Toro Z Master G3 3000 Series Service Manual
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Toro Z Master G3 3000 Series Service Manual

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Summary of Contents for Toro Z Master G3 3000 Series

  • Page 1 LCE Products Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 2 ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safely knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
  • Page 3 ABOUT THIS MANUAL THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 4: Table Of Contents

    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...
  • Page 5 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 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 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...
  • Page 7 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 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 8: Safety Information

    Never operate an engine in a confined area without Always test the safety interlock system after making proper ventilation. 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...
  • Page 9 SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK. Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 10: Specifications

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

  • Page 11: Standard Torque For Dry, Zinc Plated & Steel Fasteners (Inch Series)

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

  • Page 12: Standard Torque For Dry, Zinc & Steel Fasteners (Metric Fasteners)

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

  • Page 13: Other Torque Specifications

    All torque values are based on non- 200 ± 100 in-lb lubricated fasteners. Conversion Factors in-lb X 11.2985 = N-cm N-cm X - 0.08851 = in-lb ft-lb X 1.3558 = N-m N-cm X 0.73776 = ft-lb Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 14: Equivalents & Conversions

    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 0.5000 12.700 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...

  • Page 15: U.s. To Metric Conversions

    Newton-Meters 1.356 Work Foot-pounds Kilogram-Meters 0.1383 Inch-pounds Kilogram-Centimeters 1.152144 Quarts Liters 0.9463 Liquid Volume Gallons Liters 3.785 3.785 Gallons/Minute Liters/Minute Liquid Flows Fahrenheit Celsius 1. Subtract 32° Temperature 2. Multiply by 5/9 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 16: G3 3000/5000/6000 Series Specifications

    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 Heavy Duty Air Standard Standard Standard Standard Standard Canister Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 17: G3 3000/5000/6000 Series Specifications Cont

    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...
  • Page 18 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...

  • Page 19: Dimensions

    529.8 1216/ 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 46.8/118.9 551.6 1296/ 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 46.8/118.9 588.0 1255/ 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 46.8/118.9 569.0 2-10 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 20: Dimensions

    520.3 1147/ 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 46.8/118.9 520.3 1255/ 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 46.8/118.9 569.3 1350/ 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 46.8/118.9 612.3 Toro Z Master G3 3000/5000/6000 Series Service Manual 2-11...

  • Page 21: Dimensions

    571.1 1350/ 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 46.8/118.9 612.3 1269/ 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 46.8/118.9 575.6 1349/ 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 46.8/118.9 611.9 2-12 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 22: Chassis

    2. Remove the grease cap from the frame (Fig. 001). 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...

  • Page 23: Caster Bearing Replacement

    1. Remove the 3 Belleville washers (Fig. 004). 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 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 24 Section view of caster fork hub (Fig. 009). 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...

  • Page 25: Caster Fork Assembly Installation

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

  • Page 26: Front Wheel Bearing Replacement

    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...
  • Page 27 Fig. 021 PICT-0380a PICT-0383a 5. Remove 2 spacer nuts from the axle caster (Fig. 7. Remove the two caster seals from the wheel 020). assembly (Fig. 022). Fig. 020 PICT-0382a Fig. 022 PICT-0384a Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 28: Front Wheel Bearing Installation

    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...
  • Page 29 (Fig. 027). Fig. 029 PICT-0382a Fig. 027 PICT-0392a 7. Install the two guard seals, screw, nut and tighten (Fig. 030). 5. Install the caster axle (Fig. 028). Fig. 030 PICT-0394a Fig. 028 PICT-0393a Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 30: Fuel Tank Replacement

    (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...
  • Page 31 Fig. 037 PICT-0406a 8. Lift the seat mount from the frame (Fig. 036). 10. Unplug the fuel sender plug from the wiring harness (Fig. 038). Fig. 036 PICT-0417a Fig. 038 PICT-0409a 3-10 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 32 (Fig. 039). 041). Fig. 039 PICT-0421a Fig. 041 PICT-0426a 12. With the fuel valve in the OFF position, remove the fuel clamp from the engine fuel line (Fig. 040). Fig. 040 PICT-0422a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-11...

  • Page 33: Fuel Tank Installation

    2. Install the fuel clamp around the fuel line to the fuel valve. 3. Connect the vapor line retainers to the fuel manifold (Fig. 043). Fig. 045 PICT-0427a Fig. 043 PICT-0421a 3-12 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 34 7. Install 2 bolts and nuts on the right and left side of 9. With flange nuts, tighten the seat and seat base to the seat frame (Fig. 047). the 4 seat isolators (Fig. 049). Fig. 047 PICT-0413a Fig. 049 PICT-0396a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-13...

  • Page 35: Throttle Control Assembly Replacement (Kohler Efi Engine)

    11. Turn the valve to the “On” position. Fig. 051 DSCN-4247a 3. Remove the 4 screws securing the control panel to the RH Fender Console assembly (Fig. 052). Fig. 052 DSCN-4249a 3-14 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 36 5. Loosen the cable clamp and remove the throttle 7. Slide the throttle cable through the hose clamp next cable from underneath it (Fig. 054). to the engine (Fig. 056). Fig. 054 Fig. 056 DSCN-4253a DSCN-4259a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-15...

  • Page 37: Throttle Control Assembly Installation

    ROPS assembly (Fig. 058). Fig. 057 DSCN-4260a Fig. 058 DSCN-4260a 2. Slide the throttle cable through the hose clamp located next to the engine (Fig. 059). Fig. 059 DSCN-4259a 3-16 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 38 6. Move the throttle control to the slow idle position 4. Install the 4 screws securing the control panel to the (Fig. 063). RH Fender Console (Fig. 061). Fig. 063 Fig. 061 DSCN-4277a DSCN-4249a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-17...

