Toro 74901, 74901CP, 74902TE, 74903, 74903CP Service Manual

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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 fittings whenever they are exposed. Even a small amount of dirt or other contamination can severely damage the system.

We are hopeful that you will find 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 specifications 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 - Specifications

Torque Specifications 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 Specifications 2-4 Equivalents & Conversions 2-5

Decimal & Millimeter Equivalents 2-5 U.S. to Metric Conversions 2-6 G3 3000/5000/6000 Series Specifications 2-7 G3 3000/5000/6000 Series Specifications cont. 2-8 G3 3000/5000/6000 Series Specifications 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

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

i

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

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

iii

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

SAFETY INFORMATION

General Information

 

 

 

1

!

This symbol means WARNING or

Series mower and attachment operator’s manuals

PERSONAL SAFETY INSTRUCTION -

contain safety information and operating tips for safe

 

read the instruction because it has to do

operating practices. Operator’s manuals are available

 

with your safety. Failure to comply with the

through your Toro parts source or:

 

eveninstructiondeath.may result in personal injury or

The Toro Company

 

This manual is intended as a service and repair manual

Publications Department

8111 Lyndale Avenue South

only. The safety instructions provided herein are for

Bloomington, MN 55420

troubleshooting, service, and repair of the G3 3000/

 

5000/6000 Series Mower. The G3 3000/5000/6000

 

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.

Avoid burns...

Do not touch the engine, muffler, or other components which may increase in temperature during operation, while the unit is running or shortly after it has been running.

Avoid fires 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 confined area without proper ventilation.

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 flames away from the battery.

Avoid injury due to inferior parts...

Use only original equipment parts to ensure that important safety criteria are met.

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 modifications...

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.

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

1-1

SAFETY INFORMATION

1

THIS PAGE INTENTIONALLY LEFT BLANK.

1-2

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

SPECIFICATIONS

Torque Specifications

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.

These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual. The following factors shall be consid­ered 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 specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc.

The standard method of verifying torque shall be per­ formed 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.

Fastener Identification

2

Inch Series bolts and Screws

(A) Grade 1 & 2

(C) Grade 8

(B) Grade 5

 

 

 

 

 

 

 

 

Metric Bolts and Screws

(A) Class 8.8

(B) Class 10.9

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

2-1

SPECIFICATIONS

Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series)

 

 

 

Grade 1, 5, &

SAE Grade 1 Bolts, Screws,

SAE Grade 5 Bolts, Screws,

SAE Grade 8 Bolts, Screws,

 

 

Thread Size

8 with Thin

Studs, & Sems with Regular

Studs, & Sems with Regular

Studs, & Sems with Regular

 

 

Height Nuts

Height Nuts (SAE J995

Height Nuts (SAE J995

Height Nuts (SAE J995

 

 

 

 

 

 

 

 

Grade 2 or Stronger Nuts)

Grade 2 or Stronger Nuts)

Grade 2 or Stronger Nuts)

2

 

 

 

 

 

 

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

190

± 20

25

± 2

280

± 20

 

 

 

 

 

 

 

 

 

 

# 8 - 32 UNC

13

± 2

25

± 5

282

± 30

29

±

3

330

± 30

41

± 4

460

± 45

 

 

# 8 - 36 UNF

31 ± 3

350

± 30

43

± 4

31 ± 3

 

 

 

 

 

 

 

 

 

 

# 10 - 24 UNC

18

± 2

30

± 5

339

± 56

42

± 4

475

± 45

60

± 6

674

± 70

 

 

#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

 

 

 

ft-lb

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

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.

2-2

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

SPECIFICATIONS

Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners)

 

Class 8.8 Bolts, Screws, and Studs with

Class 10.9 Bolts, Screws, and Studs with

 

 

Thread Size

 

Regular Height Nuts

 

Regular Height Nuts (

 

 

 

 

(Class 8 or Strong Nuts)

 

Class 10 or Strong Nuts)

 

 

M5 X 0.8

57 ± 5 in-lb

644 ± 68 N-cm

78 ± 8 in-lb

881 ± 90 N-cm

 

 

2

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.

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.

