Husqvarna Z400 Series Service Manual
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Husqvarna Z400 Series Service Manual

Zero-turn mower
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Service Manual
Z400 Series Zero-Turn Mower
Husqvarna Part Number 114242727

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Summary of Contents for Husqvarna Z400 Series

  • Page 1 Service Manual Z400 Series Zero-Turn Mower Husqvarna Part Number 114242727...
  • Page 2 Page Intentionally Blank Z400 Series...

  • Page 3: Table Of Contents

    Component Location ............2-3 Z400 Series...
  • Page 4 Check Power Take-Off (PTO) Air Gap ..........4-11 Z400 Series...
  • Page 5 Replace Fuses and Relays ............5-15 Z400 Series...
  • Page 6 Left Parking Brake Wiring Harness Legend ........6-14 Z400 Series...
  • Page 7 Hour Meter Circuit Operation ........... . . 6-42 Z400 Series...
  • Page 8 Seat Assembly—Z454X and Z460X ..........8-27 Z400 Series...

  • Page 9: Foreword

    These tools and/or materials will be listed for reference as needed. Husqvarna Z448, Z454, Z454X, Z460, and Z460X Zero-Turn Mowers. Quick Reference Specifications This manual is intended to introduce and guide the user...
  • Page 10 FOREWORD Page Intentionally Blank Z400 Series...

  • Page 11: Safety

    Prepare Equipment for Service ..........1-13 Z400 Series...

  • Page 12: Introduction

    • Be prepared for emergencies. Accidents can happen even under the best conditions. Fire extinguishers and first aid kits should be well maintained and easily accessible. • Tie back long hair to prevent it from being pulled into machine. Z400 Series...

  • Page 13: Safety Label Locations

    SAFETY Safety Label Locations Become familiar with machine safety labels and locations. The following illustrations show safety label locations on the machine. Machine model Z454X is shown; other models are similar. HUS1010 Figure 1-1 Z400 Series...
  • Page 14 SAFETY HUS1011 Figure 1-2 Z400 Series...

  • Page 15: Inspect Safety Labels

    SAFETY HUS1031 Figure 1-3 Inspect Safety Labels Safety labels are important to the safe operation of the machine. Replace any damaged, missing, or unreadable labels before placing the machine back in service. Z400 Series...

  • Page 16: Keep Work Area Clean

    Always wear personal protective equipment stored in an approved safety cabinet away from possible (PPE) when servicing battery. sources of ignition. Storage areas and cabinets should be well ventilated to prevent the possible buildup of fumes. Ground cabinets when required. Z400 Series...

  • Page 17: Park Equipment Safely

    Never work under a machine while supported by one jack stand. HUS1012 Figure 1-5 5. Place control levers in the park brake position (4). 6. Move key (3) to the OFF position. 7. Remove key from ignition switch. Z400 Series...

  • Page 18: Use Compressed Air And Air Tools Safely

    • When dismounting or mounting tires, use a wheel holder or tire machine. Use proper tire mounting tools and equipment. Never use screwdrivers or makeshift tools to force a tire on or off a wheel. Z400 Series...

  • Page 19: Safety Guidelines

    • The mulch blades must only be used in familiar areas the mower deck’s drive belt are removed. when higher quality mowing is necessary. • Regularly clean the deck and the underside of the deck. Avoid spraying engine and electrical components with water. Z400 Series...

  • Page 20: General Operation Guidelines

    • Only allow responsible adults who are familiar with the instructions to operate the machine. • Clean the area of objects such as: rocks, toys, wire, etc., that could be picked up and thrown by the blades. HUS1035 Figure 1-8 Z400 Series 1-10...

  • Page 21: Safe Handling Of Gasoline

    • Check the fuel level before each use. Leave space for the fuel to expand because the heat from the engine and the sun can otherwise cause the fuel to expand and overflow. Z400 Series 1-11...

  • Page 22: Rollover Protection System

    • Keep the ROPS in safe operating condition by A spark arrestor for the muffler is available through your periodically inspecting for damage and keeping all authorized Husqvarna dealer. mounting fasteners tight. Check all bolts, including on the seat belt, for correct torque before each use.

  • Page 23: Transport

    3. Disconnect spark plug wires (2) from spark plug. limits for towed equipment. Do not tow near ditches, 4. Place the spark plug wires where it cannot come into canals, and other hazards. contact with spark plug. Z400 Series 1-13...
  • Page 24 SAFETY Page Intentionally Blank Z400 Series 1-14...

  • Page 25: Specifications

    Metric Standard ............2-7 Z400 Series...

  • Page 26: Product Identification Number Location

    (2), serial number (3), and model number (4). HUS1017 Figure 2-2 The product identification label (1) is located under the seat. The identification label provides the product number (2), serial number (3), and model number (4). Z400 Series...

  • Page 27: Component Location

    10) Deck Height Adjustment Pin 16) Power Take-Off (PTO) Switch 5) Key Switch 11) Throttle Control Lever 17) Deck Height Control Linkage (2 used) 6) Choke Lever 12) Gas Tank Cap 18) Anti-scalp Wheel (2 used) Figure 2-5 Z400 Series...

  • Page 28: Machine Specifications

    23.5 hp Power (16.4 kW) (17.2 kW) (16.4 kW) (17.5 kW) Cylinders V-twin Bore 3.1 in (78 mm) Stroke 3 in (76 mm) Displacement 44.3 cu in (726 cc) Cooling System Forced Air Ignition Solid–State Ignition Shaft Vertical Z400 Series...

