Toro Z Master 74901 Service Manual Download

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SPECIFICATIONS

2-7

Toro Z Master G3 3000/5000/6000 Series Service Manual

G3 3000/5000/6000 Series Specifications

Engines:

20.5 hp (15.4kW)

22 hp (16.2 kW)

23.5 hp (17.6kW)

24 hp (17.9 kW)

Make

Kawasaki

Kawasaki FX

Kawasaki

Kawasaki FX

Model

FX651V

FX691V

FX730V

FX691V

Hi-Idle

3600 ±100 RPM

3600 ± 100 RPM

3600 ±100 RPM

3600 ± 100 RPM

Low-Idle

1550 RPM

1800 RPM

Spark Plug

NGK BPR4ES

Oil

SAE 10w-30 /

SAE10w-40

SAE 10w-30 /

SAE10w-40

SAE 10w-30 /

SAE10w-40

SAE 10w-30 /

SAE10w-40

Oil Capacity

2.2Qt. (2.1 L)

2.2 Qt. (2.1 L)

CARB

78924

78922 / 78926 78928

EPA

Yes

Heavy Duty Air

Canister

Standard

Engines:

24.5 hp (18.5 kW)

25.5 hp (19.2 kW)

Make

Kawasaki

Kawasaki (Propane)

Model

FX751V

FX801V

Hi-Idle

3600 ± 100 RPM

3750 ± 50 RPM

Low-Idle

1550 RPM

Spark Plug

NGK BPR4ES

Oil

SAE 10w-30 / SAE10w-40 SAE 10w-30 / SAE10w-40 SAE 10w-30 / SAE10w-40

Oil Capacity

2.2 Qt. (2.1 L)

1.9 Qt. (1.8 L)

CARB

EPA

Yes

Heavy Duty Air Canister

Standard

Engines:

23 hp (17.2 kW)

25 hp (18.6 kW)

27 hp (20.1 kW)

29 hp (21.6 kW)

34 hp (25.4 kW)

Make

Kohler Command Kohler Command Kohler Command

Pro

Kohler EFI

Kohler Command

Model

CV680S

CV730S

CV740S

ECV749

FH921V

Hi-Idle

3800 ± 50 RPM 3800 ± 50 RPM 3800 ± 50 RPM 3800 ± 50 RPM

3600 ± 100

Low-Idle

1800 RPM

1550 RPM

Spark Plug

Champion

R12YC

Champion

R12YC

Champion

R12YC

Champion

R12YC

NGK BPR5ES

Oil

SAE 10w-30 /

SAE10w-40

SAE 10w-30 /

SAE10w-40

SAE 10w-30 /

SAE10w-40

SAE 10w-30 /

SAE10w-40

SAE 10w-30 /

SAE10w-40

Oil Capacity

2.0 Qt. (1.9 L)

1.8 Qt. (1.7 L)

CARB

EPA

Yes

Heavy Duty Air

Canister

Standard

Summary of Contents for Z Master 74901

Page 1: ...Toro Z Master G3 3000 5000 6000 Series Service Manual LCE Products...

Page 2: ...s Troubleshooting DVD Toro Part 492 4777 Electrical Troubleshooting Interactive Electrical Troubleshooting DVD Toro Part 492 9193 The Z Master G3 3000 5000 and 6000 model years 2009 to 2012 are covere...

Page 3: ...THIS PAGE INTENTIONALLY LEFT BLANK ABOUT THIS MANUAL...

Page 4: ...ter Bearing Replacement 3 2 Caster Fork Assembly Installation 3 4 Front Wheel Bearing Replacement 3 5 Front Wheel Bearing Removal 3 5 Front Wheel Bearing Installation 3 7 Fuel Tank Replacement 3 9 Fue...

Page 5: ...lacement 2012 later models 5 23 UHT Transmission Removal 2012 later models 5 23 UHT Transmission Installation 2012 later models 5 28 Wheel Hub Slotted Nut Installation 5 32 Adjusting the Motion Contro...

Page 6: ...ades 6 30 Installing the Blades 6 30 Electric PTO Clutch Replacement 6 31 Electric PTO Clutch Removal 6 31 Electric PTO Clutch Installation 6 32 Using the Clutch Shim 6 33 Removing the Clutch Shim 6 3...

Page 7: ...ow It Works 7 9 Testing 7 9 Fuel Sender 7 10 Purpose 7 10 Location 7 10 How It Works 7 10 Testing 7 10 Fuel Hour Meter 7 11 Purpose 7 11 Location 7 11 How It Works 7 11 Testing 7 11 Electric PTO Clutc...

Page 8: ...tarting or testing powered equipment 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 Avoid modific...

Page 9: ...SAFETY INFORMATION 1 2 Toro Z Master G3 3000 5000 6000 Series Service Manual 1 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 10: ...sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath of the fastener s head or similar condition which affects the insta...

Page 11: ...ts SAE Grade 8 Bolts Screws Studs Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts In lb In lb N cm In lb N cm In lb N cm 6 32 UNC 10 2 13 2 147 23 15 2 169 23 23 2 260 34 6 40 UNF 17 2...

Page 12: ...l strength length of thread engagement etc Note 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...

Page 13: ...cm X 0 73776 ft lb Thread Size Recommended Torque Square Head Hex Socket 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lb 145 20 in lb 3 8 16 UNC 35 10 ft lb 18 3 ft lb 1 2 13 UNC 75 15 f...

Page 14: ...6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64...

Page 15: ...ilometers Square Meters Square Centimeters Hectare 2 59 0 0929 6 452 0 4047 Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0 7646 0 02832 16 39 Weight Tons Shor...