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

2-3

SPECIFICATIONS

Other Torque Specifications

SAE Grade 8 Steel Set Screws

 

 

Thread Size

Recommended Torque

 

 

 

 

2

 

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 ft-lb

50 ± 10 ft-lb

 

 

 

 

 

Wheel Bolts and Lug Nuts

Thread Size

Recommended Torque**

 

 

 

7/16 - 20 UNF

65 ± 10 ft-lb

88 ± 14 N-m

Grade 5

 

 

 

 

 

1/2 - 20 UNF

80 ± 10 ft-lb

108 ± 14 N-m

Grade 5

 

 

 

 

 

M12 X 1.25

80 ± 10 ft-lb

108 ± 14 N-m

Class 8.8

 

 

 

 

 

M12 X 1.5

80 ± 10 ft-lb

108 ± 14 N-m

Class 8.8

 

 

** For steel wheels and non-lubricated fasteners.

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

 

 

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

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Threads per Inch

Baseline Torque*

 

 

Size

Type A

Type B

 

 

 

 

 

 

 

No. 6

18

20

20 ± 5 in-lb

 

 

 

 

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

SPECIFICATIONS

Equivalents & Conversions

Decimal & Millimeter Equivalents

Fractions

Decimals

mm

Fractions

 

Decimals

mm

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

9/64

0.140625

3.572

 

41/64

0.640625

16.272

 

 

 

 

 

 

 

 

 

 

 

5/32

0.15625

3.969

21/32

 

0.65625

16.669

 

 

 

 

 

 

 

 

 

 

 

11/64

0.171875

4.366

 

43/64

0.671875

17.066

 

 

 

 

 

 

 

 

 

 

 

3/16

0.1875

4.762

11/16

 

0.6875

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

0.765625

19.447

 

 

 

 

 

 

 

 

 

 

 

9/32

0.28125

7.144

25/32

 

0.78125

19.844

 

 

 

 

 

 

 

 

 

 

 

19/64

0.296875

7.541

 

51/64

0.796875

20.241

 

 

 

 

 

 

 

 

 

 

 

5/16

0.3125

7.541

13/16

 

0.8125

20.638

 

 

 

 

 

 

 

 

 

 

 

21/64

0.328125

8.334

 

53/64

0.828125

21.034

 

 

 

 

 

 

 

 

 

 

 

11/32

0.34375

8.731

27/32

 

0.84375

21.431

 

 

 

 

 

 

 

 

 

 

 

23/64

0.359375

9.128

 

55/64

0.859375

21.828

 

 

 

 

 

 

 

 

 

 

 

3/8

0.3750

9.525

7/8

 

0.8750

22.225

 

 

 

 

 

 

 

 

 

 

 

25/64

0.390625

9.922

 

57/64

0.890625

22.622

 

 

 

 

 

 

 

 

 

 

 

13/32

0.40625

10.319

29/32

 

0.90625

23.019

 

 

 

 

 

 

 

 

 

 

 

27/64

0.421875

10.716

 

59/64

0.921875

23.416

 

 

 

 

 

 

 

 

 

 

 

7/16

0.4375

11.112

15/16

 

0.9375

23.812

 

 

 

 

 

 

 

 

 

 

 

29/64

0.453125

11.509

 

61/64

0.953125

24.209

 

 

 

 

 

 

 

 

 

 

 

15/32

0.46875

11.906

31/32

 

0.96875

24.606

 

 

 

 

 

 

 

 

 

 

 

31/64

0.484375

12.303

 

63/64

0.984375

25.003

 

 

 

 

 

 

 

 

 

 

 

1/2

0.5000

12.700

1

 

1.000

25.400

 

 

 

 

 

 

 

 

 

 

 

1 mm = 0.03937 in.

 

 

0.001 in. = 0.0254 mm

 

 

 

 

 

 

 

 

 

 

 

 

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

2-5

SPECIFICATIONS

U.S. to Metric Conversions

 

 

 

To Convert

Into

Multiply By

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Miles

Kilometers

 

1.609

 

 

 

Yards

Meters

 

0.9144

2

 

 

 

 

Linear

Feet

Meters

 

0.3048

 

Feet

Centimeters

 

30.48

 

Measurement

Inches

Meters

 

 

 

0.0254

 

 

 

Inches

Centimeters

 

2.54

 

 

 

Inches

Millimeters

 

 

 

 

 

25.4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Square Miles

Square Kilometers

 

2.59

 

 

Area

Square Feet

Square Meters

 

0.0929

 

 

Square Inches

Square Centimeters

 

6.452

 

 

 

 

 

 

 

Acre

Hectare

 

0.4047

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cubic Yards

Cubic Meters

 

0.7646

 

 

Volume

Cubic Feet

Cubic Meters

 

0.02832

 

 

 

Cubic Inches

Cubic Centimeters

 

16.39

 

 

 

 

 

 

 

 

 

 

Tons (Short)

Metric Tons

 

0.9078

 

 

Weight

Pounds

Kilograms

 

0.4536

 

 

 

Ounces

Grams

 

28.3495

 

 

 

 

 

 

 

 

 

Pressure

Pounds/Sq. In.