  • Page 39: Park Brake Handle Assembly Replacement (2012 & Later)

    Fig. 065 DSCN-4281a 9. Move the throttle control back and forth checking the operation of the throttle arm assembly. Fig. 067 DSCN-2617a 10. Connect the negative battery cable to the battery. 3-18 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 40 Fig. 068 DSCN-2619a Fig. 070 DSCN-2626a 4. Remove the two cotter pins and clevis pins retaining the right and left park brake cables to the handle assembly (Fig. 069). Fig. 069 DSCN-2623a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-19...

  • Page 41: Park Brake Handle Installation (2012 & Later)

    (Fig. 072). Fig. 074 DSCN-2614a Fig. 072 DSCN-2635a 6. Operate the park brake handle to make sure everything is moving freely. 3-20 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 42: Park Brake Cable Replacement (2011 & Prior)

    (Fig. 078). Fig. 075 PICT-8962 2. Disengage the park brake lever. 3. Remove the two nuts located on the end of park brake cable (Fig. 076). Fig. 078 PICT-8970a Fig. 076 PICT-9075a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-21...
  • Page 43 D. Retainer (5) cradle (Fig. 080). 9. Remove the cotter pin located on the clevis pin hold- ing the cable clevis to the brake lever (Fig. 082). Fig. 080 PICT-8977a Fig. 082 PICT-8999a 3-22 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 44 13. Pull the cable out over the frame cross bar and 11. Release the brake cable retainer holding the brake remove it from the unit (Fig. 086). cable to the frame (Fig. 084). Fig. 086 PICT-9017a Fig. 084 PICT-9008a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-23...

  • Page 45: Left Park Brake Cable Installation (2011 & Prior)

    2. Route the brake cable up through the slotted hole in the frame and push the snap end fitting of the brake cable into the slot (Fig. 088). Fig. 090 PICT-8999a Fig. 088 PICT-9021a 3-24 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 46 6. Install the left hand brake cable retainer into the cradle so that the retainer tab is installed in the slot on the cradle (Fig. 092). Fig. 094 PICT-9065a Fig. 092 PICT-9027a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-25...
  • Page 47 10. Install a tie strap securing the brake cable to the cradle (Fig. 096). 12. Adjust the park brake. Refer to “Adjusting the Parking Brake” on page 3-32. Fig. 096 PICT-9070a 3-26 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 48: Right Park Brake Cable Removal (2011 & Prior)

    (Fig. 101). 2. Disengage the park brake lever. 3. Remove the two nuts located on the end of the park brake cable (Fig. 099). Fig. 101 PICT-9084a Fig. 099 PICT-9075 Toro Z Master G3 3000/5000/6000 Series Service Manual 3-27...
  • Page 49 (Fig. 105). Fig. 103 cables routing #4 Fig. 105 PICT-9090a A. Right side brake C. Left side brake assembly assembly B. Cradle D. Retainer (5) E. Hole (2) 3-28 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 50: Right Park Brake Cable Installation (2011 & Prior)

    PICT-9092a 2. Position the brake cable clevis to the brake lever assembly. Install a clevis pin through the brake cable clevis and the brake lever assembly (Fig. 108). Fig. 108 PICT-9099a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-29...
  • Page 51 (Fig. 112). Fig. 110 PICT-9103a Fig. 112 cables routing #4 A. Right side brake C. Left side brake assembly assembly B. Cradle D. Retainer (5) E. Hole (2) 3-30 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 52 (Fig. 114). Fig. 116 PICT-9075a A. Standard nut B. Lock nut Fig. 114 PICT-9113a 11. Adjust the park brake. Refer to “Adjusting the Parking Brake” on page 3-32. Toro Z Master G3 3000/5000/6000 Series Service Manual 3-31...

  • Page 53: Adjusting The Parking Brake

    Note: The left side brake is being adjusted in the swivel. Spin the standard nut against the swivel (Fig. following steps; the right side adjustment is 119). performed the same way. Fig. 119 PICT-8680a 3-32 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 54 G. Pull cable threaded rod C. Push lever this direction this direction D. Caliper lever arm H. Hold threaded rod with E. Standard nut (shown pliers against swivel) Swivel (pivot head) Toro Z Master G3 3000/5000/6000 Series Service Manual 3-33...

  • Page 55: Park Brake Cable Replacement (2012 & Later)

    (Fig. 125). Fig. 122 DSCN-4311a 2. Disengage the park brake lever. 3. Remove the e-ring, washer, and brake pin from the L-Bracket (Fig. 123). Fig. 125 DSCN-4318a Fig. 123 DSCN-4314a 3-34 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 56 9. Remove the two screws retaining the right hand from cable bracket located on the frame (Fig. 127). motion control cover assembly to the frame and remove (Fig. 129). Fig. 127 DSCN-4327a Fig. 129 DSCN-2614a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-35...
  • Page 57 (Fig. 131). park brake pivot assembly and slide the cables out of the slots (Fig. 133). Slide the brake cable out of the unit. Fig. 131 DSCN-2619a Fig. 133 DSCN-4333 3-36 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 58: Left Park Brake Cable Installation (2012 & Later)

