MOWER DECKS/PTO A A B B
Contents
1. MOWER DECKS PTO Electric PTO Clutch Removal This procedure is on the Air Cooled Engine Models and follows the same procedure for the Liquid Cooled Engine Model The electric PTO clutch removal and installation are similar on both the air cooled engine models and the liquid cooled model The only difference is the clutch guard removal The figure below points to the bolts that need to be removed in both units Fig 355 The procedure shows an air cooled unit 1 Loosen and remove 2 bolts and nuts located on the clutch guard Fig 357 Fig 357 DSC 3131 Fig 355 DSC 3131 A Top strap bolts B Clutch guard bolts 2 Remove the right and left top bolt and nut on the top strap guards to remove the clutch guard from the unit Fig 358 On the Kawasaki liquid cooled models remove 6 bolts to access the clutch Fig 356 Fig 358 DSC 3134 Fig 356 DSC 3794 1 2 Z Master 500 Gas Series Service Manual MOWER DECKS PTO 3 Disconnect the electric PTO clutch connector from 5 Loosen the two nuts located on the idler plate to the clutch Fig 359 relieve tension on the belt Fig 361 Fig 359 DSC 3135 Fig 361 DSC 3137 4 Lift the floor pan and remove the right side mower 6 Slip the mower drive belt off the right mower spindle belt cover Fig 360 pulley Fig 362 Fig 360 DSC 3136 Fig 362 DSC 3138 Z Master 500 Gas Series Service Manual 7 3 MOWER DECKS PTO 7 Remove the belt from the electric PTO c2. eve tension on the belt Fig 402 Mower Spindle Removal This applies to removing any of the three mower spindles This procedure shows removing the right side spindle 1 Either use a hoist or the Z Stand to raise the front of the mower deck 2 Chock or block the drive wheels 3 Disconnect the battery negative cable 4 Lower the mower deck to the lowest position Fig 402 DSC 3137 7 14 Z Master 500 Gas Series Service Manual MOWER DECKS PTO 7 Slip the mower drive belt off the left mower spindle 9 Raise the mower deck to the transport position pulley Fig 403 10 Remove the mower blade from the spindle assembly 11 Remove the 6 bolts and nuts from the spindle assembly Remove the spindle assembly Fig 405 Fig 403 DSC 3138 8 Remove three bolts retaining the pulley to the pulley hub Fig 404 Fig 405 DSC 2666 Mower Spindle Installation Reverse the order of mower spindle removal Fig 404 DSC 2662 Z Master 500 Gas Series Service Manual 7 15
3. he pulleys Make sure it is only rear idler arm and the rubber stop Fig 374 what is specified in Figure 372 Fig 374 DSC 3148 Fig 372 fig 70 m 6825 8 Direction to rotate B Idler plate nut 1 Clutch 4 Belt guide idler plate 2 Mower belt 5 Mower spindle pulley 3 1 4 turn belt twist 6 Mower idler pulley 7 6 Z Master 500 Gas Series Service Manual MOWER DECKS PTO 9 Tighten the pivot bolt on the idler plate once the 11 Install the right belt cover on the mower deck adjustment is achieved Fig 375 12 Install the right and left top strap guards with the clutch guard to the unit Fig 377 Fig 375 DSC 3149 Fig 377 DSC 3134 10 Connect the PTO clutch connector to the clutch Fig 376 13 Install and tighten the two bolts and nuts on the top strap guards and the two bolts in the clutch guard Fig 378 Fig 376 DSC 3135 Fig 378 DSC 3131 A Top strap bolts B Clutch guard bolts Z Master 500 Gas Series Service Manual 1 1 MOWER DECKS PTO Mower Deck Removal 52 60 72 3 aH cir o belt off the right mower spindle pulley Fig 1 Lift the floor pan and remove the right hand belt cover Fig 379 Fig 381 DSC 3138 Fig 379 DSC 3136 4 Remove the belt around the electric PTO clutch pulley and the two rear idler pulleys Fig 382 2 Loosen the two nuts located on the idler plate to relieve tension on the mower drive belt Fig 380 Fig 382 DSC 3139 Note Clutch g
4. k 8 Install the strut pin in the strut assembly Install and tighten the bolt and nut 9 Install the rear and front lift chains to the mower 10 Raise the mower deck and remove the wood block Fig 395 DSC 3145 A Idler pulley B Stationary idler 7 12 Z Master 500 Gas Series Service Manual MOWER DECKS PTO 13 Route the belt around all of the mower deck pulleys 14 Install a 1 2 socket ratchet and extension in the and install the belt around the right side mower square hole in the idler plate Fig 398 spindle pulley Fig 396 Fig 398 DSC 3147 Fig 396 DSC 3146 15 Rotate the mower idler plate toward the front of the Important Check the amount of twist in the belt mower deck until light contact is made between the between the pulleys Make sure it is only idler arm and the rubber stop Fig 399 what is specified in Fig 397 below Fig 399 DSC 3148 Fig 397 fig 70 m 6825 8 Direction to rotate B Idler plate nut 1 Clutch 4 Belt guide idler plate 2 Mower belt 5 Mower spindle pulley 3 1 4 turn belt twist 6 Mower idler pulley Z Master 500 Gas Series Service Manual 7 13 MOWER DECKS PTO 16 Tighten the pivot bolt on the idler plate once the 5 Lift the floor pan and remove the right side mower adjustment is achieved Fig 400 belt cover Fig 401 Fig 400 DSC 3149 Fig 401 DSC 3136 17 Install the right belt cover on the mower deck 6 Loosen the two nuts located on the idler plate to reli
