Toro Z Master 7500-D Series Service Manual
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Toro Z Master 7500-D Series Service Manual

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L C E P r o d u c t s
Z Ma s t e r 7 5 0 0 - D S e r i e s
S e r v i c e Ma n u a l
I s s u e d : Ma r c h 2 0 1 8

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Summary of Contents for Toro Z Master 7500-D Series

  • Page 1 L C E P r o d u c t s Z Ma s t e r 7 5 0 0 - D S e r i e s S e r v i c e Ma n u a l I s s u e d : Ma r c h 2 0 1 8...
  • Page 2 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.
  • Page 3 This includes how often oil or other aspects of a specific system within this manual should be changed or adjusted in any way. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 4 TABLE OF CONTENTS Safety ............................1-1 Specifications ........................2-1 Troubleshooting ........................3-1 Engine ............................. 4-1 Chassis ........................... 5-1 Deck ............................6-1 Drive............................7-1 Electrical..........................8-1 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 5 SAFETY Table of Contents Icons ............................1-2 Think Safety First ........................1-2 Additional Safety ........................1-5 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 6 Avoid injury due to projectiles… Always clear the area of sticks, rocks or any other debris that could be picked up and thrown by the powered equipment. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 7 Do not rely on jacks to support the machine. If you are unsure of the operation of any lifts, hoists, and jacks do not use. Z Master 7500-D Series Service Manual Table of Contents...
  • Page 8 ABC fire extinguishers are a dry chemical type used for multiple purposes. See above information for description. Ensure fire extinguishers are serviceable and replace any that are discharged or out of inspection dates. Z Master 7500-D Series Service Manual Table of Contents...
  • Page 9 Keep hands and feet away from hot, rotating components. Do not operate in an enclosed environment. Attachments Follow all instruction in the operators manual for attachments. Different attachments present different hazards. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 10 ......2-5 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) ....2-6 Equivalents and Conversions ....................2-8 U.S. to Metric Conversions ....................2-9 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 11 Side Discharge Deck Spindles Cast Iron Sealed Ball Bearings Blade Tip Speed 18,200 fpm 18,500 fpm Cutting Height 1 in. - 5-1/2 in. 1/4 in. increments Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 12 Rear Discharge Deck Spindles Cast Iron Sealed Ball Bearings Blade Tip Speed 18,500 fpm 18,100 fpm Cutting Height 1 in. - 5-1/2 in. 1/4 in. increments Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 13 The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
  • Page 14 The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately ± 10% of the nominal torque value. Thin nuts include jam nuts. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 15 The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 16 All torque values are based on non- lubricated fasteners. Conversion Factors in-lb. X 11.2985 = N-cm ft-lb. X 1.3558 = N-m N-cm X 0.08851 = in-lb. N-cm X 0.73776 = ft-lb. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 17 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 63/64 0.484375 12.303 0.984375 25.003 0.5000 12.700 1.000 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 18 Inch-Pounds Kilogram-Centimeters 1.152144 Liquid Volume Quarts Liters 0.9463 Gallons Liters 3.785 Liquid Flows Gallons/Minute Liters/Minute 3.785 Temperature Fahrenheit Celsius 1. Subtract 32° 2. Multiply by 5/9 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 19 TROUBLESHOOTING Table of Contents General Troubleshooting Table .................... 3-2 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 20 The tracking needs adjustment Adjust the tracking (with levers fully forward) The rear tire pressure is unmatched. Check and adjust the tire pressure to 124 kPa (18 psi) Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 21 Verify proper engine RPM settings on the Horizon Logic Display Oil filter is plugged Change filter Transaxle bypass valve is loosened Fully close bypass valve or damaged Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 22 Inspect brake cables/mechanism Transaxle is worn or damaged Replace Wheel motors will not hold load Transaxle is worn or damaged Replace when traction lever is in neutral Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 23 Engine Exploded View 3 ....................... 4-4 Engine Exploded View 4 ....................... 4-5 Engine Exploded View 5 ....................... 4-6 Yanmar Engine Replacement ....................4-7 Removal ......................... 4-7 Installation ........................4-25 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 24 Figure 1 A. Air Shield E. Center Bumper Plate B. Cross Channel F. Power Frame G. LH Bumper Plate C. RH Bumper Plate D. Exhaust Plate Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 25 ENGINE Engine Exploded View 2 Figure 2 A. Lock Nut D. Isolator Mount B. Flat Washer E. Thrust Washer C. Flywheel Housing F. HH Screw Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 26 ENGINE Engine Exploded View 3 Figure 3 A. Air Hose D. Air Cleaner Asm. B. Yanmar Engine E. Snubbing Washer C. Iso Mount F. HH Screw Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 27 L. Hydraulic Tube Asm. E. Hose M. Fuel Hose F. Upper Radiator Hose N. Hydraulic Tube Asm. G. Top Shroud O. Bulkhead Bracket H. Bottom Shroud Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 28 Engine Exploded View 5 Figure 5 A. RH Tank Suction D. LH Tank Return B. LH Tank Suction E. Engine Return C. RH Tank Return F. Engine Suction Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 29 “Engine Cover Removal,” chapter 5, page 5-40. 2. Remove the engine hood, 3. Using a jack, secure the rear of the machine with jack stands. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 30 5. Remove the two carriage bolts and two button head screws securing the skid plate to the machine (Figure 6). Figure 6 6. Remove the rear bumper. NOTE: Bumper mount holes are slotted (Figure 7). Figure 7 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 31 11. Loosen the drive wheel release valve to a quarter turn on the left and right side of the transmission. 12. Remove the e-clip and washer securing the left and right motion control linkage. Z Master 7500-D Series Service Manual Table of Contents...
