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.
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 �������������������������������������������������������������������������������������������������������
TABLE OF CONTENTS 3 - Chassis cont.
TABLE OF CONTENTS 6 - Mower Decks cont.
TABLE OF CONTENTS 7 - Electrical cont.
SAFETY INFORMATION General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the G3 3000/ 5000/6000 Series Mower.
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SPECIFICATIONS Torque 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. 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.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated & Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size 2 Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 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 Nu
SPECIFICATIONS Standard Torque for Dry, Zinc & Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height 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 M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N-cm 133 ± 14 in-lb 1503 ± 158 N-cm M8 X 1.
SPECIFICATIONS OtherTorque TorqueSpecifications Specifications Other Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size 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 Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.
SPECIFICATIONS Equivalents & Conversions Equivalents and Conversions Decimal & Millimeter Equivalents Decimal and Millimeter Equivalents Fractions Decimals 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 mm 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.
SPECIFICATIONS U.S. to Metric Conversions 2 U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.
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.
SPECIFICATIONS G3 3000/5000/6000 Series Specifications cont. Fuel System: Fuel Tank Capacity 2 8 Gallon (US) (26.5 L) Fuel Gauge Fuel Delivery System 12 Gallon (US) (45.4 L) 43.5 lb Propane (19.7 kg) Located on top of tank. Located on tank Fuel pump Vapor draw Traction Drives: Hydraulic Drive System Unitized Pump & Motor 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.
SPECIFICATIONS G3 3000/5000/6000 Series Specifications cont.
SPECIFICATIONS Dimensions Commercial 3000 Series 2 Overall Length Overall Height Wheel Base ROPS Up ROPS Folded Width Outside Tires Overall Width (Chute Down) Gate Width ROPS Up ROPS Folded Weight in./cm in./cm in./cm in./cm in./cm in./cm in./cm in./cm lbs./kg 74952 47.7/ 121.2 79.2/ 201.2 80.9/ 205.5 45.7/ 116.1 63.6/ 161.5 54.0/ 137.2 70.5/ 179.1 46.8/ 118.9 1120/ 508.0 74953 47.7/ 121.2 79.2/ 201.2 80.9/ 205.5 45.7/ 116.1 67.6/ 171.7 57.5/ 146.1 70.5/ 179.1 46.
SPECIFICATIONS Dimensions G3/Professional 6000 Series Overall Height Wheel Base Overall Length Width Outside Tires Overall Width (Chute Down) Gate Width ROPS Up ROPS Folded Weight 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.
SPECIFICATIONS Dimensions G3/Professional 6000 Series cont. 2 Overall Height Wheel Base Overall Length Width Outside Tires Overall Width (Chute Down) Gate Width ROPS Up ROPS Folded Weight 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.
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 Fig. 001 PICT-0355 PICT-0351 3. Remove the locknut (Fig. 002). Fig.
CHASSIS Caster Bearing Replacement 3. Remove the bottom grease seal (Fig. 006). 1. Remove the 3 Belleville washers (Fig. 004). 3 Fig. 006 Fig. 004 PICT-0364a PICT-0359a 4. Remove the bottom tapered bearing (Fig. 007). 2. Remove the top tapered bearing (Fig. 005). Fig. 007 Fig.
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 bearing cup into the caster fork hub so that the thick er part of the taper is pressed in first.
CHASSIS Caster Fork Assembly Installation 10. Install the upper bearing fork hub (Fig. 012). 1. Install 3 Belleville washers as shown (Fig. 013). C B 3 Fig. 012 A PICT-0372a Fig. 013 A. Spring washer (3) B. Lock nut fig. 69 G001297 C. Dust Cap 2. Slide the caster fork assembly into the hub (Fig. 014). Fig.
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 hub. Install a grease fitting. Apply grease (No.