Page 16: ...3600 100 RPM 3600 100 RPM 3750 50 RPM Low Idle 1550 RPM 1550 RPM 1550 RPM Spark Plug NGK BPR4ES NGK BPR4ES NGK BPR4ES Oil SAE 10w 30 SAE10w 40 SAE 10w 30 SAE10w 40 SAE 10w 30 SAE10w 40 Oil Capacity 2...

Page 17: ...low unit to be moved without engine running Pump drive Belt tension via spring loaded idler Mowing Decks 48 52 60 72 Cutting Deck Turbo Force Turbo Force Turbo Force Turbo Force Cutting Height 1 0 to...

Page 18: ...olt negative ground Battery Type Wet Battery Fuses Blade Type Hourmeter with Service Indicator Standard Equipment Controls Steering Levers Dual wrap around hydraulic dampened with cushioned grips Park...

Page 19: ...5 7 192 2 61 7 156 8 70 5 179 1 46 8 118 9 1165 528 0 Commercial 3000 Series Overall Height Model Wheel Base Overall Length Width Outside Tires Overall Width Chute Down Gate Width ROPS Up ROPS Folded...

Page 20: ...5 179 1 46 8 118 9 1350 612 3 74935 50 6 128 5 83 1 211 1 53 0 134 6 75 7 192 3 61 7 156 7 70 5 179 1 46 8 118 9 1269 575 6 74936 50 6 128 5 83 1 211 1 53 0 134 6 75 7 192 3 61 7 156 7 70 5 179 1 46...

Page 21: ...6 75 7 192 3 61 7 156 7 70 5 179 1 46 8 118 9 1301 590 1 74941CP 47 7 121 2 79 2 201 2 45 7 116 1 63 6 161 5 54 0 137 2 70 5 179 1 46 8 118 9 1205 546 6 74943CP 47 7 121 2 79 2 201 2 45 7 116 1 67 6...

Page 22: ...embly Removal 1 Raise the front of the machine off the ground leaving enough clearance to remove the caster fork from the frame 2 Remove the grease cap from the frame Fig 001 Fig 001 PICT 0351 3 Remov...

Page 23: ...Caster Bearing Replacement 3 Remove the bottom grease seal Fig 006 Fig 004 PICT 0359a 2 Remove the top tapered bearing Fig 005 Fig 005 PICT 0361a Fig 006 PICT 0364a 4 Remove the bottom tapered bearing...

Page 24: ...008 PICT 0367a 6 Install new tapered bearing cups by pressing each bearing cup into the caster fork hub so that the thick er part of the taper is pressed in first The bearing cups should seat against...

Page 25: ...k Assembly Installation 1 Install 3 Belleville washers as shown Fig 013 Fig 012 PICT 0372a Fig 013 fig 69 G001297 A Spring washer 3 C Dust Cap B Lock nut 2 Slide the caster fork assembly into the hub...

Page 26: ...bolt and nut Fig 017 Fig 015 PICT 0373a 4 Remove the plug located on the side of the caster hub Install a grease fitting Apply grease No 2 general purpose lithium base or molybdenum grease into the hu...

Page 27: ...al 3 6 Remove the axle caster Fig 021 Fig 019 PICT 0380a 5 Remove 2 spacer nuts from the axle caster Fig 020 Fig 020 PICT 0382a Fig 021 PICT 0383a 7 Remove the two caster seals from the wheel assembly...

Page 28: ...l hub so that the thicker part of the taper is pressed into the wheel hub first The bearing cups should seat against the shoulder divots inside the wheel hub Fig 025 Fig 023 PICT 0385a 9 Drive the bea...

Page 29: ...l the 2 spacer nuts and tighten Fig 029 Fig 027 PICT 0392a 5 Install the caster axle Fig 028 Fig 028 PICT 0393a Fig 029 PICT 0382a 7 Install the two guard seals screw nut and tighten Fig 030 Fig 030 P...

Page 30: ...from the tank is by using a siphon pump 3 Remove the 4 bolts retaining the seat base as sembly to the frame Fig 031 5 Remove the 4 screws retaining the right and left hand motion control covers Fig 0...

Page 31: ...und the fuel sender plug Fig 037 Fig 035 PICT 0401a 8 Lift the seat mount from the frame Fig 036 Fig 036 PICT 0417a Fig 037 PICT 0406a 10 Unplug the fuel sender plug from the wiring harness Fig 038 Fi...

Page 32: ...nnect the vapor line retainers from the fuel manifold Fig 039 13 Remove the fuel tank from the frame of the unit Fig 041 Fig 039 PICT 0421a 12 With the fuel valve in the OFF position remove the fuel c...

Page 33: ...044 Fig 042 PICT 0426a 2 Install the fuel clamp around the fuel line to the fuel valve 3 Connect the vapor line retainers to the fuel manifold Fig 043 Fig 043 PICT 0421a Fig 044 PICT 0409a 5 Install a...

Page 34: ...rame Fig 046 8 Install seat and connect the seat switch Fig 048 Fig 046 PICT 0415a 7 Install 2 bolts and nuts on the right and left side of the seat frame Fig 047 Fig 047 PICT 0413a Fig 048 PICT 0398a...

Page 35: ...negative battery cable from the battery terminal 2 Remove the knob from the throttle control assembly Fig 051 Fig 050 DSCN 4238a Fig 051 DSCN 4247a 3 Remove the 4 screws securing the control panel to...

Page 36: ...to the control panel Fig 053 6 Remove the Z bend end of the cable from the throttle arm assembly Fig 055 Fig 053 DSCN 4250a 5 Loosen the cable clamp and remove the throttle cable from underneath it Fi...

