side Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Right Side Fuel Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 3-16
Fuel Check Valve
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Fuel Shut Off Valve
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Pro 400 Series V-Twin Kohler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Z Master Z400 Service Manual i

TABLE OF CONTENTS
Chassis continued
Parking Brake Handle/Shaft Assembly Removal All models . . . . . . . . . . . . . . . . . . 3-18
Parking Brake Handle/Shaft Assembly Installation All models . . . . . . . . . . . . . . . . . 3-20
Brake Bar Removal (Estate Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Adjusting the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Brake Band Removal (Pro Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Brake Band Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Brake Shaft Removal (Pro Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Brake Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Deck Lift Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Deck Lift Lever Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Motion Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Motion Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Hydraulic System
Hydrostatic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hydrostatic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Replacing the Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installing the Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Idler Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Idler Arm Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Wheel Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Adjusting the Handle Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Setting the Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Setting the LH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Setting the RH Hydraulic Pump Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Adjusting the Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Purging the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Hydraulic Flow Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Pushing the Machine by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Changing to Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Engine
Kawasaki FH580V 19 hp Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Kawasaki FH580V 19 hp Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Kohler V-Twin 20 hp Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Kohler V-Twin 20 hp Engine Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Kohler 18 hp Single Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Kohler 18 hp Single Cylinder Install . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Z 100 Series FH580V (KAI) 19 hp Kawasaki Removal . . . . . . . . . . . . . . . . . . . . 5-34
Z 100 Series FH580V (KAI) 19 hp Kawasaki Install . . . . . . . . . . . . . . . . . . . . . 5-39

Electrical
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

ii Z Master Z400 Service Manual

 TABLE OF CONTENTS
Electrical continued
Seat Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Electrical Schematics
74412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
74410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
74411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
74413 and 74415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
74414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
74416 and 74417 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
74411TE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
74416TE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Mower Decks
Mower Deck Removal Estate Series . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Mower Deck Installation Estate Series . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Mower Deck Removal Z 400 Series (48” and 50” Decks) . . . . . . . . . . . . . . . . . . . 7-6
Mower Deck Installation Z 400 Series (48” and 50” Decks) . . . . . . . . . . . . . . . . . . 7-8
Mower Deck Removal Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . . . . . 7-10
Mower Deck Installation Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . . . . 7-12
Mower Spindle Removal Pro 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Mower Spindle Installation Pro 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Mower Spindle Removal Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . . . 7-16
Mower Spindle Installation Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . . 7-18
Mower Spindle Disassembly Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . . 7-18
Mower Spindle Assembly Estate Series & Pro 400 Series . . . . . . . . . . . . . . . . . . . 7-20
Mower Spindle Disassembly Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . . 7-23
Mower Spindle Assembly Z 100 Series (44” Deck) . . . . . . . . . . . . . . . . . . . . . . 7-24
Replacing the Mower Deck Drive Belt All Z 400 models . . . . . . . . . . . . . . . . . . . . 7-24
Replacing the Mower Deck Drive Belt Z 100 Series . . . . . . . . . . . . . . . . . . . . . 7-26
Adjusting the Mower Belt Tension Z 100 Series . . . . . . . . . . . . . . . . . . . . . . . 7-27
Adjusting the Mower Belt Tension Z 400 Series . . . . . . . . . . . . . . . . . . . . . . . 7-28
Leveling the Mower at 3 Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting up the Machine All models . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Leveling the Mower Side-to-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Adjusting the Front-to-Rear Mower Pitch . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Adjusting the Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Z Master Z400 Service Manual iii

TABLE OF CONTENTS

THIS PAGE INTENTIONALLY LEFT BLANK.

iv Z Master Z400 Service Manual

 SAFETY INFORMATION

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks . . . . . . . . . . . 7

Z Master Z400 Service Manual 1-1

 SAFETY INFORMATION
SAFETY INFORMATION
General Information The riding mower and attachment operator's manual
SAFETY INFORMATION This symbol means WARNING or contain safety information and operating tips for safe
PERSONAL SAFETY INSTRUCTION operating practices. Operator's manuals are available
General
GeneralInformation
- read the instruction because it has to
Information
The ridingyour
through mower and
Toro attachment
parts source or: operator’s manual
do with your safety. Failure to comply The riding
contain mower
safety and attachment
information and operator's
operating tipsmanual
for safe
This
This symbol
with means
the instruction
symbol WARNING
may resultorin
means WARNING or contain
operatingsafety
The Toroinformation
practices.
Company and
Operator’s operating
manuals tips
are for safe
available
PERSONAL SAFETY
personal injury
PERSONAL SAFETY INSTRUCTION
or even death.
INSTRUCTION operating
through practices.
the Internet,
Publications Operator's
your Toro
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Bloomington, MN 55420
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withsafety instructions
instruction may
may result
result in
provided inherein The Toro Company
Publications Department
personal
are for troubleshooting, injury or
service,
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8111 Lyndale Department
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Bloomington, MN 55420 South
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repairmanual Bloomington, MN 55420
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the Z of the Z400
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Z Master
Series Z597 Zero-turn
Zero-turn Riding Mower. Riding Mower

Think Safety First

Avoid unexpected starting of engine... Avoid injury from batteries...

Think
AlwaysSafety First
turn off the engine and disconnect the spark Battery acid is poisonous and can cause burns. Avoid
plug wire(s) before cleaning, adjusting, or repair. contact with skin, eyes, and clothing. Battery gases
Avoid unexpected starting of engine... can explode.
Avoid injury fromKeep cigarettes, sparks, and flames away
batteries...
Avoid lacerations and amputations... from the battery.
Always turn off the engine and disconnect the spark Battery acid is poisonous and can cause burns. Avoid
plugStay clearbefore
wire(s) of all moving
cleaning,parts whenever
adjusting, the engine is
or repair. contact
Avoidwith skin,due
injury eyes, and clothing.
to inferior Battery gases
parts...
running. Treat all normally moving parts as if they were can explode. Keep cigarettes, sparks, and flames away
moving
Avoid wheneverand
lacerations theamputations...
engine is running or has the Use
from theonly original equipment parts to ensure that
battery.
potential to start. important safety criteria are met.
Stay clear of all moving parts whenever the engine is
Avoid injury due to inferior parts...
running.
AvoidTreat all normally moving parts as if they were
burns... Avoid injury to bystanders...
moving whenever the engine is running or has the Use only original equipment parts to ensure that
Do notto
potential touch
start.the engine, muffler, or other components important Always safety
clear the areaare
criteria of bystanders
met. before starting or
which may increase in temperature during operation, testing powered equipment.
whileburns...
Avoid the unit is running or shortly after it has been Avoid injury to bystanders...
running. Avoid injury due to projectiles...
Do not touch the engine, muffler, or other components Always clear the area of bystanders before starting or
which may increase in temperature during operation, Always
testing clear the
powered area of sticks, rocks, or any other
equipment.
Avoid fires and explosions...
while the unit is running or shortly after it has been debris that could be picked up and thrown by the
Avoid
running. spilling fuel and never smoke while working with powered equipment.
Avoid injury due to projectiles...
any type of fuel or lubricant. Wipe up any spilled fuel or
oil immediately.
Avoid Never remove the fuel cap or add fuel Always
fires and explosions... Avoidclear the area of sticks, rocks, or any other
modifications...
when the engine is running. Always use approved, debris that could be picked up and thrown by the
Avoid spilling
labeled fuel andfor
containers never smoke
storing while working
or transporting fuelwith Never alter
and powered or modify any part unless it is a factory
equipment.
anylubricants.
type of fuel or lubricant. Wipe up any spilled fuel or approved procedure.
oil immediately. Never remove the fuel cap or add fuel Avoid modifications...
whenAvoidthe asphyxiation...
engine is running. Always use approved, Avoid unsafe operation...
labeled containers for storing or transporting fuel and Never alter or modify any part unless it is a factory
Never operate an engine in a confined area without Always procedure.
approved test the safety interlock system after making
lubricants.
proper ventilation. adjustments or repairs on the machine. Refer to the
Electrical section in this manual for more information.
Avoid unsafe operation...
Avoid asphyxiation...
Never operate an engine in a confined area without Always test the safety interlock system after making
proper ventilation. adjustments or repairs on the machine. Refer to the
Electrical section in this manual for more information.

1-2 Z Master Z400 Service Manual

 SPECIFICATIONS

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks . . . . . . . . . . . 7

Z Master Z400 Service Manual 2-1

 SPECIFICATIONS
Z 400 Estate Series
19 hp Kawasaki OHV V-Twin

Fig 001 DSC-4765a Fig 003 DSC-4767a

Fig 002 DSC-4766a Fig 004 DSC-4768a

2-2 Z Master Z400 Service Manual

 SPECIFICATIONS
Z 400 Estate Series
18 hp Kohler

Fig 005 DSC-4842a Fig 007 DSC-4844a

Fig 006 DSC-4843a Fig 008 DSC-4846a

Z Master Z400 Service Manual 2-3

 SPECIFICATIONS
Z 450 Pro Performance Series
20 hp Kohler OHV V-Twin

Fig 009 DSC-4833a Fig 011 DSC-4835a

Fig 010 DSC-4834a Fig 012 DSC-4838a

2-4 Z Master Z400 Service Manual

 SPECIFICATIONS
Z 100 Series
19 hp Kawasaki KAI OHV V-Twin

Fig 013 DSC-0437a Fig 015 DSC-0440a

Fig 014 DSC-0436a Fig 016 DSC-0435a

Z Master Z400 Service Manual 2-5

 SPECIFICATIONS
Z 450 Pro Performance Series
23 hp Kawasaki OHV V-Twin

Fig 017 DSC-0444a Fig 019 DSC-0442a

Fig 018 DSC-0445a Fig 020 DSC-0448a

2-6 Z Master Z400 Service Manual

 SPECIFICATIONS
Z 440 Pro Value Series
19 hp Kawasaki KAI OHV V-Twin

Fig 021 DSC-0452a Fig 023 DSC-0455a

Fig 022 DSC-0451a Fig 024 DSC-0450a

Z Master Z400 Service Manual 2-7

 SPECIFICATIONS
Engines

Output Make High Idle Low Idle Charging Coil

19 HP (14.2kW) Kawasaki 3650 + 100 RPM 1500 RPM 13 AMP
OHV V-Twin Forced Air Cooled
18 HP (13.4kW) Kohler 3650 + 100 RPM 1500 RPM 13 AMP
OHV Single Forced Air Cooled
19 HP (14.2kW) Kawasaki 3650 + 100 RPM 1500 RPM 13 AMP
OHV V-Twin Forced Air Cooled

2 20 HP (14.9kW)

23 HP (17.1kW)
Kohler
OHV V-Twin Forced Air Cooled
Kawasaki
3650 + 100 RPM

3650 + 100 RPM

1500 RPM

1500 RPM
13 AMP

13 AMP
OHV V-Twin Forced Air Cooled
19 HP (14.2kW) Kawasaki 3650 + 100 RPM 1500 RPM 13 AMP
OHV V-Twin Forced Air Cooled

Dimensions and Weight

ROPS Height Width

Model Weight Folded Upright Deck Deflector Length
19 HP Kawasaki 924 lbs 51” 69” 53.7” 68” 78”
52” 7-Gauge Deck (419.2kg) (129.54cm) (175.26cm) (136.4cm) (172.72cm) (198cm)
18 HP Kohler 889 lbs 51” 69” 49.7” 64” 78”
48” 7-Gauge Deck (407.78kg) (129.54cm) 175.26cm) (126.24cm) (162.56cm) (198cm)
19 HP Kawasaki 941 lbs 52” 70” 47” 61.3” 78”
44” SFS Deck (426.83kg) (132.08cm) (177.8cm) (119.38cm) (155.7cm) (198cm)
19 HP Kawasaki 1010 lbs 52” 70” 49.7” 64” 78”
48” TF Deck (458.13kg) (132.08cm) (177.8cm) (126.24cm) (162.56cm) (198cm)
20 HP Kohler 1092 lbs 52” 70” 53.7” 68” 78”
52” TF Deck (495-32kg) (132.08cm) (177.8cm) (136.4cm) (172.72cm) (198cm)
19 HP Kawasaki 1092 lbs 52” 70” 53.7” 68” 78”
52” TF Deck (495-32kg) (132.08cm) (177.8cm) (136.4cm) (172.72cm) (198cm)
23 HP Kawasaki 1092 lbs 52” 70” 53.7” 68” 78”
52” TF Deck (495-32kg) (132.08cm) (177.8cm) (136.4cm) (172.72cm) (198cm)
23 HP Kawasaki 1067 lbs 52” 70” 49.7” 64” 78”
48” TF Deck (483-98kg) (132.08cm) (177.8cm) (126.24cm) (162.56cm) (198cm)
19 HP Kawasaki 941 lbs 52” 70” 47” 61.3” 78”
44” SFS Deck (112cm) (426.83kg) (132.08cm) (177.8cm) (119.38cm) (155.7cm) (198cm)
23 HP Kawasaki 1092 lbs 52” 70” 53.7” 68” 78”
52” TF Deck (132cm) (495.32kg) (132.08cm) (177.8cm) (136.4cm) (172.72cm) (198cm)

2-8 Z Master Z400 Service Manual

 SPECIFICATIONS
Z 400 Series Manual Specifications

Frame Assembly Consists of front and rear frames bolted together

Front Frame Welded 2 x 2 x .188” structural steel tube, 7 Gauge front cross member
Rear Frame Welded tube and fabricated steel

Fuel System

Tanks Dual fuel tanks containing large fill necks and vented caps. Rotational
molded high density polyethylene. Mounted above drive wheels.
2
Capacity 10 gallons (37.8 l) [5 gallons per tank]
Check Valve In-line check valves
Fuel Filter 15 micron, replaceable in-line filter

Traction System

Models with 7-Gauge Deck Models with SFS and TF Decks

Hydraulic Pumps HydroGear 10cc BDP-10A with HydroGear 10cc BDP-10A with no shock valve
2300psi shock valve
Pump Drive Self-tensioning belt drive
Wheel Motors Parker TE Series (13.9cc) HydroGear HGM-15E (15.4cc)
Ground Speeds Infinitely variable: Infinitely variable:
Forward: 0-7.2 mph (11.6 km/hr) Forward: 0-8.3 mph (13.3 km/hr)
Reverse: 0-4.2 mph (6.7 km/hr) Reverse: 0-5.5 mph (8.8 km/hr)
Release Valves Contained in Pumps. Allow unit to be moved without engine running.
Hydraulic Fluid Mobil 1 Extended Performance 15W-50 Synthetic
System Capacity 2.1 quarts (2.0 liters)

Z Master Z400 Service Manual 2-9

 SPECIFICATIONS
Deck Drive

Models with 7-Gauge Deck Models with SFS and TF Decks

Clutch Warner Electromagnetic “Mag-Stop” with Warner Electromagnetic “Mag-Stop” with
120 ft-lbs. (162.7 Nm) rating 175 ft-lbs. (237-3 Nm) rating
Type Deep B-Groove pulley with belt from engine to deck
Take-Up Spring Idler system

2 Tires

Models with 7-Gauge Deck Models with SFS and TF Decks

Rear Drive Tires 4-ply with “turf master” tread 4-ply with “turf master” tread
20” x 10” – 10” 23” x 9.5” – 12” [Except as noted]
Front Caster Tires 4-ply with smooth tread 4-ply with smooth tread
11” x 4” – 5” 13” x 5” – 6” [Except as noted]
Tire Pressure 13psi (90 KPA)
20# rear and 25# front if equipped with mechanical bagger

Electrical System

Voltage 12 volt, negative ground

Battery Type 230 CCA
Fuses Blade type. Located by LH Side Control

2-10 Z Master Z400 Service Manual

 SPECIFICATIONS
Cutting Decks

48” (121.9cm) 44” (111.8cm) 48” (121.9cm) 52” (132.1cm) 112cm (44”) 132cm (52”)
& SFS Deck TF Deck TF Deck SFS Deck TF Deck
52” (132.1cm)
7-Gauge Deck
Configuration Side Discharge, mid-mounted rotary with three blades.
Construction 7-Gauge, Drawn 12 7 Gauge, High Strength Drawn 12 7 Gauge,
High Strength gauge steel 50,000 psi (3515.3 Kg-f / gauge steel High Strength
50,000 psi super flow 59cm) steel 5” (12.7cm) super flow 50,000 psi
(3515.3 Kg-f
/ 59cm)
steel welded
system deck
with welded
mounting
advanced Turbo Force flow
system, welded construction.
3/8” (9.5mm) steel discharge
system deck
with welded
mounting
(3515.3 Kg-f
/ 59cm) steel
5” (12.7cm)
2
construction. brackets and reinforcement plate doubles brackets and advanced
3/8” (9.5mm) gage wheel as a bagger attachment point. gage wheel Turbo Force
steel brackets. 1/2” brackets. 1/2” flow system,
discharge (12.7mm) (12.7mm) welded
reinforcement diameter steel diameter steel construction.
plate reinforcement reinforcement 3/8” (9.5mm)
rod on left rod on left steel
side. 11 gauge side. 11 gauge discharge
steel front steel front reinforcement
reinforcement reinforcement plate doubles
plate doubles plate doubles as a bagger
as bagger as bagger attachment
attachment attachment point.
point point.
Discharge Rubber discharge chute, spring Rubber discharge chute, spring Rubber Rubber
biased down toward operating biased down toward operating discharge discharge
position position. Adjustable flow chute, spring chute, spring
control baffle. biased down biased down
toward toward
operating operating
position position.
Adjustable
flow control
baffle.
Blade Tip 18,000+ ft/min (548.640cm/min) at high idle
Speed
Height of Cut Adjustable from the seat with range of 1.5” (38mm) – 4.5” (114mm) in .25” (6.4mm) increments.

Z Master Z400 Service Manual 2-11

 SPECIFICATIONS
Cutting Decks cont.

48” (121.9cm) 44” (111.8cm) 48” (121.9cm) 52” (132.1cm) 112cm (44”) 132cm (52”)
& SFS Deck TF Deck TF Deck SFS Deck TF Deck
52” (132.1cm)
7-Gauge Deck
Deck Deck Deck suspended from machine by four lift chains, and attached to rear
Suspension suspended wheel supports by two struts. The deck is pulled along the ground.
from machine
by four lift

2
chains, and
attached to
front cross
member by flat
strut arms and
cross brace.
The deck is
pulled along
the ground.
Belt Covers Plastic HDPE 14-gauge, Plastic HDPE deck covers. 14-gauge, Plastic HDPE
deck covers. formed steel Attached with swell latches. formed steel deck covers.
Attached with covers with covers with Attached with
swell latches. access holes access holes swell latches.
to allow to allow
greasing of greasing of
outer spindles outer spindles
without without
removal. removal.
Attached with Attached with
draw latches. draw latches.
Gage Wheels Three Three adjustable gage wheels to reduce scalping: three on front of deck (one
adjustable on left-hand side and two in center). Wheels have four adjustment positions.
gage wheels Rear gage wheels are optional.
to reduce
scalping on
the front of
deck (one on
the left-hand
side and two
in the center).
Wheels
have four
adjustment
positions.