  • Page 32 14. Disconnect the four torque motor hoses from the transmission and cap/plug the lines and fittings (Figure 10). NOTE: If the lines and fittings are not capped/plugged there will be leakage. Figure 10 4-10 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 33 19. Remove the fuel tank vent line from the ROPS tube, slide the line through the three clamps. Repeat for opposite side. 20. Mark and remove fuel supply and return line for both left and right fuel tank (Figure 12). Figure 12 4-11 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 34 22. Disconnect the global power port and alarm (Figure 14). Figure 14 23. Disconnect the wire harness clip retainers. 24. Lift the air shield and cross channel from the machine. 4-12 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 35 26. Remove the upper radiator hose. 27. Disconnect the overflow hose from the top of the radiator. 28. Cut the zip tie securing the drain hose. 4-13 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 36 31. Remove the lower radiator hose from water pump. 32. Remove the four screws (two per side) securing the radiator shroud to the radiator brackets (Figure 17). Figure 17 4-14 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 37 34. Once draining has completed, fully disconnect the upper and lower transmission cooler lines. 35. Remove the radiator. 36. Remove the two lock nuts securing the RH ROPS brace to the radiator bracket (Figure 19). Figure 19 4-15 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 38 37. Remove the two lock nuts securing the RH ROPS brace to the ROPS (Figure 20). Figure 20 38. Remove the RH ROPS brace from the ROPS with overflow tank intact (Figure 21). Figure 21 4-16 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 39 39. Disconnect the air intake hose from the air cleaner to the engine (Figure 22). Figure 22 40. Disconnect the harness plug from the air filter sensor (Figure 23). Figure 23 4-17 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 40 Figure 24 42. LH ROPS brace removal, repeat steps 35-37. Brace will be removed with power distribution, ECU, and air canister intact (Figure 25). Figure 25 4-18 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 41 43. Remove the two chassis grounds from the machine (Figure 26). Figure 26 44. Remove the six bolts (three per side) of the radiator brackets (Figure 27). Figure 27 4-19 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 42 45. Remove the three torx screws and lock nuts securing the exhaust plate to the machine. Remove the exhaust plate (Figure 28). Figure 28 46. Remove the four nuts on the two exhaust clamps (Figure 29). Figure 29 4-20 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 43 Figure 30 50. Disconnect the two transmission cooler lines from the bulk head fittings above right torque motor. Remove cooler lines (Figure 31). Figure 31 4-21 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 44 53. Remove the bulk head plate (Figure 32). Figure 32 54. Remove the hydraulic line from the bottom of the auxiliary pump (controls deck lift and fold) (Figure 33). Figure 33 4-22 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 45 55. Remove the two transmission mount bolts located on the bell housing (accessible on bottom of machine) (Figure 34). Figure 34 56. Remove the two motor mount bolts (LH and RH) located on the rear frame (Figure 35). Figure 35 4-23 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 46 58. Continue to slightly raise and move the engine rearward until engine is free of the machine. NOTE: Drive shaft spline will separate on its own during engine removal (Figure 37). Figure 37 4-24 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 47 4. Using an overhead hoist, move the engine and transmission forward and down into the engine compartment until transmission mounts can be aligned. NOTE: Make sure all hoses and wiring are free from engine compartment before install. 4-25 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 48 17. Install the radiator fan shroud and radiator, secure the shroud with four screws (two per side) and secure the upper radiator support with two fasteners (one per side). 4-26 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 49 26. Repeat step 21 for the LH ROPS brace. 27. Install the air intake hose from the air cleaner to the engine. 28. Install the two chassis grounds. 4-27 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 50 33. Place the battery on the machine and secure the battery with a bolt. Do NOT connect the battery. 4-28 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 51 Figure 41 36. Install the gold bracket on the hydro reservoir. 37. Install a zip tie on the hydraulic cooler hose (Figure 42). Figure 42 4-29 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 52 “Seat Installation,” chapter 5, page 5-24. 48. Install the seat, 49. Tighten the drive wheel release valve, located on the LH and RH side of the transmission. 