CHASSIS 4. Remove the 2 seal guards (Fig. 019). 6. Remove the axle caster (Fig. 021). 3 Fig. 019 PICT-0380a 5. Remove 2 spacer nuts from the axle caster (Fig. 020). Fig. 020 3-6 PICT-0382a Fig. 021 PICT-0383a 7. Remove the two caster seals from the wheel assembly (Fig. 022). Fig.
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). 3 Fig. 023 PICT-0385a 9. Drive the bearing cup out of the wheel assembly (Fig. 024). Fig. 025 PICT-0389a 2.
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 Fig. 027 7. Install the two guard seals, screw, nut and tighten (Fig. 030). 5. Install the caster axle (Fig. 028). Fig. 028 3-8 PICT-0382a PICT-0392a PICT-0393a Fig.
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 sembly to the frame (Fig. 031). 3 Fig. 033 PICT-0412a 6. Remove the two bolts and nuts retaining the seat mount to the frame (Fig. 034). Fig.
CHASSIS 7. Remove 2 bolts retaining the front of the seat mount to the frame (Fig. 035). 9. Cut the tie strap around the fuel sender plug (Fig. 037). 3 Fig. 035 PICT-0401a 8. Lift the seat mount from the frame (Fig. 036). Fig. 036 Fig. 037 10. Unplug the fuel sender plug from the wiring harness (Fig. 038). PICT-0417a Fig.
CHASSIS 11. Disconnect the vapor line retainers from the fuel manifold (Fig. 039). 13. Remove the fuel tank from the frame of the unit (Fig. 041). 3 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.
CHASSIS Fuel Tank Installation 4. Plug the fuel sender plug to the wiring harness (Fig. 044). 1. Install fuel tank into the frame (Fig. 042). 3 Fig. 044 Fig. 042 PICT-0409a PICT-0426a 2. Install the fuel clamp around the fuel line to the fuel valve. 5. Install a tie strap around the red, yellow, and black wires around the wiring connector (Fig. 045). 3. Connect the vapor line retainers to the fuel manifold (Fig. 043). Fig. 045 Fig.
CHASSIS 6. Install the seat mount to the frame (Fig. 046). 8. Install seat and connect the seat switch (Fig. 048). 3 Fig. 046 PICT-0415a 7. Install 2 bolts and nuts on the right and left side of the seat frame (Fig. 047). Fig. 047 PICT-0413a Toro Z Master G3 3000/5000/6000 Series Service Manual Fig. 048 PICT-0398a 9. With flange nuts, tighten the seat and seat base to the 4 seat isolators (Fig. 049). Fig.
CHASSIS 10. Install the right and left motion control covers with 2 screws each (Fig. 050). Throttle Control Assembly Replacement (Kohler EFI Engine) Throttle Control Assembly Removal 1. Disconnect the negative battery cable from the battery terminal. 2. Remove the knob from the throttle control assembly (Fig. 051). 3 Fig. 050 DSCN-4238a 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.
CHASSIS 4. Remove the locknuts and carriage bolts securing the throttle control to the control panel (Fig. 053). 6. Remove the Z-bend end of the cable from the throttle arm assembly (Fig. 055). 3 Fig. 053 DSCN-4250a 5. Loosen the cable clamp and remove the throttle cable from underneath it (Fig. 054). Fig. 054 DSCN-4253a Toro Z Master G3 3000/5000/6000 Series Service Manual Fig. 055 DSCN-4258a 7. Slide the throttle cable through the hose clamp next to the engine (Fig. 056). Fig.
CHASSIS 8. Continue sliding the cable through the second hose clamp next to the frame brace for the ROPS assembly and pull the throttle cable out of the unit (Fig. 057). Throttle Control Assembly Installation 1. Slide the throttle cable through the hose clamp next to the frame brace for the ROPS assembly (Fig. 058). 3 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.