  • Page 29: Drive System

    (145 cm) (162 cm) (140 cm) (162 cm) Height 49.25 in (125 cm) 49.75 in (127 cm) Weight 725 lb (329 kg) 745 lb (388 kg) 823 lb (373 kg) 865 lb (392 kg) 877 lb (398 kg) Z400 Series...

  • Page 30: Special Torques

    SAE Grade 8 Flangelock Nut Size (in) lb-ft N•m lb-ft N•m lb-ft N•m – – 5/16 7/16 – – – – 9/16 – – – – – – – – 1-1/8 1060 1410 1912 – – HUS1008 Figure 2-6 Z400 Series...

  • Page 31: Metric Standard

    Refer to your torque wrench operator manual for specifications before use. Grade Grade 8.8 Grade 10.9 Grade 12.9 10.9 12.9 Size lb-ft N•m lb-ft N•m lb-ft N•m 13.5 18.8 21.8 35.2 43.5 43.5 62.2 70.5 1226 HUS1009 Figure 2-7 Z400 Series...
  • Page 32 SPECIFICATIONS Page Intentionally Blank Z400 Series...

  • Page 33: Maintenance

    Purging Procedure ............. . 3-7 Z400 Series...

  • Page 34: Maintenance Schedule

    Air cleaner paper filter cartridge ALSO ✓ ✓ ✓ ✓ Examine muffler/spark arrestor Start the engine & blades; ✓ listen for unusual sounds ✓ ✓ Sharpen or replace mower blades HUS1021 Figure 3-1 (Maintenance schedule continued on next page) Z400 Series...

  • Page 35: Tire Wear And Replacement Guideline

    Correct and equal tire pressure is important for best cutting performance. Using a tire pressure gauge, set tire pressure to 15 psi (103 kPa) (1 bar) or use pressure shown on the tire sidewall if different. Z400 Series...

  • Page 36: Lubrication

    HUS1023 Figure 3-3 Synthetic Engine Oil 2. Remove dirt and debris away from engine oil filter Grease Molybdenum Disulfide (2). 3. Remove engine oil dipstick (1). Qualified Hydraulic Oil Castrol™ Syntec 5W-50 Amsoil AW ISO 68 Shell™ TTF-SB Z400 Series...

  • Page 37: Lubricate Front Wheel Bearings

    3. Lubricate front wheel bearing with 3–4 strokes. 3. Lubricate mower deck mandrel with 2–3 strokes. 4. Remove grease gun. 4. Remove grease gun. 5. Repeat steps 2–4 for other front wheel bearing. 5. Repeat steps 2–4 for other mower deck mandrels. Z400 Series...

  • Page 38: Check And Fill Transmission Fluid

    3. Remove hydraulic oil dipstick (1 or 2) and check hydraulic oil. 4. Add hydraulic oil if needed. 5. Purge the transmission. See “Purging Procedure” on page 3-7. HUS1040 Figure 3-9 3. Remove transmission oil dipstick (1 or 2). 4. Place appropriate container under transmission. Z400 Series...

  • Page 39: Purging Procedure

    When the hydraulic drive operates at normal wheel. noise levels and moves smoothly in forward and reverse at normal speeds, the hydraulic drive is considered purged. Z400 Series...
  • Page 40 MAINTENANCE Page Intentionally Blank Z400 Series...

  • Page 41: Adjustments

    Check Power Take-Off (PTO) Air Gap ..........4-11 Z400 Series...

  • Page 42: Install And Adjust Rops

    4. On discharge side, measure distance from the bottom of the blade to the floor (1) and record measurement. 5. On the non-discharge side, measure distance from the bottom of the blade to the floor and record measurement. Z400 Series...

  • Page 43: Front-To-Back (Rake) Adjustment

    7. If the measurement is not within specification, turn 3. Rotate blades so that they align front-to-back with the the deck adjustment linkage fasteners (2) clockwise deck. to raise the deck and counterclockwise to lower the deck. 8. Verify measurements after adjustment. Z400 Series...

  • Page 44: Adjust Mower Deck Anti-Scalp Wheels

    Make sure the carburetor throttle valve (3) moves smoothly. HUS1053 Figure 4-7 NOTICE The rollers must be approximately 0.25 in (6.5 mm) from the ground. 4. Install fastener, spacer, nut, and anti-scalp wheel. Adjust anti-scalp wheel to the appropriate height (5). Z400 Series...

  • Page 45: Check And Adjust Choke Cable

    7. Install pin and repeat steps 1–6 until machine does not move in the neutral position. 3. Loosen fastener (1). 4. Remove slack from choke cable (2). 5. Tighten fastener. 6. Open and close choke to verify that the carburetor choke valve (3) opens and closes completely. Z400 Series...

  • Page 46: Adjust The Return To Neutral For Controls

    (right side) until the unit noticeably starts to drift right. 6. Drive forward at full throttle with the motion controls in the full forward position. Gradually turn in the tracking bolt (left side) until the unit tracks straight. Z400 Series...

  • Page 47: Adjust Deck Belt Tension

    3. Attach pull force gauge to eyebolt (1) and pull until specified force is met. Specification 48 in Deck Belt Tension 20–23 lb (9.0–10.5 kg) 4. Insert pin (2) to hold tensioner in place. Z400 Series...

  • Page 48: Z454

    5. Check belt tension again and repeat step 4 if 3. Check belt tension using a belt tension gauge at necessary until the belt tension is within the specified location marked (1) in Figure 4-14. range. Specification 54 in Deck Belt Tension 34–37 lb (15.5–17.0 kg) Z400 Series...