2-12 Z Master Z400 Service Manual

 SPECIFICATIONS
Lubrication Fittings

48”/52” (132.1cm/121.9cm) SFS and TF Decks

7-Gauge Decks
Front Caster Pivots 2 removable plugs (1 per side) for periodic lubrication
Front Caster Wheels n/a 2 fittings (1 per side)
Lift Assembly 5 fittings
Brake Arms 2 fittings (1 per side)
Rear Deck Struts 2 fittings (1 per side)
Deck Spindles
Pump Idler Pivot
3 fittings (1 per spindle)
1 fitting 2
General Specifications
Greasing and Lubrication:
Grease: No. 2 general purpose lithium base or molybdenum grease
Where to add grease: See Service Aid and Belt Routing decals below (Fig. 025, 026, 027, 028).
4 3

4 3 2 1
Service Aid Decals D
SERVICE
NOTES: AID AND BELT ROUTING
11 12
D 12. MUST NOT SHOW LOSS
2 OF ADHESION OR LEGIBILITY
AFTER 15 MINUTES IMMERSION IN GASOLINE.
1 Every 10 hours (daily):
SERVICE AID AND BELT ROUTING 3 3 1. Check engine oil
11 12 11. MUST BE PROVIDED BY A SILKSCREEN VENDOR.
2
1 10. MUST BE PROVIDED INEvery
ROLL 50 DISPENSE,
hours: SHEET FORM
3 3 Every 10 hours (daily): 10 OR SPLIT BACKING. 2. Check hydraulic oil
1. Check engine oil 3. Check tire pressure--13 psi
4. Grease
9. MUST HAVE TEDLAR CLEAR blade spindle
OVER LAMINATE bearingsFOR ABRASION
Every 50 hours: 5. Grease front wheel bearings
10 GASOLINE RESISTANCE.6. Grease deck lift linkage
2. Check hydraulic oil 8 8
3. Check tire pressure--13 psi 7. Grease belt idler
4. Grease blade spindle bearings 9 8. MUST COMPLY WITH
7 (TURF) ANSI B71.4-1999 WHEN
5.
6.
C
Grease front wheel bearings
Grease deck lift linkage
APPLIED TO PAINTED METAL OR POLYETHYLENE
Every 250 hours:
FOR A PERIOD OF 24 HOURS.
9 9 7. Grease belt idler 6 6 8. Grease brake linkage
9. Inspect belt and tension
8 7 Every 250 hours: 7. ORIGINAL ARTWORK SHALL BEbelt
PROVIDED BY TORO
C 6 8. Inspect belt and tension
10. Grease idler
ENGINEERING DEPARTMENT, BLOOMINGTON, MN.
9. Grease brake linkage
6 10. Grease belt idler Every OF
6. DECAL SHALL LOSE NONE 1000ITS
hours (yearly):
INITIAL PROPERTIES
OR DIMENSIONS WHEN11. STORED BY and
Inspect covers TORO FOR ONE
Every 1000 hours (yearly): YEAR AT TEMPERATURESsafety systems
BELOW 100o F AND OUT OF
11. Inspect covers and 12. Inspect
DIRECT SUNLIGHT.3 DURING fasteners and
STORAGE, hoses
ADHESIVE
safety systems 3 13. Grease front caster pivot
12. Inspect fasteners and hoses SHALL NOT MIGRATE OR LOSE EFFECTIVENESS.
13. Grease front caster pivot
5 5.
4
ARTWORK MUST 5 BE CENTERED ON DECAL WITHIN
3 3 ±.030 UNLESS OTHERWISE SPECIFIED.
See operator's manual for
additional details.
13 4. LETTERING
13 COLOR: TORO CORDLESS BLUE NO. 500-97.
5 4 4 5 See operator's manual for B 107-1687

additional details. 3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26

B 13 13 2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-4

108-4050
Fig 026 107-1687A
1. MATERIAL: AVERY MX3200 WITH 1 MIL. TEDLAR CLEAR OVER
LAMINATE.
19 hp Kawasaki / 52” 7-Gauge Deck
Fig 025 108-4050
18 hp Kohler / 48”PRODUCT:
7-Gauge Deck
Z 100 SERIES
SIMILAR PARTS: -
19 hp Kawasaki / 44” SFS Deck 19 hp Kawasaki /SIZE:
48” TF Deck
width= 5.875 height= 5.50 radii= .12
20 hp Kohler / 52” TF Deck
19 hp Kawasaki / 52” TF Deck DRAWING
AUTH. #: C0312.04 L
A
CONFIDENTIAL

SYMBOLS
CONFORM

23 hp Kawasaki / 52” TF Deck RELEASE/CHANGE AUTHORIZATION NUMBER

TO ANSI STD
Y14.5M-1994
D
-SERVICE AID, TITLE

A 23 hp Kawasaki / 48” TF Deck DECAL BELT ROUTING

THIRD
ANGLE
PROJECTION
® THIS UNPUBLISHED DOCUMENT CONTAINS TORO CONFIDENTIAL AND
BLOOMINGTON, MINNESOTA INFORMATION. IT MAY NOT WHOLLY OR PARTLY BE COPIED, DISCLOS
OR USED FOR ANY PURPOSE WITHOUT WRITTEN PERMISSION FROM
DO NOT SCALE DRAWING CATION OCCURS, THE FOLLOWING NOTICE APPLIES: "© 1998 ALL RIG
UNLESS OTHERWISE SPECIFIED PRODUCED BY SIZE DRAWING NUMBER

Z Master Z400 Service Manual TOLERANCE IN

2-13
4
THREE PLACES TWO PLACES
DECIMALS
±.030
DECIMALS ANGLES
±.06 ±1
CAE3 B 108-4050
ORIGINATOR SCALE FILE
MARK MANTEUFUL 1:1 108-4050

4 3 2 RELEASED Version
1©Toro 2004
 4 3 2 1

SPECIFICATIONS NOTES:
12. MUST NOT SHOW LOSS OF ADHESION OR LEGIBILITY
AFTER 15 MINUTES IMMERSION IN GASOLINE.

11. MUST BE PROVIDED BY A SILKSCREEN VENDOR.

10. MUST BE PROVIDED IN ROLL DISPENSE, SHEET FORM
OR SPLIT BACKING.
11 12
2 10 9. MUST HAVE TEDLAR CLEAR OVER LAMINATE FOR ABRASION,
1
1. GASOLINE RESISTANCE.
3 3
8. MUST COMPLY WITH (TURF) ANSI B71.4-1999 WHEN
50 APPLIED TO PAINTED METAL OR POLYETHYLENE
2. FOR A PERIOD OF 24 HOURS.
10 3.
4. 7. ORIGINAL ARTWORK SHALL BE PROVIDED BY TORO
5. ENGINEERING DEPARTMENT, BLOOMINGTON, MN.
8 8 6.
7. 6. DECAL SHALL LOSE NONE OF ITS INITIAL PROPERTIES
9 7 OR DIMENSIONS WHEN STORED BY TORO FOR ONE
250 YEAR AT TEMPERATURES BELOW 100o F AND OUT OF
6 6 DIRECT SUNLIGHT. DURING STORAGE, ADHESIVE
SHALL NOT MIGRATE OR LOSE EFFECTIVENESS.

2
8.
9.
10. 5. ARTWORK MUST BE CENTERED ON DECAL WITHIN
±.030 UNLESS OTHERWISE SPECIFIED.
1000 4. LETTERING COLOR: TORO CORDLESS BLUE NO. 500-97.
3 3 11.
12. 3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26.
13.
2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-41.
5 4 5
Fig 029 fig. 55 m-5615
1. MATERIAL: AVERY MX3200 WITH 1 MIL. TEDLAR CLEAR OVER
LAMINATE.
13 13
107-1686 1. Cap 3. Cold fluid level - full
PRODUCT: Z 100 SERIES CE
2. Baffle 4. Hot fluid level - full
SIMILAR PARTS: -
SIZE: width= 5.875 height= 5.50 radii= .12
Fig 027 107-1686A
DRAWING

23 hp Kawasaki / 132cm (52” TF Deck) AUTH. #: C0312.04 LMK

CONFIDENTIAL
SYMBOLS
CONFORM
TO ANSI STD RELEASE/CHANGE AUTHORIZATION NUMBER DRFT.
Y14.5M-1994
TITLE
-SERVICE AID,
4 3 2 THIRD
ANGLE
PROJECTION
®
DECAL 1
BELT ROUTING (CE)
THIS UNPUBLISHED DOCUMENT CONTAINS TORO CONFIDENTIAL AND PROPR
BLOOMINGTON, MINNESOTA INFORMATION. IT MAY NOT WHOLLY OR PARTLY BE COPIED, DISCLOSED TO
OR USED FOR ANY PURPOSE WITHOUT WRITTEN PERMISSION FROM TORO.
DO NOT SCALE DRAWING CATION OCCURS, THE FOLLOWING NOTICE APPLIES: "© 1998 ALL RIGHTS RE
UNLESS OTHERWISE SPECIFIED PRODUCED BY SIZE DRAWING NUMBER
NOTES: TOLERANCE IN

CAE B 107-1686
THREE PLACES TWO PLACES
DECIMALS
12. MUST NOT SHOW LOSS OF ADHESION OR LEGIBILITY
±.030
DECIMALS ANGLES
±.06 ±1
ORIGINATOR SCALE FILE SHEET
MARK MANTEUFUL
AFTER 15 MINUTES IMMERSION IN1:1GASOLINE.
107-1686

4 11 12
2 10 3 2 BE PROVIDED BY A SILKSCREEN VENDOR.
11. MUST
RELEASED Version
1 ©Toro 2004-200

1 1.
3 3 10. MUST BE PROVIDED IN ROLL DISPENSE, SHEET FORM
OR SPLIT BACKING.
50
10
2. 9. MUST HAVE TEDLAR CLEAR OVER LAMINATE FOR ABRASION,
3. GASOLINE RESISTANCE.
4.
5. 8. MUST COMPLY WITH (TURF) ANSI B71.4-1999 WHEN
9 9 6. APPLIED TO PAINTED METAL OR POLYETHYLENE
7. FOR A PERIOD OF 24 HOURS.
8 7
6 7. ORIGINAL ARTWORK SHALL BE PROVIDED BY TORO
250 ENGINEERING DEPARTMENT, BLOOMINGTON, MN.
6
8.
9. 6. DECAL SHALL LOSE NONE OF ITS INITIAL PROPERTIES
10. OR DIMENSIONS WHEN STORED BY TORO FOR ONE
YEAR AT TEMPERATURES BELOW 100o F AND OUT OF
DIRECT SUNLIGHT. DURING STORAGE, ADHESIVE
1000 SHALL NOT MIGRATE OR LOSE EFFECTIVENESS.
3 3 11.
12. 5. ARTWORK MUST BE CENTERED ON DECAL WITHIN
13. ±.030 UNLESS OTHERWISE SPECIFIED.
5 4 4 5 4. LETTERING COLOR: TORO CORDLESS BLUE NO. 500-97.
3. LETTERING AND GRAPHICS COLOR: TORO WHITE NO. 500-26.
13 13
108-4051 2. BACKGROUND COLOR: TORO SEMI-GLOSS BLACK NO. 500-41.

1. MATERIAL: AVERY MX3200 WITH 1 MIL. TEDLAR CLEAR OVER

LAMINATE.
Fig 028 108-4051
PRODUCT: Z 100 SERIES CE
19 hp Kawasaki / 112cm (44” SFS Deck) SIMILAR PARTS: -
SIZE: width= 5.875 height= 5.50 radii= .12

DRAWING
AUTH. #: C0312.04 LMK 5-
CONFIDENTIAL

SYMBOLS
CONFORM
TO ANSI STD RELEASE/CHANGE AUTHORIZATION NUMBER DRFT. DA
Y14.5M-1994
TITLE
-SERVICE AID,
THIRD
ANGLE
PROJECTION
®
DECAL BELT ROUTING (CE)
THIS UNPUBLISHED DOCUMENT CONTAINS TORO CONFIDENTIAL AND PROPRIE
BLOOMINGTON, MINNESOTA INFORMATION. IT MAY NOT WHOLLY OR PARTLY BE COPIED, DISCLOSED TO OT
OR USED FOR ANY PURPOSE WITHOUT WRITTEN PERMISSION FROM TORO. IF
DO NOT SCALE DRAWING CATION OCCURS, THE FOLLOWING NOTICE APPLIES: "© 1998 ALL RIGHTS RESE
UNLESS OTHERWISE SPECIFIED PRODUCED BY SIZE DRAWING NUMBER
TOLERANCE IN

2-14 Z Master Z400 CAE

Service
B Manual
THREE PLACES TWO PLACES
DECIMALS
±.030
108-4051
DECIMALS ANGLES
±.06 ±1
ORIGINATOR SCALE FILE SHEET
MARK MANTEUFUL 1:1 108-4051 1

4 3 2 RELEASED Version
1 ©Toro 2004-2004
 SPECIFICATIONS
Hydraulic System Oil Capacity: 2.1 quarts (2.0 liters)
Fluid Type: Mobil 1 Extended Performance 15W-50 Synthetic
Fluid Level: Check the fluid level while the fluid is warm. The fluid should be between cold
and hot.
Note: The fluid level should be to the top of the hot level of the baffle,
when the fluid is hot (Fig. 000 above).

Model and Serial Number The unit model and serial number plate is located on the right hand side of the unit,

2
Location below the right side motion control lever (Fig. 000).

Fig 030 PICT-0046 Fig 031 configuration

Engine Model and Serial Number Consult the appropriate engine manufacture’s service literature for the
Identification: location and translation of the engine model and serial number information.
Hydrostatic Pumps Model and Serial The label (Fig. 000), can be located on the pump housing. It identifies the
Number: model and configuration of the BDP pump.

Available Service Manuals / Service Aids

Hydrostatic Pumps: Hydro-Gear BDP-10A/16A/21L – Service and Repair Manual
Form # 492-4789
Wheel Motors: Parker/Ross Wheel Motor Service Manual
Form # 492-4753
Hydraulic Troubleshooting: Interactive hydraulic troubleshooting and failure analysis on compact disk
Form #492-4777
Electrical Troubleshooting: Interactive electrical troubleshooting and wiring diagrams on compact disk
Form #492-9143

Z Master Z400 Service Manual 2-15

 SPECIFICATIONS

Torque Specifications Fastener Identification

Recommended fastener torque values are listed in the

following tables. For critical applications, as
determined by Toro, either the recommended torque or
a torque that is unique to the application is clearly
identified and specified in the service manual.

These torque specifications for the installation and

tightening of fasteners shall apply to all fasteners which

2 do not have a specific requirement identified in the

service manual. The following factors shall be
considered when applying torque: cleanliness of the
fastener, use of a thread sealant (Loctite), degree of
lubrication on the fastener, presence of a prevailing
torque feature, hardness of the surface underneath of
the fastener’s head, or similar condition which affects Figure A
the installation.
Inch Series Bolts and Screws
As noted in the following tables, torque values should
be reduced by 25% for lubricated fasteners to (A) Grade 1 (C) Grade 8
achieve the similar stress as a dry fastener. Torque (B) Grade 5
values may also have to be reduced when the fastener
is threaded into aluminum or brass. The specific
torque value should be determined based on the
aluminum or brass material strength, fastener size,
length of thread engagement, etc.

The standard method of verifying torque shall be

performed by marking a line on the fastener (head or
nut) and mating part, then back off fastener 1/4 of a
turn. Measure the torque required to tighten the
fastener until the lines match up.

Figure B

Metric Bolts and Screws

(A) Class 8.8 (B) Class 10.9

2-16 Z Master Z400 Service Manual

2
 SPECIFICATIONS

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws,
8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular
Thread Size
Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995
Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts)
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
# 6 - 32 UNC 15 ± 2 170 ± 20 23 ± 2 260 ± 20
10 ± 2 13 ± 2 147 ± 23
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20

2
# 8 - 32 UNC 29 ± 3 330 ± 30 41 ± 4 460 ± 45
# 8 - 36 UNF
13 ± 2 25 ± 5 282 ± 30
31 ± 3 350 ± 30 43 ± 4 31 ± 3 2
# 10 - 24 UNC 42 ± 4 475 ± 45 60 ± 6 674 ± 70
18 ± 2 30 ± 5 339 ± 56
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 17 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81

Note: Reduce torque values listed in the table above Note: The nominal torque values listed above for
by 25% for lubricated fasteners. Lubricated fasteners Grade 5 and 8 fasteners are based on 75% of the
are defined as threads coated with a lubricant such as minimum proof load specified in SAE J429. The
oil, graphite, or thread sealant such as Loctite. tolerance is approximately ± 10% of the nominal torque
value. Thin height nuts include jam nuts.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.

Z Master Z400 Service Manual 2-17

 SPECIFICATIONS

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with
Thread Size Regular Height Nuts Regular Height Nuts (
(Class 8 or Strong Nuts) Class 10 or Strong Nuts)
M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm
M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 53 ± 5 ft-lb 72 ± 7 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 92 ± 9 ft-lb 125 ± 12 N-m

2 M16 X 2.0
M20 X 2.5
166 ± 15 ft-lb
325 ± 33 ft-lb
225 ± 20 N-m
440 ± 45 N-m
229 ± 22 ft-lb
450 ± 37 ft-lb
310 ± 30 N-m
610 ± 50 N-m

Note: Reduce torque values listed in the table above Note: The nominal torque values listed above are
by 25% for lubricated fasteners. Lubricated fasteners based on 75% of the minimum proof load specified in
are defined as threads coated with a lubricant such as SAE J1199. The tolerance is approximately ± 10% of
oil, graphite, or thread sealant such as Loctite. the nominal torque value. Thin height nuts include jam nuts.

Note: Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.

2-18 Z Master Z400 Service Manual

 SPECIFICATIONS

Other Torque Specifications

SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts

Recommended Torque Thread Size Recommended Torque**

Thread Size
Square Head Hex Socket 7/16 - 20 UNF
65 ± 10 ft-lb 88 ± 14 N-m
Grade 5
1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb
1/2 - 20 UNF
5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 80 ± 10 ft-lb 108 ± 14 N-m
Grade 5
3/8 - 16 UNC

1/2 - 13 UNC
35 ± 10 ft-lb

75 ± 15 ft-lb
18 ± 3 ft-lb

50 ± 10 ft-lb
M12 X 1.25
Class 8.8
80 ± 10 ft-lb 108 ± 14 N-m 2
M12 X 1.5
80 ± 10 ft-lb 108 ± 14 N-m
Class 8.8

** For steel wheels and non-lubricated fasteners.

Thread Cutting Screws Thread Cutting Screws

(Zinc Plated Steel) (Zinc Plated Steel)

Type 1, Type 23, or Type F Thread Threads per Inch

Baseline Torque*
Size Type A Type B
Thread Size Baseline Torque*

No. 6 - 32 UNC 20 ± 5 in-lb No. 6 18 20 20 ± 5 in-lb

No. 8 - 32 UNC 30 ± 5 in-lb No. 8 15 18 30 ± 5 in-lb

No.10 - 24 UNC 38 ± 7 in-lb No. 10 12 16 38 ± 7 in-lb

1/4 - 20 UNC 85 ± 15 in-lb No. 12 11 14 85 ± 15 in-lb

5/16 - 18 UNC 110 ± 20 in-lb * Hole size, material strength, material thickness and
finish must be considered when determining specific
3/8 - 16 UNC 200 ± 100 in-lb
torque values. All torque values are based on non-
lubricated fasteners.

