Toro 74901, 74901CP, 74902TE, 74903, 74903CP Service Manual
...
LCE Products
Toro Z Master G3
3000/5000/6000 Series
Service Manual
ABOUT THIS MANUAL
This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to
make the information in this manual complete and correct.
Basic shop safely knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems
and the related topics covered in this manual.
The following service materials are available in addition to this service manual:
Hydrostatic Transmissions: Parker UHT Series HB Hydrostatic Transmission Service Manual (HY13-1512-M2/US)
Wheel Motors: Parker/Ross Wheel Motor Service Manual (HY13-1512-006-M1/US 3/07)
Engine: Engine service manuals (available through Kohler and Kawasaki)
Hydraulic Troubleshooting: Interactive Hydraulic Systems 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 covered in this manual.
The hydrostatic drive system is precision machinery. Maintain strict cleanliness control during all stages of service
and repair. Cover or cap all hose ends and ttings whenever they are exposed. Even a small amount of dirt or other
contamination can severely damage the system.
We are hopeful that you will nd this manual a valuable addition to your service shop. If you have any questions or
comments regarding this manual, please contact us at the following address:
The Toro Company
RLC Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
The Toro Company reserves the right to change product specications or this manual without notice.
Copyright© All Rights Reserved
©2012 The Toro Company
ABOUT THIS MANUAL
THIS PAGE INTENTIONALLY LEFT BLANK.
TABLE OF CONTENTS
1 - Safety Information
General Information .........................................................................................................................................1-1
Think Safety First.............................................................................................................................................1-1
2 - Specications
Torque Specications ......................................................................................................................................2-1
Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) ...........................................................2-2
Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) ..............................................................2-3
Other Torque Specications ............................................................................................................................2-4
Equivalents & Conversions..............................................................................................................................2-5
Decimal & Millimeter Equivalents ..............................................................................................................2-5
U.S. to Metric Conversions .......................................................................................................................2-6
G3 3000/5000/6000 Series Specications ......................................................................................................2-7
G3 3000/5000/6000 Series Specications cont...............................................................................................2-8
G3 3000/5000/6000 Series Specications cont...............................................................................................2-9
Dimensions ....................................................................................................................................................2-10
Commercial 3000 Series .........................................................................................................................2-10
G3/Professional 5000 Series ..................................................................................................................2-10
Dimensions .................................................................................................................................................... 2-11
G3/Professional 6000 Series .................................................................................................................. 2-11
Dimensions ....................................................................................................................................................2-12
G3/Professional 6000 Series cont. .........................................................................................................2-12
3 - Chassis
Caster Fork Assembly Replacement ...............................................................................................................3-1
Caster Fork Assembly Removal ................................................................................................................3-1
Caster 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
Fuel Tank Removal ...................................................................................................................................3-9
Fuel Tank Installation ..............................................................................................................................3-12
Throttle Control Assembly Replacement (Kohler EFI Engine).......................................................................3-14
Throttle Control Assembly Removal ........................................................................................................3-14
Throttle Control Assembly Installation .....................................................................................................3-16
Park Brake Handle Assembly Replacement (2012 & Later) ..........................................................................3-18
Park Brake Handle Removal (2012 & Later) ...........................................................................................3-18
Park Brake Handle Installation (2012 & Later) ........................................................................................3-20
Park Brake Cable Replacement (2011 & Prior) .............................................................................................3-21
Left Park Brake Cable Removal (2011 & Prior).......................................................................................3-21
Left Park Brake Cable Installation (2011 & Prior)....................................................................................3-24
Right Park Brake Cable Removal (2011 & Prior) ....................................................................................3-27
Right Park Brake Cable Installation (2011 & Prior) .................................................................................3-29
Adjusting the Parking Brake ..........................................................................................................................3-32
Park Brake Cable Replacement (2012 & Later) ............................................................................................3-34
Left Park Brake Cable Removal (2012 & Later) ......................................................................................3-34
Left Park Brake Cable Installation (2012 & Later) ...................................................................................3-37
Right Park Brake Cable Removal (2012 & Later) ...................................................................................3-41
Right Park Brake Cable Installation (2012 & Later) ................................................................................3-44
iToro Z Master G3 3000/5000/6000 Series Service Manual
TABLE OF CONTENTS
3 - Chassis cont.