4-30 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 53 55. Perform visual inspection prior to test run. 56. Start the machine to verify no leaks are present. 57. Purge the hydraulics, see “Charging the Hydraulic System,” chapter 7, page 7-17. 4-31 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 54 Removal ........................5-21 Installation ........................5-22 Seat ............................5-23 Removal ........................5-23 Installation ........................5-24 Front Seat Mount ......................... 5-25 Removal ........................5-25 Installation ........................5-27 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 55 Adjusting the Motion Control Neutral Lock Pivot ............5-35 Roll Over Protection System (ROPS) ................5-36 Removal ........................5-36 Installation ........................5-39 Engine Cover ........................5-40 Removal ........................5-40 Installation ........................5-41 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 56 F. Leaf Spring O. LH Motion Control and Bushing Asm. G. Flat Washer P. LH Motion Control Lever H. Spring Washer Q. HH Screw I. HF Nut Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 57 B. Side Flange Bearing G. Compression Spring C. Upper Brake Link H. NI Flange Nut D. Brake Shaft Asm. I. Trunion Pin E. Turnbuckle Asm. J. Threaded Hub Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 58 Chassis Exploded View 3 Figure 3 A. Suspension Seat D. Tilt Seat Support Plate B. Seat Latch Plate E. Isolator Seat C. Seat Plate Frame F. Seat Mount Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 59 F. Flat Washer B. Flat Washer G. Clip C. Hair Cotter Pin H. RH Tank Cover D. Hood Prop I. LH Tank Cover E. Torx Screw Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 60 E. Cone Taper Roller Bearing B. NI Lock Nut F. Grease Seal C. Bellville Washer G. Caster Fork D. Flat Washer H. Wheel and Tire Asm. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 61 C. Plain Washer I. Flat Washer D. Rubber Washer J. LH Fuel Tank Asm. E. Spacer Tube K. Fuel Filter Bracket F. RH Fuel Tank Asm. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 62 4. Support the underside of the caster wheel and remove the lock nut securing the caster bearing assembly. 5. Remove the six spring washers and one large flat washer from the caster fork shaft. NOTE: Take note of the washer orientation. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 63 6. Remove the front caster fork from the frame. Inspect the caster fork shaft for wear or damage (Figure 8). NOTE: Avoid damaging seals and bearings while removing the caster fork. Figure 8 7. Remove lower caster bearing seal (Figure 9). Figure 9 5-10 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 64 8. Remove the upper and lower taper bearings from the frame (Figure 10). Inspect bearing races for damage and excessive wear. Figure 10 9. Replace the bearings and races if worn. 5-11 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 65 A. Wheel and Tire Asm. E. Flat Washer B. Caster Fork F. Bellville Washer C. Grease Seal G. NI Lock Nut D. Cone Taper Roller Bearing H. Grease Cap 5-12 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 66 10. Using a grease gun, fill the pivot hub cavity until grease is purging out of the upper bearing. 11. Remove the grease zerk and install the grease plug back onto the machine. 12. Install caster cap. 5-13 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 67 8. Inspect the bearings for wear or damage and replace if necessary. NOTE: Bearing seals must be replaced after removal. Do not reuse bearing seals. 5-14 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 68 (more than one or two revolutions) or have any side play. If the wheel spins freely, adjust the torque on the spacer nut until there is a slight amount of drag. Reapply thread locking adhesive to the spacer nut. 5-15 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 69 9. Secure the caster wheel assembly to the caster fork using the axle bolt and nut. see “Caster Fork Assembly and Bearing 10. Install the caster fork and assembly bearing installation, Installation” chapter 5, page 5-12. 5-16 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 70 4. Raise the hood to provide clearance for tank cover removal. 5. Lift left tank cover away from the machine, leaving the fuel cap on. 5-17 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 71 3. Insert the two washers and two screws loosely on the inside of the machine. 4. Insert the four screws located on the outside of the of the left tank cover and tighten all six fasteners. 5-18 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 72 6. Remove the two washers and screws located on the inside of the right tank cover. 7. Remove the four screws located on the outside of the console. Remove the right tank cover. 