Conversion Factors

in-lb X 11.2985 - N-cm N-cm X - 0.08851 = in-lb

ft-lb X 1.3558 = N-m N-cm X 0.73776 - ft-lb

Z Master Z400 Service Manual 2-19

 SPECIFICATIONS

Equivalents and Conversions

Decimal and Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 16/32 0.53125 13.484
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288

2
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.9375 2.381 19/32 0.59375 15.081
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.541 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm

2-20 Z Master Z400 Service Manual

 SPECIFICATIONS

U.S. to Metric Conversions

To Convert Into Multiply By
Miles Kilometers 1.609
Yards Meters 0.9144
Feet Meters 0.3048
Linear Feet Centimeters 30.48
Measurement Inches Meters
0.0254
Inches Centimeters
2.54
Inches Millimeters
25.4

Area
Square Miles
Square Feet
Square Inches
Square Kilometers
Square Meters
Square Centimeters
2.59
0.0929
6.452
2
Acre Hectare 0.4047
Cubic Yards Cubic Meters 0.7646
Volume Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
Tons (Short) Metric Tons 0.9078
Weight Pounds Kilograms 0.4536
Ounces Grams 28.3495
Pressure Pounds/Sq. In. Kilopascal 6.895
Foot-pounds Newton-Meters 1.356
Work Foot-pounds Kilogram-Meters 0.1383
Inch-pounds Kilogram-Centimeters 1.152144
Quarts Liters 0.9463
Liquid Volume Gallons Liters 3.785
Liquid Flows Gallons/Minute Liters/Minute 3.785
Fahrenheit Celsius 1. Subtract 32°
Temperature
2. Multiply by 5/9

Z Master Z400 Service Manual 2-21

 SPECIFICATIONS

THIS PAGE INTENTIONALLY LEFT BLANK.

2-22 Z Master Z400 Service Manual

 CHASSIS

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks . . . . . . . . . . . 7

Z Master Z400 Service Manual 3-1

 CHASSIS
Caster Fork Assembly Removal 4. Remove the caster fork assembly from the front
frame (Fig. 034).
Estate Series with bushing front casters

1. Raise the front of the unit off the ground, allowing

enough clearance to remove the caster fork from the
bottom hub.

2. With a hammer and chisel, remove the top grease

cap (Fig. 032).

3 Fig 034 PICT-0003

5. Remove the spacer (Fig. 035).

Fig 032 PICT-0001 rev

3. Remove the E-ring (Fig. 033).

Fig 035 PICT-0004

Fig 033 PICT-0002

3-2 Z Master Z400 Service Manual

 CHASSIS
6. Remove the top and bottom bushings (Fig. 036). 2. Install the caster fork assembly into the front frame
(Fig. 038).

Fig 036 PICT-0005 rev

Fig 038 PICT-0008
3
Note: Ensure short caster spacer is installed prior
to assembling the caster assembly.
Caster Fork Assembly Installation
Estate Series with bushing front casters

1. Drive the upper and lower bushings in until they seat 3. Install the tall spacer (Fig. 039).
against the step in the housing (Fig. 037).

Fig 039 PICT-0009

Fig 037 PICT-0006 rev

Z Master Z400 Service Manual 3-3

 CHASSIS
4. When reinstalling the castor fork assembly on early 6. Install the top grease cap (Fig 042).
production Z400 Estates Series check for excessive
endplay between the E-ring groove and the top of
the spacer. To minimize endplay, adjust as needed
with 7/8” ID shims (Fig. 040).

3 Fig 042 PICT-0012

Fig 040 PICT-0010 Caster Fork Assembly Removal

Pro 100/400 Series with tapered roller front casters

5. Install the E-ring (Fig. 041). 1. Raise the front of the unit off the ground, allowing
enough clearance to remove the caster fork from the
bottom hub.

2. With a hammer and chisel, remove the top grease

cap (Fig. 043).

Fig 041 PICT-0011 rev

Fig 043 PICT-0205

3-4 Z Master Z400 Service Manual

 CHASSIS
3. Loosen and remove the caster nut (Fig. 044). 5. Remove cup washers (3) (Fig. 046).

Fig 044 PICT-0206 Fig 046 PICT-0208 3

4. Remove the caster fork and wheel assembly from 6. Remove the top tapered roller bearing (Fig. 047).
the frame (Fig. 045)

Fig 047 PICT-0209

Fig 045 PICT-0207

Z Master Z400 Service Manual 3-5

 CHASSIS
7. Remove the lower seal and lower tapered bearing 9. Remove the upper tapered bearing cup (Fig. 050)
(Fig. 048).

3 Fig 048 PICT-0210

Fig 050 PICT-0212

Caster Fork Assembly Installation

8. Remove the lower tapered bearing cup (Fig. 049)
Pro 100/400 Series with tapered roller front casters

1. Install the upper and lower tapered bearing cups

with the thick edge facing inside (Fig. 051).

Fig 049 PICT-0211

Fig 051 PICT-0213

3-6 Z Master Z400 Service Manual

 CHASSIS
2. Pack the upper and lower tapered roller bearings 4. Install the upper tapered bearing (Fig. 054).
prior to installation (Fig. 052).

Fig 052 PICT-0214

Fig 054 PICT-0216 3
5. Install the caster fork into the frame (Fig. 055).
3. Install the lower tapered bearing and lower seal with
the open end of the seal facing up (Fig. 053).

Fig 055 PICT-0207

Fig 053 PICT-0215

Z Master Z400 Service Manual 3-7

 CHASSIS
6. Install the three spring washers (Fig. 056). 8. Remove the grease plug located on the side of the
hub on the frame for the caster fork. Install a grease
fitting, and pump grease into the housing until
grease is passing through the upper bearing (Fig.

A 058).

B
C

3 Fig 056 washers line art

A. Dust cap C. Spring washers

B. Locknut
Fig 058 PICT-0217

7. Install the locknut and tighten until the spring

washers are flat, then back off 1/4 turn to properly 9. Replace the grease plug.
set the preload on the bearings (Fig. 057).
10. Install the top grease cap.

Front Wheel Removal and Bearing

Replacement (Estate Series)
1. Raise the front of the unit off the ground.

Fig 057 PICT-0206

3-8 Z Master Z400 Service Manual

 CHASSIS
2. Remove the wheel bolt and nut from the fork (Fig. 4. Remove the spacer nut from one side of the wheel
059). (Fig. 061).

Fig 059 PICT-0013 Fig 061 PICT-0015 rev

3
3. Remove the wheel from the fork (Fig. 060). 5. Remove the caster axle and second spacer nut from
the wheel (Fig. 062).

Fig 060 PICT-0014

Fig 062 PICT-0016 rev

Z Master Z400 Service Manual 3-9

 CHASSIS
6. Remove both caster seals from the wheel (Fig. 063). 7. Fill the center of the wheel cavity with grease and
work the grease into the race (Fig. 065).

3 Fig 063 PICT-0017

Fig 065 PICT-0020 rev

Caster Fork Wheel and Tire Assembly (Fig. 064)

8. Pack the wheel bearing prior to installation (Fig.
066).

H
A BC CB A

D
E E
F G
Fig 064 PICT-0018 rev

A. Seal Guard E. Spacer Nuts Fig 066 PICT-0019 rev

B. Caster Seal F. Axle Bolt
C. Taper Cone Bearing G. Axle Bolt Nut
D. Caster Axle H. Wheel & Tire Assembly

3-10 Z Master Z400 Service Manual

 CHASSIS
9. Install the wheel bearing (Fig. 067). 11. Repeat steps 8-10 for the other side of the wheel.

12. Install one spacer nut onto the caster axle (Fig. 069).

Fig 067 PICT-0022 rev 3

Fig 069 PICT-0024 rev

10. Install the caster seal (Fig. 068).

13. Insert caster axle/nut assembly into the wheel hub

and install the second spacer nut (Fig. 070).

Fig 068 PICT-0021 rev

Fig 070 PICT-0025 rev

Note: Spacer nuts should be installed an equal

distance onto each end of the caster axle.

Z Master Z400 Service Manual 3-11

 CHASSIS
14. Bearing pre-load is established by the torque of the 16. Install wheel and tire assembly into caster fork using
spacer nuts on the caster axle. Set spacer nuts at 80 wheel bolt and nut (Fig. 073). Tighten.
in-lbs. (9.0 Nm) with a torque wrench. Loosen, then
reset at 20 in-lbs. (2.3 Nm) (Fig. 071).

3 Fig 073 PICT-0028

Fig 071 PICT-0026 rev

Pro 100/400 Series with tapered roller front casters

15. Install both seal guards onto wheel hub (Fig. 072). 1. Raise the front of the unit off the ground.

2. Remove the wheel bolt and nut from the fork (Fig.
074).

Fig 072 PICT-0027

Fig 074 PICT-0218

3-12 Z Master Z400 Service Manual

 CHASSIS
3. Remove the wheel from the fork (Fig. 075). 5. Remove the front caster spacer (Fig. 077).

Fig 075 PICT-0220 Fig 077 PICT-0222 rev 3

4. Remove both bearing spacers (Fig. 076). 6. Remove both bearing seals (Fig. 078).

Fig 076 PICT-0221 rev Fig 078 PICT-0223 rev

Z Master Z400 Service Manual 3-13

 CHASSIS
7. Remove both taper cone bearings (Fig. 079). 10. Pack both tapered wheel bearings. Reassemble per
Fig. 000 (above).

Note: The axle bolt torque sets the pre-load on the

front caster wheel bearings. Tighten the axle
bolt to set the bearings then back off 1/4 turn.

Pump grease into the wheel bearings through the

grease fitting located on the rim (Fig. 081).

3 Fig 079 PICT-0224 rev

Caster Fork Wheel and Tire Assembly (Fig. 080).

G Fig 081 PICT-0227

A BC CBA Fuel Tank Removal

Left Side Fuel Tank Removal

1. Disconnect the negative battery cable from the

D battery. Drain the fuel tank.

E F
Fig 080 PICT-0225 rev

A. Seal Guard E. Axle Bolt

B. Caster Seal F. Axle Bolt Nut
C. Taper Cone Bearing G. Wheel & Tire Assembly
D. Caster Axle

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 CHASSIS
2. Remove the fuel hose clamp from the bottom of the 4. Carefully remove the control panel by lifting the
fuel tank (Fig. 082). panel and sliding it toward the middle of the unit.

Note: Do not disconnect any cables or wiring.

5. Remove the two bolts, lock washers and flat

washers from the front of the tank (Fig. 084).

Fig 082 PICT-0029

3
3. Remove the four screws retaining the control panel
to the fuel tank (Fig. 083). Fig 084 PICT-0031

6. Locate and remove the two nuts, springs, and

washers from the studs at the rear of the fuel tank
(Fig. 085).

Note: Rear tire removed for clarity.

Fig 083 PICT-0030

Fig 085 PICT-0032

Z Master Z400 Service Manual 3-15

 CHASSIS
7. Remove the fuel tank from the frame (Fig. 086). Location

There are two fuel check valves. They are located one
beneath each fuel tank approx 6” (15.2cm) down line
from the tank (Fig. 087).

3 Fig 086 PICT-0033

Left Side Fuel Tank Installation Fig 087 PICT-0001b

Reverse the order of removal.

Proper Installation

Right Side Fuel Tank Removal & Installation Flat side of the check valve faces fuel tank (Fig. 088).

Follow the same procedures for the Left Side Fuel Tank
Removal and Installation except skip the instructions for
removing the control panel.

Fuel Check Valve

Purpose
A B
The fuel check valve allows fuel to flow in only one
direction and equalizes fuel flow from both tanks.

Fig 088 PICT-0002b rev

A. From the tank B. To the engine

3-16 Z Master Z400 Service Manual

 CHASSIS
Fuel Shut-off Valve Pro 400 Series V-Twin Kohler

Fuel shut-off valve is located on the right hand side of

Purpose
the engine behind the seat (Fig. 090).

The fuel shut-off valve cuts off fuel flow to the engine for
transporting.

Location

Estate Series

Fuel shut-off valve is located on the left hand side of the

engine (Fig. 089).

3
Fig 090 PICT-0228 new

Proper Installation

The arrow at the bottom of the valve faces toward the

engine (Fig. 091).

Fig 089 PICT-0005b

Fig 091 PICT-0007b rev

Z Master Z400 Service Manual 3-17

 CHASSIS
Parking Brake Handle/Shaft 4. Remove the bolts from the outer bearing of the
parking brake shaft (Fig. 094).
Assembly Removal
All Models

1. Release the parking brake (forward position).

2. Lift the floor pan and remove the panel assembly by

removing the four fasteners retaining the panel to
the frame (Fig. 092).

3 Fig 094 PICT-0036

5. Remove the bolts from the inner bearing of the

parking brake shaft (Fig. 095).

Fig 092 PICT-0034

3. Remove the parking brake handle (Fig. 093).

Fig 095 PICT-0037

Fig 093 PICT-0035

3-18 Z Master Z400 Service Manual

 CHASSIS
6. Remove the E-ring from the outer end of the parking 8. Slide the parking brake shaft assembly out of the
brake shaft (Fig. 096). frame (Fig. 098).

Fig 096 PICT-0038 Fig 098 PICT-0040 rev

3
7. Remove the cotter pin and clevis pin holding the 9. Inspect the brake shaft and bushings for excessive
brake rod assembly to the parking brake shaft (Fig. wear. Replace any worn or broken components
097). (Fig. 099).

D E F

A B A C

Fig 097 PICT-0039 Fig 099 PICT-0041

A. Side Flange Bearings D. Clevis pin

B. Brake Shaft E. Cotter pin
C. Brake Lever F. E-Ring

Z Master Z400 Service Manual 3-19

 CHASSIS
Parking Brake Handle/Shaft 3. Remove the cotter pin and clevis pin from the brake
rod assembly where it attaches to the brake bar
Assembly Installation (Fig. 101).

All Models

Reverse the order of removal.

Brake Bar Removal (Estate Series)

1. Disengage the brake.

2. Remove the brake return spring (Fig. 100).

3
Fig 101 PICT-0043

4. Remove the two bolts and nuts retaining the brake

bar to each side of the frame (Fig. 102).

Fig 100 PICT-0042

Fig 102 PICT-0044

3-20 Z Master Z400 Service Manual

 CHASSIS
5. Remove the brake bar from the machine (Fig. 103). 3. Measure the distance vertically between the front
of the brake bar and the crown of the tire; the
measurement should be 7/8” to 1” (22 to 25mm)
(Fig. 104).

Fig 103 PICT-0045 3

Brake Installation
Reverse the order of removal

Adjusting the Parking Brake

Check the parking brake for proper adjustment.

1. Check tire pressure of all 4 tires.

2. Disengage the brake lever (lever down).

Fig 104 Figure 45

1. Brake lever 5. Vertical line from the

2. Tire front of brake bar to the
3. Brake bar tire crown
4. 7/8” to 1” (22 to 25mm)

Z Master Z400 Service Manual 3-21

 CHASSIS
4. If the measurement is not correct, proceed to the Brake Band Removal (Pro Series)
following steps.
Note: Procedure can be used for left hand or right
5. Remove the hairpin and cotter pin from the brake hand.
linkage (Fig. 105).
1. Raise the right rear wheel (Fig. 106).

3
Fig 105 Firgure 44

Fig 106 PICT-0229

1. Brake linkage 3. Hair pin and cotter pin
2. Yoke

2. Remove the four wheel lug nuts. Remove the wheel

assembly.
6. Adjust the yoke clockwise to shorten the distance;
counterclockwise to lengthen distance (Fig 105).

7. Measure the distance vertically between the front

of the brake bar and the crown of the tire; the
measurement should be 7/8” to 1” (22 to 25mm)
(Fig. 104).

8. Repeat steps 5 through 7 if additional adjustment is

needed.

9. Engage the parking brake (lever up) and ensure the

brake bar engages the tire (Fig. 104).

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 CHASSIS
3. Remove bolts, brake band retainer, spacers, and 2. Install the 3 bolts, brake band retainer, brake band,
brake band (Fig. 107). and spacers and tighten (Fig. 109).

A B
C

Fig 107 DSC-1626 rev Fig 109 DSC-1631 rev

3
A. 3 Bolts C. 3 Spacers
B. Brake Band Retainer D. Brake Band
3. Install wheel assembly and 4 wheel lug nuts.

Brake Band Installation

Brake Shaft Removal (Pro Series)
1. Install the brake band around the wheel hub (Fig.
108). 1. Raise the rear end of the machine and remove both
right and left wheels.

Note: To prevent the unit from rolling, block the two

front tires.

Fig 108 DSC-1629 rev

Z Master Z400 Service Manual 3-23

 CHASSIS
2. Remove the cotter pin and clevis pin from the brake 4. Cut the plastic tie that holds the fuel line to the brake
rod assembly (Fig. 110). shaft (Fig. 112).

3 Fig 110 PICT-0231 Fig 112 PICT-0235

3. Remove the left and right clevis spring clips from the 5. On both the right and left side, remove two bolts and
brake shaft (Fig. 111). nuts holding the flange bearings (Fig. 113).

Fig 111 PICT-0234 Fig 113 PICT-0236

3-24 Z Master Z400 Service Manual

 CHASSIS
6. Remove the brake shaft from the unit (Fig. 114). 2. Remove the lower stop bolt from the deck lift plate
(Fig. 115).

Fig 114 PICT-0237

Fig 115 PICT-0047
3
7. Inspect the brake shaft and flange bearings for
excessive wear. 3. With the mower deck in the transport position, place
a 4” x 4” block under each corner of the deck. Lower
the mower deck onto the support blocks to remove
the weight from the support chains (Fig. 116).
Brake Shaft Installation
Reverse the order of removal.

Deck Lift Lever Removal (All Models)

1. Park the machine on a level surface, disengage the
blade control (PTO), and turn the ignition key to OFF
to stop the machine. Remove the ignition key.

Fig 116 PICT-0048

Z Master Z400 Service Manual 3-25

 CHASSIS
4. Loosen jam nuts on the deck lift rods until the 6. Remove the two 4” x 4” blocks at the rear of the
deck support springs are fully extended. Repeat deck, leaving the blocks in place at the front of the
procedure for both deck lift rods (Fig. 117). mower deck. The mower deck linkage should now
be fully unloaded (Fig. 119).

3
Fig 117 PICT-0049
Fig 119 PICT-0051

5. Remove the hex nut from RH rear deck lift assembly.

Repeat procedure for LH rear deck lift assembly 7. Remove hex bolt, nut, and lift lever bushing from the
(Fig. 118). lower deck lift plate mounting location (Fig. 120).

Fig 118 PICT-0050 Fig 120 PICT-0053

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 CHASSIS
8. Loosen the top hex head flange nut at the deck lift 11. Remove the bracket that supports the lower RH
plate mounting location. Pivot the INNER deck lift corner of the panel assembly (Fig. 123).
plate up and back toward the RH motion control
lever (Fig. 121).

Fig 123 PICT-0055

3
Fig 121 PICT-0054 rev

12. Remove the hex bolts, bushings, and nylock nuts

connecting the deck lift arm plates to the mower
9. Lift the floor pan assembly to its fully opened deck rear cross-shaft lift assembly (Fig. 124).
position.

10. Remove the panel assembly by removing the four

fasteners retaining the panel to the frame (Fig. 122).

Fig 124 PICT-0057

Fig 122 PICT-0034

Z Master Z400 Service Manual 3-27

 CHASSIS
13. Remove the retainer clip from the lift lever grip 15. Inspect the deck lift lever assembly components for
assembly (Fig. 125). wear, especially the bushings (Fig. 127).

BC D E F
A

3 Fig 125 PICT-0059 rev Fig 127 PICT-0061 rev

A. Lift Handle Assembly D. Plates

B. Nuts E. Bushings
14. Carefully slide the lift lever grip assembly out of its C. Bolts F. Retainer Clip
carrier frame pivot (Fig. 126).