    (Fig. 137). 2. Install the brake cable grooved fitting into the slot on the bottom of the brake pivot assembly and install e-ring (Fig. 135). Fig. 137 DSCN-2619a Fig. 135 DSCN-4335a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-37...
  • Page 59 8. Install the end of the brake cable through the cable the cable bracket located on the frame (Fig. 139). anchor and install an e-ring (Fig. 141). Fig. 139 Fig. 141 DSCN-4327a DSCN-4361a 3-38 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 60 (Left Hand brake shown above) A. Cable anchor E. Caliper B. Hold threaded rod here F. Compression spring C. Measure G. Threaded rod D. Lock nut H. Hub Fig. 143 DSCN-4314a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-39...
  • Page 61 Fig. 147 DSCN-2614a 18. Install the rear tires and torque lug nuts between 103.5 – 126.5 ft-lbs. (140.5 – 171.5 Nm). 19. Remove the jack stands and lower the unit. 3-40 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 62: Right Park Brake Cable Removal (2012 & Later)

    (Fig. 151). 2. Disengage the park brake lever. 3. Remove the e-ring, washer, and brake pin from the L-Bracket (Fig. 149). Fig. 151 DSCN-4368 Fig. 149 DSCN-4364a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-41...
  • Page 63 9. Remove two screws and spacers retaining the park motion control cover assembly to the frame and brake handle assembly to the frame (Fig. 155). remove (Fig. 153). Fig. 155 DSCN-2619a Fig. 153 DSCN-2614a 3-42 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 64 Fig. 158 DSCN-4379a Fig. 156 DSCN-4373a 11. Remove the e-ring retaining the brake cable to the park-brake pivot assembly and slide the cable out of the slot (Fig. 157). Fig. 157 DSCN-4377a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-43...

  • Page 65: Right Park Brake Cable Installation (2012 & Later)

    (Fig. 162). 2. Install the brake cable grooved fitting into the slot on the bottom of the brake pivot assembly and install the e-ring (Fig. 160). Fig. 162 DSCN-2619a Fig. 160 DSCN-4375a 3-44 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 66 6. Slide the brake cable into the cable anchor slot on 8. Install the L-Bracket, spring, washer, and nut on the the transmission (Fig. 164). threaded end of the brake cable (Fig. 166). Fig. 164 Fig. 166 DSCN-4370a DSCN-4314a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-45...
  • Page 67 C. Measure G. Threaded rod the sheath and mounting tabs. Recheck the spring D. Lock nut H. Hub length. 13. Rotate the drive wheel release handle to the operating position. 3-46 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 68: Brake Caliper Replacement

    DSCN-4314a Fig. 170 DSCN-2614a 16. Install the rear tires and torque lug nuts between 103.5 – 126.5 ft-lbs. (140.5 – 171.5 Nm). 17. Remove the jack stands and lower the unit. Toro Z Master G3 3000/5000/6000 Series Service Manual 3-47...
  • Page 69 7. Remove the brake mount plate from the caliper (Fig. 175). 5. Remove the two bolts retaining the brake mount plate to the transmission (Fig. 173). Fig. 175 DSCN-4394a Fig. 173 DSCN-4388a 3-48 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 70: Brake Caliper Installation

    4. Install the L-bracket, spring, washer, and nut on the threaded end of the brake cable (Fig. 179). 2. Apply thread locker to the 2 bolts that retain the brake mount plate (Fig. 177). Fig. 179 DSCN-4314a Fig. 177 DSCN-4400a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-49...
  • Page 71 9. Rotate the drive wheel release handle to the operating position. 10. Install the rear tire and torque lug nuts between 103.5 – 126.5 ft-lbs. (140.5 – 171.5 Nm). 11. Remove the jack stands and lower the unit. 3-50 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 72: Motion Control Damper Replacement

    Note: You will need a T­40 Torx wrench to hold the Fig. 183 DSCN-4448a bolt while removing (Fig. 182). 4. Remove the damper assembly (Fig. 184). Fig. 182 DSCN-4445a Fig. 184 DSCN-4450a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-51...

  • Page 73: Motion Control Damper Installation

    200 in-lbs. (16.7 ft-lbs. or 22.6 Nm). For adjustments, see “Adjusting the Motion Control Damper” on page 3-52. 3-52 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 74: Adjusting The Motion Control Neutral Lock Pivot

    For more resistance, tighten the flange nut. For less Fig. 189 fig. 84 G009040 resistance, loosen the flange nut. 3. Tighten jam nut. A. Bolt C. Control lever B. Handle D. Nut Toro Z Master G3 3000/5000/6000 Series Service Manual 3-53...

  • Page 75: Motion Control Assembly Replacement

    PTO, turn the ignition key to OFF position and remove the key. 2. Remove the 2 screws retaining the LH motion control cover assembly (Fig. 191). Fig. 190 fig. 85 G009195 Fig. 191 DSCN-4454 3-54 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 76 4. Remove the lock nut from the damper motion control the LH motion control assembly (Fig. 195). from the LH motion control assembly (Fig. 193). Fig. 195 DSCN-4466a Fig. 193 DSCN-4462a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-55...
  • Page 77 10. Remove the wire harness anchor from the LH 8. Remove the bolt securing the pivot hub and the LH motion control (Fig. 199). motion control to the frame (Fig. 197). Fig. 199 DSCN-4475 Fig. 197 DSCN-4473a 3-56 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 78 A B C C D Fig. 201 DSCN-4492b Fig. 203 DSCN-4485a A. Jam nut D. Flat washer B. Nut E. LH motion control C. Spring washer (2) F. Motion control lever Toro Z Master G3 3000/5000/6000 Series Service Manual 3-57...