5-19 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 73 NOTE: Only the inside screws use washers 6. Insert the four screws located on the outside of the of the left tank cover and tighten all six fasteners. 5-20 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 74 Bolt is captured by a lock nut. 6. Remove the fuel tank. NOTE: Fuel tank may be heavy, depending on how much fuel is in it. 5-21 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 75 6. Install the left or right tank cover, see “Left Tank Cover Installation,” chapter 5, page 5-18 see “Right Tank Cover Installation,” chapter 5, page 5-20. 5-22 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 76 7. With the seat latched in the down position, remove the two back nuts securing the seat frame to the seat isolator. NOTE: Assistance will be needed to complete next step. 8. Remove the seat. 5-23 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 77 4. Install the two front nuts securing the seat frame to the seat isolator. 5. Route seat switch harness through the seat frame. Connect the seat switch. 6. Drop the seat back down to the operator’s position. 5-24 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 78 6. Remove the floor pan from the machine. 7. Using a flat head screw driver, remove the two black clips on the front seat mount (Figure 17). Figure 17 5-25 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 79 NOTE: The U-bolt will drop once lock nuts are removed but should not fall through. 11. Remove the four screws located in the corners of the seat mount. 12. Slide the seat mount away from the machine. 5-26 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 80 6. Install the wire harness by using two retainer clips on the back side of the seat mount. 7. Install remaining wire harness clip in appropriate mount hole with new zip tie and retaining clip. 5-27 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 81 9. Secure the motion control covers with four screws (two on each side). 10. Slide the floor pan onto the machine. 11. Install the operator’s seat, see “Seat Installation,” chapter 5, page 5-24. 5-28 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 82 NOTE: You will need a T-40 Torx wrench to hold the bolt while removing. Figure 19 3. Remove the nut securing the damper to the motion control assembly (Figure 20). Figure 20 4. Remove the damper assembly. 5-29 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 83 2. Install the other end of the damper to the motion control assembly, normally in the center hole and tighten the lock nut to 200 in-lbs. (22.6 Nm). 5-30 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 84 D. Medium Resistance (Medium Feel) A. Torque the lock nut to 200 in-lbs. (22.6 Nm) B. Most Resistance (Firmest Feel) E. Least Resistance (Softest Feel) C. Damper 5-31 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 85 6. Remove the wire harness from the wire anchor on the LH motion control assembly. 7. Remove screw, flat washer and nut retaining the front pump linkage to the LH motion control assembly (Figure 23). Figure 23 5-32 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 86 13. Remove the jam nut from the LH motion control lever. 14. Remove the nut, two spring washers, flat washer and LH motion control lever from the LH motion control. 5-33 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 87 Move the motion control lever to the neutral position and observe the rear tire for movement. If the rear tire creeps in the forward position, perform a neutral adjustment. A slight creep in reverse is allowable. 5-34 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 88 2. Tighten or loosen the flanged nut to the desired feel. For more resistance, tighten the flange nut. For less resistance, loosen the flange nut. 3. Tighten the jam nut. 5-35 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 89 5. Using a flat head screw driver remove the three tree clips securing the heat deflector panel to the machine. Remove the heat deflector panel. NOTE: Tree clips are intended for one time use. 5-36 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 90 NOTE: Will need assistance to continue. 9. Lift the ROPs straight up to remove. 10. Remove the two spacers from lower ROPS and set aside (Figure 29). Figure 29 5-37 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 91 Figure 30 12. Remove the four lower bolts securing the lower ROPS tubes (Figure 31). Figure 31 13. Remove the lower ROPS tubes from the machine. 5-38 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 92 12. Install the hood onto the machine, see “Engine Cover Installation,” chapter 5, page 5-41. 13. Flip the operator’s seat down and slide into position. 5-39 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 93 6. With a person on each side of the hood, slide the hood to the right on the hinge pins until free. 7. Remove the hood from the machine. 