Page 37: ...mp next to the frame brace for the ROPS assembly Fig 058 Fig 057 DSCN 4260a Fig 058 DSCN 4260a 2 Slide the throttle cable through the hose clamp located next to the engine Fig 059 Fig 059 DSCN 4259a 8...

Page 38: ...ing 2 carriage bolts and lock nuts Fig 060 Fig 060 DSCN 4250a 4 Install the 4 screws securing the control panel to the RH Fender Console Fig 061 Fig 061 DSCN 4249a 5 Install the knob to the throttle c...

Page 39: ...2012 Later 1 Remove the two screws retaining the right hand motion control cover assembly to the frame and remove the cover Fig 066 Fig 066 DSCN 2614a 2 Unplug the wire harness from the park brake sw...

Page 40: ...Fig 068 DSCN 2619a 4 Remove the two cotter pins and clevis pins retaining the right and left park brake cables to the handle assembly Fig 069 Fig 069 DSCN 2623a Fig 070 DSCN 2626a 5 Remove two e rings...

Page 41: ...e slots in the bottom of the brake pivot assembly and install the e rings Fig 071 Fig 071 DSCN 2627a Fig 072 DSCN 2635a 3 Install two screws through the park brake handle two spacers and tighten the a...

Page 42: ...me Remove the RH and LH wheels from the unit Fig 075 Fig 075 PICT 8962 2 Disengage the park brake lever 3 Remove the two nuts located on the end of park brake cable Fig 076 Fig 076 PICT 9075a Fig 077...

Page 43: ...he tie strap securing the brake cable to the cradle Fig 080 Fig 080 PICT 8977a A Right side brake C Left side brake assembly assembly B Cradle D Retainer 5 8 Remove the brake cable from the retainers...

Page 44: ...cable yoke Fig 083 Fig 083 PICT 9001a 11 Release the brake cable retainer holding the brake cable to the frame Fig 084 Fig 084 PICT 9008a Fig 085 PICT 9014a 13 Pull the cable out over the frame cross...

Page 45: ...bly Fig 089 Fig 089 PICT 9001a 4 Install a cotter pin through the clevis pin to secure Fig 090 Fig 090 PICT 8999a Left Park Brake Cable Installation 2011 Prior 1 Route the clevis end of the brake cabl...

Page 46: ...cradle so that the retainer tab is installed in the slot on the cradle Fig 092 Fig 092 PICT 9027a A Right side brake C Left side brake assembly assembly B Cradle D Retainer 5 A B C D D Fig 093 PICT 90...

Page 47: ...095 Fig 095 PICT 9077a 10 Install a tie strap securing the brake cable to the cradle Fig 096 Fig 096 PICT 9070a 12 Adjust the park brake Refer to Adjusting the Parking Brake on page 3 32 A Standard nu...

Page 48: ...heels from the unit Fig 098 Fig 098 PICT 8962 2 Disengage the park brake lever 3 Remove the two nuts located on the end of the park brake cable Fig 099 Fig 099 PICT 9075 Fig 100 PICT 9083a 5 Slide the...

Page 49: ...through the two holes in the cradle Fig 103 Fig 103 cables routing 4 9 Remove the cotter pin located on the clevis pin holding the brake cable clevis to the park brake lever Fig 105 8 Pull the brake c...

Page 50: ...e of the frame Fig 106 Fig 106 PICT 9092a Right Park Brake Cable Installation 2011 Prior Fig 107 PICT 9092a 2 Position the brake cable clevis to the brake lever assembly Install a clevis pin through t...

Page 51: ...brake snap fitting Fig 110 Fig 110 PICT 9103a 5 Route the brake cable through the side hole in the frame and down through the hole in the cradle Fig 111 Fig 111 PICT 9105a 6 Route the brake cable from...

Page 52: ...etainer into the cradle so that the retainer tab is installed in the slot on the cradle Fig 113 Fig 113 PICT 9111a Fig 114 PICT 9113a Fig 115 PICT 9114a 10 Install a standard nut and a lock nut onto t...

Page 53: ...ve vertical position on the hydro unit that you are replacing the brake cable on Fig 117 Fig 117 PICT 8677a 4 While holding the lever use the other hand or fingers to pull the cable threaded end tight...

Page 54: ...ovement between the hub rotor and the caliper then back off the standard nut one turn from the swivel and repeat step 5 7 If the hub rotor moves freely relative to the caliper then tighten the standar...

Page 55: ...the unit Fig 122 Fig 122 DSCN 4311a 4 Hold the threaded rod end with a tool and with a socket wrench remove the lock nut and washer from the end of the cable Fig 124 Continue to remove the washer and...

Page 56: ...g 126 Fig 126 DSCN 4325a 7 Squeeze the tabs on the conduit fitting and remove it from cable bracket located on the frame Fig 127 Fig 127 DSCN 4327a Fig 128 DSCN 4328a 8 Remove the two clips retaining...

Page 57: ...d clevis pin on the left side of the park brake handle Fig 132 Fig 132 DSCN 4330a 13 Remove the e ring retaining the brake cable to the park brake pivot assembly and slide the cables out of the slots...

Page 58: ...stall the brake cable grooved fitting into the slot on the bottom of the brake pivot assembly and install e ring Fig 135 Fig 135 DSCN 4335a 4 Install two screws and spacers through the park brake hand...

Page 59: ...n Fig 138 Fig 138 DSCN 4328a 6 Squeeze the tabs on the conduit fitting and install in the cable bracket located on the frame Fig 139 Fig 139 DSCN 4327a 7 Slide the brake cable into the cable anchor sl...

Page 60: ...Fig 143 Fig 143 DSCN 4314a Fig 144 fig 79 G016879 11 Engage the parking brake Measure the overall length of the compression spring Fig 144 The correct length should be between 1 1 2 and 1 9 16 3 8 an...