Brake Caliper Replacement...........................................................................................................................3-47
Brake Caliper Removal ...........................................................................................................................3-47
Brake Caliper Installation ........................................................................................................................3-49
Motion Control Damper Replacement ...........................................................................................................3-51
Motion Control Damper Removal ............................................................................................................3-51
Motion Control Damper Installation .........................................................................................................3-52
Adjusting the Motion Control Damper............................................................................................................3-52
Adjusting the Motion Control Neutral Lock Pivot ...........................................................................................3-53
Adjusting the Control Handle Position ...........................................................................................................3-53
Motion Control Assembly Replacement.........................................................................................................3-54
Motion Control Assembly Removal .........................................................................................................3-54
Motion Control Assembly Installation ......................................................................................................3-58
4 - Engine
Engine Replacement .......................................................................................................................................4-1
Engine Removal ........................................................................................................................................4-1
Engine Installation .....................................................................................................................................4-7
5 - Hydraulic System
Hydrostatic Pump Removal .............................................................................................................................5-1
G3 UHT Transmission Replacement (2009 through 2011 models) .................................................................5-1
G3 UHT Transmission Removal (2009 - 2011 models) .............................................................................5-1
G3 UHT Transmission Installation (2009 - 2011 models) ..........................................................................5-9
Burnishing the Brake .....................................................................................................................................5-20
UHT Transmission Replacement (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 Control Linkage (Neutral Adjustment) ..........................................................................5-34
Checking the Hydraulic Oil ............................................................................................................................5-36
Flow Test Instructions ....................................................................................................................................5-37
Hydraulic Pump Drive Belt Replacement ......................................................................................................5-40
Using the Drive Wheel Release Valves .........................................................................................................5-41
6 - Mower Decks
Mower Belt Replacement ................................................................................................................................6-1
Mower Belt Removal .................................................................................................................................6-1
Mower Belt Installation ..............................................................................................................................6-2
Mower Deck Replacement ..............................................................................................................................6-3
Mower Deck Removal ...............................................................................................................................6-3
Mower Deck Installation ............................................................................................................................6-6
Extension Spring Adjustment (2010 - 2012 Models) .......................................................................................6-6
Mower Spindle Replacement...........................................................................................................................6-7
Mower Spindle Removal (2009 Model G3 Series Units) ...........................................................................6-7
Mower Spindle Installation (2009 Model G3 Series Units) ........................................................................6-8
Mower Spindle Disassembly (2009 Model G3 Series Units) ...........................................................................6-9
Mower Spindle Assembly (2009 Model G3 Series Units) ..............................................................................6-12
Mower Spindle Replacement (2010 & Later Model G3, 3000/5000/6000 Series Units) ...............................6-16
Mower Spindle Removal (2010 & Later Model G3, 3000/5000/6000 Series Units) ................................6-16
Mower Spindle Installation (2010 & Later Model G3, 3000/5000/6000 Series Units) .............................6-17
ii Toro Z Master G3 3000/5000/6000 Series Service Manual
TABLE OF CONTENTS
6 - Mower Decks cont.