5-40 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 94 4. While one person is supporting the hood, place the washer and cotter pin onto the prop bracket. 5. Close the hood and secure with the hood latches. 5-41 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 95 ........................6-20 Installation ........................6-22 Gearbox Replacement......................6-23 Removal ........................6-23 Installation ........................6-23 Deck Hydraulics (Deck Fold Cylinder)................6-24 Removal ........................6-24 Installation ........................6-26 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 96 DECK Table of Contents (Cont.) Deck Wings .......................... 6-27 Removal ........................6-27 Installation ........................6-30 Spindle Assembly Rebuild ....................6-31 Disassembly ........................ 6-31 Assembly ........................6-37 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 97 DECK Deck System Exploded View 1 Figure 1 A. RH Wing Shield Asm. C. Pulley Idler B. V-Belt D. V-Idler Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 98 C. HH Screw J. Idler Pulley D. Driveshaft Asm. K. Flat Idler Pulley E. Gearbox Asm. L. Center Deck Asm. F. V-Belt M. V-Idler G. Pulley Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 99 Figure 3 A. Deck Fold Cylinder Asm. E. Locking Cotter Pin B. Fitting F. Cylinder Pin Eye C. Hose Asm. G. Cylinder Base Pin D. Hose Asm. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 100 A. Pivot Rod Cover E. LH Shield Hinge Panel B. Torsion Spring F. Deck Pin C. RH Shield Hinge Panel G. RH Fold Arm Asm. D. LH Center Shield Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 101 D. Panhard Rod Asm. K. HHF Shoulder Screw E. HH Screw L. Rear Deck Lift F. HH Screw M. Jam Nut G. Front Deck Lift N. Carr Screw Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 102 DECK Deck System Exploded View 6 Figure 6 A. LH Shield Asm. C. Pulley Idler B. V-Belt D. V- Idler Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 103 DECK Deck System Exploded View 7 Figure 7 A. RH Wing Deck Asm. C. LH Wing Deck Asm. B. Deck Asm. D. Tunnel Discharge Asm. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 104 F. HH Screw B. Roll Pin G. Sleeve Bushing C. HH Screw H. Lock Nut D. Driveshaft Asm. I. Deck Asm. E. Tunnel Discharge Asm. 6-10 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 105 N. Pulley F. V Idler O. NI HF Nut G. Gearbox Asm. P. LH Belt Cover H. Pulley Q. Idler Mount Asm. I. Deck Asm. 6-11 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 106 Deck System Exploded View 10 - 96 in. Deck Figure 10 A. Straight Fitting D. Lift Cylinder B. Elbow Fitting E. Hose Asm. C. Lift and Fold Valve 6-12 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 107 Deck System Exploded View 11 - 60 & 72 in. Deck Figure 11 A. Deck Lift Valve Asm. D. Lift Cylinder B. Elbow Fitting E. Hose Asm. C. Straight Fitting 6-13 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 108 “Belt Removal,” chapter 6, page 6-20. 4. Remove the two hydraulic lines leading from the hydraulic manifold to the deck (96 in. only) (Figure 12). Figure 12 6-14 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 109 6. Raise and secure the rear of the machine using jack stands. 7. Remove the rear wheels. 8. Remove the two deck strut bolts (one per side) and the panhard rod bolt (Figure 14). Figure 14 6-15 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 110 (Figure 15). Figure 15 12. Remove the roll pin from the deck drive shaft using a roll pin punch (Figure 16). Figure 16 6-16 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 111 16. Using assistance, remove the jack stands from the rear and slowly tip the front of the machine back until rear bumper makes contact with the ground. Secure the front of the machine with an overhead hoist (Figure 17). Figure 17 6-17 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 112 18. Slowly lower the front of the machine back to level ground, then secure the rear of the machine with jack stands to avoid unwanted tipping. 6-18 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 113 19. Install floor pan. 20. Perform purge procedure, see “Charging the Hydraulic System,” chapter 7, page 7-17. 21. Test run to operating temperature and test deck operation. 6-19 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 114 5. Repeat steps 3 and 4 to remove opposite side belt guards. 6. Remove the center floor pan. NOTE: Both left and right belts will need to be removed before center belt. 6-20 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 115 10. Remove center belt by rotating idler arm assembly clockwise with ½ drive breaker bar. NOTE: Plastic belt guards will need to be removed on 60 in. and 72 in. decks. 6-21 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 116 4. Install the two lynch pins securing the outer belt guard to the deck. Repeat for opposite side. 5. Install the two lock nuts and two carriage bolts securing the inner belt guard. Repeat for opposite side. 6-22 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 117 2. Install the three lock nuts, flat washers, and isolators to the gear box mount. 