Page 61: ...sed position Turn the wheel hub by hand in both directions relative to the caliper no drag of the caliper pad on the wheel hub is desired 14 After adjusting the brake cycle the brake handle a minimum...

Page 62: ...148 DSCN 4311a 2 Disengage the park brake lever 3 Remove the e ring washer and brake pin from the L Bracket Fig 149 Fig 149 DSCN 4364a Fig 150 DSCN 4366a 4 Hold the end of the threaded rod with a too...

Page 63: ...ame and remove Fig 153 6 Pull the brake cable out of the cable anchor on the transmission and slide it out of the slot Fig 152 Fig 152 DSCN 4370a Fig 153 DSCN 2614a 8 Unplug the wire harness from the...

Page 64: ...ining the brake cable to the park brake pivot assembly and slide the cable out of the slot Fig 157 10 Remove the cotter pin and clevis pin on the right side of the park brake handle Fig 156 Fig 156 DS...

Page 65: ...g 159 Fig 159 DSCN 4385a 3 Install the clevis and cotter pin to the right side of the park brake handle Fig 161 Fig 161 DSCN 4373a 2 Install the brake cable grooved fitting into the slot on the bottom...

Page 66: ...163 DSCN 4379a 6 Slide the brake cable into the cable anchor slot on the transmission Fig 164 Fig 164 DSCN 4370a Fig 165 DSCN 4370a 7 Install the end of the brake cable through the cable anchor and in...

Page 67: ...the caliper no drag of the caliper pad on the wheel hub is desired 12 After adjusting the brake cycle the brake handle a minimum of six times to allow the cable to seat into the sheath and mounting t...

Page 68: ...rear tires and torque lug nuts between 103 5 126 5 ft lbs 140 5 171 5 Nm 17 Remove the jack stands and lower the unit Brake Caliper Replacement Brake Caliper Removal Fig 171 DSCN 4314a Note The left s...

Page 69: ...the brake mount plate from the caliper Fig 175 Fig 175 DSCN 4394a 4 Hold the end of the threaded rod with a tool and with a socket wrench remove the lock nut and washer from the end of the cable Fig...

Page 70: ...Fig 176 DSCN 4398a 2 Apply thread locker to the 2 bolts that retain the brake mount plate Fig 177 Fig 177 DSCN 4400a Fig 178 DSCN 4402a 3 Install two washers between the brake mount plate and the tran...

Page 71: ...que lug nuts between 103 5 126 5 ft lbs 140 5 171 5 Nm 11 Remove the jack stands and lower the unit 6 Hold the end of the threaded rod with a tool and adjust the lock nut until the spring length is be...

Page 72: ...for the right damper Motion Control Damper Removal 1 Park the machine on a level surface disengage the PTO turn the ignition OFF and remove the key 2 Remove the nut securing the damper ball joint to t...

Page 73: ...or 22 6 Nm Bolt must protrude past end of locknut after torque B Most resistance firmest feel C Damper D Medium resistance medium feel E Least resistance softest feel Fig 187 fig 87 G008620 A B C D E...

Page 74: ...when moving it to the neutral lock position See Figure 188 for adjustment options Fig 188 fig 88 G008621 A B Adjusting the Control Handle Position A Bolt C Control lever B Handle D Nut Fig 189 fig 84...

Page 75: ...ig 190 Fig 190 fig 85 G009195 Motion Control Assembly Replacement Motion Control Assembly Removal Note This procedure is performed on the left hand motion control assembly follow the same procedure fo...

Page 76: ...H lever control motion Fig 192 Fig 192 DSCN 4459a 4 Remove the lock nut from the damper motion control from the LH motion control assembly Fig 193 Fig 193 DSCN 4462a Fig 194 DSCN 4464a 6 Remove the wi...

Page 77: ...ge to the LH motion control assembly Fig 196 Fig 196 DSCN 4470a 9 Remove the pivot hub from the LH motion control Fig 198 Fig 198 DSCN 4474a 10 Remove the wire harness anchor from the LH motion contro...

Page 78: ...aining the leaf spring to the LH motion control Fig 201 Fig 201 DSCN 4492b 14 Remove the nut two spring washers flat washer and LH motion control lever from the LH motion control Fig 203 A Jam nut D F...

Page 79: ...nge bushings in the LH motion control Fig 204 Fig 204 DSCN 4487a 2 Install motion control lever in the LH motion control Fig 205 Fig 205 DSCN 4488a 3 Install flat washer on motion control lever Fig 20...

Page 80: ...en so it is snug Fig 208 Fig 208 DSCN 4491a 6 Install the spring leaf with carriage bolt and nut Fig 209 Fig 209 DSCN 4492a Fig 210 DSCN 4495a 8 Install the wire harness anchor to the motion control l...

Page 81: ...be Fig 212 Fig 212 DSCN 4473a 10 Install the plug connector to the neutral switch Fig 213 Fig 213 DSCN 4500a 11 Install the wiring harness in the wire anchor located on the LH motion control assembly...

Page 82: ...control handles and the motion control neutral lock see Adjusting the Motion Control Neutral Lock Pivot on page 3 53 and Adjusting the Control Handle Position on page 3 53 17 Start the unit disengage...

Page 83: ...CHASSIS 3 62 Toro Z Master G3 3000 5000 6000 Series Service Manual 3 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 84: ...3000 5000 and 6000 Series units Engine Removal 1 Remove the battery negative and positive cables Remove the battery from the frame 2 On tilt seats lift the seat up or non tilt seats slide the seat fo...