Mower Spindle Disassembly (2010 & Later Model G3, 3000/5000/6000 Series Units) ................................6-18
Mower Spindle Assembly (2010 & Later Model G3, 3000/5000/6000 Series Units) .....................................6-20
Leveling the Mower Deck ..............................................................................................................................6-23
Deck Leveling .........................................................................................................................................6-23
Servicing the Cutting Blades .........................................................................................................................6-27
Before Inspecting or Servicing the Blades ..............................................................................................6-27
Inspecting the Blades ..............................................................................................................................6-28
Checking for Bent Blades .......................................................................................................................6-28
Removing the Blades ..............................................................................................................................6-29
Sharpening the Blades ............................................................................................................................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 .....................................................................................................................6-33
Safety Check ...........................................................................................................................................6-35
7 - Electrical
General ............................................................................................................................................................7-1
Relay ...............................................................................................................................................................7-1
Purpose .....................................................................................................................................................7-1
Location ....................................................................................................................................................7-1
How It Works .............................................................................................................................................7-1
Testing .......................................................................................................................................................7-2
PTO Switch ......................................................................................................................................................7-3
Purpose .....................................................................................................................................................7-3
Location ....................................................................................................................................................7-3
How It Works .............................................................................................................................................7-3
Testing .......................................................................................................................................................7-3
Ignition Switch .................................................................................................................................................7-5
Purpose .....................................................................................................................................................7-5
Location ....................................................................................................................................................7-5
How It Works .............................................................................................................................................7-5
Testing .......................................................................................................................................................7-5
Park Brake Switch ...........................................................................................................................................7-6
Purpose .....................................................................................................................................................7-6
Location ....................................................................................................................................................7-6
How It Works .............................................................................................................................................7-6
Testing .......................................................................................................................................................7-6
Seat Switch......................................................................................................................................................7-7
Purpose .....................................................................................................................................................7-7
Location ....................................................................................................................................................7-7
How It Works .............................................................................................................................................7-7
Testing .......................................................................................................................................................7-7
Neutral Safety Switch ......................................................................................................................................7-8
Purpose .....................................................................................................................................................7-8
Location ....................................................................................................................................................7-8
How It Works .............................................................................................................................................7-8
Testing .......................................................................................................................................................7-8
iiiToro Z Master G3 3000/5000/6000 Series Service Manual
TABLE OF CONTENTS
7 - Electrical cont.
TVS Diode .......................................................................................................................................................7-9
Purpose .....................................................................................................................................................7-9
Location ....................................................................................................................................................7-9
How 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 Clutch .......................................................................................................................................7-12
Purpose ...................................................................................................................................................7-12
Location ..................................................................................................................................................7-12
How It Works ...........................................................................................................................................7-12
Testing .....................................................................................................................................................7-12
Coil Resistance Measurement ................................................................................................................7-12
Measuring Clutch Current Draw ..............................................................................................................7-13
iv Toro Z Master G3 3000/5000/6000 Series Service Manual
General Information
SAFETY INFORMATION
This symbol means WARNING or
PERSONAL SAFETY INSTRUCTION read the instruction because it has to do
with your safety. Failure to comply with the
!
This manual is intended as a service and repair manual
only. The safety instructions provided herein are for
troubleshooting, service, and repair of the G3 3000/
5000/6000 Series Mower. The G3 3000/5000/6000
instruction may result in personal injury or
even death.
Think Safety First
Avoid unexpected starting of engine...
Always turn off the engine and disconnect the spark plug
wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations...
Stay clear of all moving parts whenever the engine is
running. Treat all normally moving parts as if they were
moving whenever the engine is running or has the
potential to start.
Series mower and attachment operator’s manuals
contain safety information and operating tips for safe
operating practices. Operator’s manuals are available
through your Toro parts source or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
Avoid injury from batteries...
Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes, and clothing. Battery gases can
explode. Keep cigarettes, sparks, and ames away from
the battery.
Avoid injury due to inferior parts...
Use only original equipment parts to ensure that
important safety criteria are met.
1
Avoid burns...
Do not touch the engine, mufer, or other components
which may increase in temperature during operation,
while the unit is running or shortly after it has been
running.
Avoid res and explosions...
Avoid spilling fuel and never smoke while working with
any type of fuel or lubricant. Wipe up any spilled fuel
or oil immediately. Never remove the fuel cap or add
fuel when the engine is running. Always use approved,
labeled containers for storing or transporting fuel and
lubricants.
Avoid asphyxiation...
Never operate an engine in a conned area without
proper ventilation.
Avoid injury to bystanders...
Always clear the area of bystanders before starting 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 modications...
Never alter or modify any part unless it is a factory
approved procedure.
Avoid unsafe operation...
Always test the safety interlock system after making
adjustments or repairs on the machine. Refer to the
Electrical section in this manual for more information.
1-1Toro Z Master G3 3000/5000/6000 Series Service Manual
1
SAFETY INFORMATION
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1-2 Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
Torque Specications
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 identied and
specied in the service manual.