Deck Lift Lever Installation

1. Install the bracket that supports the lower RH corner
of the panel assembly (Fig. 128).

Fig 126 PICT-0060

Fig 128 PICT-0055

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 CHASSIS
2. For ease of installation, make sure deck lift arm 4. Install bolt, nut and bushing through the plates into
plates, bushings and hardware are installed on the the rear deck lift cross-shaft (Fig. 131).
deck lift lever assembly prior to installation (Fig.
129).

Fig 131 PICT-0064

3
Fig 129 PICT-0062 rev

5. Install the retainer clip on the deck lift lever assembly

shaft (Fig. 132).
3. Install lift lever assembly into front frame pivot
location (Fig. 130).

Fig 132 PICT-0065

Fig 130 PICT-0063

Z Master Z400 Service Manual 3-29

 CHASSIS
6. Rotate deck lift plate (inner) downward until lower 8. Raise deck lift lever assembly until deck mount
mounting holes line up with hole in carrier frame and swivels rest against deck rod jam nuts. Install HOC
deck lift plate (outer). From the outside of the frame pin into deck lift plate HOC holes that correspond to
install hex bolt, spacer, and flanged lock nut as the 3” (7.62cm) HOC position (Fig. 135).
shown. Tighten bolt (Fig. 133).

A
A B B
C
3
Fig 135 PICT-0068
Fig 133 PICT-0066
A. Swivel B. 3” (7.62mm)
A. Hex bolt C. Spacer HOC location
B. Flange locknut

9. Install lower “stop” bolt through inner and outer deck

7. Align rear deck mount swivels with ends of deck lift lift plates. Install nylock nut and tighten until hex nut
rods (Fig. 134). and bolt are seated firmly against the deck lift plates.
DO NOT over-tighten or deck lift plates will deform
inward causing HOC pin assembly to bind (Fig. 136).

Fig 134 PICT-0067

Fig 136 PICT-0069

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 CHASSIS
10. Install hex nut on end of deck lift rod. Tighten 12. Install the panel assembly with the four fasteners
against deck mount swivel. Repeat procedure for retaining the panel to the frame (Fig. 139).
opposite side deck lift swivel (Fig. 137).

Fig 139 PICT-0034

3
Fig 137 PICT-0070

14. Lower the floor pan assembly.

11. Raise mower deck to the transport position. Remove
the support blocks. Check the deck level adjustment
(refer to Mower Deck Leveling page x-xx). Readjust
compression spring length by turning front nut. Motion Control Assembly Removal
Spring should be compressed to a length of 11-1/8”
(28.26cm) between washers. Lock the front nut into This procedure applies to either the right or left motion
position by tightening the spring jam nut (Fig. 138). control assembly.

1. Remove the panel assembly by removing the 4

fasteners retaining the panel to the frame (Fig. 140).

Fig 138 PICT-0071 rev

Fig 140 PICT-0034

Z Master Z400 Service Manual 3-31

 CHASSIS
2. Remove the two bolts and washers retaining the 4. Disconnect the motion control dampener from the
lever assembly to the control arm shaft (Fig. 141). motion control assembly (Fig. 143).

3 Fig 141 PICT-0072 Fig 143 PICT-0074

3. Remove the cotter pin and clevis pin securing the 5. Remove the bolt and nut that retaining the ball joint
adjustable yoke of the neutral return bolt (Fig. 142). to the motion control shaft (Fig. 144).

Fig 142 PICT-0073 Fig 144 PICT-0076

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 CHASSIS
6. Disconnect neutral switch wire harness from the 8. Remove the two bolts and nuts that retain the flange
neutral switch (Fig. 145). bearing on the outside of the motion control (Fig.
147).

Fig 145 PICT-0078

3
Fig 147 PICT-0080

7. Remove the two bolts and nuts that retain flange

bearing on the inside of the motion control (Fig. 9. Remove the motion control assembly from the frame
146). (Fig. 148).

Fig 146 PICT-0079 Fig 148 PICT-0081

Motion Control Assembly Installation

Reverse the order of removal.

Z Master Z400 Service Manual 3-33

 CHASSIS

3 THIS PAGE INTENTIONALLY LEFT BLANK.

3-34 Z Master Z400 Service Manual

 HYDRAULIC SYSTEM

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks . . . . . . . . . . . 7

Z Master Z400 Service Manual 4-1

 HYDRAULIC SYSTEM
Hydrostatic Pump Removal 4. Drain the hydraulic oil from the hydraulic reservoir
tank.
Note: Cleanliness is a key factor in a successful
repair of any hydrostatic system. Thoroughly 5. Remove the hose clamp from the case drain
clean all exposed surfaces prior to any type hydraulic hose, located on the top inside of the
of maintenance. Cleaning all parts by using hydrostatic pump (Fig. 150).
a solvent wash and air drying is usually
adequate. As with any precision equipment, Note: Cap the hose and the fitting to prevent entry
all parts must be kept free of foreign material of dirt and debris.
and chemicals. Protect all exposed sealing
areas and open cavities from damage and
foreign material.

Upon removal all seals, O-rings, and gaskets

should be replaced. During installation, lightly
lubricate all seals, O-rings and gaskets with
clean petroleum jelly prior to installation.

This procedure shows the LH Hydrostatic

Pump being removed. Use these same
procedures to remove the RH Hydrostatic
Pump.

4 1. Disconnect the negative battery cable from the

battery.

2. Using compressed air, clean the area around the Fig 150 PICT-0083a
hydrostatic pump to make sure it is free from any dirt
and debris.

3. Remove the bolt, washer and nut located between 6. Remove the pump suction hydraulic line, located on
the ball joint and the control arm that retains the the front of the hydrostatic pump (Fig. 151).
tracking link rod to the hydro control arm (Fig. 149).

Fig 151 PICT-0084a

Fig 149 PICT-0082a

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 HYDRAULIC SYSTEM
7. Remove the two high pressure hydraulic lines, 9. Loosen the two square head set screws located on
located at the rear of the hydrostatic pump (Fig. the pump sheave and remove the pulley (Fig. 154).
152).

Fig 154 PICT-0090a

Fig 152 PICT-0086a

4
10. Loosen and remove the two bolts and nuts retaining
8. With a spring puller, remove the extension spring the hydrostatic pump to the frame (Fig. 155).
from the idler arm assembly and remove the cog belt
(Fig. 153).

Fig 155 PICT-0091a

Fig 153 PICT-0087a

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 HYDRAULIC SYSTEM
11. Remove the seat retainer rod (Fig. 156). Hydrostatic Pump Installation
1. Place the hydrostatic pump into the frame (Fig. 158).

Fig 156 PICT-0092a

Fig 158 PICT-0093a

12. Remove the hydrostatic pump from the frame (Fig.

4 157).
2. Install the bolt, washer and nut that retain the
tracking link rod to the hydro control arm (Fig. 159).
Tighten hardware.

Fig 157 PICT-0093a rev

Fig 159 PICT-0082a

13. For service work on the pump refer to the Hydro
Gear BDP-10A (PG)/16A/21L Service Manual, form
#492-4789.

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 HYDRAULIC SYSTEM
3. Loosely install the two bolts and nuts retaining the 5. Install the pump suction hydraulic line located on the
hydrostatic pump to the frame (Fig. 160). front of the hydrostatic pump (Fig. 162).

Fig 160 PICT-0091a Fig 162 PICT-0084a

4
4. Install the case drain hydraulic hose and hose clamp 6. Install the two high pressure hydraulic lines located
located on the top inside of the hydrostatic pump at the rear of the hydrostatic pump (Fig. 163).
(Fig. 161).

Fig 163 PICT-0086a

Fig 161 PICT-0083a

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 HYDRAULIC SYSTEM
7. Tighten the pump mounting bolts (Fig. 164). 10. Install the pulley.

11. Align the outer edge of the hydrostatic pump pulley

using a straight edge, to the outer edge of the
existing pump pulley (Fig. 166).

Note: Deck drive belt was removed for clarity.

B
A

Fig 164 PICT-0091a

8. Install the key in the hydrostatic pump shaft.

4 9. Apply some anti-seize compound to the shaft (Fig.

165).
Fig 166 PICT-0096a

A. Pump pulley B. Existing pump pulley

Note: Before installing the pulley replace the set
screws. The ends of the set screws have a
knurled cup point for retention and must not
be re-used. 12. Tighten the two square head set screws on the
pump sheave (Fig. 167).
Note: Apply a drop of thread-locking material to the
threads of each set screw.

Fig 167 PICT-0090a

Fig 165 PICT-0094a

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 HYDRAULIC SYSTEM
13. Install the cog belt onto the drive pulley. With a 15. Connect the negative battery cable to the battery.
spring puller, install the extension spring to the idler
arm assembly (Fig. 168). 16. Check the hydraulic fluid in the reservoir tank. Add
oil if necessary. Air will need to be purged from
system. Follow the procedures for Purging the
Hydraulic System, page x-xx.

17. Check the neutral adjustment. Follow procedures for

Adjusting the Handle Neutral, page x-xx.

Replacing the Pump Drive Belt

1. With a spring puller, remove the extension spring
from the idler arm assembly and remove the cog belt
from the pump drive and idler pulleys (Fig. 170).

Fig 168 PICT-0087a

14. Install the seat retainer rod (Fig. 169). 4

Fig 170 PICT-0097a

Fig 169 PICT-0092a

Z Master Z400 Service Manual 4-7

 HYDRAULIC SYSTEM
2. Remove the plastic tie holding the clutch harness to 4. Loosen the clutch stop rod and pivot away from the
frame (Fig. 171). clutch (Fig. 173).

Fig 171 PICT-0099a Fig 173 PICT-0104a

4
3. Unplug the clutch pigtail harness from the main 5. Remove the belt from the clutch drive pulley (Fig.
harness (Fig. 172). 174).

Fig 172 PICT-0100a Fig 174 PICT-0106a rev

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 HYDRAULIC SYSTEM
Installing the Pump Drive Belt 3. Remove the Idler Arm (Fig. 177).

Reverse the order of replacement.

Idler Arm Removal

1. With a spring puller, remove the extension spring
from the idler arm assembly and remove the cog belt
from the pump drive and idler pulleys (Fig. 175).

Fig 177 PICT-0109a

4. Inspect the idler arm and bushings for excessive

wear. Replace any worn or broken components
(Fig. 178). 4
Fig 175 PICT-0097a
A
B
2. Remove the belt from the idler sheave (Fig. 176).

D
C E
F
Fig 178 PICT-0110a rev

A. Idler arm Assembly D. Bushing

B. Bearing Sleeve (2) E. Washer (Thick) (2)
C. Washer (Thin) F. Bolt

Fig 176 PICT-0107a

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 HYDRAULIC SYSTEM
Idler Arm Installation 3. Remove the cotter pin from the wheel motor output
shaft (Fig. 180).
Reverse the order of removal

Wheel Motor Removal

This procedure is the same for both the right and left
wheel motors.

1. Disconnect the battery negative cable.

2. Raise the rear wheels of the machine off the ground

and support the frame with jackstands. Remove the
rear wheel (Fig. 179).

Fig 180 PICT-0001a

4
4. Loosen and remove nut securing hub to the wheel
motor output shaft (Fig. 181).

Note: Hold wheel hub in place as shown by

installing a pry bar into the notch of the hub.

Fig 179 PICT-0111a

Fig 181 PICT-0010a

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 HYDRAULIC SYSTEM
5. Install a wheel hub puller to the wheel hub. Place an 8. Remove the wheel motor bolts, lock washers,
impact wrench onto the puller and remove the wheel spacers and nuts (Fig. 184).
hub (Fig. 182).

Fig 184 PICT-0005a

Fig 182 PICT-0003a

Note: Toro Wheel Hub Puller, P/N TOR 4097, is

4
available through SPX (formerly OTC) 9. Remove the wheel motor (Fig. 185).
1-800-533-0492.

6. Place a drain pan under wheel motor.

7. Clean any dirt or debris away from the hydraulic line

fittings. Remove the hydraulic lines (Fig. 183).

Note: Make sure to cap the fittings and hoses

to prevent dirt from entering the hydraulic
system.

Fig 185 PICT-0006a

10. For service on the wheel motor refer to the Parker

Ross Service Manual, Form #492-4753.

Fig 183 PICT-0004a

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 HYDRAULIC SYSTEM
Wheel Motor Installation 3. Install and tighten the two hydraulic lines to the
wheel motor fittings (Fig. 188)
Note: As a reminder, prior to connecting the
hydraulic lines, the O-rings should be
replaced with new ones and lightly lubricated
with petroleum jelly.

1. Install wheel motor using the 4 bolts, spacers, lock

washers and nuts. Install spacer between the frame
and the motor housing. (Fig. 186).

Fig 188 PICT-0009a

4
4. Install the wheel hub assembly, making sure the
woodruff key is in place. Install the castle nut on the
wheel motor shaft. Torque the wheel hub nut to 125
ft-lbs. (169 Nm) (Fig. 189).
Fig 186 PICT-0007a
Note: Re-torque nut at 100 hours, and every 500
hours thereafter. Washer 1-523157 can be
used under nut to keep cotter pin engaged
2. Torque the wheel motor bolts to 75 to 85 ft-lbs. (102 with nut castellations.
to 115 Nm) (Fig. 187).

Fig 189 PICT-0012a

Fig 187 PICT-0008a

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 HYDRAULIC SYSTEM
5. Check the alignment between the cotter pin hole on Adjusting the Handle Neutral
the motor shaft and the castle nut openings. Adjust
the castle nut as needed for cotter pin installation. If motion control levers do not align, or move easily into
the console notch, adjustment is required. Adjust each
6. Install the cotter pin in the castle nut (Fig. 190). lever, spring and rod separately.

Note: Motion control levers must be installed

correctly. See Installing the Motion Control
Levers in the set up instructions.

1. Lift seat. Install jumper wire in seat switch harness.

2. Disengage the PTO, move the motion control levers

to the neutral locked position and set the parking
brake.

3. Stop the engine, remove the key and wait for all
moving parts to stop before leaving the operating
position.

4. Unlatch the seat and tilt the seat forward.

Fig 190 PICT-0011a 5. Begin with either the left or the right motion control
lever.

6. Move the lever to the neutral position but not locked

4
7. Install the rear wheel and wheel lug nuts and tighten. (Fig. 191).

8. Reconnect the battery negative cable to the battery.

9. Check the hydraulic fluid in the reservoir. Add oil

if necessary. Air will need to be purged from the
system. Follow the procedures on Purging the
Hydraulic System, page x-xx.

Fig 191 fig 50 G001046

1. Neutral locked position 3. Neutral position

2. Control lever

Z Master Z400 Service Manual 4-13

 HYDRAULIC SYSTEM
7. Pull lever back until the clevis pin (on arm below 10. Apply slight rearward pressure on the motion
pivot shaft) just begins to contact the end of the slot control lever, turn the head of the adjustment bolt
(just beginning to put pressure on the spring) (Fig. in the appropriate direction until the control lever is
192). centered in neutral lock position (Fig. 191).

Note: Keeping rearward pressure on the lower lever

will keep the pin at the end of the slot and
allow the adjustment bolt to move the lever to
the appropriate position.

11. Tighten the nut and jam nut (Fig. 192).

12. Repeat on the opposite side of the machine.

Setting the Hydraulic Pump Neutral

Note: Adjust handle neutral before making the
following adjustment. See Adjusting the
Handle Neutral, page x-xx.
Fig 192 fig 51 G001673
Note: This adjustment must be made with the drive

4 1.
2.
3.
Clevis pin in slot
Nut
Nut - LH thread
6.
7.
8.
Double nuts
Jam nut
Yoke
wheels turning.

1. Raise the frame and block up the machine so drive

4. Adjustment bolt 9. Ball joint wheels can rotate freely (Fig. 193).
5. Pump rod

8. Check where the control lever is relative to the notch

on the console (Fig. 000). It should be centered
allowing lever to pivot outward to neutral lock
position. (fig 50)

9. If adjustment is needed, loosen the nut and jam nut

securing the yoke (Fig. 000). fig 51

Fig 193 PICT-0013a rev

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 HYDRAULIC SYSTEM
2. Slide the seat fully forward, unlatch the seat and tilt 2. Adjust the pump rod length by rotating the knob in
the seat forward. the appropriate direction, until the wheel is still or
slightly creeping in reverse (Fig. 195).
3. Disconnect the electrical connector at the seat
switch located between the two hydraulic pumps.
Temporarily install a jumper wire across the
terminals in the wiring harness connector (Fig. 194).

Fig 195 PICT-0015a

Fig 194 PICT-0014a 3. Move the motion control lever forward and reverse,
then back to neutral. The wheel must stop turning or
4
slightly creep in reverse.
Setting the LH Hydraulic Pump 4. Run the engine at full speed. Make sure wheel
Neutral remains stopped or slightly creeps in reverse; adjust
if necessary.

1. Start the engine, open the throttle 1/2 way and

release parking brake.

Note: The motion control lever must be in neutral

while making any adjustments.

Z Master Z400 Service Manual 4-15

 HYDRAULIC SYSTEM
Setting the RH Hydraulic Pump 3. Adjust the pump rod length by rotating double nuts
on the rod, in the appropriate direction, until the
Neutral wheel is still or slightly creeps in reverse (Fig. 197).

1. Loosen the locknuts at the ball joints on the pump

control rod (Fig. 196).

Fig 197 PICT-0016a rev

4
Fig 196 PICT-0016a rev

4. Move the motion control lever forward and reverse,

then back to neutral. The wheel must stop turning or
slightly creep in reverse.
2. Start the engine, open throttle 1/2 way and release
parking brake. 5. Run the engine at full speed. Make sure the wheel
remains stopped or slightly creeps in reverse; adjust
Note: The motion control lever must be in neutral if necessary.
while making any adjustments.
6. Tighten the locknuts at the ball joints.
Note: The front nut on the pump rod has left-hand
threads. 7. After both pump neutrals are set, shut off the
machine.

8. Remove the jumper wire from the wire harness

connector and plug the connector into the seat
switch.

9. Reinstall the seat rod and lower the seat into

position.

10. Remove the jack stands.

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 HYDRAULIC SYSTEM
Adjusting the Tracking 2. Stop the machine and set the parking brake.

The left hand pump has a knob for adjusting the tracking 3. Unlatch the seat and tilt the seat forward to access
(Fig. 198). the tracking knob.

Note: Determine the left and right sides of the

machine from normal operating position.

4. To make the machine go right, turn the knob towards

the right side of the machine (Fig. 200).

Fig 198 PICT-0015a

1. Push both control levers forward the same distance

4
(Fig. 199). The machine should travel in a straight
Fig 200 fig. 57 m-6280
line. If not, proceed to step 2.
1. Pump rod 3. Tracking knob
2. Turn this way to 4. Turn this way to
track left track right

5. To make the machine go left, turn the knob towards

the left side of the machine (Fig. 000, above)

6. Repeat this adjustment until the tracking is correct.

Fig 199 PICT-0018a

Z Master Z400 Service Manual 4-17

 HYDRAULIC SYSTEM
Purging the Hydraulic System 3. When the wheel begins to spin on its own, keep it
engaged until the wheel drives smoothly (minimum 2
The traction system is self bleeding; however, it may be minutes).
necessary to bleed the system if fluid is changed or after
work is performed on the system. 4. Check the hydraulic fluid level and add fluid as
required to maintain proper level.
1. Raise the machine so the wheels are off the ground
and supported with jack stands (Fig. 201). 5. Repeat this procedure on the opposite wheel.