CHASSIS 3. Install the throttle control in the control panel using 2 carriage bolts and lock nuts (Fig. 060). 5. Install the knob to the throttle control assembly (Fig. 062). 3 Fig. 060 DSCN-4250a 4. Install the 4 screws securing the control panel to the RH Fender Console (Fig. 061). Fig. 061 DSCN-4249a Toro Z Master G3 3000/5000/6000 Series Service Manual Fig. 062 DSCN-4247a 6. Move the throttle control to the slow idle position (Fig. 063). Fig.
CHASSIS 7. Install the throttle cable under the throttle clamp. Install the throttle Z-bend in the middle hole on the throttle arm assembly (Fig. 064). Park Brake Handle Assembly Replacement (2012 & Later) Park Brake Handle Removal (2012 & Later) 1. Remove the two screws retaining the right hand motion control cover assembly to the frame and remove the cover (Fig. 066). 3 Fig. 064 DSCN-4279a 8. Move the throttle arm assembly to the low idle position and tighten the throttle cable clamp (Fig. 065). Fig.
CHASSIS 3. Remove two screws and spacers retaining the park brake handle assembly to the frame (Fig. 068). 5. Remove two e-rings retaining the park brake cables to the park-brake pivot assembly and slide the cables out of the slots. Remove the park-brake handle assembly from the unit (Fig. 070). 3 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.
CHASSIS Park Brake Handle Installation (2012 & Later) 3. Install two screws through the park brake handle, two spacers, and tighten the assembly to the frame (Fig. 073). 1. Install the left and right brake cables in the slots in the bottom of the brake pivot assembly and install the e-rings (Fig. 071). 3 Fig. 073 Fig. 071 DSCN-2627a 2. Install the clevis ends of the right and left brake cables to the parking brake handle assembly using two clevis pins and cotter pins (Fig. 072). 4.
CHASSIS Park Brake Cable Replacement (2011 & Prior) 4. With needle nose pliers, squeeze the tabs on the brake cable and pull the brake cable out of the slot in the cable anchor (Fig. 077). Left Park Brake Cable Removal (2011 & Prior) 1. Raise the rear end of the unit and install jack stands under the tie down loops on the frame. Remove the RH and LH wheels from the unit (Fig. 075). 3 Fig. 077 PICT-8969a 5. Slide the brake cable out of the cable anchor and out towards the front (Fig. 078). Fig.
CHASSIS 6. Release the brake cable retainer holding the brake cable to the cradle. Push the cable through the routing hole and remove (Fig. 079). 8. Remove the brake cable from the retainers located on the cradle (Fig. 081). Note: The cable is routed around the cradle. C B 3 A Fig. 079 D D PICT-8974a Fig. 081 7. Remove the tie strap securing the brake cable to the cradle (Fig. 080). cables routing #4 A. Right side brake C. Left side brake assembly assembly B. Cradle D. Retainer (5) 9.
CHASSIS 10. Remove the clevis pin from the cable yoke (Fig. 083). 12. Slide the cable out of the slot (Fig. 085). 3 Fig. 085 Fig. 083 11. Release the brake cable retainer holding the brake cable to the frame (Fig. 084). Fig. 084 PICT-9014a PICT-9001a 13. Pull the cable out over the frame cross bar and remove it from the unit (Fig. 086). Fig.
CHASSIS Left Park Brake Cable Installation (2011 & Prior) 3. 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. 089). 1. Route the clevis end of the brake cable over the frame cross bar (Fig. 087). 3 Fig. 089 Fig. 087 PICT-9001a PICT-9017a 4. Install a cotter pin through the clevis pin to secure (Fig. 090). 2.
CHASSIS 5. Route the brake cable into the retainers on the cradle following the routing diagram (Fig. 091). C B A 7. Slide the brake cable behind the wheel hub and slide the threaded end of the brake cable through the trunnion located in the brake caliper (Fig. 093). D Fig. 091 D 3 cables routing #4 A. Right side brake C. Left side brake assembly assembly B. Cradle D. Retainer (5) Fig. 093 PICT-9063a 8. Install the brake cable snap fitting into the slotted bracket (Fig. 094). 6.