These torque specications for the installation and
tightening of fasteners shall apply to all fasteners
which do not have a specic requirement identied
in the service manual. The following factors shall be
consid ered when applying torque: cleanliness of the
fastener, use of a thread 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
installation.
As noted in the following tables, torque values should
be reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specic torque value should
be determined based on the aluminum or brass material
strength, fastener size, length of thread engagement,
etc.
Fastener Identication
Inch Series bolts and Screws
(A) Grade 1 & 2
(B) Grade 5
2
(C) Grade 8
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
2-1Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series)
Grade 1, 5, &
Thread Size
2
# 6 - 32 UNC
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8 - 32 UNC
# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10 - 24 UNC
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 15 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
8 with Thin
Height Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
10 ± 2 13 ± 2 147 ± 23
13 ± 2 25 ± 5 282 ± 30
18 ± 2 30 ± 5 339 ± 56
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
15 ± 2 169 ± 23 23 ± 2 260 ± 34
29 ± 3 330 ± 30 41 ± 4 460 ± 45
42 ± 4 475 ± 45 60 ± 6 674 ± 70
SAE Grade 8 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: 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 height nuts include jam nuts.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
2-2 Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 644 ± 68 N-cm 78 ± 8 in-lb 881 ± 90 N-cm
M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 28 ± 3 ft-lb 38 ± 4 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 54 ± 6 ft-lb 73 ± 8 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 93 ± 10 ft-lb 126 ± 14 N-m
M16 X 2.0 166 ± 15 ft-lb 225 ± 23 N-m 229 ± 23 ft-lb 310 ± 31 N-m
M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 36 ft-lb 610 ± 62 N-m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Strong Nuts)
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 torque value. Thin height nuts include jam
nuts.
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts (
Class 10 or Strong Nuts)
2
2-3Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
Other Torque Specifications
Other Torque Specications
SAE Grade 8 Steel Set Screws
Recommended Torque
Square Head Hex Socket
2
Thread Size
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 ft-lb 50 ± 10 ft-lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non-lubricated fasteners.
Thread Cutting Screws
Thread
Size
No. 6 18 20 20 ± 5 in-lb
Threads per Inch
Type A Type B
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
(Zinc Plated Steel)
Baseline Torque*
No. 8 - 32 UNC 30 ± 5 in-lb
No.10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors
in-lb X 11.2985 = N-cm
ft-lb X 1.3558 = N-m
No. 8 15 18 30 ± 5 in-lb
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and
finish must be considered when determining specific
torque values. All torque values are based on nonlubricated fasteners.
N-cm X - 0.08851 = in-lb
N-cm X 0.73776 = ft-lb
2-4 Toro Z Master G3 3000/5000/6000 Series Service Manual
Equivalents & Conversions
Equivalents and Conversions
Decimal and Millimeter Equivalents
Decimal & Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 16/32 0.53125 13.484
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.9375 2.381 19/32 0.59375 15.081