Hydraulic Flow Testing Procedure

Note: Cleanliness is a key factor in successful flow
testing of the hydraulic system. Thoroughly
clean all exposed surfaces prior to any type
of maintenance. Cleaning all parts by using
a solvent wash and air drying is usually
adequate. As with any precision equipment,
all parts must be kept free of foreign material
and chemicals. Protect all exposed sealing
areas and open cavities from damage and
foreign material.

4 Fig 201 PICT-0013a rev

Flow tester shown in this procedure, P/N
70661, contact your Distributor Sales Manager
to order.

2. Start the engine and run at low idle speed. Slowly

engage the motion control lever. If the wheel does
not rotate immediately, it may be necessary to spin
the wheel by hand to start purging air that is trapped
in the system (Fig. 202).

Fig 202 PICT-0019a

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 HYDRAULIC SYSTEM
1. Lift the back of the machine so the rear tires (left and 3. Loosen hydraulic lines at the pump to obtain enough
right) are off the ground. Place jack stands under clearance to connect flow tester to the hydrostatic
the rear frame to support the unit. Remove the rear high pressure lines (Fig. 205). Retighten fittings at
wheel from side of machine being flow tested; in this the pump.
case, the left rear wheel is removed (Fig. 203).

Note: Be careful not to place jack stands near

any moving parts or areas not capable of
supporting the weight of the machine.

Fig 205 PICT-0022a

4. Connect the hydraulic hose fittings to the hydraulic

4
Fig 203 PICT-0020a flow tester and tighten the fittings (Fig. 206). If the
flow tester is not bidirectional, make sure to connect
hoses correctly.

2. Clean all dirt and debris away from the hydraulic line
fittings. Remove the hydraulic lines. Make sure you
mark which hydraulic line goes to which fitting on
the wheel motor. If the hydraulic lines are reversed,
the motor will operate in the opposite direction (Fig.
204).

Fig 206 PICT-0023a

Fig 204 PICT-0021a

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 HYDRAULIC SYSTEM
5. Check the hydraulic reservoir and fill as needed with 11. Stroke the left hand hydrostatic lever fully forward.
Mobil 1 Extended Performance, 15w50 oil. Very slowly, rotate the “T” handle of the adjustable
flow tester restrictor valve until the pressure gauge
6. Disconnect the electric PTO clutch from the wiring reaches 300 psi (21 bar). Record the measured flow
harness to prevent accidental engagement of the (gallons/liters per minute).
mower deck.
12. With the unit at full engine speed, slowly rotate the
7. Disconnect the seat switch from the harness. “T” handle of the flow tester restrictor valve clock-
Temporarily install a jumper wire across the harness wise until the pressure gauge reads approximately
(Fig. 207). Move the seat back to the operating 1000 to 1200 psi (69 to 83 bar).
position.
CAUTION: DO NOT operate the machine for
extended period of time at high pressure.

13. Record the difference of “flow droop” of the pump.

For the Hydro-Gear 10A and BDP 12 pump,
maximum allowable “flow droop” is 1.5 gpm (6.8
liters/min). Any droop greater than 1.5 gpm (6.8
liters/min) is considered unacceptable and the pump
should be replaced, barring any other potential
causes for the pressure drop.

14. Return the motion control lever to neutral position

4
and return the levers to the neutral lock position.
Engage the parking brake. Slow the engine speed to
idle and turn the ignition switch to the OFF position.

15. Disconnect the hydraulic flow tester from the

Fig 207 PICT-0014a hydraulic lines.

16. Reconnect the hydraulic lines to the wheel motor.

Tighten the fittings.
8. Verify the restrictor valve on the hydraulic flow tester
is in the fully “Opened” position. 17. Tighten the hydraulic lines at the pump.

9. Start the machine. Run the unit for approximately 5 18. Check the hydraulic reservoir and fill as necessary to
minutes to warm the oil in the hydrostatic pumps. the “HOT” level mark. See, Checking the Hydraulic
Fluid, page x-xx.
10. Release the parking brake and bring both levers to
the inside neutral position. Run the engine at full 19. Reinstall the rear tire and lower the unit to the
RPM. ground. Remove the temporary jumper cable for the
seat and reconnect the seat switch. Reconnect the
electric PTO clutch connector.

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 HYDRAULIC SYSTEM
Pushing the Machine by Hand Changing to Machine Operation
Important: Always push the machine by hand. 1. Rotate the by-pass valves clockwise 1 turn to
Never tow the machine because operate the machine (Fig. 209).
hydraulic damage may occur.
Note: Do not over-tighten the by-pass valves.
1. Disengage the power take off (PTO) and turn the
ignition key to OFF. Move the levers to the neutral Note: The machine will not drive unless the by-pass
position and apply the parking brake. valves are turned in.

2. To hand push, rotate the by-pass valves counter-

clockwise 1 turn. This allows hydraulic fluid to by-
pass the pump enabling the wheels to turn (Fig.
208).

Important: Do not rotate the by-pass valves more

than 1 turn or the valves can come out of
the body and cause fluid to run out.

4
Fig 209 PICT-0024a

Fig 208 PICT-0024a

3. Disengage the parking brake before pushing.

Z Master Z400 Service Manual 4-21

 HYDRAULIC SYSTEM

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4-22 Z Master Z400 Service Manual

 ENGINE

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks/PTO . . . . . . . . . 7

Z Master Z400 Service Manual 5-1

 ENGINE
Kawasaki FH580V 19 hp Engine 4. Disconnect the oil pressure switch harness (Fig.
212).
Removal
1. Remove the battery negative cable from the battery.

2. Disconnect the choke cable by removing the top

clamp (Fig. 210).

Note: Rear Bumper removed for clarity.

Fig 212 PICT-0008c

5. Remove the positive (red) wire from the starter (Fig.

213).

Fig 210 PICT-0003b

5 3. Disconnect the throttle cable by removing the bottom

clamp (Fig. 211).

Fig 213 PICT-0009c

Fig 211 PICT-0004b

5-2 Z Master Z400 Service Manual

 ENGINE
6. Remove the (violet) wire from the voltage rectifier/ 8. Disconnect the white wire from the black wire
regulator (Fig. 214). connected to the engine magneto (Fig. 216).

Fig 214 PICT-0010c Fig 216 PICT-0012c

7. Disconnect the pink wire from the green wire 9. Turn the fuel shot-off valve to the “on” position (Fig.
connected to the fuel solenoid (Fig. 215). 217).

Fig 215 PICT-0011c Fig 217 PICT-0406

Z Master Z400 Service Manual 5-3

 ENGINE
10. Remove the fuel line clamp holding the fuel line to 13. Unplug the clutch pigtail harness from the main
the fuel pump. Remove the fuel line from the fuel harness (Fig. 220).
pump (Fig. 218).

Fig 220 PICT-0100a

Fig 218 PICT-0013c

14. Remove the center bolt and two spring washers

11. Remove the Mower Deck Drive Belt. Refer to Re- holding the electric PTO clutch (Fig. 221).
placing the Mower Deck Drive Belt on page x-xx.

12. Remove the plastic tie holding the clutch harness to

frame (Fig. 219).

Fig 221 PICT-0014c

Fig 219 PICT-0099a

5-4 Z Master Z400 Service Manual

 ENGINE
15. Remove the electric PTO clutch (Fig. 222). 17. Remove the drive belt from the pulley (Fig. 224).

Fig 222 PICT-0015c Fig 224 PICT-0017c

16. With a spring puller, remove the extension spring 18. Remove the pulley (Fig. 225).
from the idler arm assembly and remove the cog belt
from the pump drive and idler pulleys (Fig. 223).

Fig 225 PICT-0018c

Fig 223 PICT-0016c

Z Master Z400 Service Manual 5-5

 ENGINE
19. Remove the five engine mounting bolts (Fig. 226). Kawasaki FH580V 19 hp Engine
Note: The left rear mounting bolt has 4 ground Installation
wires attached.
1. Lower the engine to the frame (Fig. 228).

Fig 226 PICT-0019c

Fig 228 PICT-0021c

20. Connect a lift chain to the lift points on the engine.

Raise the engine from the frame (Fig. 227). 2. Install the five engine mounting bolts.

a. Install the clutch stop rod in the right rear engine

5
mounting bolt hole (Fig. 229). Do not tighten.

Fig 227 PICT-0020c

Fig 229 PICT-0022c

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 ENGINE
b. Install the four ground wires in the left rearmost 4. Apply a thread-locking compound to the clutch
mounting bolt hole (Fig. 230). retainer bolt (Fig. 232).

Fig 230 PICT-0019c Fig 232 PICT-0026c

3. Apply anti-seize compound to the engine shaft (Fig. 5. Install the hydro pump drive pulley and the electric
231). PTO clutch with the bolt and spring washers. Torque
the bolt to 55 ft-lbs. (74.6 Nm) (Fig. 233).

Fig 231 PICT-0025c

Fig 233 PICT-0027c

Z Master Z400 Service Manual 5-7

 ENGINE
6. Install the hydro pump drive belt (Fig. 234). 8. Install the mower drive belt. Refer to Replacing the
Mower Deck Drive Belt on page 7-24.

9. Plug the clutch pigtail harness into the main harness

(Fig. 236).

Fig 234 PICT-0106a rev

7. Align the clutch stop rod with the slot of the electric Fig 236 PICT-0100a
PTO clutch (Fig. 235). Rotate the clutch stop rod into
the slot on the clutch. Tighten the stop rod mounting
bolt.
10. Replace the plastic tie holding the clutch harness to
frame (Fig. 237).

Fig 235 PICT-0104a

Fig 237 PICT-0099a

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 ENGINE
11. Install the fuel line clamp that holds the fuel line to 13. Reconnect the pink wire to the green wire that
the fuel pump. Reinstall the fuel line to the fuel pump connects to the fuel solenoid (Fig. 240).
(Fig. 238).

Fig 240 PICT-0011c

Fig 238 PICT-0013c

14. Reconnect the (violet) wire to the voltage rectifier/

12. Reconnect the white wire to the black wire that regulator (Fig. 241).
connects to the engine magneto (Fig. 239).

Fig 241 PICT-0010c

Fig 239 PICT-0012c

Z Master Z400 Service Manual 5-9

 ENGINE
16. Reconnect the oil pressure switch harness (Fig. 17. Reconnecting the choke cable:
242).
a. Reconnect the z-bend of the choke cable to the
choke linkage (Fig. 244).

Note: The air cleaner cover has been removed for

clarity.

Fig 242 PICT-0008c

15. Reconnect the positive (red) wire to the starter (Fig.

243). Fig 244 PICT-0030c

Fig 243 PICT-0009c

5-10 Z Master Z400 Service Manual

 ENGINE
b. With the choke knob in the full down position 18. Reconnect the throttle cable:
(Fig. 245) and the choke linkage in the full open
position (left), tighten the cable clamp (Fig. 246). a. Reconnect the z-bend of the throttle cable to the
throttle linkage (Fig. 247).

Fig 245 PICT-0031c

Fig 247 PICT-0034c

b. Position the throttle control lever so that there is

approximately 1/2” (12.7mm) between the lever
and the full throttle position of the throttle slot
(Fig. 248).

Fig 246 PICT-0032c

Fig 248 PICT-0035c

Z Master Z400 Service Manual 5-11

 ENGINE
c. Pull the cable housing until the throttle linkage 3. Remove the eight bolts, washers and nuts that hold
is in the full throttle position. Tighten the cable the notched weight onto the rear of the machine.
clamp (Fig. 249). Remove the notched weight from the rear of the
machine (Fig. 250).

Fig 249 PICT-0036c

Fig 250 PICT-0265

19. Connect the battery negative cable.

4. Remove the 4 bolts and nuts that hold the tailpipe
guard to the right hand guard strap (Fig. 251).

Kohler V-Twin 20 hp Engine Removal

5 1. Remove the battery negative cable from the battery.

2. Raise the rear wheels of the machine off the ground

and support frame with jack stands. Remove both
rear wheels.

Fig 251 PICT-0267

5-12 Z Master Z400 Service Manual

 ENGINE
5. Remove the three sets of fasteners holding the right 7. Remove the two sets of fasteners holding the
hand muffler guard and guard strap to the frame hydraulic oil tank to the guard strap and fuel tank
(Fig. 252). support (Fig. 254).

Fig 252 PICT-0269 Fig 254 PICT-0272

6. Remove the right hand muffler guard and guard 8. Remove the two sets of fasteners holding the left
strap (Fig. 253). hand guard strap and muffler guard to the frame
(Fig. 255).

Fig 253 PICT-0275

Fig 255 PICT-0273

Z Master Z400 Service Manual 5-13

 ENGINE
9. Remove the left hand guard strap and muffler guard 11. Loosen the right clamp and disconnect the throttle
(Fig. 256). cable (Fig. 258).

Fig 256 PICT-0274 Fig 258 PICT-0280

10. Loosen the left clamp and disconnect the choke 12. Turn the fuel shut-off valve to the “Off” position (Fig.
cable (Fig. 257). 259).

Fig 257 PICT-0279 Fig 259 PICT-0281

5-14 Z Master Z400 Service Manual

 ENGINE
13. Remove the fuel hose clamp, then the fuel hose 15. Remove the blue wire located on the starter solenoid
located at the fuel pump (Fig. 260). (Fig. 262).

Fig 260 PICT-0282 Fig 262 PICT-0284

14. Remove the red wires located on the starter solenoid 16. Unplug the engine wiring harness (Fig. 263).
(Fig. 261).

Fig 263 PICT-0285

Fig 261 PICT-0283

Z Master Z400 Service Manual 5-15

 ENGINE
17. Remove the mower drive belt from the electric PTO 20. Remove the electric PTO clutch (Fig. 266).
clutch, refer to Replacing the Mower Deck Drive Belt
page x-xx.

18. Unplug the clutch pigtail harness from the main

harness (Fig. 264).

Fig 266 PICT-0015c

21. With a spring puller, remove the extension spring

Fig 264 PICT-0100a from the idler arm assembly. Remove the cog belt
from the pump drive and idler pulleys (Fig. 267).

19. Remove the center bolt and two spring washers

holding the electric PTO clutch to the engine

5
crankshaft (Fig. 265).

Fig 267 PICT-0016c

Fig 265 PICT-0014c

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 ENGINE
22. Remove the drive belt from the engine pulley (Fig. 24. Remove the 4 engine mounting bolts (Fig. 270).
268).
Note: The left rear engine mounting bolt has 3
ground wires attached.

Fig 268 PICT-0017c

Fig 270 PICT-0287

23. Remove the engine pulley (Fig. 269).

25. Connect chains to the two lift points on the engine

and raise the engine from the frame (Fig. 271).

Fig 269 PICT-0018c

Fig 271 PICT-0290

Z Master Z400 Service Manual 5-17

 ENGINE
Kohler V-Twin 20 hp Engine Install 4. Install the engine pulley (Fig. 274).

1. Lower the engine onto the frame. Install 4 bolts and

spring washers through the frame and into the base
of the engine. Tighten the bolts (Fig. 000). 0287 left

Note: The 3 ground wires attach to the left rear

engine mounting bolt.

2. Apply anti-seize compound to the engine shaft (Fig.

272).

Fig 274 PICT-0018c

5. Install the drive belt onto the engine pulley (Fig.

275).

Fig 272 PICT-0025c

5
3. Apply a thread-locking compound to the clutch
retainer bolt (Fig. 273).

Fig 275 PICT-0017c

Fig 273 PICT-0026c

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 ENGINE
6. Install the cog belt onto the pump drive and idler 8. Install the center bolt and two spring washers that
pulleys. With a spring puller, install the extension hold the electric PTO clutch to the engine crankshaft
spring onto the idler arm assembly (Fig. 276). (Fig. 278).

Fig 276 PICT-0016c Fig 278 PICT-0014c

7. Install the electric PTO clutch (Fig. 277). 9. Torque the center bolt to 55 ft-lbs. (74.6 Nm) (Fig.
279).

Fig 277 PICT-0015c

Fig 279 PICT-0027c

Z Master Z400 Service Manual 5-19

 ENGINE
10. Plug the clutch pigtail harness into the main harness 13. Connect the blue wire onto the starter solenoid (Fig.
(Fig. 280). 282).

Fig 280 PICT-0100a Fig 282 PICT-0284

11. Install the mower drive belt onto the electric PTO 14. Connect the red wires onto the starter solenoid (Fig.
clutch. Refer to Replacing the Mower Deck Drive 283).
Belt page 7-24.

12. Plug in the engine wiring harness (Fig. 281).

Fig 283 PICT-0283

Fig 281 PICT-0285

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 ENGINE
15. Connect the fuel hose clamp onto the fuel hose at 17. Reconnect the throttle cable:
the fuel pump (Fig. 284).
a. Position the throttle control lever so that there is
approximately 1/2” (12.7mm) between the lever
and the full throttle position of the throttle slot
(Fig. 286).

”
1/2
Fig 284 PICT-0282

16. Turn the fuel shut-off valve to the “on” position (Fig. Fig 286 PICT-0293
285).

b. Reconnect the z-bend of the throttle cable to the

throttle linkage (the hole furthest from the pivot

5
point). Pull the cable housing until the throttle
linkage is in the full throttle position. Tighten the
cable clamp (Fig. 287).

Fig 285 PICT-0281

Fig 287 PICT-0294

Z Master Z400 Service Manual 5-21

 ENGINE
18. Reconnecting the choke cable: 19. Install the left hand guard strap and muffler guard to
the frame using the two sets of fasteners (Fig. 290).
a. Push the choke knob into the full down position
(Fig. 288).

Fig 290 PICT-0273

Fig 288 PICT-0296

20. Install the hydraulic oil tank to the guard strap and
fuel tank support using the two sets of fasteners
b. Reconnect the z-bend of the choke cable to the (Fig. 291).
choke linkage. The choke linkage should be in
the full open position (right). Tighten the cable
clamp (Fig. 289).

Fig 291 PICT-0272

Fig 289 PICT-0297

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 ENGINE
21. Install the right hand muffler guard and strap guard 23. Install the notched weight onto the rear of the
using three sets of fasteners (Fig. 292). machine using eight bolts, washers and nuts (Fig.
294).

Fig 292 PICT-0269

Fig 294 PICT-0265

22. Install the tailpipe guard to the right hand guard strap
using two bolts and nuts on the right hand side of the 24. Install the rear wheels. Lower the rear of the
machine (Fig. 293). machine.

25. Reconnect the battery negative cable.

Fig 293 PICT-0267

Z Master Z400 Service Manual 5-23

 ENGINE
Kohler 18 hp Single Cylinder Removal 5. Remove the front cable clamp and disconnect the
throttle cable (Fig. 297).
1. Remove the battery negative cable from the battery.

2. Raise the rear wheels of the machine off the ground

and support the frame with jack stands. Remove
both rear wheels.

3. Remove the 6 bolts, washers and nuts holding the

rear bumper to the frame (Fig. 295). Remove the
rear bumper.

Fig 297 PICT-0324

6. Remove the green oil sending wire from the oil

pressure switch (Fig. 298).

Fig 295 PICT-0321

5
4. Loosen the rear cable clamp and disconnect the
choke cable (Fig. 296).

Fig 298 PICT-0325

Fig 296 PICT-0323

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 ENGINE
7. Unplug the magneto and charging circuit wire 9. Turn the fuel shut-off valve to the “off” position (Fig.
harness (Fig. 299). 301).