  • Page 49: Z454X And Z460X

    28.5–31.5 lb (13.0–14.5 kg) 4. If deck belt tension measures below the specified range, turn tension nut (2) clockwise to increase tension. If deck belt tension measures above specified range, turn tension nut (2) counterclockwise to reduce tension. Z400 Series...

  • Page 50: Adjust Ground Drive Belt Tension

    (1). 7. Loosen jam nut (3). 8. To increase tension on park brake, turn nut (2) clockwise or turn counterclockwise to reduce tension on park brake. 9. Engage and disengage park brake to ensure smooth operation. Z400 Series 4-10...

  • Page 51: Setting Mower Deck Height

    PTO clutch does not stay engaged, replace as necessary. For more information on PTO troubleshooting, see “Diagnose Power Take-Off (PTO) Clutch” on page 7-7 and see “Diagnose Clutch Slips” on page 7-8. HUS1137 Figure 4-19 Z400 Series 4-11...
  • Page 52 ADJUSTMENTS Page Intentionally Blank Z400 Series 4-12...
  • Page 53 Installation ............. . . 5-14 Z400 Series...
  • Page 54 Contamination of Crankcase ........... . . 5-22 Z400 Series...

  • Page 55: Repair

    If the blade is unbalanced, sharpen the heavier side and retest the blade balance. If the blade is balanced, install mower blade. See “Remove and Install Mower Blades” on page 5-3. Z400 Series...

  • Page 56: Remove And Install Mower Deck Belt

    Install new mower deck belt in accordance to the model of mower. Installation is done in reverse order of removal. • Adjust mower deck belt tension. See “Adjust Deck Belt Tension” on page 4-7. HUS1152 Figure 5-5: Z454 Shown Z400 Series...

  • Page 57: Remove And Install Mandrels

    6. Clean and inspect mower height deck box. Repair or Installation replace as necessary. Installation is done in reverse order of removal. Installation • Adjust deck belt tension. See “Adjust Deck Belt Installation is done in reverse order of removal. Tension” on page 4-7. Z400 Series...

  • Page 58: Remove And Install Mower Deck

    8. Clean and inspect mower deck. Repair or replace as necessary. Installation Installation is done in reverse order of removal. • Adjust deck belt tension. See “Adjust Deck Belt Tension” on page 4-7. • Adjust mower deck. See “Adjust Mower Deck” on page 4-2. Z400 Series...

  • Page 59: Remove And Install Throttle Cable

    1. Park and prepare machine for service. See “Prepare Equipment for Service” on page 1-13. HUS1076 Figure 5-16 3. Remove knob (2). 4. Remove fasteners (3) and throttle lever assembly (4). HUS1013 Figure 5-18 2. Remove fasteners (1). Z400 Series...

  • Page 60: Installation

    HUS1081 Figure 5-22 3. Install identification tags and disconnect float level sensor (B2). 4. Install identification tags and disconnect fuel line (3) and rollover valve hose (4). Close all openings using caps and plugs. 5. Remove fasteners (5). Z400 Series...

  • Page 61: Installation

    3. Remove fasteners (1) and brackets (2). connector (X4). 10. Install identification tags and disconnect fuel line (9). Close all openings using caps and plugs. 11. Remove belt from power take-off (PTO) pulley. See “Remove and Install Mower Deck Belt” on page 5-4. Z400 Series...

  • Page 62: Installation

    16. Attach appropriate lifting device to engine. • Adjust choke cable. See “Check and Adjust Choke Cable” on page 4-5. Specification • Add engine oil. See “Engine Oil and Filter Change” Engine Weight on page 3-4. 110 lb (50 kg) (approximate) Z400 Series 5-10...

  • Page 63: Remove And Install Front Vertical Caster Bearings

    Installation is done in reverse order of removal. HUS1121 Figure 5-30 Tighten fastener (2) to specification. 4. Remove fastener (2). Specification Fastener (2) Torque 50 ft-lb (68 N•m) • Grease caster bearing. See “Lubricate Caster Bearings” on page 3-5. Z400 Series 5-11...

  • Page 64: Remove And Install Ground Drive Belt

    • Adjust deck belt. See “Adjust Deck Belt Tension” on • Adjust deck belt. See “Adjust Deck Belt Tension” on page 4-7. page 4-7. • Adjust ground drive belt. See “Adjust Ground Drive Belt Tension” on page 4-10. Z400 Series 5-12...

  • Page 65: Remove And Install Transmission

    Figure 5-34 Specification 5. Loosen nut (1). Fastener (1) Torque 160 ft-lb (216 N•m) 6. Remove nuts (2), spacer (3), and spring (4). Fastener (6 and 10) Torque 75 ft-lb (101 N•m) 7. Remove control rod (5). Z400 Series 5-13...

  • Page 66: Remove And Install Brake Cables

    7. Clean and inspect brake cable. Repair or replace as Installation is done in reverse order of removal. necessary. Installation Installation is done in reverse order of removal. • Adjust brake cable. See “Adjust Brakes” on page 4-10. Z400 Series 5-14...

  • Page 67: Remove And Install Battery

    4. Remove fastener (3) and battery (4). 5. Clean and inspect battery. Replace as necessary. Installation Installation is done in reverse order of removal. • Install positive (+) battery lead first and negative (-) battery lead second. Z400 Series 5-15...