1/8 0.1250 3.175 5/8 0.6250 15.875
5/32 0.15625 3.969 21/32 0.65625 16.669
3/16 0.1875 4.762 11/16 0.6875 17.462
7/32 0.21875 5.556 23/32 0.71875 18.256
1/4 0.2500 6.350 3/4 0.7500 19.050
9/32 0.28125 7.144 25/32 0.78125 19.844
5/16 0.3125 7.541 13/16 0.8125 20.638
11/32 0.34375 8.731 27/32 0.84375 21.431
3/8 0.3750 9.525 7/8 0.8750 22.225
13/32 0.40625 10.319 29/32 0.90625 23.019
7/16 0.4375 11.112 15/16 0.9375 23.812
15/32 0.46875 11.906 31/32 0.96875 24.606
1/2 0.5000 12.700 1 1.000 25.400
9/64 0.140625 3.572 41/64 0.640625 16.272
11/64 0.171875 4.366 43/64 0.671875 17.066
13/64 0.203125 5.159 45/64 0.703125 17.859
15/64 0.234375 5.953 47/64 0.734375 18.653
17/64 0.265625 6.747 49/64 0.765625 19.447
19/64 0.296875 7.541 51/64 0.796875 20.241
21/64 0.328125 8.334 53/64 0.828125 21.034
23/64 0.359375 9.128 55/64 0.859375 21.828
25/64 0.390625 9.922 57/64 0.890625 22.622
27/64 0.421875 10.716 59/64 0.921875 23.416
29/64 0.453125 11.509 61/64 0.953125 24.209
31/64 0.484375 12.303 63/64 0.984375 25.003
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm
SPECIFICATIONS
2
2-5Toro Z Master G3 3000/5000/6000 Series Service Manual
2
U.S. to Metric Conversions
SPECIFICATIONS
U.S. to Metric Conversions
To Convert Into Multiply By
Miles
Yards
Linear
Measurement
Area
Volume
Weight
Pressure
Work
Liquid Volume
Liquid Flows
Temperature
Feet
Feet
Inches
Inches
Inches
Square Miles
Square Feet
Square Inches
Acre
Cubic Yards
Cubic Feet
Cubic Inches
Tons (Short)
Pounds
Ounces
Pounds/Sq. In. Kilopascal
Foot-pounds
Foot-pounds
Inch-pounds
Quarts
Gallons
Gallons/Minute Liters/Minute
Fahrenheit Celsius
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
Square Kilometers
Square Meters
Square Centimeters
Hectare
Cubic Meters
Cubic Meters
Cubic Centimeters
Metric Tons
Kilograms
Grams
Newton-Meters
Kilogram-Meters
Kilogram-Centimeters
Liters
Liters
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
6.895
1.356
0.1383
1.152144
0.9463
3.785
3.785
1. Subtract 32°
2. Multiply by 5/9
2-6 Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
G3 3000/5000/6000 Series Specications
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 1550 RPM 1550 RPM 1800 RPM
Spark Plug NGK BPR4ES NGK BPR4ES NGK BPR4ES NGK BPR4ES
Oil SAE 10w-30 /
SAE10w-40
Oil Capacity 2.2Qt. (2.1 L) 2.2 Qt. (2.1 L) 2.2 Qt. (2.1 L) 2.2 Qt. (2.1 L)
CARB No No 78924 78922 / 78926 78928
EPA Yes Yes Yes Yes
Heavy Duty Air
Canister
Engines: 24.5 hp (18.5 kW) 25.5 hp (19.2 kW) 25.5 hp (19.2 kW)
Make Kawasaki Kawasaki Kawasaki (Propane)
Model FX751V FX801V FX801V
Hi-Idle 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 2.2 Qt. (2.1 L) 2.2 Qt. (2.1 L) 1.9 Qt. (1.8 L)
CARB No No No
EPA Yes Yes Yes
Heavy Duty Air Canister Standard Standard Standard
Standard Standard Standard Standard
SAE 10w-30 /
SAE10w-40
SAE 10w-30 /
SAE10w-40
SAE 10w-30 /
SAE10w-40
2
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
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 1800 RPM 1800 RPM 1800 RPM 1550 RPM
Spark Plug Champion
Oil SAE 10w-30 /
Oil Capacity 2.0 Qt. (1.9 L) 2.0 Qt. (1.9 L) 2.0 Qt. (1.9 L) 2.0 Qt. (1.9 L) 1.8 Qt. (1.7 L)
CARB No No No No No
EPA Yes Yes Yes Yes Yes
Heavy Duty Air
Canister
Kohler Command Kohler Command
Champion
R12YC
SAE10w-40
Standard Standard Standard Standard Standard
R12YC
SAE 10w-30 /
SAE10w-40
Kohler Command
Pro
Champion
R12YC
SAE 10w-30 /
SAE10w-40
Kohler EFI Kohler Command
Champion
R12YC
SAE 10w-30 /
SAE10w-40
NGK BPR5ES
SAE 10w-30 /
SAE10w-40
2-7Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
G3 3000/5000/6000 Series Specications cont.