  • Page 79: Motion Control Assembly Installation

    4. Install the two spring washers with the crown side of the washers facing out (Fig. 207). 2. Install motion control lever in the LH motion control (Fig. 205). Fig. 207 DSCN-4490 Fig. 205 DSCN-4488a 3-58 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 80 6. Install the spring leaf with carriage bolt and nut (Fig. 209). 8. Install the wire harness anchor to the motion control lever (Fig. 211). Fig. 209 DSCN-4492a Fig. 211 DSCN-4496a Toro Z Master G3 3000/5000/6000 Series Service Manual 3-59...
  • Page 81 10. Install the plug connector to the neutral switch (Fig. 12. Install the lock nut from the damper motion control to 213). the LH motion control assembly (Fig. 215). Fig. 213 Fig. 215 DSCN-4500a DSCN-4462a 3-60 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 82 15. For adjustments on the control handles and the motion control neutral lock, see “Adjusting the Motion Control Neutral Lock Pivot” on page 3-53 and “Adjusting the Control Handle Position” on page 3-53. Toro Z Master G3 3000/5000/6000 Series Service Manual 3-61...
  • Page 83 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK. 3-62 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 84: Engine

    OFF position (Fig. 219). 4. Remove the 3 carriage bolts and nuts retaining the RH bumper to the frame (Fig. 221). Fig. 219 DSCN-4635a Fig. 221 DSCN-4637a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 85 6. Remove the 2 nuts retaining the rear guard to the frame and 1 carriage bolt and nut retaining the arm assembly (Fig. 225). muffler guard to the rear guard (Fig. 223). Fig. 225 DSCN-4258a Fig. 223 DSCN-0012a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 86 PTO clutch (Fig. 229). Fig. 227 DSCN-0011a Fig. 229 DSCN-0020a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 87 Fig. 230 DSCN-0025a 16. Remove the engine sheave from the engine crankshaft (Fig. 233). 14. Unplug the wire plug from the electric PTO clutch (Fig. 231). Fig. 233 DSCN-0032a Fig. 231 DSCN-0028a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 88 20. Remove the starter motor bolt at the top of the retaining the engine to the frame (Fig. 235). starter, then remove the battery ground wire and the wiring harness ground wire (Fig. 237). Fig. 235 DSCN-0038a Fig. 237 DSCN-0043a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 89 23. Remove the engine from the frame (Fig. 240). harness plug (Fig. 238). Fig. 240 DSCN-0053a Fig. 238 DSCN-0049a 22. On the bottom of the starter solenoid disconnect the red wire and red positive cable (Fig. 239). Fig. 239 DSCN-0050a Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 90: Engine Installation

    30 ± 3 ft-lbs. (40.7 ± 4.07 Nm) (Fig. 244). 3. Install red positive cable and red wire to the bottom of the starter solenoid (Fig. 242). Fig. 244 DSCN-0055 Fig. 242 DSCN-0050a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 91 Using the bolt, spring washers, and washer torque the clutch bolt to 55 ± 6 ft-lbs. (74.6 ± 8.1 Nm) (Fig. 248). Fig. 246 DSCN-0032a Fig. 248 DSCN-0061a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 92 14. Install the floor pan. the v-belt around the engine pulley (Fig. 250). 15. Install the vent line to the air filter assembly (Fig. 252). Fig. 250 DSCN-0025a Fig. 252 DSCN-0018a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 93 19. Install the z-bend of the throttle cable into the middle 17. Install the fuel line and fuel clamp on the fuel filter hole in the throttle arm assembly (Fig. 256). (Fig. 254). Fig. 256 DSCN-4261 Fig. 254 DSCN-0013a 4-10 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 94 24. Install 2 nuts retaining the rear guard to the frame and 1 carriage bolt nut retaining the muffler guard to the rear guard (Fig. 260). Fig. 258 DSCN-4277a Fig. 260 DSCN-0012a Toro Z Master G3 3000/5000/6000 Series Service Manual 4-11...
  • Page 95 28. Lower the machine to the ground with a floor jack, after removing the jack stands. 29. Install the battery in the frame. Install the positive and negative battery cables. 4-12 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 96: Hydraulic System

    3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Fig. 264 PICT-8695a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 97 7. With a 3/8” drive breaker bar installed in the square clears the hydro cradle assembly (Fig. 268). hole of the idler bracket, rotate the idler bracket clockwise to relieve belt tension (Fig. 266). Fig. 268 PICT-8693a Fig. 266 PICT-8545a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 98 13. With tension removed, remove the v-belt from around the transmission pulleys and the engine drive 11. Remove the two rear wheels (Fig. 270). pulley (Fig. 272). Fig. 270 PICT-8550a Fig. 272 PICT-8561a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 99 (Fig. 274). the castle nut from the wheel hub (Fig. 276). Note: Be careful to not damage the trunnion shaft seal. Fig. 276 PICT-8580 Fig. 274 PICT-8566 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 100 UHT (Fig. 278). 23. On the side of the machine being serviced, use a wheel hub puller (Toro part no. TOR6006) to remove Note: There is a spacer washer on each bolt be- the wheel hub from the UHT wheel shaft (Fig. 280).
  • Page 101 (Fig. 284). Note: Only the left hand brake cable is installed in the cradle retainers. Fig. 282 PICT-8591a Fig. 284 PICT-8649a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 102 2 carriage bolts and nuts located on either side the machine being serviced. Raise the floor jack to of the UHT securing it to the cradle (Fig. 286). contact the cradle (Fig. 288). Fig. 286 Fig. 288 PICT-8607a PICT-8617 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 103 Note: Ensure the control arm shaft clears the frame and the control arm linkage doesn’t get caught between the frame and the UHT as it is being lowered. Fig. 292 PICT-8624 Fig. 290 PICT-8620 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 104: G3 Uht Transmission Installation (2009 - 2011 Models)