  • Page 68: Remove And Install Control Lever Assembly

    9. Remove spring (14). 10. Install identification tags and disconnect parking brake switch (X2). HUS1130 Figure 5-46 HUS1128 Figure 5-44 11. Remove fasteners (15) and control lever sub 5. Remove fasteners (6) and control lever (7). assembly (16). Z400 Series 5-16...

  • Page 69: Installation

    7. Clean and inspect part. Replace as necessary. 6. Remove fasteners (2) and seat assembly (3). 8. Repeat steps 2—7 for right motion control lever switch. Installation Installation Installation is done in reverse order of removal. Installation is done in reverse order of removal. Z400 Series 5-17...

  • Page 70: Engine Does Not Crank

    Does engine have See authorized “Starter Motor Solenoid solenoid as compression? Husqvarna dealer Test” on page 6-27. necessary. for assistance. YES: Checks complete. Are valves adjusted properly? See See authorized authorized engine Husqvarna dealer dealer for specification. for assistance. Z400 Series 5-18...

  • Page 71: Engine Hard To Start

    0.03 in Are valves adjusted (0.76 mm). properly? See See authorized authorized engine YES: Go to next check. Husqvarna dealer dealer for specification. for assistance. Is spark plug seated Tighten spark plug correctly? to 192 lb-in (22 N•m). Z400 Series 5-19...

  • Page 72: Engine Runs Erratically

    YES: Go to next check. Does the engine See authorized smooth out if partial Husqvarna dealer choke is applied? for assistance. YES: Checks complete. Is carburetor operating See authorized correctly? Husqvarna dealer for assistance. Z400 Series 5-20...

  • Page 73: Engine Malfunctions At Low Rpm

    YES: Go to next check. Checks complete. Is timing gear aligned See authorized correctly? Husqvarna dealer for assistance. YES: See authorized Is there excessive Husqvarna dealer carbon buildup in for assistance. combustion chamber? Checks complete. Z400 Series 5-21...

  • Page 74: Excessive Oil Consumption

    Diagnostic Checks Results for assistance. YES: Checks complete. Change engine oil and filter. See “Engine Oil and Is the crankcase oil Filter Change” on free of fuel and debris? page 3-4. See authorized Husqvarna dealer for assistance. Z400 Series 5-22...

  • Page 75: Electrical

    Voltage Test ............. . 6-18 Z400 Series...
  • Page 76 Hour Meter Circuit Operation ........... . . 6-42 Z400 Series...

  • Page 77: Main Schematic (Continued)

    ELECTRICAL Main Schematic RED/BLK RED/BLK POSITION CIRCUIT “MAKE” G+M+L RED/BLK RUN/OVERRIDE YEL/RED START B + L + S RED/BLK RED/BLK YEL/RED YEL/RED RED/BLK RED/BLK HUS1045 Figure 6-1 Z400 Series...
  • Page 78 ELECTRICAL Main Schematic (Continued) YEL/RED YEL/RED RED/BLK A1 B2 B5 C5 A2 C4 C6 HUS1073 Figure 6-2 Z400 Series...

  • Page 79: Main Schematic Legend

    X12) Clutch Interconnect Starter Relay X13) Fuel Shutoff Solenoid Interconnect Motion Control Lever Relay X14) Ignition Coil – Primary Side Starter Motor Solenoid Seat Switch Electric Clutch Left Parking Brake Switch Fuel Shutoff Solenoid Right Parking Brake Switch Z400 Series...

  • Page 80: Electrical Wiring Harness Component Location

    ELECTRICAL Electrical Wiring Harness Component Location HUS1132 Figure 6-3 Z400 Series...

  • Page 81: Electrical Wiring Harness Component Location Legend

    Battery Ground Interconnect Low-Fuel Switch X11) Engine Ground Battery X12) Clutch Interconnect Voltage Regulator X13) Fuel Shutoff Solenoid Interconnect Starter Motor X14) Ignition Coil – Primary Side Seat Switch Solenoid Left Parking Brake Switch Electric Clutch Right Parking Brake Switch Z400 Series...

  • Page 82: Main Wiring Harness

    33.8 10.7 CAVITY CIRCUIT COLOR 30.R11 121110 9 8 7 SP10 CAVITY CIRCUIT COLOR 40.1 40.R8 40.2 SP10 Continued on Next Page CAVITY CIRCUIT COLOR CAVITY CIRCUIT COLOR 48.2 33.3 45.1 45.R3 33.1 10.A 33.2 HUS1043 Figure 6-4 Z400 Series...

  • Page 83: Main Wiring Harness (Continued)

    SP1 SP5 Continued 10.E 10.S1 from Previous Page 10.S1 10.6 10.4 10.1 10.2 CAVITY CIRCUIT COLOR 10.A RED/BLK 10.7 21.2 RED/BLK 10.5 CAVITY CIRCUIT COLOR 21.1 RED/BLK 10.R1 21.R6 RED/BLK 10.D2 33.7 21.D3 RED/BLK 10.8 10.E HUS1044 Figure 6-5 Z400 Series...

  • Page 84: Main Wiring Harness Table

    Iris Lite Module Connector Right Console Interconnect Right Parking Brake Interconnect 33.1 Accessory Outlets 33.2 Battery Positive Interconnect 33.3 X10) Battery Ground Interconnect 33.6 X12) Clutch Interconnect Solenoid 33.7 33.8 BLK/WHT 40.1 SP10 40.2 SP10 40.R8 SP10 Z400 Series 6-10...