Fuel System:
Fuel Tank Capacity 8 Gallon (US) (26.5 L) 12 Gallon (US) (45.4 L) 43.5 lb Propane (19.7 kg)
Fuel Gauge Located on top of tank. Located on tank
Fuel Delivery System Fuel pump Vapor draw
2
Traction Drives:
Hydraulic Drive
System
Pump 12cc No Fans 12cc w/Check Valve 12cc w/Shock Valve 16cc w/Shock Valve
Motor 14.6 cir 14.6 cir 14.6 cir 17.1 cir
Hydraulic Fluid Toro Hypr-Oil (500 hr service) or Mobil 1 15w50 Motor Oil (250 hr service)
Hydraulic Fluid
Capacity
Ground Speed 0 to 8 mph fwd 0 to 10 mph fwd 0 to 10 mph fwd 0 to 12 mph fwd
Release Valves External lever on each unit. Allow 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 5.5” (25.4mm - 139.7mm) in .25” (6.3mm) increments
Blade Tip Speed 18500 + ft/min 18500 + ft/min 18500 + ft/min 18500 + ft/min
Spindle
Conguration Tools Adjust or Hand Adjust Bafe
Clutch Models with 29 hp and under utilize a 200 ft-lb clutch.
PTO Idler Spring-loaded idler system
Construction 7 gauge (.179”/ 4.5mm) Steel Welded Construction
Blades 16.5” long, .250”
Standard Greasable
Ball Bearing
thick, 2.5” wide, heat
treated steel blades,
qty 3
52 oz. (1.5 liters) per side w/ lter change
Standard Greasable
Models above 29 hp utilize a 250 ft-lb clutch.
18.0” long, .250”
thick, 2.5” wide, heat
treated steel blades,
Unitized Pump & Motor
Ball Bearing
qty 3
Standard Greasable
Ball Bearing
20.5” long, .250”
thick, 2.5” wide, heat
treated steel blades,
qty 3
Tapered Roller or
Greasable Ball
Bearing
24.5” long, .250”
thick, 2.5” wide, heat
treated steel blades,
qty 3
2-8 Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
G3 3000/5000/6000 Series Specications cont.
Electrical System:
Voltage 12 volt, negative ground
Battery Type Wet-Battery
Fuses Blade Type
Hourmeter with
Service Indicator
Controls:
Steering Levers Dual, wrap-around, hydraulic dampened, with cushioned grips
Parking Brake Right hand operated lever with cushioned grip
Deck Lift Foot lift assist via foot pedal
Cutting Height Controlled by keyed height of cut pin
Standard Equipment
2
2-9Toro Z Master G3 3000/5000/6000 Series Service Manual
2
SPECIFICATIONS
Dimensions
Commercial 3000 Series
Overall Length Overall Height
Model #
74952
74953
74954
Wheel
Base
in./cm in./cm in./cm in./cm in./cm in./cm in./cm in./cm lbs./kg
47.7/
121.2
47.7/
121.2
50.6/
128.5
ROPS
Up
79.2/
201.2
79.2/
201.2
83.1/
211.1
ROPS
Folded
80.9/
205.5
80.9/
205.5
84.8/
215.4
Width
Outside
Tires
45.7/
116.1
45.7/
116.1
53.0/
134.6
Overall
Width
(Chute
Down)
63.6/
161.5
67.6/
171.7
75.7/
192.2
Gate
Width
54.0/
137.2
57.5/
146.1
61.7/
156.8
ROPS
Up
70.5/
179.1
70.5/
179.1
70.5/
179.1
ROPS
Folded
46.8/
118.9
46.8/
118.9
46.8/
118.9
Weight
1120/
508.0
1168/
529.8
1165/
528.0
G3/Professional 5000 Series
Overall Height
Wheel
Model #
74901 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
74903 47.7/121.2 79.2/201.2 45.7/116.1 67.6/171.7 57.5/146.1 70.5/179.1 46.8/118.9
74915 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
74916 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
74930 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
Base
in./cm in./cm in./cm in./cm in./cm in./cm in./cm lbs./kg
Overall
Length
Width
Outside
Tires
Overall
Width
(Chute
Down)
Gate
Width
ROPS Up
Folded
ROPS
Weight
1120/
508.0
1168/
529.8
1216/
551.6
1296/
588.0
1255/
569.0
2-10 Toro Z Master G3 3000/5000/6000 Series Service Manual
SPECIFICATIONS
Dimensions
G3/Professional 6000 Series
Overall Height
Wheel
Model #
74922 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
74923 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
74925 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
74926 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
74927 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
74928 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
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
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 46.8/118.9
74937 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
74938 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
74975 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
74977 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
78922 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
78924 47.7/121.2 79.2/201.2 45.7/116.1 67.6/171.7 57.5/146.1 70.5/179.1 46.8/118.9
78926 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
78928 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/168.9 70.5/179.1 46.8/118.9
Base
in./cm in./cm in./cm in./cm in./cm in./cm in./cm lbs./kg
Overall
Length
Width
Outside
Tires
Overall
Width
(Chute
Down)
Gate
Width
ROPS Up
Folded
ROPS
Weight
1147/
520.3
1147/
520.3
1254/
568.8
1255/
569.3
1334/
605.1
1350/
612.3
1269/
575.6
1269/
575.6
1349/
611.9
1349/
611.9
1255/
569.3
1352/
613.3
1147/
520.3
1147/
520.3
1255/
569.3
1350/
612.3
2
2-11Toro Z Master G3 3000/5000/6000 Series Service Manual
2
SPECIFICATIONS
Dimensions
G3/Professional 6000 Series cont.