Kilopascal

 

6.895

 

 

 

 

 

 

 

 

 

 

Foot-pounds

Newton-Meters

 

1.356

 

 

Work

Foot-pounds

Kilogram-Meters

 

0.1383

 

 

 

Inch-pounds

Kilogram-Centimeters

 

1.152144

 

 

 

 

 

 

 

 

 

Liquid Volume

Quarts

Liters

 

0.9463

 

 

Gallons

Liters

 

3.785

 

 

 

 

 

 

 

 

 

 

 

 

 

Liquid Flows

Gallons/Minute

Liters/Minute

 

3.785

 

 

 

 

 

 

 

 

 

Temperature

Fahrenheit

Celsius

1.

Subtract 32°

 

 

 

 

2.

Multiply by 5/9

 

 

 

 

 

 

 

 

 

 

 

 

2-6

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

SPECIFICATIONS

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

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 /

 

SAE 10w-30 /

 

SAE 10w-30 /

 

 

 

 

SAE 10w-30 /

 

 

 

 

 

SAE10w-40

 

 

SAE10w-40

 

SAE10w-40

 

 

 

 

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

 

 

Standard

 

 

Standard

 

 

Standard

 

 

 

 

Standard

 

 

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

 

 

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

 

Kohler EFI

 

 

Kohler Command

 

 

 

 

 

 

 

 

 

 

 

Pro

 

 

 

 

 

 

 

 

 

 

 

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

 

 

Champion

Champion

 

 

Champion

 

 

NGK BPR5ES

 

 

 

 

R12YC

 

 

R12YC

R12YC

 

 

R12YC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Oil

SAE 10w-30 /

 

 

SAE 10w-30 /

SAE 10w-30 /

 

 

SAE 10w-30 /

 

 

SAE 10w-30 /

 

 

 

 

SAE10w-40

 

 

SAE10w-40

SAE10w-40

 

 

SAE10w-40

 

 

SAE10w-40

 

 

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

 

Standard

 

 

Standard

Standard

 

 

Standard

 

 

Standard

 

 

Canister

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

2-7

SPECIFICATIONS

G3 3000/5000/6000 Series Specifications 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

 

 

 

 

Unitized Pump & Motor

 

 

 

 

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

 

 

52 oz. (1.5 liters) per side w/ filter change

 

 

 

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

Standard Greasable

Standard Greasable

Standard Greasable

Tapered Roller or

 

 

 

Greasable Ball

 

 

 

Ball Bearing

Ball Bearing

Ball Bearing

 

 

 

 

 

Bearing

 

 

 

 

 

 

 

 

 

 

 

 

 

Configuration

 

 

Tools Adjust or Hand Adjust Baffle

 

 

 

 

Clutch

 

Models with 29 hp and under utilize a 200 ft-lb clutch.

 

 

 

 

 

Models above 29 hp utilize a 250 ft-lb clutch.

 

 

 

PTO Idler

 

 

 

Spring-loaded idler system

 

 

 

 

Construction

 

7 gauge (.179”/ 4.5mm) Steel Welded Construction

 

 

Blades

16.5” long, .250”

18.0” long, .250”

20.5” long, .250”

24.5” long, .250”

 

 

 

thick, 2.5” wide, heat

thick, 2.5” wide, heat

thick, 2.5” wide, heat

thick, 2.5” wide, heat

 

 

 

treated steel blades,

treated steel blades,

treated steel blades,

treated steel blades,

 

 

 

 

qty 3

 

qty 3

qty 3

 

qty 3

2-8

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

SPECIFICATIONS

G3 3000/5000/6000 Series Specifications cont.