  • Page 85: Battery Positive Harness

    Figure 6-6 Figure 6-7 Battery Positive Harness Table Battery Ground Harness Table COLOR FROM COLOR FROM Battery Positive Harness Legend Battery Ground Harness Legend Battery Battery Starter Motor X10) Battery Ground Interconnect Battery Positive Interconnect X11) Engine Ground Z400 Series 6-11...

  • Page 86: Right Console Wiring Harness

    — — — — 23.N4 F2N5 CAVITY CIRCUIT COLOR 10.F1 F2N5 CAVITY CIRCUIT COLOR 21.4 RED/BLK 23.5 33.4 — — YEL/RED 30.1 65.3 10.3 3 4 5 — — 33.5 11 12 — — HUS1066 Figure 6-8 Z400 Series 6-12...

  • Page 87: Right Console Wiring Harness Table

    YEL/RED 33.4 33.5 65.3 65.4 F2N5 Left Console Wiring Harness CAVITY CIRCUIT COLOR CAVITY CIRCUIT COLOR HUS1063 Figure 6-9 Left Console Wiring Harness Table Left Console Wiring Harness Legend Hour Meter CIRCUIT COLOR FROM Hour Meter Interconnect Z400 Series 6-13...

  • Page 88: Right Parking Brake Wiring Harness

    45.J2 45.J2 48.J1 10.J3 10.J3 10.J4 10.J4 HUS1061 Figure 6-11 Left Parking Brake Wiring Harness Left Parking Brake Wiring Harness Table Legend Left Parking Brake Switch CIRCUIT COLOR FROM Left Parking Brake Interconnect 10.J3 10.J4 45.J2 48.J1 Z400 Series 6-14...

  • Page 89: Power Take-Off (Pto) Clutch Harness

    — — — — CAVITY CIRCUIT COLOR HUS1069 Figure 6-13 Engine Wiring Harness Table Engine Wiring Harness Legend Voltage Regulator CIRCUIT COLOR FROM Starter Engine Connector X13) Fuel Shutoff Solenoid Interconnect X14) Ignition Coil – Primary Side Z400 Series 6-15...

  • Page 90: Battery, Charging, And Starting Systems Tests

    12.6 V 100% 1.265 g/cm3 cranking. When this occurs, the battery may be 12.4 V 1.225 g/cm3 close to the end of its useful life. 12.2 V 1.190 g/cm3 12.0 V 1.155 g/cm3 11.8 V 1.120 g/cm3 Z400 Series 6-16...

  • Page 91: Charging System Check

    5. Start engine, turn on all accessories, and engage power take-off (PTO) switch. 6. Run engine at low-idle while monitoring the battery voltage. 7. If the meter reads between 13 and 14 volts, the charging system is working properly. Z400 Series 6-17...

  • Page 92: Common Circuit Tests

    NOTE: Electrical connector is connected to component during test. 5. With the component switched on, check voltage. If voltage is not within specification, repair circuit. Z400 Series 6-18...

  • Page 93: Spark Test

    8. If continuity was shown in both checks or if no continuity was shown in either check, replace the 4. Connect other meter lead to the other fuse terminal. diode. 5. Check for continuity. If continuity is shown, fuse is good. Z400 Series 6-19...

  • Page 94: Relay Test

    5. Connect the meter lead to relay terminal 30. and check for continuity. If continuity is shown, 6. Connect the other meter lead to relay terminal 87a replace relay. and check for continuity. If continuity is shown, relay is good. Z400 Series 6-20...

  • Page 95: Key Switch Test

    5. With the key switch in the RUN/LIGHTS position, connect meter lead to key switch terminal B. 6. Connect other meter lead to key switch terminal L. If no continuity is shown, replace key switch. Z400 Series 6-21...

  • Page 96: Seat Switch Test

    If continuity is shown, replace seat switch. HUS1115 Figure 6-30 1. Disconnect seat switch connector. 2. Remove seat switch. 3. Set multimeter to ohms. 4. With seat switch released, connect meter lead to seat switch terminal 1. Z400 Series 6-22...

  • Page 97: Power Take-Off (Pto) Switch Test

    HUS1109 Figure 6-33 10. Connect other meter lead to PTO switch terminal 7. If no continuity is shown, replace switch. 5. With the PTO switch in the OFF position, connect meter lead to PTO switch terminal 4. Z400 Series 6-23...

  • Page 98: Check For Power

    HUS1110 Figure 6-37 13. With the PTO switch in the ON position, connect meter lead to PTO switch terminal 5. 14. Connect other meter lead to PTO switch terminal 11. If no continuity is shown, replace switch. Z400 Series 6-24...

  • Page 99: Power Take-Off (Pto) Clutch Test

    3. On the main harness, connect the red lead from the meter to the electrical connector terminal with the red wire. 4. Connect the black lead from the meter to the electrical connector terminal with the black wire. Z400 Series 6-25...

  • Page 100: Fuel Shutoff Solenoid Test

    4. Connect the red lead from the meter to the engine connector terminal 3 (purple wire). 5. Connect the black lead from the meter to the engine ground. If reading is within 30—40 ohms, fuel solenoid is good. Z400 Series 6-26...

  • Page 101: Starter Motor Solenoid Test

    2. stud. 6. Start engine. 8. Connect the black lead from the meter to the ground 7. With engine at full throttle, stator output should be at stud. If continuity is shown, replace solenoid. least 28 volts. Z400 Series 6-27...