    (horizontal) position. Fig. 295 PICT-8633a Fig. 293 PICT-8629a 2. Loosely install a nut onto each of the bolts securing the UHT to the cradle (Fig. 294). Fig. 296 PICT-8637a Fig. 294 PICT-8631a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 105 6. Loosely install 3 bolts and nuts securing the cradle to the UHT that was not serviced. The floor jack may have to be repositioned to align holes (Fig. 298). Fig. 300 PICT-8615a Fig. 298 PICT-8615a 5-10 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 106 11. Install the control arm bolt and washer securing the and into the cable retainers (Fig. 304). control arm linkage to the UHT. Torque the bolt to 10 ft-lbs. (13.55 Nm) (Fig. 302). Fig. 304 PICT-8649a Fig. 302 PICT-8644a Toro Z Master G3 3000/5000/6000 Series Service Manual 5-11...
  • Page 107 UHT (Fig. 308). shaft. Loosely install the castle nut (Fig. 306). Note: Do not use anti-seize compound on the wheel hub. Fig. 308 PICT-8665a Fig. 306 PICT-8661a 5-12 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 108 (Fig. 311). Note the order of the standard nut and the lock nut on the end of the brake cable. Fig. 311 PICT-8679a A. Standard nut B. Lock nut Toro Z Master G3 3000/5000/6000 Series Service Manual 5-13...
  • Page 109 C. Push lever this direction this direction against the swivel and repeat step 26. D. Caliper lever arm H. Hold threaded rod with E. Standard nut (shown pliers against swivel) Swivel (pivot head) 5-14 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 110 A. 0.1” (25mm) max B. No more than 2 threads 33. Torque the castle nut to 200 ft-lbs. (271 Nm) (Fig. (0.1” (25mm) max) 315). should be showing here Fig. 315 PICT-8687 Toro Z Master G3 3000/5000/6000 Series Service Manual 5-15...
  • Page 111 Do not loosen the nut to align the slot. 38. Install the cotter pin. Use a new cotter pin if needed (Fig. 318). Fig. 320 PICT-8561a Fig. 318 PICT-8689 5-16 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 112 42. With a 3/8” drive breaker bar installed into the square hole in the idler bracket, rotate the idler clockwise to relieve tension (Fig. 322). Fig. 323 decal 115-7445 Fig. 322 PICT-8545a Toro Z Master G3 3000/5000/6000 Series Service Manual 5-17...
  • Page 113 45. Lower the machine to the ground. 46. Connect the negative battery cable to the battery (Fig. 324). Fig. 326 PICT-8543 Fig. 324 PICT-8541a 47. Reinstall the guard above the UHT (Fig. 325). Fig. 325 PICT-8696 5-18 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 114 Fig. 327 fig. 76 G008967 This is a top view (under seat) A. Oil level within B. Dipstick locations knurled section Toro Z Master G3 3000/5000/6000 Series Service Manual 5-19...

  • Page 115: Burnishing The Brake

    5. Engage the parking brake. 6. Install a 1/2” x 6” (approximately) rod or bolt through the 2” height -of-cut hole (Fig. 331). Fig. 329 PICT-8550a Fig. 331 G3CheckValveParkBrake_a 5-20 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 116 (Fig. 332). Fig. 333 PICT-8679a A. Standard nut B. Lock nut Fig. 332 fig. 36 G008957 A. Vertical: “released” B. Horizontal: “operating” to push the machine to drive the machine Toro Z Master G3 3000/5000/6000 Series Service Manual 5-21...
  • Page 117 C. Push lever this direction this direction against the swivel and repeat step 18. D. Caliper lever arm H. Hold threaded rod with E. Standard nut (shown pliers against swivel) Swivel (pivot head) 5-22 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 118: Uht Transmission Replacement (2012 & Later Models)

    24. Remove the jack stands and lower the machine to jack stands under the right and left tie down loops. the ground. Remove the RH and LH wheels from the unit (Fig. 337). Fig. 337 DSCN-4311a Toro Z Master G3 3000/5000/6000 Series Service Manual 5-23...
  • Page 119 7. With the tension removed from the belt, remove the 341). v-belt from around the left side transmission pulley (Fig. 339). Note: Be careful to not damage the trunnion shaft seal. Fig. 339 DSCN-4508a Fig. 341 DSCN-4515a 5-24 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 120 12. Remove the e-ring, washer, and brake pin from the 14. Remove the e-ring from the groove in the cable end L-Bracket (Fig. 343). and the cable anchor located on the transmission (Fig. 345). Fig. 343 DSCN-4314a Fig. 345 DSCN-4318a Toro Z Master G3 3000/5000/6000 Series Service Manual 5-25...
  • Page 121 16. On the side of the machine being serviced, use a 18. On the side of the machine being serviced, remove wheel hub puller (Toro part number TOR6006) to the bottom carriage bolt and nut securing the UHT remove the wheel hub from the UHT wheel shaft transmission to the cradle (Fig.
  • Page 122 UHT transmission to the frame (Fig. 351). Fig. 352 DSCN-4529a 23. Remove the UHT transmission from the cradle (Fig. 353). Caution: The UHT weighs approximately 80 lbs. (36.29kg). Fig. 351 DSCN-4528a Fig. 353 DSCN-4533 Toro Z Master G3 3000/5000/6000 Series Service Manual 5-27...