3. Install all belts, see “Belt Installation,” chapter 6, page 6-22. 6-23 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 118 “Releasing Pressure from the Hydraulic System,” chapter 7, page 7-6. 6. Remove the center floor pan. 7. Remove the hydraulic lines attached to the lift cylinder. 6-24 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 119 9. Remove the locking cotter pins (two on each cylinder) on both ends of the deck fold cylinder (Figure 22). Figure 22 10. Remove the deck fold cylinder by pulling to the outside of the deck. 6-25 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 120 7. Install the two lock nuts and two carriage bolts securing the inner belt guard. Repeat for opposite side. 8. Perform purge procedure, see “Charging the Hydraulic System,” chapter 7, page 7-17. 9. Test run to operating temperature and test deck operation. 6-26 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 121 5. Using a floor jack, raise the rear of the machine. Support the rear of the machine with jack stand, remove the rear tire. 6. Remove the two cap screws securing the wing stop bracket (Figure 23). Figure 23 6-27 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 122 7. Remove the locking cotter pin from the outer wing ram lift pin (Figure 24). Figure 24 8. Support the wing with a floor jack (Figure 25). Figure 25 6-28 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 123 TECH TIP: Wiggling the deck wing up and down may benefit in pin removal. Figure 26 10. While supporting, roll the wing from the center deck to separate from the machine (Figure 27). Figure 27 6-29 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 124 “Belt Installation,” chapter 6, page 6-22. 8. Perform purge procedure, see “Charging the Hydraulic System,” chapter 7, page 7-17. 9. Test run to operating temperature and test deck operation. 6-30 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 125 “Belt Removal,” chapter 6, page 6-20. 3. Remove the blade. 4. Remove the fasteners securing the pulley to the spindle hub and discard. 5. Remove belt guide bracket, if applicable. 6-31 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 126 6. Remove the fasteners securing the spindle to the deck (from bottom) (Figure 29). Figure 29 7. Lift spindle assembly from the deck. 8. Remove the housing ring (if applicable) (Figure 30). Figure 30 6-32 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 127 Figure 31 10. With spindle assembly firmly secured, remove the lock nut that captures the top side of the spindle shaft (Figure 32). Figure 32 6-33 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 128 Disassembly (Cont.) 11. Remove lock nut, washer, and hub (Figure 33 and 34). Figure 33 Figure 34 12. Slide spindle shaft out of spindle housing. 6-34 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 129 14. Gently tap inner race of lower bearing to remove from the housing. Alternate in a star pattern to avoid binding when removing (Figure 36). NOTE: Bearings may be damaged during removal. Replace as needed. Figure 36 6-35 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 130 15. Remove bearing spacer. 16. Rotate spindle housing and repeat bearing removal for opposite side. 17. Inspect spindle housing for internal or external damage (Figure 37). Figure 37 6-36 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 131 15. Install the belt, see “Belt Installation,” chapter 6, page 6-22. 16. Start the mower and engage the deck several time to ensure proper operation. 6-37 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 132 .................... 7-15 Flushing the Hydraulic System ..................7-16 Charging the Hydraulic System ..................7-17 60/72 in. Hydraulic Schematic .................... 7-19 96 in. Hydraulic Schematic ....................7-20 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 133 L. Hose E. Hydraulic Tank Support Rod M. Hose F. Hydraulic Reservoir Asm. N. Tube Asm. G. Hydraulic Tank Support Rod O. Return Hose H. Suction Hose Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 134 DRIVE Drive System Exploded View 2 Figure 2 A. Hose Asm. B. Hose (Routed) C. Hose (Routed) Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 135 DRIVE Drive System Exploded View 2 (Cont.) Figure 3 A. Transmission Asm. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 136 DRIVE Wheel Motor Exploded View Figure 4 A. RH Wheel Motor D. Hydraulic Hose B. Motor Plate E. Hydraulic Hose C. LH Wheel Motor Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 137 2. Turn the key switch to the OFF position and allow the engine to stop. 3. After lowering the cutting deck, ensure that the lift cylinder does not support the cutting deck. Z Master 7500-D Series Service Manual Table of Contents...