Overall Height
Wheel
Model #
74902TE 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
74923TE 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
74925TE 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
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
74943CP 47.7/121.2 79.2/201.2 45.7/116.1 67.6/171.7 57.5/146.1 70.5/179.1 46.8/118.9
74945CP 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
74955CP 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
74957CP 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
74960CP 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
74961CP 53.6/136.1 86.1/218.7 59.1/150.1 87.6/222.5 73.6/186.9 70.5/179.1 46.8/118.9
Base
in./cm in./cm in./cm in./cm in./cm in./cm in./cm lbs./kg
Overall
Length
Width
Outside
Tires
Overall
Width
(Chute
Down)
Gate
Width
ROPS Up
ROPS
Folded
Weight
1226/
556.0
1190/
539.8
1301/
590.1
1205/
546.6
1210/
548.8
1254/
568.8
1259/
571.1
1350/
612.3
1269/
575.6
1349/
611.9
2-12 Toro Z Master G3 3000/5000/6000 Series Service Manual
CHASSIS
Caster Fork Assembly Replacement
Caster Fork Assembly 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).
4. Slide the caster fork assembly out of the frame (Fig.
003).
3
Fig. 003 PICT-0355
Fig. 001 PICT-0351
3. Remove the locknut (Fig. 002).
Fig. 002 PICT-0352a
3-1Toro Z Master G3 3000/5000/6000 Series Service Manual
CHASSIS
3
Caster Bearing Replacement
1. Remove the 3 Belleville washers (Fig. 004).
Fig. 004 PICT-0359a
2. Remove the top tapered bearing (Fig. 005).
3. Remove the bottom grease seal (Fig. 006).
Fig. 006 PICT-0364a
4. Remove the bottom tapered bearing (Fig. 007).
Fig. 007 PICT-0365
Fig. 005 PICT-0361a
3-2 Toro Z Master G3 3000/5000/6000 Series Service Manual
CHASSIS
5. Drive the top and bottom tapered bearing cups out of
the caster fork hub (Fig. 008).
Fig. 008 PICT-0367a
6. Install new tapered bearing cups by pressing each
bearing cup into the caster fork hub so that the thicker part of the taper is pressed in rst. The bearing
cups should seat against the shoulder inside the
frame.
7. Pack the upper and lower tapered bearings with
grease (No. 2 general purpose lithium base or
molybdenum grease).
8. Install the lower bearing into the caster fork hub (Fig.
010).
3
Fig. 010 PICT-0368a
9. Install the lower grease seal into the bottom of the
caster fork hub (Fig. 011).
Section view of caster fork hub (Fig. 009).
A
B
C
A
Fig 009 tapered bearing cup install
A. Tapered Bearing Cup (2)
B. Caster fork hub (sectioned)
C. Machined shoulder inside caster fork hub (2)
Fig. 011 PICT-0371a
3-3Toro Z Master G3 3000/5000/6000 Series Service Manual
CHASSIS
3
10. Install the upper bearing fork hub (Fig. 012).
Fig. 012 PICT-0372a
Caster Fork Assembly Installation
1. Install 3 Belleville washers as shown (Fig. 013).
C
B
A
Fig. 013 g. 69 G001297
A. Spring washer (3) C. Dust Cap
B. Lock nut
2. Slide the caster fork assembly into the hub (Fig.
014).