  • Page 123: Uht Transmission Installation (2012 & Later Models)

    Fig. 354 DSCN-4535a transmission (Fig. 357). 2. Loosely install a nut onto each of the bolts securing the UHT transmission to the cradle (Fig. 355). Fig. 357 DSCN-4539a Fig. 355 DSCN-4536a 5-28 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 124 (Fig. 361). to 75 ± 8 ft-lbs. (101.7 ± 10.8 Nm) (Fig. 359). Fig. 361 DSCN-4552a Fig. 359 DSCN-4550a A. Cradle to UHT nuts B. UHT mounted frame bolts Toro Z Master G3 3000/5000/6000 Series Service Manual 5-29...
  • Page 125 UHT shaft. Loosely install the nut (Fig. 363). Note: Do not use anti-seize compound on the wheel hub. Fig. 365 DSCN-4361a Fig. 363 DSCN-4555a 5-30 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 126 (Left Hand brake shown above) A. Cable anchor E. Caliper B. Hold threaded rod here F. Compression spring C. Measure G. Threaded rod D. Lock nut H. Hub Fig. 367 DSCN-4314a Toro Z Master G3 3000/5000/6000 Series Service Manual 5-31...

  • Page 127: Wheel Hub Slotted Nut Installation

    Recheck the spring length. 21. Rotate the drive wheel release handle to the operating position. Fig. 371 fig. 67 G011815_B C. Style B (yellow zinc) B. 0.24” (6mm) 5-32 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 128 The rear tires should not move forward or reverse. If they do creep, see “Adjusting the Motion Control Linkage (Neutral Adjustment)” on page 5-34. 27. Remove the jack stands and lower the unit down. Toro Z Master G3 3000/5000/6000 Series Service Manual 5-33...

  • Page 129: Adjusting The Motion Control Linkage (Neutral Adjustment)

    4. Unplug the seat switch and temporarily install a jumper wire across the terminals in the connector of the main wiring harness (Fig. 375). Fig. 373 fig. 86 G009033 A. Double nuts Fig. 375 DSCN-4620a 5-34 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 130 (Fig. 376). Note: A slight creep in reverse is acceptable. Fig. 376 DSCN-4622a Toro Z Master G3 3000/5000/6000 Series Service Manual 5-35...

  • Page 131: Checking The Hydraulic Oil

    Important: Do not overfill the hydraulic units with oil as damage may occur. Do not run the machine with oil below the add mark. 10. Install the dipstick. 11. Repeat procedure for the other dipstick. 5-36 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 132: Flow Test Instructions

    High temperatures can be generated. removed to get to the seat switch (Fig. 380). Follow all safety procedures in the vehicle owner’s manual. Fig. 380 PICT-0398a Fig. 378 9792_a Part number 116-1373 Toro Z Master G3 3000/5000/6000 Series Service Manual 5-37...
  • Page 133 Caution: All fittings and hoses must be securely attached. The test is accomplished using the vehicle’s high-pressure system lines. Failure to secure connections could result in bodily injury. Fig. 383 DSCN-4626a 5-38 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 134 2 gpm indicates a defective pump. 11. Tighten the restriction valve unit the difference between the pressure gauge readings is 1000 psi (69 bar) and record the flow reading again. Toro Z Master G3 3000/5000/6000 Series Service Manual 5-39...

  • Page 135: Hydraulic Pump Drive Belt Replacement

    9. Using a ratchet in the square hole in the idler arm, install the idler spring to the frame (Fig. 385). 10. Install the mower belt. Refer to “Mower Belt Installation” on page 6-2. 11. Lower the machine to the ground. 5-40 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 136: Using The Drive Wheel Release Valves

    1. Disengage the PTO (blade control switch) and turn the ignition key to off. Move the levers to neutral locked position and apply the parking brake. Remove the key. Toro Z Master G3 3000/5000/6000 Series Service Manual 5-41...
  • Page 137 HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK. 5-42 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 138: Mower Decks

    4. Remove the RH belt cover (Fig. 387) and the LH belt cover. Fig. 388 DSCN-0066a 7. Remove the belt from the mower deck pulleys (Fig. 389). Fig. 387 DSCN-0064a Fig. 389 DSCN-0067a Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 139: Mower Belt Installation

    3. Using a 3/8” ratchet or breaker bar in the square hole in the idler arm, install the idler spring (Fig. 391). Make sure the spring ends are seated in the anchor grooves. Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 140: Mower Deck Replacement

    4. Remove the RH and LH belt covers (Fig. 393). Fig. 393 DSCN-0072 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 141 C. Spring-loaded idler F. Idler grease zerk pulley G. Belt guide D. Ratchet 6. Rotate the deck idler assembly clockwise and remove the mower drive belt from electric PTO clutch pulley (Fig. 394). Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 142 C. Remove the rear deck lift attachment position. Slide the deck out on the right side of the shoulder bolt & nut machine. D. Remove the front deck lift attachment shoulder bolt & nut Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 143: Extension Spring Adjustment (2010 - 2012 Models)

    MOWER DECKS Extension Spring Adjustment (2010 - Mower Deck Installation 2012 Models) Reverse the order of mower deck removal. Fig. 397 DSCN-0136 Fig. 398 116-5700K12 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 144: Mower Spindle Replacement

    3. Remove the RH mower deck belt cover (Fig. 399). Fig. 400 DSCN-0020a 5. Remove three bolts retaining the pulley to the pulley hub (Fig. 401). Fig. 399 DSCN-0072 Fig. 401 DSCN-2662a Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 145: Mower Spindle Installation (2009 Model G3 Series Units)