  • Page 102: Diagnose Power Circuit

    Is battery voltage solenoid as • Check for battery See “Key Switch shown at fuel shutoff necessary. voltage at key switch. Test” on solenoid? page 6-21. Repair Is battery voltage or replace switch shown at key switch? as necessary. Z400 Series 6-28...

  • Page 103: Diagnose Cranking Circuit

    “Diagnose Run See “Power Take-Off Repair circuit as necessary. Circuit” on page 6-30. (PTO) Switch Test” on necessary. page 6-23. Is run circuit functioning properly? Is PTO switch in the OFF position and functioning properly? Z400 Series 6-29...

  • Page 104: Diagnose Run Circuit

    START position to Replace relay as start engine. necessary. • Check voltage at Repair circuit as terminal 1 (blue wire) necessary. of the right motion control lever connector. Is voltage shown at the right motion control lever? Z400 Series 6-30...

  • Page 105: Diagnose Charging Circuit

    YES: Checks complete. (PTO) Switch Test” on switch as See “Stator Output Check flywheel page 6-23. necessary. Test” on page 6-27. magnets. See Is PTO switch good? Is stator output at least authorized 28 volts? Kawasaki dealer for assistance. Z400 Series 6-31...

  • Page 106: Diagnose Hour Meter Circuit

    2 motor solenoid. See Replace starter (black wire) of the “Starter Motor motor solenoid. hour meter connector Solenoid Test” on and ground. page 6-27. Is continuity shown at Is the starter motor hour meter connector? solenoid good? Z400 Series 6-32...

  • Page 107: Power Circuit Operation

    Battery Ground Interconnect Main 20A Fuse Key Switch X11) Engine Ground Clutch/Starter 15A Fuse Engine Connector X14) Ignition Coil – Primary Side Battery Right Console Interconnect Voltage Regulator Battery Positive Interconnect Figure 6-48: Key Switch in the OFF Position Z400 Series 6-33...
  • Page 108 Power Take-Off (PTO) Switch X14) Ignition Coil – Primary Side Figure 6-49: Key Switch in the RUN Position NOTE: PTO switch (S5) is shown in the off position and seat switch (S1) is shown in the released position. Z400 Series 6-34...
  • Page 109 Hour Meter Interconnect Starter Relay Right Parking Brake Interconnect Motion Control Lever Relay Figure 6-50: Key Switch in the RUN Position NOTE: Left parking brake switch (S2) and right parking brake switch (S3) are shown in the parked position. Z400 Series 6-35...

  • Page 110: Cranking Circuit Operation

    6. park brake is set, and the key switch is in the START position. RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK C4 C6 HUS1143 Figure 6-51 Z400 Series 6-36...

  • Page 111: Cranking Circuit Operation Legend

    • Seat switch (S1) is shown in the released position. • Left parking brake switch (S2) is shown in the parked position. • Right parking brake switch (S3) is shown in the parked position. • PTO switch (S5) is shown in the off position. Z400 Series 6-37...

  • Page 112: Run Circuit Operation

    PTO switch terminal 9 (green wire). The PTO switch sends signal to the engine connector terminal 2 (white wire). RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK RED/BLK HUS1141 Figure 6-52 Z400 Series 6-38...

  • Page 113: Run Circuit Operation (Continued)

    ELECTRICAL Run Circuit Operation (Continued) RED/BLK A1 B2 B5 C5 A2 C4 C6 HUS1142 Figure 6-53 Z400 Series 6-39...

  • Page 114: Run Circuit Operation Legend

    AC to DC voltage. The voltage regulator uses the DC voltage to maintain the battery charge. HUS1138 Fuse Block Assembly Voltage Regulator Battery Positive Interconnect Main 20A Fuse Starter Motor X11) Engine Ground Battery Engine Connector Figure 6-54 Z400 Series 6-40...

  • Page 115: Power Take-Off (Pto) Circuit Operation

    Engine Ground Clutch/Starter 15A Fuse SP4) Splice S4 X12) Clutch Interconnect Battery Clutch Diode Electric Clutch Starter Motor Right Console Interconnect Key Switch Battery Positive Interconnect Figure 6-55 NOTE: PTO switch (S5) is shown in the off position. Z400 Series 6-41...

  • Page 116: Hour Meter Circuit Operation

    Engine Ground Main 20A Fuse Hour Meter Interconnect X13) Fuel Shutoff Solenoid Interconnect Clutch/Starter 15A Fuse Engine Connector X14) Ignition Coil – Primary Side Battery Right Console Interconnect Fuel Shutoff Solenoid Voltage Regulator Battery Positive Interconnect Figure 6-56 Z400 Series 6-42...
  • Page 117 Diagnose Noisy Clutch or Vibration ..........7-8 Z400 Series...

  • Page 118: Diagnose Machine Will Not Drive Straight

    See “Check and Go to next check. Adjust Throttle Is engine reaching max Cable” on YES: Checks complete. RPM? page 4-4. Is transmission system See an authorized See an authorized operating correctly? Husqvarna dealer Husqvarna dealer for assistance. for assistance. Z400 Series...

  • Page 119: Diagnose Machine Will Not Move When Controls Are Engaged

    “Engine Runs for assistance. Erratically” on page 5-20. YES: Go to next check. Is the transmission YES: Checks complete. See an authorized operating correctly? Husqvarna dealer Is transmission See an authorized for assistance. operating correctly? Husqvarna dealer for assistance. Z400 Series...