  • Page 138 10. Properly dispose of the drain oil when full. Then place the drain pan under the hydraulic tank. 11. Note orientation of all hoses and routing. Tech Tip: Take a picture of the hose routings for later reference. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 139 15. Before removing the deck drive shaft mark the orientation of the deck drive shaft and gear box shaft (for roll pin orientation) (Figure 7). Figure 7 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 140 19. Disconnect the two main reservoir line hoses. 20. Disconnect the output line to the gear pump (Figure 9). NOTE: Mark the location of the wheel motor hoses. Figure 9 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 141 24. Attach a lift chain to the transmission case by installing two M8 X 1.25 bolts into the open threaded holes in the top of the transmission case (Figure 10 and 11). Figure 10 Figure 11 7-10 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 142 26. Remove the seven bolts connecting the transmission assembly to the bell housing. 27. Pull transmission assembly away from the bell housing and lift up with the overhead hoist (Figure 12). Figure 12 7-11 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 143 14. Using new fluid, refill the hydro tank to the full line see “Charging the Hydraulic System,” chapter 7, page 7-17. 15. Perform a Purge Procedure, 16. Top off hydraulic fluid 7-12 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 144 13. Remove the upper two motor plate mount bolts. 14. Remove the wheel motor away from the machine. 15. Remove the four bolts securing the plate mount to the wheel motor. 7-13 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 145 10. Install the cap screw and lock nut on the upper portion of the park brake linkage. 11. Place rear wheel back onto the machine and torque to 95 ft-lbs. (128 Nm). 7-14 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 146 Repeat the cranking procedure for the second time. 5. Disconnect the remote starter switch leads from the starter motor solenoid terminal and positive post of the battery. 7-15 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 147 14. Check the condition of the hydraulic fluid. If new fluid shows any signs of contamination, repeat steps 1-13 until the fluid is clean. 15. Assume the normal operation and follow the recommended maintenance intervals. 7-16 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 148 • The oil filter or suction lines are loose • Incorrect hose routing • Suction line is blocked • Implement relief valve is damaged • Gear pump is damaged 7-17 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 149 15. Stop the machine. Check the hydraulic fluid level in the hydraulic reservoir and add correct quantity of fluid if necessary. See operator’s manual for additional information. 16. Check the hydraulic components for leaks and tighten any loose connections. 7-18 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 150 DRIVE 60/72 in. Hydraulic Schematic (Click to View Enlarged) Figure 14 7-19 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 151 DRIVE 96 in. Hydraulic Schematic (Click to View Enlarged) Figure 15 7-20 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 152 ..................... 8-15 Testing .......................... 8-15 Fusible Link .......................... 8-16 Deck Limit Switch (96 in. Deck Only)................. 8-17 Testing .......................... 8-17 TVS Diode ..........................8-18 Testing .......................... 8-18 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 153 ELECTRICAL Table of Contents (Cont.) 37 HP Electrical Wiring Schematic ..................8-19 60/72 in. Electrical Wiring Schematic ................8-20 96 in. Electrical Wiring Schematic ..................8-21 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 154 D. Horizon LDU Module L. Temperature Sensor E. MCU Module M. Bail Switch F. Yanmar Wire Harness N. Wire Harness G. Engine Controller O. Switch H. 12V Power Port Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 155 ELECTRICAL Electrical System Exploded View 2 Figure 2 A. Proximity Switch Asm. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 156 NOTE: Jumper wires should be used for troubleshooting only, NEVER leave a jumper wire in place to bypass a safety circuit. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 157 2. Using a digital multi-meter set to the OHM or continuity setting, check the continuity between the fuse blades. If the fuse is OPEN (no continuity), replace the fuse and test the circuit. Z Master 7500-D Series Service Manual Table of Contents...