Fig 299 PICT-0327 Fig 301 PICT-0329

8. Disconnect the three ground wires located at the 10. Remove the fuel hose clamp on the fuel hose
right hand engine lift point (Fig. 300). Reinstall the located at the fuel pump (Fig. 302).
engine lift bracket.

Fig 302 PICT-0330

Fig 300 PICT-0328

Z Master Z400 Service Manual 5-25

 ENGINE
11. Remove the red wires located on the starter solenoid 13. Remove the mower drive belt from the electric PTO
(Fig. 303). clutch. Refer to Replacing the Mower Deck Drive
Belt page x-xx.

14. Remove the plastic tie holding the clutch harness to

frame (Fig. 305).

Fig 303 PICT-0331

12. Remove the blue wire located on the starter solenoid Fig 305 PICT-0099a
(Fig. 304).

15. Unplug the clutch pigtail harness from the main

harness (Fig. 306).

Fig 304 PICT-0332

Fig 306 PICT-0100a

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 ENGINE
16. Remove the center bolt and two spring washers 18. With a spring puller, remove the extension spring
holding the electric PTO clutch to the engine from the idler arm assembly and remove the cog belt
crankshaft (Fig. 307). from the pump drive and idler pulleys (Fig. 309).

Fig 307 PICT-0014c Fig 309 PICT-0016c

17. Remove the electric PTO clutch (Fig. 308). 19. Remove the drive belt from the engine pulley (Fig.
310).

Fig 308 PICT-0015c

Fig 310 PICT-0017c

Z Master Z400 Service Manual 5-27

 ENGINE
20. Remove the engine pulley (Fig. 311). 22. Connect chains to the two lift points on the engine
and raise the engine from the frame (Fig. 313).

Fig 311 PICT-0018c

Fig 313 PICT-0341

21. Remove the 4 engine mounting bolts and washers

(Fig. 312). Kohler 18 hp Single Cylinder Install
1. Lower the engine onto the frame. Install 4 bolts and
spring washers through the frame and into the base
of the engine. Tighten the bolts.

5 2. Apply anti-seize compound to the engine crankshaft

(Fig. 314).

Fig 312 PICT-0334

Fig 314 PICT-0025c

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 ENGINE
3. Install the engine pulley (Fig. 315). 5. Install the cog belt onto the pump drive and idler
pulleys. With a spring puller, install the extension
spring onto the idler arm assembly (Fig. 317).

Fig 315 PICT-0018c

Fig 317 PICT-0016c

4. Install the drive belt onto the engine pulley (Fig.

316).
6. Install the electric PTO clutch (Fig. 318).

Fig 316 PICT-0017c

Fig 318 PICT-0015c

Z Master Z400 Service Manual 5-29

 ENGINE
7. Apply a thread locking compound to the clutch 9. Torque the center bolt to 55 ft-lbs. (Fig. 321).
retainer bolt (Fig. 319).

Fig 321 PICT-0027c

Fig 319 PICT-0026c

10. Plug the clutch pigtail harness into the main harness
8. Install the center bolt and two spring washers that (Fig. 322).
hold the electric PTO clutch to the engine crankshaft
(Fig. 320).

Fig 322 PICT-0100a

Fig 320 PICT-0014c

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 ENGINE
11. Replace the plastic tie holding the clutch harness to 15. Connect the fuel hose clamp onto the fuel hose
frame. located at the fuel pump (Fig. 325).

12. Install the mower drive belt onto the electric PTO
clutch. Refer to Replacing the Mower Deck Drive
Belt page 7-24.

13. Plug in the engine wiring harness (Fig. 323).

Fig 325 PICT-0330

16. Turn the fuel shut-off valve to the “On” position (Fig.
326).
Fig 323 PICT-0283

5
14. Connect the red wires to the starter solenoid (Fig.
324).

Fig 326 PICT-0329

Fig 324 PICT-0331

Z Master Z400 Service Manual 5-31

 ENGINE
17. Connect the three ground wires located at the right 19. Connect the green oil sending wire to the oil
hand engine lift point (Fig. 327). Reinstall the engine pressure switch (Fig. 329).
lift bracket.

Fig 329 PICT-0325

Fig 327 PICT-0328

20. Reconnecting the choke cable:

18. Plug in the magneto and charging circuit wire
harness (Fig. 328). a. Position the choke knob in the full down position
(Fig. 330).

Fig 328 PICT-0327

Fig 330 PICT-0296

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 ENGINE
b. Reconnect the z-bend of the choke cable to b. Reconnect the z-bend of the throttle cable to the
the choke linkage (the middle hole in the choke throttle linkage (the lowermost hole of the throttle
plate). The choke linkage should be in the full plate). Push down on the throttle linkage to
open position (up). Tighten the cable clamp hold it in the wide open throttle (WOT) position.
(Fig. 331). Tighten the cable clamp (Fig. 333).

Fig 331 PICT-0342 Fig 333 PICT-0343 rev

21. Reconnect the throttle cable: 22. Install the 6 bolts, washers and nuts holding the rear
bumper to the frame (Fig. 334).
a. Position the throttle control lever so that there is

5
approximately 1/2” (12.7mm) between the lever
and the full throttle position of the throttle slot
(Fig. 332).

Fig 334 PICT-0321

Fig 332 PICT-0293 23. Install the rear wheels. Lower the machine to the
ground.

24. Connect the battery negative cable.

Z Master Z400 Service Manual 5-33

 ENGINE
Z 100 Series FH580V (KAI) 19 hp 4. Remove the two bolts and nuts holding the hydraulic
oil tank to the guard strap and fuel tank support (Fig.
Kawasaki Removal 336).
1. Remove the battery negative cable from the battery.

2. Raise the rear wheels of the machine off the ground

and support frame with jack stands. Remove both
rear wheels.

3. Remove the four bolts and nuts that hold the tailpipe
guard to the right hand guard strap and rear muffler
guard (Fig. 335).

Fig 336 PICT-0398

5. Remove the plastic tie holding the throttle and choke

cable to the right hand guard strap (Fig. 337).

5 Fig 335 PICT-0397

Fig 337 PICT-0399

5-34 Z Master Z400 Service Manual

 ENGINE
6. Remove the 9 sets of fasteners holding the right 8. Remove the bottom cable clamp and disconnect the
hand muffler guard and guard strap to the frame. throttle cable (Fig. 340).
Remove the muffler guard assembly (Fig. 338).

Fig 340 PICT-0402

Fig 338 PICT-0400

9. Remove the green oil sending wire from the oil

7. Remove the top cable clamp and disconnect the pressure switch (Fig. 341).
choke cable (Fig. 339).

Fig 341 PICT-0404

Fig 339 PICT-0401

Z Master Z400 Service Manual 5-35

 ENGINE
10. Unplug the electric PTO clutch plug (Fig. 342). 12. Remove the fuel hose clamp on the fuel hose
located at the fuel pump (Fig. 344).

Fig 342 PICT-0405

Fig 344 PICT-0407

11. Turn the fuel shut-off valve to the “off” position (Fig.
343). 13. Unplug the violet wire from the B+ side of the
regulator (Fig. 345).

Fig 343 PICT-0406

Fig 345 PICT-0408

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 ENGINE
14. Unplug the pink wire from the green wire (fuel shut- 16. With a spring puller, remove the extension spring
off solenoid) and the white wire from the black wire from the mower deck (Fig. 348).
(magneto) (Fig. 346).

Fig 348 PICT-0375

Fig 346 PICT-0409

17. Remove the belt from the electric PTO clutch (Fig.
15. Remove the red wire located on the starter solenoid 349).
(Fig. 347).

Fig 349 PICT-0122

Fig 347 PICT-0413

Z Master Z400 Service Manual 5-37

 ENGINE
18. Remove the center bolt and two spring washers 20. With a spring puller, remove the extension spring
holding the electric PTO clutch to the engine from the idler arm assembly and remove the cog belt
crankshaft (Fig. 350). from the pump drive and idler pulleys (Fig. 352).

Fig 350 PICT-0014c Fig 352 PICT-0016c

19. Remove the electric PTO clutch (Fig. 351). 21. Remove the drive belt from the engine pulley (Fig.
353).

Fig 351 PICT-0015c

Fig 353 PICT-0017c

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 ENGINE
22. Remove the engine pulley, spacer and key (Fig. 24. Connect chains to the two lift points on the engine
354). and raise the engine from the frame (Fig. 356).

Fig 354 PICT-0414 Fig 356 PICT-0419

23. Remove the 4 engine mounting bolts, washers and Z 100 Series FH580V (KAI) 19 hp
nuts (Fig. 355).
Kawasaki Install
1. Lower the engine onto the frame. Install the 4
engine mounting bolts, washers and nuts through

5
the frame and engine mounts. Tighten the bolts.

2. Apply anti-seize compound to the engine shaft (Fig.

357).

Fig 355 PICT-0416

Fig 357 PICT-0025c

Z Master Z400 Service Manual 5-39

 ENGINE
3. Install the engine pulley, spacer and key (Fig. 358). 5. Install the cog belt onto the pump drive and idler
pulleys. With a spring puller, install the extension
spring onto the idler arm assembly (Fig. 360).

Fig 358 PICT-0414

Fig 360 PICT-0016c

4. Install the drive belt onto the engine pulley (Fig.

359).
6. Install the electric PTO clutch (Fig. 361).

Fig 359 PICT-0017c

Fig 361 PICT-0015

5-40 Z Master Z400 Service Manual

 ENGINE
7. Apply a thread-locking compound to the clutch 9. Torque the center bolt to 55 ft-lbs. (74.6 Nm) (Fig.
retainer bolt (Fig. 362). 364).

Fig 362 PICT-0026c Fig 364 PICT-0027c

8. Install the clutch retainer bolt and two spring 10. Plug the clutch pigtail harness into the main harness
washers that hold the electric PTO clutch to the (Fig. 365).
engine crankshaft (Fig. 363).

Fig 365 PICT-0100a

Fig 363 PICT-0014

Z Master Z400 Service Manual 5-41

 ENGINE
11. Connect the red wire onto the starter solenoid (Fig. 13. Connect the violet wire to the B+ side of the
366). regulator (Fig. 368).

Fig 366 PICT-0413 Fig 368 PICT-0408

12. Connect the pink wire to the green wire (fuel shut-off 14. Install the fuel hose clamp onto the fuel hose located
solenoid) and the white wire to the black wire at the fuel pump (Fig. 369).
(magneto) (Fig. 367).

Fig 369 PICT-0407

Fig 367 PICT-0409

5-42 Z Master Z400 Service Manual

 ENGINE
15. Turn the fuel shut-off valve to the “on” position (Fig. 17. Reconnect the throttle cable:
370).
a. Position the throttle control lever so that there is
approximately 1/2” (12.7mm) between the lever
and the full throttle position of the throttle slot
(Fig. 372).

”
1/2
Fig 370 PICT-0406

16. Connect the green oil sending wire to the oil Fig 372 PICT-0293
pressure switch (Fig. 371).

b. Reconnect the z-bend of the throttle cable to

the throttle linkage (the top hole of the throttle

5
plate). Pull the throttle linkage all the way to the
right and hold it in the wide open throttle (WOT)
position. Install and tighten the cable clamp
(Fig. 373).

Fig 371 PICT-0404

Fig 373 PICT-0420

Z Master Z400 Service Manual 5-43

 ENGINE
18. Reconnecting the choke cable: 19. Install the muffler guard assembly using 9 sets of
fasteners (Fig. 376).
a. Position the choke knob in the full down position
(Fig. 374).

Fig 376 PICT-0400

Fig 374 PICT-0296

20. Install the hydraulic oil tank using two bolts and nuts.
Secure the tank to the guard strap and fuel tank
b. Reconnect the z-bend of the choke cable to the support (Fig. 377).
choke linkage. The choke linkage should be in
the full open position (far left). Tighten the cable
clamp (Fig. 375).

Fig 377 PICT-0398

Fig 375 PICT-0421

5-44 Z Master Z400 Service Manual

 ENGINE
21. Install the four bolts and nuts that hold the tailpipe
guard to the right hand guard strap and rear muffler
guard (Fig. 378).

Fig 378 PICT-0397

22. Install a plastic tie to hold the throttle and choke

cable to the right hand guard strap (Fig. 379).

Fig 379 PICT-0422

23. Install the rear wheels. Lower the machine to the

ground.

24. Connect the battery negative cable.

Z Master Z400 Service Manual 5-45

 ENGINE

THIS PAGE INTENTIONALLY LEFT BLANK.

5-46 Z Master Z400 Service Manual

 ELECTRICAL

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks/PTO . . . . . . . . . 7

Z Master Z400 Service Manual 6-1

 ELECTRICAL
General How It Works

Note: Interactive Electrical Troubleshooting CD, A relay is an electrically actuated switch.

Form 492-9143 is also available.
1. Coil: Terminals 85 and 86 are connected to a coil.
Applying 12 volts to these terminals energizes the
coil turning it into an electromagnet.
Relays
2. Switch: Terminals 30, 87 and 87a are actually part of
Purpose a single pole, double throw (SPDT) switch. Terminal
30 is the common lead. The switch is spring loaded
so that 30 and 87a are connected when the coil is
There are 2 relays:
not energized, the switch is “thrown” and 30 and 87
are connected (Fig. 381).
1. Start Relay
2. Kill Relay

1. Start Relay: Functions as an electronic switch. Once

the safety connections are met, the relay will activate
completing the circuit to the starter solenoid.

2. Kill Relay: Functions like an electronic switch. If

all conditions for operation are not met, the relay
closes, grounding the engine ignition system.

Location

The relays are located under the panel assembly (Fig.

380).
Fig 381 DSC-2517

6
A B

Fig 380 PICT-0189

A - Start relay B - Kill relay

6-2 Z Master Z400 Service Manual

 ELECTRICAL
Testing 5. Disconnect voltage and multimeter leads from relay
terminals (Fig. 383).

85

87 87a 30

86

Fig 382 relay pin diagram

Fig 383 xl relay

1. Disconnect the relay from the harness.

PTO Switch
2. Verify the coil resistance between terminals 85 and
86 with a multimeter (ohms setting). Resistance Purpose
should be from 70 to 90 ohms. There should be
continuity between terminals 87a and 30.
The PTO (Power Take Off) switch is typically used to
3. Connect multimeter (ohms setting) leads to relay activate the Electric PTO Clutch and to function as part
terminals 30 and 87. Ground terminal 86 and apply of the safety interlock system.
+12 VDC to 85. The relay should make and break
continuity between terminals 30 and 87 when 12
VDC is applied and removed from terminal 85.

4. Connect multimeter (ohms setting) leads to relay

terminals 30 and 87a. Apply +12VDC to terminal
85. With terminal 86 still grounded, the relay should
6
break and make continuity between terminals 30
and 87a as 12 VDC is applied and removed from
terminal.

Z Master Z400 Service Manual 6-3

 ELECTRICAL
Location Testing

The PTO Switch is located on the control panel on the 1. Disengage the PTO, set the parking brake, and turn
left side of the operator (Fig. 384). the ignition to OFF. Remove the key.

2. Remove the 4 screws holding the control panel to

the fuel tank.

3. Disconnect the wiring harness from the PTO switch.

4. Press in the locking tabs, on each side of the switch,

and pull the switch out of the control panel.

5. Verify that there is continuity between the

appropriate terminals in the ON and OFF positions
(Fig. 385).

OFF (IN) ON (OUT)

Y Y

Cont. Cont.
Fig 384 PICT-0190

Y Y

Cont. Cont.

How It Works
N N

Contacts inside the switch electrically connect various Open Open

terminals in both “On” and “Off” position. When the Continuity?
PTO is pulled out to the ON position, current flows to N N
Y = Yes
the electric clutch and it engages. When the switch is Open Open N = No
pushed in to the OFF position, current flows through the not used not used
PTO switch to the Park Brake switch as part of the circuit
Fig 385 PTO switch test
used to ensure safe starting.

6-4 Z Master Z400 Service Manual

 ELECTRICAL
6. Replace the switch if your test results do not Ignition Switch
correspond with those given in (Fig. 385).
Purpose
7. Mount the PTO switch back into the control panel
and reinstall the wiring harness (Fig. 386).
The ignition switch makes the proper connections for the
starter, accessories, and safety circuits.
Violet

Location

The ignition switch is located on the control panel, to the

left side of the operator (Fig. 387).
Gray
Gray Gray

Orange

Orange Orange

Fig 386 PTO clutch switch

Fig 387 PICT-0191

Z Master Z400 Service Manual 6-5

 ELECTRICAL
How It Works Neutral Safety Switch
Detents inside the switch give it 3 positions: OFF, RUN, Purpose
and START. The START position is spring loaded so the
cylinder automatically returns to RUN once the key is Used to ensure the motion control handles are in neutral
released (Fig. 388). to start the unit. It is activated by moving the motion
control handles to the neutral position (handles outward).

Location

To gain access to the neutral safety switches, remove

the panel assembly. There are 2 neutral switches. One
for the right motion control handle and one for the left
motion control handle (Fig. 389 Right Hand side) (Fig.
390 Left Hand side).

Note: Harness removed for clarity

Fig 388 MVC-166

Ignition Switch Wiring Connections

B = Battery voltage “in”
S = Starting Circuit
I = Safety Circuit, Gauges, and Start Circuit
A = Alternator/Charge Circuit
Y = Safety and Start Circuit
X = Safety/Start/Delay Module

6 Testing

1. Disconnect the switch from the wiring harness.

Fig 389 PICT-0192

2. Verify that continuity exists between the terminals

listed for the switch position.

3. Verify that there is NO continuity between terminals

not listed for the switch position.

OFF No continuity between terminals

RUN Continuity - B I A XY
START Continuity - B I S

6-6 Z Master Z400 Service Manual

 ELECTRICAL
Testing

1. Disconnect the switch from the wiring harness.

2. Using a VOM or test light, check first to ensure there

is no continuity between the terminals, plunger out.

3. With the plunger pushed in, there should be

continuity between the terminals.

Park Brake Switch

Purpose
Fig 390 PICT-0197
The purpose of the brake switch is to ensure the
machine is in neutral and the parking brake is applied
before attempting to start the machine.
How It Works

This single pole plunger (normally open) type switch

has two terminals. When the motion control handles Location
are in the neutral position (handles in the out position),
it pushes on the plunger, closing the contact and The park brake switch is located in the middle of the
connecting the terminals (Fig. 391). machine under the panel assembly (Fig. 392).

Fig 391 DSC-2527 Fig 392 PICT-0193

Z Master Z400 Service Manual 6-7

 ELECTRICAL
How It Works 2. Using a multimeter, follow the procedures listed
below (Fig. 394).
When starting, it functions to ensure the park brake is
in the ON position. At the same time it allows current to
flow through the remainder of the starting safety circuit.
When the park brake is released in the (Off position) it
bypasses both neutral switches, permitting the control
levers to be used, as long as the operator is in the seat
to maintain current for the safety circuit (Fig. 393).
A C
B D

Fig 394 brake switch a

Plunger Not Depressed Plunger Depressed

A/B Terminals - Closed A/B Terminals - Open
Circuit - Continuity Circuit - No Continuity
C/D Terminals - Open C/D Terminals - Closed
Fig 393 DSC-2528 Circuit - No Continuity Circuit - Continuity

Testing Seat Switch

1. Disconnect the switch from the wiring harness.
The park brake is a double pole switch. When the Purpose
park brake is in the “On” position, a pair of closed

6 terminals is part of the starting safety interlock

circuit. When the brake is released after starting, the
other pair of terminals closes, bypassing the neutral
The switch is in the safety circuit. If the engine is running
and the operator vacates the seat with either the PTO
engaged or the parking brake disengaged, the engine
switches and applying power to the seat switch will shut down.
circuit.
Note: There is a delay module in the system; there
will be a slight delay before the engine shuts
down after the operator vacates the seat.