5. lutch Fig 9 Remove the electric PTO clutch from the engine 363 crankshaft Fig 365 Fig 363 DSC 3139 Fig 365 DSC 3141 8 Remove the electric PTO clutch bolt Fig 364 Electric PTO Clutch Installation 1 Apply anti seize compound to the engine crankshaft Fig 366 Fig 364 DSC 3140 Fig 366 DSC 3142 1 4 Z Master 500 Gas Series Service Manual MOWER DECKS PTO 2 Install the electric PTO clutch to the engine crank 4 Install the mower drive belt around the electric PTO shaft Fig 367 clutch pulley Fig 369 Fig 367 DSC 3141 Fig 369 DSC 3144 3 Apply medium strength threadlocking material to the 5 Check and make sure the mower drive belt is in the bolt Install the bolt and two spring washers to the groves of the two idler pulleys located under the crankshaft Torque the bolt to 65 ft Ibs 88 13 Nm electric PTO clutch Fig 370 Fig 368 Fig 370 DSC 3145 Fig 368 DSC 3143 A Idler pulley B Stationary idler Z Master 500 Gas Series Service Manual 7 5 MOWER DECKS PTO 6 Route the belt around all of the mower deck pulleys 7 Install a 1 2 ratchet and extension into the square and install the belt around the right side mower hole in the idler plate Fig 373 spindle pulley Fig 371 Fig 373 DSC 3147 Fig 371 DSC 3146 8 Rotate the mower idler plate toward the front of the Important Check the amount of twist in the belt mower deck until light contact is made between the between t
6. ower deck Fig 387 DSC 2635 12 Remove the 4 x 4 wood block from under the left side of the mower deck and lower the deck to the floor 7 10 Z Master 500 Gas Series Service Manual MOWER DECKS PTO 13 Turn the right front wheel so the caster fork is angled Mower Deck Installation 52 60 72 forward This will allow more clearance to slide the mower deck from under the frame Fig 389 1 Slide the mower deck under the unit 2 Install a 4 x 4 block of wood under the left side of the mower deck Fig 391 Til i HAL oe oo eel al Fig 389 DSC 2637 Fig 391 DSC 2635 14 Slide the mower out the right side of the unit Fig 390 3 Install the strut pin through the strut assembly Install the bolt and nut retaining the strut pin Fig 392 Fig 390 DSC 2638 Fig 392 DSC 2639 Z Master 500 Gas Series Service Manual 7 11 MOWER DECKS PTO 4 Install the rear and front chains to the mower deck 11 Install the belt around the electric PTO clutch pulley Fig 393 Fig 394 Fig 393 DSC 2640 Fig 394 DSC 3139 Note Clutch guard removed for clarity 5 Remove the hitch pin on the lift handle and raise the mower in the transport position 12 Check and make sure the mower drive belt is in the 6 Install a 4 x 4 wood block under the right side of the grooves of the two idler pulleys located under the mower deck electric PTO clutch Fig 395 7 Lower the mower deck down on the wood bloc
7. uard removed for clarity Fig 380 DSC 3137 A Idler plate bolt 7 8 Z Master 500 Gas Series Service Manual MOWER DECKS PTO 5 Raise the mower deck to the transport position 7 Remove the bolt and nut holding the right rear strut Install a 4 x 4 wood block under the right side of the pin into the strut assembly Fig 385 mower deck Lower the deck to relieve tension on the lift chains on the right side Fig 383 Fig 385 DSC 2632 Fig 383 DSC 2623 8 Remove the strut pin from the strut assembly and remove the assembly from the mower deck Fig 6 Remove the front and rear lift chains from the mower 386 deck Fig 384 Fig 386 DSC 2633 Fig 384 DSC 2631 Z Master 500 Gas Series Service Manual 7 9 MOWER DECKS PTO Tie strap the strut assembly up so it will be out of 10 Push the lift handle to the lowest HOC position to the way of the mower deck when sliding it out under overcome the tension of the lift assist springs Use the frame Remove the 4 x 4 block of wood from the the hitch pin above the lift handle to lock the handle right side of the deck and allow the deck to rest on in the down position Fig 388 the floor 9 Raise the deck to transport position Install a 4 x 4 wood block under the left side of the mower deck Lower the mower deck until it rests on the block of wood to relieve tension on the lift chains Fig 387 Fig 388 DSC 2636 11 Follow steps 5 through 8 on the left side of the m
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