Page 85: ...e z bend end of the cable from the throttle arm assembly Fig 225 Fig 225 DSCN 4258a 6 Remove the 2 nuts retaining the rear guard to the frame and 1 carriage bolt and nut retaining the muffler guard to...

Page 86: ...e clamp and pull the hose forward away from the engine Fig 227 Fig 227 DSCN 0011a 11 Remove the vent line from the air filter assembly Fig 228 Fig 228 DSCN 0018a 12 Lift and remove the floor pan then...

Page 87: ...CN 0031a 16 Remove the engine sheave from the engine crankshaft Fig 233 Fig 233 DSCN 0032a Fig 231 DSCN 0028a 14 Unplug the wire plug from the electric PTO clutch Fig 231 13 Using a 1 2 drive breaker...

Page 88: ...oist raise the engine approximately 6 above the frame Fig 236 Fig 236 DSCN 0047a 18 Remove the 4 engine bolts and Belleville washers retaining the engine to the frame Fig 235 Fig 235 DSCN 0038a 20 Rem...

Page 89: ...23 Remove the engine from the frame Fig 240 Fig 240 DSCN 0053a Fig 239 DSCN 0050a 22 On the bottom of the starter solenoid disconnect the red wire and red positive cable Fig 239 21 Unplug the wiring h...

Page 90: ...otor bolt Fig 241 Fig 241 DSCN 0043a 4 Plug the wiring harness plug into the engine wiring harness plug connector Fig 243 Fig 243 DSCN 0049a 5 Lower the engine to the frame 6 Align the four holes of t...

Page 91: ...clutch fits on the clutch anchor Using the bolt spring washers and washer torque the clutch bolt to 55 6 ft lbs 74 6 8 1 Nm Fig 248 Fig 248 DSCN 0061a 9 Install the bolt spring washers with crown of t...

Page 92: ...y rotate the pump idler arm counter clockwise to allow room to install the v belt around the engine pulley Fig 250 Fig 250 DSCN 0025a 13 Using a 3 8 breaker bar install the mower idler arm assembly an...

Page 93: ...assembly Fig 256 Fig 256 DSCN 4261 18 Slide the throttle cable through the hose clamp located next to the engine Fig 255 16 Route the fuel line and the throttle cable through the hose clamp located o...

Page 94: ...throttle cable clamp Fig 259 Fig 257 DSCN 4253a Fig 259 DSCN 4281a 23 Move the throttle control back and forth checking the operation of the throttle arm assembly 24 Install 2 nuts retaining the rear...

Page 95: ...e to the On position for tilt seats lift the seat for non tilt seats slide the seat forward to access the fuel shut off valve 28 Lower the machine to the ground with a floor jack after removing the ja...

Page 96: ...rial G3 UHT Transmission Replacement 2009 through 2011 models Note The following procedures cover replacing the left hand UHT Transmission The same procedures can be followed to remove the right hand...

Page 97: ...e the mower deck drive belt from around the electric PTO clutch and pull the belt forward so it clears the hydro cradle assembly Fig 268 8 Remove the mower deck drive belt from the center mower spindl...

Page 98: ...6 15 2cm off the floor 12 Using a 1 2 drive breaker bar installed in the square hole in the pump idler assembly rotate the pump idler arm counter clockwise to relieve tension on the v belt Fig 271 Fi...

Page 99: ...the machine being serviced pry the control arm off the square tapered shaft Fig 274 Note Be careful to not damage the trunnion shaft seal Fig 274 PICT 8566 Fig 275 PICT 8578 17 On the side of the mach...

Page 100: ...ig 277 PICT 8582a 20 Remove the 2 bolts and washers securing the brake caliper to the UHT Fig 278 Note There is a spacer washer on each bolt be tween the caliper bracket and the UHT Fig 278 PICT 8584...

Page 101: ...cable through the routing holes so the slack is on the front side Fig 283 Fig 281 PICT 8655 Fig 282 PICT 8591a Fig 283 PICT 8592a 27 Repeat steps 24 26 on the opposite side of the machine 28 Pull 2 or...

Page 102: ...oor jack under the cradle on the side of the machine being serviced Raise the floor jack to contact the cradle Fig 288 29 On the side of the machine being serviced remove the bottom carriage bolt and...

Page 103: ...the frame by lowering the floor jack Take care that the brake cables and UHT fan are clear of the frame Fig 290 Note Ensure the control arm shaft clears the frame and the control arm linkage doesn t g...

Page 104: ...HT drive pulley Make sure the dump valve is in the closed horizontal position 3 Lift the UHT cradle assembly up to the frame with a floor jack Align the UHT mounting holes with the holes in the frame...

Page 105: ...cradle to the UHT and the 2 bolts securing the UHT to the frame Fig 299 Fig 297 PICT 8638a Fig 298 PICT 8615a Fig 299 PICT 8640a A Cradle to UHT nuts B UHT mounted to frame bolts 8 Tighten the 3 bolts...

Page 106: ...5 Nm Fig 302 9 Remove the floor jack 10 Apply thread locking compound to control arm bolt Fig 301 12 Install the left hand brake cable retainer into the cradle so that the retainer tab is installed in...

Page 107: ...install the castle nut Fig 306 Note Do not use anti seize compound on the wheel hub Fig 306 PICT 8661a Fig 307 PICT 8663a 18 Position the brake caliper onto the wheel hub aligning the holes in the bra...

Page 108: ...vel nut to secure Fig 309 Adjust the Parking Brake Note For this example the left side brake is being adjusted the right side brake adjustment is the same procedure 22 Open the valve s vertical positi...

Page 109: ...standard nut one turn against the swivel and repeat step 26 29 Once step 26 is achieved hold the threaded rod end with a tool and tighten the lock nut against the standard nut Do not allow the cable...