Electrical System:

 

 

 

 

Voltage

12 volt, negative ground

 

 

 

Battery Type

Wet-Battery

 

 

 

Fuses

Blade Type

 

 

 

2

Hourmeter with

Standard Equipment

 

 

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

 

 

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

2-9

SPECIFICATIONS

Dimensions

Commercial 3000 Series

 

 

 

 

Overall Length

 

 

 

Overall Height

 

2

 

 

 

 

 

Width

Overall

 

 

 

 

 

 

Wheel

ROPS

ROPS

Width

Gate

ROPS

ROPS

 

 

 

Outside

Weight

 

Model #

Base

Up

Folded

(Chute

Width

Up

Folded

 

 

 

 

 

 

Tires

Down)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

lbs./kg

 

 

74952

47.7/

79.2/

80.9/

45.7/

63.6/

54.0/

70.5/

46.8/

1120/

 

 

121.2

201.2

205.5

116.1

161.5

137.2

179.1

118.9

508.0

 

 

 

 

 

74953

47.7/

79.2/

80.9/

45.7/

67.6/

57.5/

70.5/

46.8/

1168/

 

 

121.2

201.2

205.5

116.1

171.7

146.1

179.1

118.9

529.8

 

 

 

 

 

74954

50.6/

83.1/

84.8/

53.0/

75.7/

61.7/

70.5/

46.8/

1165/

 

 

128.5

211.1

215.4

134.6

192.2

156.8

179.1

118.9

528.0

 

 

 

G3/Professional 5000 Series

 

 

 

 

 

 

Overall Height

 

 

 

 

Width

Overall

 

 

 

 

 

Wheel

Overall

Width

Gate

 

ROPS

 

 

Outside

ROPS Up

Weight

Model #

Base

Length

(Chute

Width

Folded

Tires

 

 

 

 

 

Down)

 

 

 

 

 

 

 

 

 

 

 

 

 

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

lbs./kg

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

1120/

508.0

 

 

 

 

 

 

 

 

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

1168/

529.8

 

 

 

 

 

 

 

 

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

1216/

551.6

 

 

 

 

 

 

 

 

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

1296/

588.0

 

 

 

 

 

 

 

 

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

1255/

569.0

 

 

 

 

 

 

 

 

2-10

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

SPECIFICATIONS

Dimensions

G3/Professional 6000 Series

 

 

 

 

 

 

Overall Height

 

 

 

 

 

 

Width

Overall

 

 

 

 

 

2

 

Wheel

Overall

Width

Gate

 

ROPS

 

 

 

Outside

ROPS Up

Weight

 

Model #

Base

Length

(Chute

Width

Folded

 

 

 

 

Tires

Down)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

lbs./kg

 

 

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

1147/

 

 

520.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1147/

 

 

520.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1254/

 

 

568.8

 

 

 

 

 

 

 

 

 

 

 

 

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

1255/

 

 

569.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1334/

 

 

605.1

 

 

 

 

 

 

 

 

 

 

 

 

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

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

46.8/118.9

1269/

 

 

575.6

 

 

 

 

 

 

 

 

 

 

 

 

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

1349/

 

 

611.9

 

 

 

 

 

 

 

 

 

 

 

 

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

1349/

 

 

611.9

 

 

 

 

 

 

 

 

 

 

 

 

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

1255/

 

 

569.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1352/

 

 

613.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1147/

 

 

520.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1147/

 

 

520.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1255/

 

 

569.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1350/

 

 

612.3

 

 

 

 

 

 

 

 

 

 

 

 

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

2-11

SPECIFICATIONS

Dimensions

G3/Professional 6000 Series cont.

 

 

 

 

 

 

 

 

Overall Height

 

2

 

 

 

 

Width

Overall

 

 

 

 

 

 

Wheel

Overall

Width

Gate

 

ROPS

 

 

 

Outside

ROPS Up

Weight

 

Model #

Base

Length

(Chute

Width

Folded

 

 

 

 

 

Tires

Down)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

in./cm

lbs./kg

 

 

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

1226/

 

 

556.0

 

 

 

 

 

 

 

 

 

 

 

 

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

1190/

 

 

539.8

 

 

 

 

 

 

 

 

 

 

 

 

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

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

67.6/171.7

57.5/146.1

70.5/179.1

46.8/118.9

1210/

 

 

548.8

 

 

 

 

 

 

 

 

 

 

 

 

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

1254/

 

 

568.8

 

 

 

 

 

 

 

 

 

 

 

 

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

1259/

 

 

571.1

 

 

 

 

 

 

 

 

 

 

 

 

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

1350/

 

 

612.3

 

 

 

 

 

 

 

 

 

 

 

 

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

1269/

 

 

575.6

 

 

 

 

 

 

 

 

 

 

 

 

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

1349/

 

 

611.9

 

 

 

 

 

 

 

 

 

 

2-12

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

CHASSIS

Caster Fork Assembly Replacement

4.Slide the caster fork assembly out of the frame (Fig. 003).