    Reverse the order of mower spindle removal (2009 model G3 Series units). 8. Remove the 5 bolts and nuts retaining the spindle assembly to the mower deck (Fig. 402). Fig. 402 DSCN-2666a Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 146: Mower Spindle Disassembly (2009 Model G3 Series Units)

    DSCN-2671a 5. Remove the spindle housing from the spindle shaft assembly (Fig. 406). Fig. 403 DSCN-2669a 3. Remove the pulley hub and square key (Fig. 404). Fig. 406 DSCN-2672a Fig. 404 DSCN-2670a Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 147 7. Remove the seal spacer from the bottom of the 9. Remove the bearing from the top of the spindle spindle housing (Fig. 408). housing (Fig. 410). Fig. 408 DSCN-2674a Fig. 410 DSCN-2676a 6-10 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 148 (Fig. 414). open end of the seal faces outwards to help relieve pressure from over-greasing the spindle assembly. Fig. 414 DSCN-2681a Fig. 412 DSCN-2679a Toro Z Master G3 3000/5000/6000 Series Service Manual 6-11...

  • Page 149: Mower Spindle Assembly (2009 Model G3 Series Units)

    Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing. Fig. 416 DSCN-2684a A. Brearing race spacer B. Center spacer Fig. 418 DSCN-2689a 6-12 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 150 (Fig. 422). 4. Pack the bearing with No. 2 grease and install the bearing (Fig. 420). Fig. 422 DSCN-2693a Fig. 420 DSCN-2691a Toro Z Master G3 3000/5000/6000 Series Service Manual 6-13...
  • Page 151 8. Pack the bearing with No. 2 grease and install the bearing (Fig. 424). 10. Install the bearing shield and the seal spacer onto the spindle shaft (Fig. 426). Fig. 424 DSCN-2694a Fig. 426 DSCN-2702a 6-14 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 152 12. Install the seal spacer on the top of the spindle housing (Fig. 428). 15. Install the pulley hub on the spindle shaft (Fig. 430). Fig. 428 Fig. 430 DSCN-2707a DSCN-2704a Toro Z Master G3 3000/5000/6000 Series Service Manual 6-15...

  • Page 153: Mower Spindle Replacement (2010 & Later Model G3, 3000/5000/6000 Series Units)

    17. Torque the top nut to 100 - 120 ft-lbs. (135.58 - 162.7 Nm) (Fig. 432). Fig. 433 DSCN-0072 Fig. 432 DSCN-2709a 18. Grease the spindle assembly using a grease gun with No. 2 grease. 6-16 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 154: Mower Spindle Installation (2010 & Later Model G3, 3000/5000/6000 Series Units)

    Remove the mower blade from the spindle shaft. 6. Remove the 6 flange nuts retaining the spindle assembly to the mower deck and remove the spindle assembly from the deck (Fig. 435). Fig. 435 DSCN-0079a Toro Z Master G3 3000/5000/6000 Series Service Manual 6-17...

  • Page 155: Mower Spindle Disassembly (2010 & Later Model G3, 3000/5000/6000 Series Units)

    DSCN-0089a 4. Remove the spindle shaft (Fig. 439). Fig. 436 DSCN-0082a 2. Remove the top lock nut and washer from the spindle shaft (Fig. 437). Fig. 439 DSCN-0090a Fig. 437 DSCN-0087a 6-18 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 156 (Fig. 8. Using a hammer and driver with a square edge, 441). drive the bottom bearing and seal out of the spindle housing (Fig. 443). Fig. 441 DSCN-0093 Fig. 443 DSCN-0096a Toro Z Master G3 3000/5000/6000 Series Service Manual 6-19...

  • Page 157: Mower Spindle Assembly (2010 & Later Model G3, 3000/5000/6000 Series Units)

    Fig. 444 DSCN-0106a Fig. 445 DSCN-0118a 2. Apply a film of grease around the lip of the seal and install the lip of the seal face inward (Fig. 446). Fig. 446 DSCN-0119a 6-20 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 158 (Fig. 448). Fig. 447 DSCN-0116a Fig. 448 DSCN-0111a Note: The open lip of the seal should be facing outward (Fig. 449). Fig. 449 DSCN-0112a Toro Z Master G3 3000/5000/6000 Series Service Manual 6-21...
  • Page 159 9. Install the pulley on the spindle hub and torque the 3 flange nuts to 37 ± 4 ft-lbs. (50 ± 5.4 Nm). 10. Grease the spindle assembly using No. 2 grease. 6-22 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 160: Leveling The Mower Deck

    2. 3-1/4” (8.3cm) at B surface is correct 4. Measure at A & B on both sides Fig. 454 fig. 92 G017027 A. Deck lift pedal C. Transport lock B. Height -of-cut pin Toro Z Master G3 3000/5000/6000 Series Service Manual 6-23...
  • Page 161 94 G012430 Fig. 457 fig. 95 G010251 A. Adjustment nut C. Rear deck adjustment A. Whizlock nut C. Jam nut B. Jam nut D. Front deck adjustment B. Adjuster screw D. Yoke 6-24 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 162 Fig. 458 fig. 96 G017029 A. Bolts at the bottom of the height-of-cut plate Fig. 459 fig. 97 G017036 A. Single point adjustment bolt Toro Z Master G3 3000/5000/6000 Series Service Manual 6-25...
  • Page 163 2. 3-1/4” (8.3cm) at B surface is correct 4. Measure at A & B on both sides Fig. 460 fig. 96 G017029 A. Bolts at the bottom of the height-of-cut plate 6-26 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 164: Servicing The Cutting Blades

    File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand.