6-8 Z Master Z400 Service Manual

 ELECTRICAL
Location Testing

The seat switch is mounted to the frame directly under 1. Disconnect the switch from the wiring harness.
the seat (Fig. 395).
2. Using a VOM or test light, check first to ensure there
is no continuity between either terminal, plunger out.

3. With the plunger pushed in, there should be

continuity between the terminals.

Seat Delay Module

Purpose

When operating the unit on rough terrain, if the operator

should come off the seat momentarily, the seat delay
module will temporarily delay the engine shutting down.

Fig 395 PICT-0198

Location

The seat delay module is located under the panel

How It Works assembly (Fig. 397).

When the seat is vacated, the switch is open and there

should be NO continuity between the two terminals.
When the seat is occupied, the switch closes and there
should be continuity between the two terminals (Fig.
396) (Deluxe suspension seat switch shown).

Fig 397 PICT-0194

Fig 396 DSC-2556

Z Master Z400 Service Manual 6-9

 ELECTRICAL
How It Works 2. Remove the 4 bolts mounting the console panel to
the frame.
The seat delay module circuit board is made up with
several different electronic components such as transient 3. Connect a VOM positive lead to the violet wires on
voltage suppressor diodes, capacitor, transistors, the module. Connect the negative lead to the battery
carbon film resistors, and a relay. The components work negative terminal.
together to allow a short term voltage interruption by the
seat switch and supplies temporary voltage to the safety 4. While sitting in the seat, follow the procedure below
circuit to keep the engine running (Fig. 398). to test the delay module function.
a. Disengage the parking brake.
b. Pull the right and left motion control levers out of
the neutral position.
c. Turn the ignition key to the RUN position.
d. The meter should read approximately 12 volts
DC.
e. Lift off the seat or disconnect one of the seat
jumper wire leads. The meter should hold
around 12 volts and then read 0 volts DC after
approximately 1 to 3 seconds. This test shows
the delay module is working.

5. If you do not get 12 volts DC at the violet wire when

turning the ignition switch to the RUN position, verify
the following:
a. 12VDC at the Tan wire terminal.
b. 12VDC at the Brown wire terminal.
c. 0 VDC at the Gray wire terminal.
Fig 398 DSC-2532
d. If all these conditions are met, replace the seat
delay module.

Testing

1. Raise the seat and disconnect the seat switch.

Install a jumper wire in place of the seat switch (Fig.

6
399).

Fig 399 rev DSC-3157

6-10 Z Master Z400 Service Manual

 ELECTRICAL
Hour Meter How It Works

Purpose Since a normal clock might be affected by variations in

voltage and current, the hour meter is made up of an
The hour meter keeps track of the actual unit running electric “winder” and a mechanical clock movement.
hours or the time that the ignition key switch is in the When power is applied, a coil is energized to wind the
RUN position. movement. The movement unwinds in about 2 seconds.
As it finishes its rotation, it re-energizes the coil so that
the cycle can start over (Fig. 401).

Location

The hour meter is located on the control panel as shown

(Fig. 400).

Fig 401 DSC-2560

Testing
Fig 400 PICT-0199
Verify that 12 volts DC is present across the two
terminals when the ignition key is in the RUN position. If

6
so, and the meter is not running, replace the meter. If 12
volts is not present, check the connections. The meter is
a permanently sealed unit and is not repairable.

Z Master Z400 Service Manual 6-11

 ELECTRICAL
Electric PTO Clutch Coil Resistance Measurement

Purpose 1. Disengage the PTO, set the parking brake, turn the
ignition to the “off” position and remove the ignition
The electric clutch controls the engagement and key.
disengagement of the Power Take Off (PTO) pulley.
2. Disconnect the clutch harness from the main
harness.

3. Set the multimeter or volt/ohm meter to check

Location resistance (ohms).

The electric clutch is located on the PTO end of the 4. Connect the meter lead wires to the clutch wires as
crankshaft. shown (Fig. 402).

How It Works

The PTO clutch is composed of three major

components; the field, the clutch plate, and the friction
plate. The clutch plate always turns with the engine. The
field is a coil of wire wound around an iron core, which
acts like an electromagnet when power is applied. The
friction plate is the only piece that can slide inward and
outward on the crankshaft axis. It is spring loaded away
from contact with the clutch plate. When the clutch is
not energized, the clutch plate rests against the brake
material opposite the clutch plate. When energized the
friction plate is drawn into the clutch plate magnetically
and the two rotate as one component.
Fig 402 coil resist measure

Testing
6 If the electric PTO clutch does not engage or is suspect
5. The meter should read around 1.84 ohms (meter
readings may vary). If the reading is above or below
these readings, the field has failed and needs to
as the cause of an electrical problem in the PTO circuit,
use the following troubleshooting steps to determine be replaced. If the reading falls between 2-4 ohms,
whether the clutch has failed or another electrical measure clutch current draw.
problem exists.

6-12 Z Master Z400 Service Manual

 ELECTRICAL
Measuring Clutch Current Draw 7. Turn the ignition switch to the “RUN” position. Turn
the PTO switch to the “ON” position.
1. Disengage the PTO, set the parking brake, turn the
ignition key to OFF, and remove the key. 8. If the meter reading is 6.5 amps or above, the
system is functioning properly. If the meter reading
2. Disconnect the PTO clutch harness from the main is below 6.5 amps, check the electrical system for
harness. problems (i.e., the battery, ignition switch. PTO
switch, or wiring harness). Make sure the negative
3. Set the multimeter to check amps (10 amp scale). side of the wiring has a good connection to chassis
ground.
4. Connect the positive meter lead to terminal (1) of the
main harness (Fig. 403).

Solenoid
Purpose

The solenoid’s purpose is simply to connect the battery

to the starter motor when the ignition switch is turned
to “START”. The solenoid is used to protect the ignition
switch from the high current drawn by the starter motor.

Location

The starter solenoid is located under the left hand fuel

tank (Fig. 404).
Fig 403 diag 3-7

5. Connect the negative meter lead to the clutch

harness terminal (3), Fig. 403.

6. Connect a short jumper lead from terminal (2) to

terminal (4) Fig. 403.
6

Fig 404 PICT-0200

Z Master Z400 Service Manual 6-13

 ELECTRICAL
How It Works Testing

The solenoid has two primary parts. One is a coil of 1. Disconnect the solenoid from the wiring harness.
wire wrapped around an iron core. Whenever 12 volts is
applied to the coil, it becomes a magnet. The other part 2. With a multimeter (ohms setting), check to ensure
is a bar type switch (Fig. 405). that terminals “C” and “D” are open (no continuity)
(Figure 20).

3. Apply +12 VDC between terminal “A” and ground

terminal “B”. Terminals “C” and “D” should now be
closed (continuity) (Figure 20).

4. You should be able to hear the solenoid switch

“click” when you make the connection (Fig. 406).

C D

Fig 405 xl solenoid a

Because it has a large contact area with the contact

terminals it can easily handle the high current loads A B
required by the starter motor. When 12 volts is applied
to the coil, it becomes an electromagnet. This quickly
pulls the bar toward contacts and closes the switch. Fig 406 PICT-0204 rev
When power is removed from the coil, the spring loaded
bar returns to its “normally open” position. The solenoid A & B Coil Terminals C & D Contact Terminals
closes and opens the switch very quickly. This minimizes

6 the “arcing” that can damage other types of switches.

The ignition switch is protected because only a small

amount of current is needed to activate the coil.

6-14 Z Master Z400 Service Manual

 ELECTRICAL
Fuse Block
Purpose

House the electrical system fuses.

Location

Located below the control panel on the left hand side of

the frame (Fig. 407).

A B C

Fig 407 PICT-0202

A. Main circuit (30 amp)

B. Charge circuit (25 amp)
C. Optional head light kit circuit (10 amp)

6
How It Works

The fuse block contains the fuses that protect the

system from electrical surges.

Z Master Z400 Service Manual 6-15

 ELECTRICAL
74412
Schematics

6
Wire Diagram (Rev. A)

6-16 Z Master Z400 Service Manual

 ELECTRICAL
74410
Schematics

Wire Diagram (Rev. A)

Z Master Z400 Service Manual 6-17

 ELECTRICAL
74411
Schematics

6 Wire Diagram (Rev. A)

6-18 Z Master Z400 Service Manual

 ELECTRICAL
74413 and 74415
Schematics

Wire Diagram (Rev. A)

6

Z Master Z400 Service Manual 6-19

 ELECTRICAL
74414
Schematics

Wire Diagram (Rev. A)

6-20 Z Master Z400 Service Manual

 ELECTRICAL
74416 and 74417
Schematics

Wire Diagram (Rev. A)

6

Z Master Z400 Service Manual 6-21

 6
WIRE COLOR CODES

6-22
SW1
(IGNITION) BK BLACK PK PINK
KEY SWITCH PN 88–9830 X S Y I B A BN BROWN R RED
KAWASAKI TWIN AIR–COOLED OFF NO CONNECTION
ON BIA AND X Y BU BLUE T TAN
START BIS GN GREEN
GREY
VIO VIOLET
WHITE
74411TE
GY W
X OR ORANGE Y
I YELLOW
Y S
OR BN PK PK R VIO
A B
F3
KEY SW VIO B HEADLIGHT
SW2 10A HARNESS
Wiring Diagram

TERMINAL VIEW FROM BK A CONNECTOR

(PTO) BACK OF SWITCH
BN
PK F1 F2 SPARK PLUG SPARK PLUG
30A 25A
ELECTRICAL

SHOWN IN IGNITION
OFF POSITION MODULES
GY R
PK W MAG
AC
VIO REG
Y OR HOUR

+
OR METER
AC
SW3

–
(BRAKE) SW6 SOLINIOD
(SEAT SW) FUEL
SHOWN WITH SHOWN WITH FUEL
GN PK
PARK BRAKE OPERATOR
BN P1–A
DISENGAGED IN SEAT
DELAY MODULE
100–6186 GN OIL
VIO OIL
PTO VIO P1–C P2–C T SWITCH
CLUTCH

SHOWN WITH P1–B

SW4 LEVER IN
BK (NEUTRAL) NEUTRAL
BK
POSITION
BN
Y + –
BATTERY GND

2
W

1
R
K2
SHOWN WITH (START RELAY)

5
4
3
SW5
LEVER IN
(NEUTRAL) NEUTRAL STARTER
POSITION GY BU

Y
Y GYW GND
SOLENOID
4
3

BK
K1
(KILL RELAY)
1

GND

BK

BK

GND

Z Master Z400 Service Manual

 WIRE COLOR CODES
SW1
(IGNITION) BK BLACK PK PINK
KEY SWITCH PN 88–9830 X S Y I B A BN BROWN R RED
KAWASAKI TWIN AIR–COOLED OFF NO CONNECTION
ON BIA AND X Y BU BLUE T TAN
START BIS GN GREEN VIO VIOLET
GY GREY W WHITE
X OR ORANGE Y
I YELLOW
Y S
OR BN PK PK R VIO
A B F3
KEY SW VIO B HEADLIGHT
SW2 10A HARNESS
Wiring Diagram

TERMINAL VIEW FROM BK A CONNECTOR

(PTO) BACK OF SWITCH

Z Master Z400 Service Manual

BN
PK F1 F2 SPARK PLUG SPARK PLUG
30A 25A
SHOWN IN IGNITION
OFF POSITION MODULES
GY R
PK W MAG
AC
VIO REG
Y OR HOUR

+
OR METER
AC
SW3

–
(BRAKE) SW6 SOLINIOD
(SEAT SW) FUEL
SHOWN WITH SHOWN WITH FUEL
GN PK
BN PARK BRAKE OPERATOR
P1–A
DISENGAGED IN SEAT
DELAY MODULE
GN OIL
100–6186
VIO OIL
PTO VIO P1–C P2–C T SWITCH
CLUTCH

SHOWN WITH P1–B

SW4 LEVER IN
BK (NEUTRAL) NEUTRAL
BK
POSITION
BN
Y + –
BATTERY GND

2
W

1
R
K2
SHOWN WITH (START RELAY)

5
4
3
SW5
LEVER IN
(NEUTRAL) NEUTRAL STARTER
POSITION GY BU

Y
Y GYW GND
SOLENOID
4
3

BK
K1
(KILL RELAY)
1

GND

BK

BK

GND

6-23
74416TE
ELECTRICAL

6
 ELECTRICAL

THIS PAGE INTENTIONALLY LEFT BLANK.

6-24 Z Master Z400 Service Manual

 MOWER DECKS/PTO

Safety Information . . . . . . . . . 1

Specifications . . . . . . . . . . . 2

Chassis . . . . . . . . . . . . . . 3

Hydraulic System . . . . . . . . . 4

Engine . . . . . . . . . . . . . . . 5

Electrical . . . . . . . . . . . . . . 6

Mower Decks/PTO . . . . . . . . . 7

Z Master Z400 Service Manual 7-1

 MOWER DECKS/PTO
Mower Deck Removal 4. Remove the belt from the electric PTO clutch (Fig.
410).
Estate Series

1. Disengage the PTO, move the motion control levers

to the neutral locked position, and set the parking
brake.

2. Lift the floor pan and remove the right side mower
belt cover (Fig. 408).

Fig 410 PICT-0122

5. Raise the mower deck to the transport position.

Place 4 x 4 wood blocks under the edge of the
mower deck. Lower the mower deck to relieve the
tension on all four lift chains (Fig. 411).
Fig 408 PICT-0116
Note: It may be necessary to push down on the lift
lever and pin into place to relieve tension on
the lift chains.
3. Loosen the two nuts located on the idler plate to
remove tension on the belt (Fig. 409)

Fig 411 PICT-0124

Fig 409 PICT-0121

7-2 Z Master Z400 Service Manual

 MOWER DECKS/PTO
6. Remove the front and rear lift chains from the mower 8. Secure the cross brace to the frame so it is out of
deck (Fig. 412). the way when removing the mower deck.

9. Raise the lift lever to the transport position.

10. Remove the 4 x 4 wood blocks from under the deck.

11. Turn the right front wheel so the castor fork is angled
forward. This will allow more clearance to slide the
mower deck out from under the frame (Fig. 414).

Fig 412 PICT-0126

7. Remove the bolts holding the cross brace to the

deck (Fig. 413).

Note: Check the cross brace bushings for wear.

Replace as needed. Fig 414 PICT-0130

12. Slide the mower deck out the right side of the unit
(Fig. 415).

7
Fig 413 PICT-0128

Fig 415 PICT-0129

Z Master Z400 Service Manual 7-3

 MOWER DECKS/PTO
Mower Deck Installation 5. Install the cross brace to the deck using the
hardware as shown (Fig. 417).
Estate Series

1. Slide the deck under the unit.

2. Place 4 x 4 wood blocks under the edge of the B

mower deck.

3. Position the lift handle to the lowest position and pin

A
in place (Fig. 416).

D
C

Fig 417 PICT-0143

A. Bolt C. Washer (2)

B. Bushing D. Nut

6. Attach the front and rear lift chains to the mower

deck (Fig. 418).
Fig 416 PICT-0138

4. Inspect the cross brace bushings for wear. Replace

as needed.

7
Fig 418 PICT-0126

7-4 Z Master Z400 Service Manual

 MOWER DECKS/PTO
7. Raise the deck to the transport position. Remove 10. Insert a ratchet with a short extension or a breaker
the 4x4 wood blocks. bar into the square hole in the fixed idler arm.
Rotate the ratchet or breaker bar counterclockwise
8. Set the lift handle at the 3” (7.6cm) height-of-cut to move the fixed idler arm until you feel increased
position. Pin in place (Fig. 419). resistance and the spring-loaded idler pulley stops
moving.

Note: Do not increase the belt tension beyond the

point where the fixed idler arm stops.

Tighten the nut on the slotted idler plate (Fig. 421).

Fig 419 PICT-0146

9. Route the belt around the spindles, idler pulleys and

the PTO clutch (Fig. 420).
Fig 421 PICT-0147

11. Tighten the pivot bolt (Fig. 422).

7
Fig 420 fig. 46 G001678

1. Fixed idler arm 4. Mower belt

2. Square hole 5. Belt guide
3. Fixed idler pulley 6. Spring-loaded idler
pulley Fig 422 PICT-0150

Z Master Z400 Service Manual 7-5

 MOWER DECKS/PTO
Mower Deck Removal 4. Remove the belt from the electric PTO clutch (Fig.
425).
Z 400 Series (48” and 50” Decks)

1. Disengage the PTO, move the motion control levers

to the neutral locked position, and set the parking
brake.

2. Lift the floor pan and remove the right side mower
belt cover (Fig. 423).

Fig 425 PICT-0122

5. Raise the mower deck to the transport position.

Place 4 x 4 wood blocks under the edge of the
mower deck. Lower the mower deck to relieve the
tension on all four lift chains (Fig. 426).
Fig 423 PICT-0299
Note: It may be necessary to push down on the lift
lever and pin into place to relieve tension on
the lift chains.
3. Loosen the two nuts located on the idler plate to
remove tension on the belt (Fig. 424).

Fig 426 PICT-0304

Fig 424 PICT-0302

7-6 Z Master Z400 Service Manual

 MOWER DECKS/PTO
6. Remove the front and rear lift chains from the mower 8. Check the bolt, bushing and strut base for wear (Fig.
deck (Fig. 427). 429).

D
C B A A B C

Fig 427 PICT-0305 Fig 429 PICT-0312 rev

A. Bolt C. Nut
B. Bushing D. Strut base
7. Remove the right and left struts from the strut bases
(Fig. 428).
9. Raise the lift lever to the transport position.

10. Remove the 4 x 4 wood blocks from under the deck.

11. Turn the right front wheel so the castor fork is angled
forward. This will allow more clearance to slide the
mower deck out from under the frame (Fig. 430).

Fig 428 PICT-0306 7

Fig 430 PICT-0307

Z Master Z400 Service Manual 7-7

 MOWER DECKS/PTO
12. Slide the mower deck out the right side of the unit 2. Slide the deck under the unit.
(Fig. 431).
3. Place 4 x 4 wood blocks under the edge of the
mower deck (Fig. 433).

Fig 431 PICT-0308

Fig 433 PICT-0304

Mower Deck Installation

4. Install the right and left struts into the strut bases.
Z 400 Series (48” and 50” Decks)
Note: When installing the rear push struts you must
1. Turn the right front wheel so the castor fork is angled
mount the push strut into the lower hole on
forward. This will allow more clearance to slide the
the inside of the strut base (Fig. 434).
mower deck under the frame (Fig. 432).

A
B

7
Fig 434 PICT-312 rev
Fig 432 PICT-0307

A. Right hand push B. Left hand push

strut install strut install

7-8 Z Master Z400 Service Manual

 MOWER DECKS/PTO
5. Install the front and rear lift chains to the mower 8. Route the belt around the spindles, idler pulleys and
deck (Fig. 435). the PTO clutch (Fig. 437).