Page 110: ...the opposite side of the machine 32 Engage the parking brake 33 Torque the castle nut to 200 ft lbs 271 Nm Fig 315 Fig 315 PICT 8687 34 Check the distance from the bottom of the slot in the castle nut...

Page 111: ...ts line up with the cross hole in the shaft Do not loosen the nut to align the slot 38 Install the cotter pin Use a new cotter pin if needed Fig 318 Fig 318 PICT 8689 Fig 319 PICT 8557a 40 While holdi...

Page 112: ...uare hole in the idler bracket rotate the idler clockwise to relieve tension Fig 322 41 Route the mower deck drive belt around the electric PTO clutch Fig 321 43 Route the mower deck drive belt around...

Page 113: ...the floor pan Fig 326 Fig 324 PICT 8541a 47 Reinstall the guard above the UHT Fig 325 Fig 325 PICT 8696 Fig 326 PICT 8543 44 Install rear wheels and torque lug nuts to 90 95 ft lbs 122 129 Nm 45 Lowe...

Page 114: ...nt Do not overfill the UHT with oil as dam age may occur Do not run the machine with oil below the knurled section or damage may occur 54 Install the dipstick Repeat for opposite side 55 Operate the m...

Page 115: ...Fig 328 PICT 8548 2 Remove the two rear wheels Fig 329 Fig 329 PICT 8550a 5 Engage the parking brake 6 Install a 1 2 x 6 approximately rod or bolt through the 2 height of cut hole Fig 331 Fig 331 G3C...

Page 116: ...ff the engine and completely release the parking brake by removing the 1 2 x 6 rod or bolt 13 Allow the hubs to cool until they are cool enough to safely touch 14 Rotate the drive wheel release valve...

Page 117: ...st swivel I Swivel pivot head Fig 335 fig 63 G010208 A I H BC DE F G 18 Try to turn the wheel hub in both directions relative to the caliper There should be slight movement be tween them some friction...

Page 118: ...procedures cover replacing the left hand UHT transmission The same procedures can be followed to remove the right hand UHT Transmission 1 Position the machine on a level surface 2 Disengage the PTO m...

Page 119: ...emoved from the belt remove the v belt from around the left side transmission pulley Fig 339 Fig 339 DSCN 4508a Fig 340 DSCN 4510a 9 Pry the control arm off the square tapered shaft Fig 341 Note Be ca...

Page 120: ...tool With a socket wrench remove the lock nut and washer from the end of the cable Fig 344 Remove the washer and spring Fig 342 DSCN 4516a Fig 344 DSCN 4315a 11 Disengage the park brake lever 12 Remo...

Page 121: ...48 DSCN 4518a 15 Pull the brake cable out of the cable anchor on the transmission and slide it out of the slot Fig 346 16 On the side of the machine being serviced use a wheel hub puller Toro part num...

Page 122: ...Lower the UHT transmission cradle assembly from the frame by lowering the floor jack Take care that the UHT transmission fan clears the frame Note Ensure the control arm shaft clears the frame and the...

Page 123: ...serviced loosely install two mounting bolts coming from the top down through the frame and into the UHT transmission Fig 356 Fig 354 DSCN 4535a Fig 356 DSCN 4546a Fig 357 DSCN 4539a 1 Using the top tw...

Page 124: ...e machine being serviced tighten the 3 bolts and nuts securing the cradle to the UHT transmission and the 2 bolts securing the UHT transmission to the frame torque the nuts and bolts to 75 8 ft lbs 10...

Page 125: ...4a 12 Slide the wheel hub onto the UHT transmission shaft aligning the keyway in the wheel hub with the key in the UHT shaft Loosely install the nut Fig 363 Note Do not use anti seize compound on the...

Page 126: ...liper Fig 367 Fig 367 DSCN 4314a 17 Engage the parking brake Measure the overall length of the compression spring Fig 368 The correct length should be between 1 1 2 and 1 9 16 3 8 and 4 9cm If the spr...

Page 127: ...ngth 21 Rotate the drive wheel release handle to the operating position Fig 369 DSCN 4315a 22 Installing the wheel Hub slotted nut Style A black finish Fig 370 Torque the slotted nut to 211 260 ft lbs...

Page 128: ...t lbs 140 5 171 5 Nm 25 Install the negative battery cable to the battery 26 Start the unit up and allow the unit to warm up for about 5 minutes moving the motion control levers from forward to revers...

Page 129: ...onal injury Keep fingers hands and clothing clear of rotating components and hot surfaces Fig 373 fig 86 G009033 Adjusting the Motion Control Linkage Neutral Adjustment 1 Prior to starting the engine...

Page 130: ...ust pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels do not move forward or reverse Fig 376 Note A slight creep in reverse is acceptable Fi...

Page 131: ...ating temperature 5 Move the seat forward 7 Remove one dipstick from the hydraulic reservoir Fig 377 8 Wipe the dipstick off and thread the dipstick into the reservoir 9 Remove the dipstick and look a...

Page 132: ...d position Ensure vehicle is properly secured to prevent injury to the service technician or bystanders Do not attempt any adjustments with the engine running When working around vehicle linkages use...

Page 133: ...m ports 3 Unplug the seat switch and temporarily install a jumper wire across the terminals in the connector of the main wiring harness Fig 381 Fig 381 DSCN 4620a Fig 382 DSCN 4625a There is no need t...

Page 134: ...the pressure gauge readings is 300 psi 21 bar Record the flow reading from the bidirectional flow meter 11 Tighten the restriction valve unit the difference between the pressure gauge readings is 1000...

Page 135: ...llation on page 6 2 11 Lower the machine to the ground 5 Use a ratchet or breaker bar in the square hole of the idler arm to remove the idler spring Fig 385 1 Disengage the PTO and set the parking bra...