  • Page 165: Inspecting The Blades

    098). If you notice any damage, wear, or a slot forming in this area (Fig. 463), immediately install a new blade. Fig. 464 fig. 99 G000975 1. Measure here from 2. Position A blade to hard surface 6-28 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 166: Removing The Blades

    • Never file or create sharp notches in the edges or surfaces of blade. Fig. 465 fig. 100 G004536 A. Sail area of blade C. Curved washer B. Blade D. Blade bolt Toro Z Master G3 3000/5000/6000 Series Service Manual 6-29...

  • Page 167: Sharpening The Blades

    Fig. 468 fig. 100 G004536 A. Sail area of blade D. Blade bolt B. Blade E. Cone towards bolt head C. Spring disk Fig. 467 fig. 102 G000277 A. Blade B. Balancer 6-30 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 168: Electric Pto Clutch Replacement

    (Fig. 472). Fig. 469 DSCN-0020a 3. Raise the machine in the rear and support it with jack stands (Fig. 470). Fig. 472 DSCN-0031a Fig. 470 DSCN-0071a Toro Z Master G3 3000/5000/6000 Series Service Manual 6-31...

  • Page 169: Electric Pto Clutch Installation

    Fig. 476 DSCN-0020a 5. Install the floor pan. 6. Remove the jack stands and lower the machine to the ground. Fig. 474 DSCN-0061a 7. Install the battery negative cable to the battery. 6-32 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 170: Using The Clutch Shim

    B. Field shell F. Re-gap shim necessary. C. Rotor G. Brake pole D. Brake mounting bolt 4. Verify that 12V is present at the clutch connector when the PTO switch is engaged. Toro Z Master G3 3000/5000/6000 Series Service Manual 6-33...
  • Page 171 Fig. 479 fig. 72 G010870 A. Brake mounting bolt 9. Re-torque each bolt (M6 x 1) to 10 ± 0.5 ft-lbs. (13 ± 0.7 Nm). 6-34 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 172: Safety Check

    If the gap is less than 0.010 inch, then reinstall the shim and reference the Troubleshooting section of the Owner’s Manual. • If the gap is sufficient, proceed with the “Safety Check” on page 6-35. Toro Z Master G3 3000/5000/6000 Series Service Manual 6-35...
  • Page 173 MOWER DECKS THIS PAGE INTENTIONALLY LEFT BLANK. 6-36 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 174: Electrical

    Location The relay is located on the frame, right side of the engine, in front of the battery (Fig. 483). Fig. 484 DSC-2517a Fig. 483 DSCN-0008 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 175: Testing

    30 and 87a. Apply +12 VDC to terminal 85. With terminal 86 still grounded, the relay should break and make continuity between terminals 30 and 87a as 12 VDC is applied and removed from terminal. Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 176: Pto Switch

    When the switch is pushed in to OFF position, current flows through the PTO switch to the Park Brake switch as part of the circuit used to ensure safe starting. Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 177 Fig. PTO switch test. 7. Mount the PTO switch back into the control panel and reinstall the wiring harness (Fig. 489). Pink/Black Grey Orange Fig. 489 PTO clutch switch b Brown Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 178: Ignition Switch

    3. Verify there is NO continuity between terminals not listed for the position. No continuity between terminals Continuity – B R I A START Continuity – B R I S Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 179: Park Brake Switch

    2. Using a VOM or test light, check first to ensure there is no continuity between either terminal, plunger out. 3. With the plunger pushed in, there should be continuity between the terminals. Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 180: Seat Switch

    2. Using a VOM, check first to ensure there is NO continuity between either terminal, plunger out. 3. With the plunger pushed in, there should be continuity between the terminals. Fig. 494 PICT-0398a Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 181: Neutral Safety Switch

    1. Disconnect the switch from the wiring harness. 2. Use a VOM, check first to ensure there is no Fig. 496 DSCN-0147a continuity between the terminals, plunger out. 3. With the plunger pushed in, there should continuity between the terminals. Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 182: Tvs Diode

    1. Check to see if the 10 amp fuse is blown for the PTO clutch. 2. With a multi-tester, check the oms. It should read an Fig. 498 DSCN-0005a open line both ways. Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 183: Fuel Sender

    Apply 12 volts to the red lead, ground the black lead and measure the voltage at the yellow lead. The voltage should be between 0.5 volts (empty) and 4.5 volts (full). 7-10 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 184: Fuel/Hour Meter

    The fuel/hour meter is located on the control panel on the right fender (Fig. 502). Testing No test procedure. Cannot be bypassed without extreme modifications to the electrical system. Fig. 502 DSCN-0142a Toro Z Master G3 3000/5000/6000 Series Service Manual 7-11...

  • Page 185: Testing

    PTO circuit, use the following troubleshooting steps to determine whether the clutch has failed or another electrical problem exists. 7-12 Toro Z Master G3 3000/5000/6000 Series Service Manual...

  • Page 186: Measuring Clutch Current Draw

    6.5 amps, check the electrical system for problems (i.e., the battery, ignition switch. PTO switch, or wiring harness). Make sure the negative side of the wiring has a good connection to chassis ground. Toro Z Master G3 3000/5000/6000 Series Service Manual 7-13...
  • Page 187 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 7-14 Toro Z Master G3 3000/5000/6000 Series Service Manual...
  • Page 188 Toro Z Master G3 3000/5000/6000 Series Service Manual Form Number 492-9237...

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