CHASSIS 9. Slide the rubber boot over the snap fitting (Fig. 095). 11. Install a standard nut and a lock nut onto the threaded brake cable rod (Fig. 097). A B 3 Fig. 095 PICT-9077a Fig. 097 10. Install a tie strap securing the brake cable to the cradle (Fig. 096). A. Standard nut PICT-9075a B. Lock nut 12. Adjust the park brake. Refer to “Adjusting the Parking Brake” on page 3-32. Fig.
CHASSIS Right Park Brake Cable Removal (2011 & Prior) 4. With needle nose pliers, squeeze the tabs on the brake cable and pull brake cable out of the slot in the cable anchor (Fig. 100). 1. Raise the rear end of the unit and install jack stands under the tie down loops on the frame. Remove the RH and LH wheels from the unit (Fig. 098). 3 Fig. 100 Fig. 098 PICT-8962 PICT-9083a 5. Slide the brake cable out of the cable anchor and out towards the rear of the unit (Fig. 101). 2.
CHASSIS 6. Release the brake cable retainer holding the brake cable to the cradle (Fig. 102). 8. Pull the brake cable through the hole in the side of the frame (Fig. 104). 3 Fig. 102 PICT-9085a 7. Guide the brake cable through the two holes in the cradle (Fig. 103). E E D Fig. 103 A. Right side brake C. assembly B. Cradle D. E. 3-28 PICT-9087a 9. Remove the cotter pin located on the clevis pin holding the brake cable clevis to the park brake lever (Fig. 105). C B A Fig.
CHASSIS 10. Squeeze the tabs on the brake cable snap fitting and remove the brake cable from the slot on the side of the frame (Fig. 106). Right Park Brake Cable Installation (2011 & Prior) 1. Install the brake cable snap fitting into the slot located on the side of the frame (Fig. 107). 3 Fig. 106 PICT-9092a Fig. 107 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.
CHASSIS 3. Install a cotter pin through the clevis pin (Fig. 109). 5. Route the brake cable through the side hole in the frame and down through the hole in the cradle (Fig. 111). 3 Fig. 109 PICT-9101a Fig. 111 4. Install the rubber seal over the end of the brake snap fitting (Fig. 110). PICT-9105a 6. Route the brake cable from the hole in the cradle, back to the slot of the cradle (Fig. 112). C B E Fig. 110 PICT-9103a A E D Fig. 112 A. Right side brake C. assembly B. Cradle D. E.
CHASSIS 7. Install the right hand brake cable retainer into the cradle so that the retainer tab is installed in the slot on the cradle (Fig. 113). 9. Install the snap fitting into the slotted bracket (Fig. 115). 3 Fig. 115 Fig. 113 8. Route the brake cable behind the wheel hub and slide the threaded end into the trunnion on the caliper (Fig. 114). 10. Install a standard nut and a lock nut onto the threaded brake cable rod (Fig. 116). A B Fig. 116 Fig. 114 PICT-9114a PICT-9111a PICT-9113a A.
CHASSIS Adjusting the Parking Brake 1. Open the push valve (vertical position) on the hydro unit that you are replacing the brake cable on (Fig. 117). 3. Using hands and fingers only, push the caliper lever arm forward to engage the brake pads on the wheel hub until the lever stops (Fig. 118). A B 3 Fig. 118 Fig. 117 PICT-8677a 2. Ensure the parking brake is disengaged. Note: The left side brake is being adjusted in the following steps; the right side adjustment is performed the same way. A.
CHASSIS 5. Try to turn the wheel hub in both directions relative to the caliper. There should be slight movement between them; some friction/resistance is acceptable. 9. Close the drive wheel release valve (horizontal operating position) (Fig. 121). 6. If there is no movement between the hub rotor and the caliper then back off the standard nut one turn from the swivel and repeat step 5. 7.