Fig 435 PICT-0305 Fig 437 fig. 49 G001678

1. Fixed idler arm 4. Mower belt

2. Square hole 5. Belt guide
6. Raise the deck to the transport position. Remove the 3. Fixed idler pulley 6. Spring-loaded idler
4x4 wood blocks. pulley

7. Set the lift handle at the 3” (7.6cm) height-of-cut

position. Pin in place (Fig. 436).

7
Fig 436 PICT-0313

Z Master Z400 Service Manual 7-9

 MOWER DECKS/PTO
9. Insert a ratchet or breaker bar with a short extension Mower Deck Removal
into the square hole in the fixed idler arm. Rotate the
ratchet or breaker bar counterclockwise to move the Z 100 Series (44” Deck)
fixed idler arm until you feel increased resistance
and the spring-loaded idler pulley stops moving. 1. Disengage the PTO, move the motion control levers
to the neutral locked position, and set the parking
Note: Do not increase the belt tension beyond the brake.
point where the fixed idler arm stops.
2. Lift the floor pan and remove both the right and left
Tighten the nut on the slotted idler plate (Fig. 438). side mower belt cover (Fig. 440).

Fig 438 PICT-0315 Fig 440 PICT-0374

10. Tighten the pivot bolt (Fig. 439). 3. With a spring puller, remove the spring from the idler
arm assembly to remove tension on the belt (Fig.
441).

Fig 439 PICT-0316

Fig 441 PICT-0375

7-10 Z Master Z400 Service Manual

 MOWER DECKS/PTO
4. Remove the belt from the electric PTO clutch (Fig. 6. Remove the four sets of bolts, spacers and washers
442). holding the front and rear lift chains to the mower
deck (Fig. 444).

Fig 442 PICT-0122

Fig 444 PICT-0377

5. Raise the mower deck to the transport position.

Place 4 x 4 wood blocks under the edge of the 7. Remove the nut and bolt holding the strut pin to the
mower deck. Lower the mower deck to relieve the deck (Fig. 445).
tension on all four lift chains (Fig. 443).

Note: It may be necessary to push down on the lift

lever and pin into place to relieve tension on
the lift chains.

Fig 445 PICT-0379

7

Fig 443 PICT-0376

Z Master Z400 Service Manual 7-11

 MOWER DECKS/PTO
8. Remove the strut pin (Fig. 446). 12. Slide the mower deck out the right side of the unit
(Fig. 448).
Note: The gauge wheels may need to be loosened
or removed to remove the strut pin.

Fig 448 PICT-0382

Fig 446 PICT-0380

Mower Deck Installation

9. Raise the lift lever to the transport position. Z 100 Series (44” Deck)
10. Remove the 4 x 4 wood blocks from under the deck. 1. Turn the right front wheel so the castor fork is angled
forward. This will allow more clearance to slide the
11. Turn the right front wheel so the castor fork is angled mower deck under the frame (Fig. 449).
forward. This will allow more clearance to slide the
mower deck from under the frame (Fig. 447).

Fig 449 PICT-0393

Fig 447 PICT-0381

7-12 Z Master Z400 Service Manual

 MOWER DECKS/PTO
2. Slide the deck under the frame. 5. Install the nut and bolt that holds the strut pin to the
deck (Fig. 452).
3. Place 4 x 4 wood blocks under the edge of the
mower deck (Fig. 450).

Fig 452 PICT-0379

Fig 450 PICT-0394

6. If needed tighten the anti-scalp roller bolts.

4. Install the right and left strut pins (Fig. 451). 7. Set the lift handle at the 3” (7.6cm) height-of-cut
position. Pin in place (Fig. 453).
Note: The gauge wheels may need to be loosened
or removed to install the strut pin.

7
Fig 453 PICT-0396

Fig 451 PICT-0380

Z Master Z400 Service Manual 7-13

 MOWER DECKS/PTO
8. Route the belt around the spindles, idler pulleys and 10. Lower the lift lever.
the PTO clutch (Fig. 454).
11. Install the lift chains with the four sets of bolts,
spacers and washers that hold the front and rear lift
chains to the mower deck (Fig. 456).

Fig 454 108-4050

Fig 456 PICT-0377

9. With a spring puller, install the extension spring to
the idler arm assembly (Fig. 455).

12. Install the left and right deck belt covers (Fig. 457).

7 Fig 455 PICT-0375

Fig 457 PICT-0374

13. Raise the deck to the transport position. Remove

the 4x4 wood blocks.

7-14 Z Master Z400 Service Manual

 MOWER DECKS/PTO
Mower Spindle Removal 6. With a spring puller, remove the spring from the idler
arm assembly to remove tension on the belt (Fig.
Pro 100 Series 459).

This applies to removing any of the three mower

spindles. This procedure shows removing the right side
spindle.

1. Raise the front of the mower.

Note: The mower deck was removed for photo

clarity.

2. Chock or block the drive wheels.

3. Disconnect the battery negative cable.

4. Lower the mower deck to the lowest position.

5. Lift the floor pan and remove the right side mower
belt cover (Fig. 458). Fig 459 PICT-0375

7. Remove the mower belt from the right side spindle

pulley.

8. Block the mower blade using a 4 x 4 wood block.

Remove the spindle shaft nut located at the top of
the pulley (Fig. 460).

Fig 458 PICT-0374

7
Fig 460 PICT-0384

Z Master Z400 Service Manual 7-15

 MOWER DECKS/PTO
9. Remove the nut, washer, key, and pulley from the 11. Remove spindle from mower deck (Fig. 463).
spindle shaft (Fig. 461).

Fig 463 PICT-0387

Fig 461 PICT-0385

Mower Spindle Installation

10. Remove the mower blade. Remove the 4 bolts that
mount the spindle to the deck housing (Fig. 462).
Pro 100 Series

Reverse the order of mower spindle removal

Mower Spindle Removal

Estate Series and Pro 400 Series

This applies to removing any of the three mower

spindles. This procedure shows removing the right side
spindle.

1. Use a hoist or the Z-Stand to raise the front of the

mower deck.

7 Fig 462 PICT-0386

2. Chock or block the drive wheels.

3. Disconnect the battery negative cable.

4. Lower the mower deck to the lowest position.

7-16 Z Master Z400 Service Manual

 MOWER DECKS/PTO
5. Lift the floor pan and remove the right side mower 7. Slip the mower drive belt off the right mower spindle
belt cover (Fig. 464). pulley (Fig. 466).

Fig 464 PICT-0116 Fig 466 PICT-0151

6. Loosen the two nuts located on the idler plate to 8. Lock the blade in position with a 4 x 4 wood block
remove tension on the belt (Fig. 465). and remove the three bolts retaining the pulley to the
pulley hub (Fig. 467).

Fig 465 PICT-0121

Fig 467 PICT-0152
7

Z Master Z400 Service Manual 7-17

 MOWER DECKS/PTO
9. Remove the blade (Fig. 468). Mower Spindle Installation
Note: Mower deck was removed for photo clarity. Estate Series and Pro 400 Series

Reverse the order of mower spindle removal

Mower Spindle Disassembly

Estate Series and Pro 400 Series

1. Remove the nut and washer (Fig. 470).

Fig 468 PICT-0133

10. Remove the six bolts and nuts from the spindle
assembly (Fig. 469).

Fig 470 PICT-0153 rev

2. Remove the pulley hub and square key (Fig. 471).

7 Fig 469 PICT-0134

11. Remove the spindle assembly.

Fig 471 PICT-0157

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3. Remove the bearing shield and thrust washer (Fig. 5. Remove the ball bearing from the top of the spindle
472). housing (Fig. 474).

Fig 472 PICT-0158 Fig 474 PICT-0160 rev

4. Remove the spindle housing from the spindle shaft 6. Remove the bearing spacer (Fig. 475).
assembly (Fig. 473).

Fig 473 PICT-0159 rev

Fig 475 PICT-0161
7

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7. Remove the ball bearing from the bottom of the Mower Spindle Assembly
spindle housing (Fig. 476)
Estate Series and Pro 400 Series
Note: On later production models the bottom
ball bearing may be locked into place with 1. Install the bottom bearing:
a chemical locking compound or half the
bearing race may be press-fit into the spindle For a press-fit bearing:
housing. If a chemical locking compound is
used, the lower housing may require heat to 2. Using a press, install the lower bearing with the open
release the locking compound. end of the bearing to the inside of the housing (Fig.
477).

a. Press until the bearing is fully seated.

Fig 476 PICT-0165

Fig 477 PICT-0172

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For a compound locked bearing: 3. Install the bearing shield and thrust washer onto the
spindle shaft (Fig. 480).
b. Thoroughly clean the spindle housing and the
outer race of the bearing.

c. Apply an even coat of chemical locking

compound to the outer race and inner spindle
housing (Fig. 478).

Caution: DO NOT get chemical locking compound

on the inside of the bearing.

Fig 480 PICT-0173 rev

4. Install the housing (bearing installed) onto the

spindle shaft (Fig. 481).

Fig 478 PICT-0168

d. Install the open end of the bearing to the inside

of the housing until the bearing is fully seated
(Fig. 479).

Fig 481 PICT-0175 7

Fig 479 PICT-0170

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5. Install the bearing spacer into the spindle housing 7. Install the upper thrust washer and bearing shield
opening (Fig. 482). onto the spindle shaft (Fig. 484).

Fig 482 PICT-0176 rev Fig 484 PICT-0181 rev

6. Install the upper ball bearing with the open end of 8. Install the pulley hub onto the spindle shaft.
the bearing to the inside of the housing (Fig. 483).
Note: The raised center of the hub faces away from
the spindle (Fig. 485).

7 Fig 483 PICT-0180

Fig 485 PICT-0183 rev

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9. Install the key into the spindle shaft (Fig. 486). 11. Torque the top nut to 100 to 120 ft-lbs. (135.6 to
162.7 Nm) (Fig. 488).

Fig 486 PICT-0184

Fig 488 PICT-0187

10. Install the washer and the nut onto the spindle shaft
(Fig. 487). Mower Spindle Disassembly
Z 100 Series (44” Deck)

1. Remove the spindle shaft, bearing shield and

hardened washer from the spindle housing assembly
(Fig. 489).

Fig 487 PICT-0185

7

Fig 489 PICT-0388 rev

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2. Remove the spindle bearings and spacer (Fig. 490) 2. Lift the floor pan and remove the mower belt covers
(Fig. 491).

A B
C

B
Fig 490 PICT-0390
Fig 491 PICT-0116

A. Spindle housing C. Spacer

B. Bearings (2)

3. Loosen the two nuts located on the idler plate to

remove tension on the belt (Fig. 492).
Mower Spindle Assembly
Z 100 Series (44” Deck)

Reverse the order of mower spindle removal

Replacing the Mower Deck Drive Belt

All Z 400 models

Squealing when the belt is rotating, blades slipping when

cutting grass, frayed belt edges, burn marks and cracks
are signs of a worn mower belt. Replace the mower belt

7
if any of these conditions are evident.
Fig 492 PICT-0121
1. Disengage the PTO, move the motion control levers
to the neutral locked position, and set the parking
brake.

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4. Remove the worn/broken belt. 7. Route the belt around the idlers as shown (Fig. 495).

5. Route the new belt through the left side belt guide
(Fig. 493).

Fig 495 fig. 47 G001679

1. Ratchet with short 2. Square hole

Fig 493 PICT-0188 extension or breaker bar

6. Install the new belt onto the electric PTO clutch (Fig. 8. Insert a ratchet with a short extension or a breaker
494). bar into the square hole in the fixed idler arm.
Rotate the ratchet or breaker bar counterclockwise
to move the fixed idler arm until you feel increased
resistance and the spring-loaded idler pulley stops
moving.

Note: Do not increase the belt tension beyond the

point where the fixed idler arm stops.

7
Fig 494 PICT-0122

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9. Tighten the nut on the slotted on the idler plate (Fig. Replacing the Mower Deck Drive Belt
496).
Z 100 Series

1. Disengage the PTO, move the motion control levers

to the neutral locked posistion, and set the parking
brake.

2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.

3. Remove the belt covers over the outside spindles.

4. Loosen the outer nut on the spring eye bolt (Fig.

498).

Fig 496 PICT-0147

10. Tighten the pivot bolt (Fig. 497).

Fig 498 fig. 45 G002034

1. Outer nut 5. Spring

2. Idler pulley 6. 9-3/8 + 1/8 inch
3. Idler arm (238 + 3mm)
4. Spring eye bolt 7. Mower belt

7 Fig 497 PICT-0150

11. Reinstall belt covers.

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5. Remove the old belt. 9. Tighten the outer nut on the spring eye bolt (Fig.
498).
Note: Start at the outside pulley and rotate the belt
off (Fig. 499). Note: Check the spring length. The spring should
measure 9-3/8 + 1/8 inch (238 + 3mm) with belt
installed. Adjust it if it does not (Fig. 498).

10. Install the belt covers over the outside spindles.

Adjusting the Mower Belt Tension

Z 100 Series

1. Disengage the PTO, move the motion control levers

to the neutral locked position, and set the parking
brake.

2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
Fig 499 fig. 46 G002035 position.

1. Mower belt 4. Spring 3. Remove the belt covers over the outside spindles.
2. Idler arm 5. Idler pulley
3. Outside pulley 4. Loosen the outer nut on the spring eye bolt (Fig.
500).

Note: Do not remove the spring from the eye bolt.

!
The spring is under tension when installed
and can cause personal injury.
Do not remove the spring from the spring
eye bolt.

6. Remove the spring loaded idler pulley (Fig. 498).

7
7. Route the new bolt through the idler arm (Fig. 498).

8. Install the idler pulley and route the belt onto the
other pulleys (Fig. 499).
Fig 500 fig. 45 G002034

1. Outer nut 5. Spring

2. Idler pulley 6. 9-3/8 + 1/8 inch
3. Idler arm (238 + 3mm)
4. Spring eye bolt 7. Mower belt

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 MOWER DECKS/PTO
5. Install the belt covers over the outside spindles. 5. To increase the belt tension, rotate the ratchet or
breaker bar counterclockwise to move the fixed
6. Tighten the outer nut on the spring eye bolt (Fig. idler arm until you feel increased resistance and the
500). spring-loaded idler pulley stops moving (Fig. 502).

Note: Check the spring length. The spring should Note: Do not increase the belt tension beyond the
measure 9-38 + 1/8 inch (238 + 3mm) with belt point where the fixed idler arm stops.
installed. Adjust it if it does not (Fig. 500).

Adjusting the Mower Belt Tension

Z 400 Series

1. Disengage the PTO, move the motion control levers

to the neutral locked position, and set the parking
brake.

2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
postition.

3. Remove the belt covers over the outside spindles.

Fig 502 fig. 50 G001679
4. Loosen the fixed idler arm and adjust it to relieve the
belt tension on the fixed idler pulley (Fig. 501). 1. Ratchet with short 2. Square hole
extension or breaker
bar

6. While holding the belt in tension, tighten the 2 nuts

that secure the fixed idler arm.

7. Remove the ratchet or breaker bar from the square

hole in the fixed idler arm.

8. Install the belt covers over the outside spindles.

7
Fig 501 fig. 49 G001678

1. Fixed idler arm 4. Mower belt

2. Square hole 5. Belt guide
3. Fixed idler pulley 6. Spring-loaded idler
pulley

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Leveling the Mower at 3 Postions Leveling the Mower Side-to-Side

Setting Up the Machine 1. Position the right blade side-to-side (Fig. 503).

All models

1. Position mower on a flat surface.

2. Disengage the PTO, move the motion control levers

to the neutral locked position and set the parking
brake.

3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.

4. Check tire pressure of all four tires. If needed, adjust

to 13 psi (90kPa).

5. Lower the mower to the 3 inch (76mm) height-of-cut

position. Fig 503 fig. 65 m-1078

6. Inspect the four chains. The chains need to have

tension.
2. Measure the right blade at the B location, from a
Note: Adjust the rear chains to the top of the slot, flat surface to the cutting edge of the blade tip (Fig.
where they are attached to the mower. 503).

• If one rear chain is loose, lower (loosen) the front 3. Record this measurement. Measurement should be
support arm on the same side. Refer to Adjusting 3-1/8 to 3-1/4 inches (79 - 83mm).
the Front-to-Rear Mower Pitch page 7-30.
4. Position the left blade side-to-side (Fig. 503).
• If one front chain is loose, raise (tighten) the front
support arm for that chain. Refer to Adjusting the 5. Measure the left blade at the C location (Fig. 503),
Front-to-Rear Mower Pitch page 7-30. from a flat surface to the cutting edge of the blade
tip.
7. Level the mower side-to-side and front-to-rear.
6. Record this measurement. With the height of cut set
at 3 inches (76mm) this measurement should be 3-
1/8 to 3-1/4 inches (79 to 83mm).

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7. If the measurements at positions B or C are not Adjusting the Front-to-Rear Mower Pitch
correct, loosen the bolt attaching the rear chain to
the rear support arm (Fig. 504). 1. Position the right blade front-to-rear (Fig. 505).

Fig 504 fig. 57 G001924

Fig 505 fig. 58 G001041

1. Rear chain 5. Adjustment bolt

1. Measure here from 2. Measure at A and B
2. Rear support arm 6. Front swivel
blade to flat surface
3. Bolt 7. Front support arm
4. Jam nut

2. Measure the right blade at the A location, from a

flat surface to the cutting edge of the blade tip (Fig.
8. Loosen the jam nut under the rear support arm and 505).
turn the adjustment bolt to get a measurement of 3-
1/8 to 3-1/4 inches (79 - 83mm) (Fig. 504). 3. Record this measurement.
Note: It is recommended that both sides of the 4. Measure the right blade at the B location, from a
mower are adjusted the same distance. level surface to the cutting edge of the blade tip
(Fig. 505).
9. Tighten the jam nut under the rear support arm and
tighten the bolt securing the chain to the rear support 5. Record this measurement.
arm.
6. The mower blade should be 1/4 to 3/8 inch (6 to
10. Adjust the opposite side if needed. 10mm) lower at position A than at position B (Fig.

7 505). If it is not correct, proceed to the following

steps.

Note: Both of the front swivels need to be adjusted

the same amount to maintain equal chain
tension and side-to-side level.

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7. Loosen the front swivel jam nuts, at the front of the 3. Adjust this distance, by loosening the spring jam nut
right and left swivels, approximately 1/2 inch (13mm) and turning the nut in front of each spring (Fig. 506).
(Fig. 504).
Note: Turning the nut clockwise will shorten the
8. Adjust the lift nuts on both the left and the right spring; counter-clockwise will lengthen the
side of the machine to achieve 1/4 to 3/8 inch (6 to spring.
10mm) lower in front at A than in the rear at B (Fig.
504). 4. Lock the nut into position by tightening the spring
jam nut (Fig. 506).
9. Tighten both swivel jam nuts against the front swivel
to lock the height.

10. Check to make sure there is equal tension on the

chains and adjust again if needed.

Adjusting the Compression Spring

1. Raise the mower lift lever to the transport position.

2. Check the distance between the two large washers.

It should be 11-1/8 inches (28.2cm) for 52 inch
(132.1cm) mower decks (Fig. 506).

1. 11-1/8” (28.2cm)
Fig 506

5.
fig. 59 G001925

Swivel jam nut

7
2. Front nut 6. Lift nut
3. Spring jam nut 7. Front support arm
4. Front swivel 8. Large washer

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THIS PAGE INTENTIONALLY LEFT BLANK.

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 Z Master Z400
Series
Service Manual

Form No. 492-9166