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).

3

Fig. 003

PICT-0355

Fig. 001

PICT-0351

3. Remove the locknut (Fig. 002).

Fig. 002

PICT-0352a

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

3-1

CHASSIS

Caster Bearing Replacement

3. Remove the bottom grease seal (Fig. 006).

1. Remove the 3 Belleville washers (Fig. 004).

3

Fig. 006

PICT-0364a

Fig. 004

PICT-0359a

4. Remove the bottom tapered bearing (Fig. 007).

2. Remove the top tapered bearing (Fig. 005).

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).

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. 008

PICT-0367a

 

 

 

 

 

 

6. Install new tapered bearing cups by pressing each

Fig. 010

PICT-0368a

 

 

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 the shoulder inside the

9. Install the lower grease seal into the bottom of the

frame.

 

caster fork hub (Fig. 011).

 

Section view of caster fork hub (Fig. 009).

A

B

C

A

Fig. 011

PICT-0371a

 

Fig 009 tapered bearing cup install

A.Tapered Bearing Cup (2)

B.Caster fork hub (sectioned)

C.Machined shoulder inside caster fork hub (2)

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

3-3

CHASSIS

10. Install the upper bearing fork hub (Fig. 012).

 

Caster Fork Assembly Installation

 

 

1. Install 3 Belleville washers as shown (Fig. 013).

 

 

 

 

 

 

 

C

 

 

B

3

 

 

A

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 (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 flat, then back the nut off 1/4 turn to properly set the preload on the bearings (Fig. 015).

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. 015 PICT-0373a

4. Remove the plug located on the side of the caster

Fig. 017

PICT-0378a

hub. Install a grease fitting. Apply grease (No. 2

 

 

general purpose lithium base or molybdenum

 

 

grease) into the hub until it passes through the upper

3. Remove the wheel assembly from the fork (Fig.

bearing. Fill the top cavity with grease (Fig. 016).

 

018).

 

 

 

 

Fig. 016

PICT-0375a

Fig. 018

PICT-0379a

5.Remove the grease fitting and install the grease plug.

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

3-5

CHASSIS

4. Remove the 2 seal guards (Fig. 019).

6. Remove the axle caster (Fig. 021).

3

Fig. 019

PICT-0380a

Fig. 021

PICT-0383a

5.Remove 2 spacer nuts from the axle caster (Fig. 020).

7.Remove the two caster seals from the wheel assembly (Fig. 022).

Fig. 020

PICT-0382a

Fig. 022

PICT-0384a

3-6

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

CHASSIS

8.Remove the 2 tapered bearings from the wheel assembly (Fig. 023).

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 first. The bearing cups should seat against the shoulder divots inside the wheel hub (Fig. 025).

Fig. 023

PICT-0385a

9.Drive the bearing cup out of the wheel assembly (Fig. 024).

3

Fig. 025

PICT-0389a

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. 024

PICT-0387a

Fig. 026

PICT-0390a

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

3-7

CHASSIS

4.Install the grease seals into each side of the wheel hub (Fig. 027).

6. Install the 2 spacer nuts and tighten (Fig. 029).

3

Fig. 029

PICT-0382a

Fig. 027

PICT-0392a

5. Install the caster axle (Fig. 028).

7.Install the two guard seals, screw, nut and tighten (Fig. 030).

Fig. 028

PICT-0393a

Fig. 030

PICT-0394a

3-8

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

CHASSIS

Fuel Tank Replacement

5.Remove the 4 screws retaining the right and left hand motion control covers (Fig. 033).

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 as­

 

3

 

sembly to the frame (Fig. 031).

 

 

 

 

 

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. 034

PICT-0413a

Fig. 032

PICT-0398a

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

3-9

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