  • Page 120: Diagnose Sluggish Operation Under Load

    Adjust engine as See an authorized Is engine operating operating correctly? necessary. See Husqvarna dealer correctly? “Engine Runs for assistance. Erratically” on page 5-20. YES: Checks complete. Is transmission See an authorized operating correctly? Husqvarna dealer for assistance. Z400 Series...

  • Page 121: Diagnose Excessive Noise

    Repair or replace YES: Go to next check. Take-Off (PTO) PTO clutch as Replace ground Clutch Test” on necessary. drive belt. See Is ground drive belt in page 6-25. “Remove and good condition? Install Ground Drive Belt” on page 5-12. Z400 Series...

  • Page 122: Diagnose Mower Deck Will Not Run

    Install Mower Is power take-off (PTO) as necessary. See Deck Belt” on clutch tight on engine “Remove and page 5-4. crankshaft and is the Install Power key present without Take-Off (PTO) any damage? Clutch and Pulleys” on page 5-12. Z400 Series...

  • Page 123: Diagnose Mower Cuts Unevenly

    Replace PTO fasteners. See “Power Take-Off clutch as (PTO) Clutch Test” on YES: Go to next check. necessary. page 6-25. Replace mandrels Are mandrel bearings as necessary. See in good operational “Remove and condition? Install Mandrels” on page 5-5. Z400 Series...

  • Page 124: Diagnose Clutch Slips

    Is mower deck belt deck belt. See tension correct? “Adjust Deck Belt Tension” on page 4-7. YES: Go to next check. Replace mandrels Are mandrel bearings as necessary. See in good operational “Remove and condition? Install Mandrels” on page 5-5. Z400 Series...

  • Page 125: Exploded Views

    Seat Assembly—Z454X and Z460X ..........8-27 Z400 Series...

  • Page 126: Frame Assembly

    EXPLODED VIEWS Frame Assembly HUS1030 Figure 8-1 Z400 Series...

  • Page 127: Frame Assembly Legend

    42) Bumper Stud (2 used) 20) Guard Skid 43) Seat Deck 21) Nut Hex Lock Flange (8 used) 44) Bolt (2 used) 22) U-Clip Nut Retainer (9 used) 45) Zip Tire Panel Edge Clip (2 used) 23) Plate Wedge Z400 Series...

  • Page 128: Engine Mounting, Guard, And Muffler

    21) Lock Washer (4 used) 6) Bolt Cup Head (2 used) 14) Lock Washer 22) Lock Nut Hex 7) Muffler 15) Bolt 23) Bolt (2 used) 8) Shield Muffler 16) Washer 24) U-Clip Nut Retainer (2 used) Figure 8-2 Z400 Series...

  • Page 129: Engine Mounting, Guard, And Muffler-Z454X, Z460, And Z460X

    5) Adapter Oil Drain 13) Bolt 21) Lock Nut Hex 6) Bolt Cup Head (2 used) 14) Lock Washer 22) Bolt (2 used) 7) Muffler 15) Clutch 23) U-Clip Nut Retainer (2 used) 8) Shield Muffler 16) Spacer Figure 8-3 Z400 Series...

  • Page 130: Steering Assembly

    EXPLODED VIEWS Steering Assembly 14.1 14.2 14.3 14.5 14.4 HUS1131 Figure 8-4 Z400 Series...

  • Page 131: Steering Assembly Legend

    RH (14). See detail image in Figure 8-4 on page 8-6. • Pivot bracket LH (not shown) (6) is similar to pivot bracket RH (44). • Arm LH (not shown) (7) is similar to arm RH (33). Z400 Series...

  • Page 132: Fuel System

    7) Fuel Tank Pick-up Tube 16) Cover Fuel Tank LH 25) Fuel Tank Assembly 8) Clamp Hose (2 used) 17) Console LH 26) Bushing Snap (2 used) 9) Hose Vapor Line 18) Screw (8 used) 27) Cover Fuel Tank RH Figure 8-5 Z400 Series...

  • Page 133: Ignition System

    18) Nut Cap Cover 5) Bracket Battery Mount 12) Throttle 19) Screw Pan Head (2 used) 6) Hour Meter 13) Shift Knob 20) Switch PTO 7) Screw Socket Head (5 used) 14) Tie Wrap (3 used) 21) Fuel Gauge Figure 8-6 Z400 Series...

  • Page 134: Brake Assembly

    4) Bolt (4 used) 10) Bracket Mounting Caliper (2 used) 16) Hub Casting w/ Studs (2 used) 5) Nut Hex Flange (4 used) 11) Bolt Hex Head (8 used) 6) Bracket Cable Brake LH 12) Nut (2 used) Figure 8-7 Z400 Series 8-10...

  • Page 135: Wheels And Tires

    12) Caster Fork 3) Cap Spring 8) Bolt 13) Nut 4) Spring 9) Washer 14) Rear Tire and Wheel Assembly 5) Tapered Roller Bearing Cone (2 used) 10) Spacer 15) Nut (4 used) Figure 8-8: Left Side Shown Z400 Series 8-11...

  • Page 136: Hydrostatic Assembly

    EXPLODED VIEWS Hydrostatic Assembly Hydrostatic Assembly—Z448, Z454, and Z460 HUS1032 Figure 8-9 Z400 Series 8-12...

  • Page 137: Hydrostatic Assembly-Z448, Z454, And Z460 Legend

    37) Bracket Anchor Tensioner 17) Bolt 38) Nut Hex Flange (2 used) 18) Pulley Idler 39) Spring 19) Spacer Pivot Tension Arm 40) Washer Hex Lock Nut w/ Flange 20) Bolt 41) Nut Hex Jam 21) Bearing Flange (2 used) Z400 Series 8-13...