CHASSIS Park Brake Cable Replacement (2012 & Later) Left Park Brake Cable Removal (2012 & Later) 4. Hold the threaded rod end with a tool, and with a socket wrench remove the lock nut and washer from the end of the cable (Fig. 124). Continue to remove the washer and spring. 1. Raise the rear end of the unit and install jack stands under the tie down loop on the frame. Remove the RH and LH wheels from the unit (Fig. 122). 3 Fig. 124 Fig. 122 DSCN-4311a DSCN-4315a 5.
CHASSIS 6. Pull the brake cable out of the cable anchor on the transmission and slide it out of the slot (Fig. 126). 8. Remove the two clips retaining the brake cable to the frame (Fig. 128). 3 Fig. 126 DSCN-4325a 7. Squeeze the tabs on the conduit fitting and remove it from cable bracket located on the frame (Fig. 127). Fig. 127 Fig. 128 DSCN-4328a 9. Remove the two screws retaining the right hand motion control cover assembly to the frame and remove (Fig. 129). DSCN-4327a Fig.
CHASSIS 10. Unplug the wire harness from the park brake switch (Fig. 130). 12. Remove the cotter pin and clevis pin on the left side of the park brake handle (Fig. 132). 3 Fig. 130 DSCN-2617a 11. Remove two screws and spacers retaining the park brake handle assembly to the frame (Fig. 131). Fig. 131 Fig. 132 13. Remove the e-ring retaining the brake cable to the park brake pivot assembly and slide the cables out of the slots (Fig. 133). Slide the brake cable out of the unit. DSCN-2619a Fig.
CHASSIS Left Park Brake Cable Installation (2012 & Later) 3. Install the clevis pin through the clevis end of the brake cable to the park-brake handle assembly and install a cotter pin (Fig. 136). 1. Install brake cable with the clevis end out toward the park brake handle (Fig. 134). 3 Fig. 136 Fig. 134 DSCN-4358a 2. Install the brake cable grooved fitting into the slot on the bottom of the brake pivot assembly and install e-ring (Fig. 135). 4.
CHASSIS 5. Route the brake cable through the two clips located under the frame of the unit and tighten (Fig. 138). 7. Slide the brake cable into the cable anchor slot on the transmission (Fig. 140). 3 Fig. 138 DSCN-4328a 6. Squeeze the tabs on the conduit fitting and install in the cable bracket located on the frame (Fig. 139). Fig. 139 3-38 DSCN-4327a Fig. 140 DSCN-4325a 8. Install the end of the brake cable through the cable anchor and install an e-ring (Fig. 141). Fig.
CHASSIS 9. Install the L-bracket, spring, washer, and nut on the threaded end of the brake cable (Fig. 142). 11. Engage the parking brake. Measure the overall length of the compression spring (Fig. 144). The correct length should be between 1-1/2” and 1-9/16” (3.8 and 4.9cm). If the spring length is within this range, no adjustment is needed. If it is not, proceed. A BC D 3 AF Fig. 142 DSCN-4336a HG E 10. Install the L-Bracket with brake pin, washer, and e-ring to the brake caliper (Fig. 143).
CHASSIS 12. Hold the end of the threaded rod with a tool and adjust the lock nut until the spring length is between 1-1/2” and 1-9/16” (3.8 and 4.0cm) (Fig. 145). 16. Plug the wire harness to the park brake switch (Fig. 146). Note: Do not allow the cable to turn when the nut are being turned. 3 Fig. 146 Fig. 145 DSCN-4315a DSCN-2617a 17. Install the two screws retaining the right hand motion-control cover assembly to the frame (Fig. 147). 13. Disengage the parking brake.