  • Page 158 4. Using a digital multi-meter set to the OHM or Continuity setting, verify that NO continuity exists between the terminals not listed for each switch position. Position Circuit “Make” 1. Off None 2. Run A+C+D 3. Start B+C+D Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 159 D. Hours Until Engine Oil Maintenance Testing 1. With the ignition switch in the RUN position and the PTO switch closed (ON), verify battery voltage and ground to the control module. Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 160 - When the seat is vacated, the switch should NOT have continuity (open). - When the operator is present, the switch should have continuity (closed). Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 161 Motion Control Levers in neutral position (OUT), the switch will have continuity (closed). Motion Control Levers in the operating position (IN), the switch will NOT have continuity (open). Figure 8 Figure 9 8-10 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 162 This allows battery voltage to flow to the rest of the safety interlock system. Parking Brake ON, the switch should have continuity (closed). Parking Brake OFF, the switch should NOT have continuity (open). Figure 10 Figure 11 8-11 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 163 4. With a multi-meter set to the OHM or continuity setting, check to ensure that terminals 30 and 87 do not have continuity (open) (Figure 13). Figure 13 8-12 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 164 4. With the switch in the ON position (button pushed IN): - Terminal A and B should have continuity (closed) - Terminals B and C should NOT have continuity (open) 8-13 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 165 The deck lift-lower switch (Figure 15 and 16) provides battery power to the solenoid valve, directing hydraulic pressure to the lift cylinder. Figure 15 Figure 16 Switch Position Connection Made Normal Position None Front Depressed B+C, E+D Back Depressed B+A, E+F 8-14 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 166 2. Measure the resistance between the two connector terminals of the solenoid coil. NOTE: The resistance of the solenoid coil must be approximately 7.5Ω. 3. Connect the wire harness connector to the solenoid coil. 8-15 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 167 Connect the positive battery cable to the battery terminal and then connect the negative cable to the battery. Figure 18 Figure 19 8-16 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 168 The deck limit switch prevents the cutting deck from being folded (Figure 20 and 21). Figure 20 Figure 21 Testing No testing procedure available. If the switch is suspected to be faulty, replace the switch. 8-17 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 169 The TVS Diode protects the electrical system from current surges caused by PTO engagement and disengagement (Figure 22). Figure 22 Testing No testing procedure available. If the diode is suspected to be faulty, replace the diode. 8-18 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 170 ELECTRICAL 37 HP Electrical Wiring Schematic (Click to View Enlarged) Figure 23 8-19 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 171 ELECTRICAL 60/72 in. Electrical Wiring Schematic (Click to View Enlarged) Figure 24 8-20 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 172 ELECTRICAL 96 in. Electrical Wiring Schematic (Click to View Enlarged) Figure 25 8-21 Z Master 7500-D Series Service Manual Table of Contents March 2018 - Digital Edition...
  • Page 173 60/72 in. Hydraulic Schematic DECK CYLINDER C1-CYLINDER P2-AUX PUMP 3.04 in DISP P3-TEMPERA TURE .75 X 6.9 in SENDER T-OIL COOLER .040 DECK LIFT MANIFOLD .047” CHARGE PRESSURE TEST PORT PORT 2 OIL COOLER 4000 PSI 1.1 CID 17.8 CID 43 PSI Line Filter VALVE...
  • Page 174 96 in. Hydraulic Schematic Back to Page in Document Formatted to print 11X17...
  • Page 175 37 HP Electrical Wiring Schematic 126-9272 ENGINE SENSORS - HARNESS B-1 ENG10 P9022 Yellow 126-9272 ENGINE SENSORS - HARNESS B-2 ENG11 EGR GAS TEMP SENSOR P9023 Green Yellow EXH TEMP Blue SENSOR INTAKE THROTTLE Blue FUEL TEMP Green SENSOR Brown Brown White RAIL PRESSURE...
  • Page 176 60/72 in. Electrical Wiring Schematic 100-1535 126-6285 (ON)-OFF-(ON) IGNITION SWITCH SW05 SW06 Green/White DOWN 131-5510 CLUTCH - TRANSMISSION Red/White Red/White Orange START Orange Black Red/White Orange Violet/Red Blue 32180-197 Red/Green Red/Green Black DUST CAP SP01 CAP01 Red/Green Red/Green Red/Green Orange ACC SIGNAL 126-4233 126-7698...
  • Page 177 96 in. Electrical Wiring Schematic 100-1535 126-6285 (ON)-OFF-(ON) IGNITION SWITCH SW05 SW06 Green/White DOWN 131-5510 Red/White Red/White CLUTCH - TRANSMISSION Orange START Black Orange Violet/Red Blue 32180-197 Red/Green Red/Green DUST CAP SP01 Black Red/Green Red/Green CAP01 Red/Green ACC SIGNAL Orange 135-3427 126-7698 HORIZON-2 MASTER CONTROL UNIT...
  • Page 178 L C E P r o d u c t s...

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