  • Page 138: Hydrostatic Assembly-Z454X And X460X

    EXPLODED VIEWS Hydrostatic Assembly—Z454X and X460X HUS1033 Figure 8-10 Z400 Series 8-14...

  • Page 139: Hydrostatic Assembly-Z454X And X460X Legend

    15) Spacer 34) Bracket Anchor Tensioner 16) Spacer 35) Nut Hex Flange (2 used) 17) Pulley Idler 36) Spring 18) Bolt 37) Washer Hex Lock Nut w/ Flange 19) Spacer Pivot Tension Arm 38) Nut Hex Jam Z400 Series 8-15...

  • Page 140: Deck Lift

    9) Bolt 21) Plate Reinforcement (2 used) 33) Pedal Deck Height 10) Spacer 22) Bolt (4 used) 34) Bolt 11) Spacer Idler (2 used) 23) Shaft Deck Lift 12) Bolt (2 used) 24) Bolt (3 used) Figure 8-11 Z400 Series 8-16...

  • Page 141: Deck Lift-Z454X, Z460, And Z460X

    8) Bellcrank Handle 19) Nut Hex Flange (4 used) 30) Bolt 9) Bolt 20) Support Pillow Block (4 used) 10) Spacer 21) Plate Reinforcement (2 used) 11) Spacer Idler (2 used) 22) Bolt (4 used) Figure 8-12 Z400 Series 8-17...

  • Page 142: Mower Deck

    EXPLODED VIEWS Mower Deck Mower Deck—Z448 HUS1000 Figure 8-13 Z400 Series 8-18...

  • Page 143: Mower Deck-Z448 Legend

    37) Rod Hinge 17) Link Assembly Adjustable (4 used) 38) Spring 18) Shoulder Bolt (6 used) 39) Nut 19) Bolt (12 used) 40) Cover Mandrel RH 20) Bolt Hex (2 used) 41) Deflector Assembly 21) Plug (6 used) Z400 Series 8-19...

  • Page 144: Mower Deck-Z454

    EXPLODED VIEWS Mower Deck—Z454 HUS1014 Figure 8-14 Z400 Series 8-20...

  • Page 145: Mower Deck-Z454 Legend

    18) Hose Coupling 41) Spring Deflector 19) Deck Decal 42) Deflector Assembly 20) Bumper Assembly 43) Nut 21) Bolt Shoulder (2 used) 44) Deck Shell 22) Link Assembly Adjustable (4 used) 45) Cover Mandrel RH 23) Foot Pad Z400 Series 8-21...

  • Page 146: Mower Deck-Z454X

    EXPLODED VIEWS Mower Deck—Z454X HUS1015 Figure 8-15 Z400 Series 8-22...

  • Page 147: Mower Deck-Z454X Legend

    44) U-Clip Nut Retainer (2 used) 22) Link Assembly Deck Suspension (4 used) 45) Plate Backing Discharge 23) Nut Lock (4 used) 46) Chute Discharge NOTE: Bracket deck LH (not shown) (25) is similar to bracket deck RH (12). Z400 Series 8-23...

  • Page 148: Mower Deck-Z460 And Z460X

    EXPLODED VIEWS Mower Deck—Z460 and Z460X HUS1016 Figure 8-16 Z400 Series 8-24...

  • Page 149: Mower Deck-Z460 And Z460X Legend

    46) U-Clip Nut Retainer (2 used) 23) Nut Lock Flange (4 used) 47) Plate Backing Discharge 24) Cover Mandrel LH 48) Chute Discharge NOTE: Bracket deck LH (not shown) (25) is similar to bracket deck RH (12). Z400 Series 8-25...

  • Page 150: Seat Assembly

    16) Bolt Hex Flange (4 used) 5) Locking Nut Hex (2 used) 11) Bracket Rear Seat 17) Screw Hex Head (2 used) 6) Nut Hex Lock (2 used) 12) Bolt (2 used) 18) Support Seat Figure 8-17 Z400 Series 8-26...

  • Page 151: Seat Assembly-Z454X And Z460X

    11) Bracket Rear Seat 18) Support Seat 5) Locking Nut Hex (2 used) 12) Bolt (2 used) 19) Seat Adjuster 6) Nut Hex Lock (2 used) 13) Bolt (3 used) 7) Spring (2 used) 14) Stop Seat Figure 8-18 Z400 Series 8-27...
  • Page 152 EXPLODED VIEWS Page Intentionally Blank Z400 Series 8-28...
  • Page 153 Wear and replacement ........3-3 Z400 Series...
  • Page 154 Excessive oil consumption ......5-21 Fuel shutoff solenoid test ......6-26 Z400 Series...
  • Page 155 Deck lift ..........8-16 Engine mounting, guard, and muffler ..... 8-4 Z400 Series...
  • Page 156 Tracking adjustment ........4-6 Z400 Series...
  • Page 157 Engine ..........5-8 Front vertical caster bearings ......5-10 Z400 Series...
  • Page 158 Notices ..........1-2 Z400 Series...
  • Page 159 Wear and replacement ........3-3 Z400 Series...
  • Page 160 Keep ventilated ......... 1-6 Z400 Series...
  • Page 161 Page Intentionally Blank Z400 Series...

This manual is also suitable for:

Z448Z454Z460Z454xZ460x

Table of Contents