Page 136: ...ease valves The drive wheel release valves are located in the back of each hydraulic drive unit under the seat Note Make sure the release valves are in fully horizontal position when operating the mac...

Page 137: ...HYDRAULIC SYSTEM 5 42 Toro Z Master G3 3000 5000 6000 Series Service Manual 5 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 138: ...emove the key and wait for all moving parts to stop before leaving the operating position 3 Lower the mower to the 3 76mm height of cut 4 Remove the RH belt cover Fig 387 and the LH belt cover Fig 387...

Page 139: ...B Mower belt arm for the ratchet C Spring loaded idler F Idler grease zerk pulley G Belt guide D Ratchet 8 Remove the belt guide on the spring loaded idler arm shown in Fig 390 Fig 390 DSCN 0069a 9 R...

Page 140: ...the stored energy can cause serious injury or death Do not attempt to disassemble the deck from the front frame without locking out the stored energy 1 Stop engine wait for all moving parts to stop an...

Page 141: ...lt from electric PTO clutch pulley Fig 394 5 Lift up the floor pan and insert a ratchet or breaker bar into the square hole in the deck idler assembly Fig 394 Fig 394 fig 81 G009038 A Clutch pulley E...

Page 142: ...252 7 Remove and retain the hardware on both sides of the deck Fig 395 or Fig 396 A Right stabilizer B Deck strut right side shown C Remove the rear deck lift attachment shoulder bolt nut D Remove the...

Page 143: ...KS 6 6 Toro Z Master G3 3000 5000 6000 Series Service Manual 6 Mower Deck Installation Reverse the order of mower deck removal Extension Spring Adjustment 2010 2012 Models Fig 398 116 5700K12 Fig 397...

Page 144: ...ee bolts retaining the pulley to the pulley hub Fig 401 Fig 401 DSCN 2662a Mower Spindle Removal 2009 Model G3 Series Units The following procedure applies to removing any of the three mower spindles...

Page 145: ...09 Model G3 Series Units 6 Raise the mower deck to the transport position 7 Remove the mower blade from the spindle assembly 8 Remove the 5 bolts and nuts retaining the spindle assembly to the mower d...

Page 146: ...Series Units 4 Remove the bearing shield Fig 405 Fig 403 DSCN 2669a 3 Remove the pulley hub and square key Fig 404 Fig 404 DSCN 2670a Fig 405 DSCN 2671a 5 Remove the spindle housing from the spindle s...

Page 147: ...top of the spindle housing Fig 407 8 Remove the top oil seal from the spindle housing Fig 409 Fig 407 DSCN 2673a 7 Remove the seal spacer from the bottom of the spindle housing Fig 408 Fig 408 DSCN 26...

Page 148: ...e the bearing from the bottom of the spindle Fig 413 Fig 411 DSCN 2677a 11 Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing Fig 412 Note the orientation of...

Page 149: ...the spindle housing Fig 417 Fig 415 DSCN 2682a 15 This view shows the 2 bearing races and the large spacer in the spindle housing Fig 416 A Brearing race spacer B Center spacer Fig 416 DSCN 2684a Fig...

Page 150: ...til the seal is flush with the outer edge of the housing Fig 422 5 Install the lower seal Fig 421 Note The open lip of the seal should be facing outward Fig 419 DSCN 2690a Fig 420 DSCN 2691a Fig 421 D...

Page 151: ...9 Install the seal Press it flush with the top of the housing Fig 425 Note The open lip of the faces inward Fig 423 DSCN 2700a 8 Pack the bearing with No 2 grease and install the bearing Fig 424 Fig 4...

Page 152: ...ig 427 DSCN 2703a 12 Install the seal spacer on the top of the spindle housing Fig 428 Fig 428 DSCN 2704a Fig 429 DSCN 2705a 11 Lower the spindle housing over the spindle shaft Fig 427 14 Install the...

Page 153: ...s 135 58 162 7 Nm Fig 432 Fig 432 DSCN 2709a Mower Spindle Replacement 2010 Later Model G3 3000 5000 6000 Series Units Mower Spindle Removal 2010 Later Model G3 3000 5000 6000 Series Units Fig 433 DSC...

Page 154: ...the top transport position Remove the mower blade from the spindle shaft 6 Remove the 6 flange nuts retaining the spindle assembly to the mower deck and remove the spindle assembly from the deck Fig...

Page 155: ...to the spindle hub Fig 436 Fig 436 DSCN 0082a 2 Remove the top lock nut and washer from the spindle shaft Fig 437 Fig 437 DSCN 0087a Mower Spindle Disassembly 2010 Later Model G3 3000 5000 6000 Series...

Page 156: ...the bearing out of the spindle housing Fig 441 5 Remove the top oil seal Fig 440 Fig 440 DSCN 0092a Fig 441 DSCN 0093 8 Using a hammer and driver with a square edge drive the bottom bearing and seal...

Page 157: ...ls only there is no need to remove the snap ring unless it shows damage Fig 444 DSCN 0106a Mower Spindle Assembly 2010 Later Model G3 3000 5000 6000 Series Units Fig 445 DSCN 0118a 2 Apply a film of g...

Page 158: ...acer in the spindle housing Fig 447 Fig 447 DSCN 0116a 4 Turn the spindle housing over and press the bearing in the bottom of the housing until the bearing seats against the spacer Fig 448 Fig 448 DSC...

Page 159: ...g Fig 451 Fig 451 DSCN 0122a 8 Install the washer and lock nut retaining the spindle hub to the spindle shaft Torque the nut to 120 5 ft lbs 162 7 6 8 Nm Fig 453 Fig 452 DSCN 0123a Fig 453 DSCN 0125 7...