Fig. 014 PICT-0355
3-4 Toro Z Master G3 3000/5000/6000 Series Service Manual
CHASSIS
3. Install the locknut. Tighten the locknut until the
Belleville washers are at, then back the nut off 1/4
turn to properly set the preload on the bearings (Fig.
015).
Fig. 015 PICT-0373a
4. Remove the plug located on the side of the caster
hub. Install a grease tting. Apply grease (No. 2
general purpose lithium base or molybdenum
grease) into the hub until it passes through the upper
bearing. Fill the top cavity with grease (Fig. 016).
Front Wheel Bearing Replacement
Front Wheel Bearing Removal
1. Raise the front of the machine off the ground.
2. Remove the wheel the axle bolt and nut (Fig. 017).
3
Fig. 017 PICT-0378a
3. Remove the wheel assembly from the fork (Fig.
018).
Fig. 016 PICT-0375a
5. Remove the grease tting and install the grease
plug.
Fig. 018 PICT-0379a
3-5Toro Z Master G3 3000/5000/6000 Series Service Manual
CHASSIS
3
4. Remove the 2 seal guards (Fig. 019).
Fig. 019 PICT-0380a
5. Remove 2 spacer nuts from the axle caster (Fig.
020).
6. Remove the axle caster (Fig. 021).
Fig. 021 PICT-0383a
7. Remove the two caster seals from the wheel
assembly (Fig. 022).
Fig. 020 PICT-0382a
3-6 Toro Z Master G3 3000/5000/6000 Series Service Manual
Fig. 022 PICT-0384a
CHASSIS
8. Remove the 2 tapered bearings from the wheel
assembly (Fig. 023).
Fig. 023 PICT-0385a
9. Drive the bearing cup out of the wheel assembly
(Fig. 024).
Front Wheel Bearing Installation
1. Install a new tapered bearing cup into the wheel
assembly by pressing each bearing cup into the
wheel hub so that the thicker part of the taper is
pressed into the wheel hub rst. The bearing cups
should seat against the shoulder divots inside the
wheel hub (Fig. 025).
3
Fig. 025 PICT-0389a
Fig. 024 PICT-0387a
2. Pack both tapered bearings with grease (No. 2
general purpose lithium base or molybdenum
grease).
3. Install the tapered bearings into each side of the
wheel hub (Fig. 026).
Fig. 026 PICT-0390a
3-7Toro Z Master G3 3000/5000/6000 Series Service Manual
CHASSIS
3
4. Install the grease seals into each side of the wheel
hub (Fig. 027).
Fig. 027 PICT-0392a
5. Install the caster axle (Fig. 028).
6. Install the 2 spacer nuts and tighten (Fig. 029).
Fig. 029 PICT-0382a
7. Install the two guard seals, screw, nut and tighten
(Fig. 030).
Fig. 028 PICT-0393a
3-8 Toro Z Master G3 3000/5000/6000 Series Service Manual
Fig. 030 PICT-0394a
CHASSIS
Fuel Tank Replacement
Fuel Tank Removal
1. Turn the fuel valve to the “Off” position.
2. Siphon the fuel from the fuel tank.
Note: The only recommended way to remove the
fuel from the tank is by using a siphon pump.
3. Remove the 4 bolts retaining the seat base assembly to the frame (Fig. 031).
5. Remove the 4 screws retaining the right and left
hand motion control covers (Fig. 033).
3
Fig. 033 PICT-0412a
6. Remove the two bolts and nuts retaining the seat
mount to the frame (Fig. 034).
Fig. 031 PICT-0396a
4. Lift the seat up enough to remove the wiring plug to
the seat switch (Fig. 032).
Fig. 032 PICT-0398a
Fig. 034 PICT-0413a
3-9Toro Z Master G3 3000/5000/6000 Series Service Manual
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