Page 160: ...the way forward and the deck will latch at the 5 1 2 14cm transport position Fig 454 6 Insert the height adjustment pin into the 3 7 6cm cutting height location 7 Release the transport lock and allow...

Page 161: ...djustment nut on the front deck lift assembly by turning it Fig 457 Note To increase the height turn the adjustment nut clockwise to decrease turn counter clockwise Fig 456 fig 94 G012430 Fig 457 fig...

Page 162: ...oo low tighten the single point adjust ment bolt by rotating it clockwise If the deck is too high loosen the single point adjustment bolt by rotating it counterclockwise Fig 459 Note Loosen or tighten...

Page 163: ...the two bolts at the bottom of the height of cut plate Fig 460 Torque to 27 33 ft lbs 37 45 Nm Note In most conditions the back blade tip should be adjusted 1 4 6 4mm higher than the front Fig 460 fi...

Page 164: ...nut D Front deck adjustment Fig 462 fig 94 G012430 A B C D B A Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades Teari...

Page 165: ...TO move the motion control levers to the neutral locked position and set the parking brake 2 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position...

Page 166: ...ged could break apart and could seriously injure or kill you or bystanders Always replace bent or damaged blade with a new blade Never file or create sharp notches in the edges or surfaces of blade Bl...

Page 167: ...t be pointing upward toward the inside of the mower to ensure proper cutting 2 Install the spring disk and blade bolt The spring disk cone must be installed toward the bolt head Fig 468 Torque the bla...

Page 168: ...the clutch Fig 472 1 Remove the battery negative cable from the battery 2 Lift and remove the floor pan With a 3 8 breaker bar in the hole for the idler arm loosen the mower deck drive belt and remove...

Page 169: ...hers and washer torque the clutch bolt to 55 6 ft lbs 74 6 8 Nm Fig 474 Fig 474 DSCN 0061a Fig 475 DSCN 0028a 4 Using a 3 8 breaker bar install the mower idler arm assembly and relieve the tension on...

Page 170: ...ke mounting bolt Some later model year units have been built with clutches that contain a brake shim When the clutch brake has worn to the point where the clutch no longer engages consistently the shi...

Page 171: ...871 5 Measure the gap between the rotor and armature If the gap is greater than 0 04 1mm proceed 6 Loosen both brake mounting bolts one half to one full turn Fig 479 Note Do not remove the brake pole...

Page 172: ...hen reinstall the shim and reference the Troubleshooting section of the Owner s Manual If the gap is sufficient proceed with the Safety Check on page 6 35 Fig 482 fig 75 G010873 A Safety Check 1 Sit o...

Page 173: ...MOWER DECKS 6 36 Toro Z Master G3 3000 5000 6000 Series Service Manual 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 174: ...ame right side of the engine in front of the battery Fig 483 Fig 483 DSCN 0008 How It Works A relay is an electrically actuated switch 1 Coil Terminals 85 and 86 are connected to a coil Applying 12 vo...

Page 175: ...to 90 ohms There should be continuity between terminals 87a and 30 3 Connect multimeter ohms setting leads to relay terminals 30 and 87 Ground terminal 86 and apply 12 VDC to 85 The relay should make...

Page 176: ...TO switch to the Park Brake switch as part of the circuit used to ensure safe starting 1 Disengage the PTO set the parking brake and turn the ignition to OFF and remove the key 2 Remove the 4 screws h...

Page 177: ...eplace the switch if your test results do not corre spond with those given in Fig PTO switch test 7 Mount the PTO switch back into the control panel and reinstall the wiring harness Fig 489 Fig 489 PT...

Page 178: ...and START The START position is spring loaded so the key automatically returns to RUN when released Fig 491 Ignition Switch Wiring Connections B Battery voltage In S Starting Circuit I Fuel sender Sta...

Page 179: ...e operator is in the seat to maintain current to the safety circuit Fig 493 Testing 1 Disconnect the switch from the wiring harness 2 Using a VOM or test light check first to ensure there is no contin...

Page 180: ...r the operator vacates the seat Location The seat switch is mounted under the seat to the seat frame Fig 494 Fig 494 PICT 0398a How It Works When the seat is vacated the switch is open and there shoul...

Page 181: ...nect the switch from the wiring harness 2 Use a VOM check first to ensure there is no continuity between the terminals plunger out 3 With the plunger pushed in there should continuity between the term...

Page 182: ...ted on the right hand side of the engine plugged into the wiring harness Fig 498 Fig 498 DSCN 0005a How It Works This is a surge protector for the electric PTO clutch It clamps the voltage off of the...

Page 183: ...it takes for and ultrasonic signal to travel from the sender to the fuel in the fuel tank and back to the sender to determine the fuel level Fig 501 Apply 12 volts to the red lead ground the black le...

Page 184: ...hours the engine has operated A fuel gauge which a light will light up when the fuel is low about 1 gallon of fuel left and also has indicator bars to indicate how much fuel is in the fuel tank Batter...

Page 185: ...Location The electric clutch is located on the PTO end of the engine crankshaft How It Works The PTO clutch is composed of three major compon ents the field the clutch plate and the friction plate The...

Page 186: ...s Fig 504 5 Connect the negative meter lead to the clutch harness terminal 3 Fig 504 6 Connect a short jumper lead from terminal 2 to terminal 4 Fig 000 above 7 Turn the ignition switch to the RUN pos...

Page 187: ...ELECTRICAL 7 14 Toro Z Master G3 3000 5000 6000 Series Service Manual 7 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 188: ...Toro Z Master G3 3000 5000 6000 Series Service Manual Form Number 492 9237...

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