CHASSIS Right Park Brake Cable Removal (2012 & Later) 1. Raise the rear end of the unit and install jack stands under the tie down loop on the frame. Remove the RH and LH wheels from the unit (Fig. 148). 4. Hold the end of the threaded rod with a tool and with a socket wrench remove the lock nut and washer from the end of the cable (Fig. 150). Remove the washer, spring and the L-Bracket. 3 Fig. 150 Fig. 148 DSCN-4366a DSCN-4311a 5.
CHASSIS 6. Pull the brake cable out of the cable anchor on the transmission and slide it out of the slot (Fig. 152). 8. Unplug the wire harness from the park brake switch (Fig. 154). 3 Fig. 152 DSCN-4370a 7. Remove the two screws retaining the right hand motion control cover assembly to the frame and remove (Fig. 153). Fig. 154 9. Remove two screws and spacers retaining the park brake handle assembly to the frame (Fig. 155). Fig. 155 Fig.
CHASSIS 10. Remove the cotter pin and clevis pin on the right side of the park brake handle (Fig. 156). 12. Remove the brake cable from the unit (Fig. 158). 3 Fig. 158 Fig. 156 DSCN-4379a 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.
CHASSIS Right Park Brake Cable Installation (2012 & Later) 3. Install the clevis and cotter pin to the right side of the park brake handle (Fig. 161). 1. Install brake cable with the clevis end out toward the park brake handle (Fig. 159). 3 Fig. 161 Fig. 159 DSCN-4385a DSCN-4373a 4. Install two screws and spacers retaining the park brake handle assembly to the frame (Fig. 162). 2.
CHASSIS 5. Route the brake cable back to the inside of the frame (Fig. 163). 7. Install the end of the brake cable through the cable anchor and install the e-ring (Fig. 165). 3 Fig. 163 DSCN-4379a 6. Slide the brake cable into the cable anchor slot on the transmission (Fig. 164). Fig. 164 DSCN-4370a Toro Z Master G3 3000/5000/6000 Series Service Manual Fig. 165 DSCN-4370a 8. Install the L-Bracket, spring, washer, and nut on the threaded end of the brake cable (Fig. 166). Fig.
CHASSIS 9. Engage the parking brake. Measure the overall length of the compression spring (Fig. 167). Measure the overall length of the compression spring. The correct length should be between 1-1/2” and 1-9/16” (3.8 and 4.9cm). If the spring length is within this range, no adjustment is needed. If it is not, proceed. 10. Hold the end of the threaded rod with a tool and adjust the lock nut until the spring length is between 1-1/2” and 1-9/16” (3.8 and 4.0cm) (Fig. 168).
CHASSIS 14. Plug the wire harness to the park brake switch (Fig. 169). Brake Caliper Replacement Brake Caliper Removal Note: The left side is being removed; use the same instructions for right side removal. 1. Raise the rear end of the unit and install jack stands under the tie down loop on the frame. Remove the wheel. 2. Disengage the park brake lever. 3. Remove the e-ring, washer, and brake pin from the L-Bracket (Fig. 171). Fig. 169 DSCN-2617a 15.
CHASSIS 4. Hold the end of the threaded rod with a tool, and with a socket wrench, remove the lock nut and washer from the end of the cable (Fig. 172). Remove the washer and spring. 6. Remove the brake caliper from the transmission (Fig. 174). 3 Fig. 174 Fig. 172 DSCN-4315a 5. Remove the two bolts retaining the brake mount plate to the transmission (Fig. 173). 7. Remove the brake mount plate from the caliper (Fig. 175). Fig. 175 Fig.
CHASSIS Brake Caliper Installation 3. Install two washers between the brake mount plate and the transmission and tighten the bolts (Fig. 178). 1. Install the brake mount plate to the caliper (Fig. 176). 3 Fig. 178 Fig. 176 DSCN-4398a 2. Apply thread locker to the 2 bolts that retain the brake mount plate (Fig. 177). 4. Install the L-bracket, spring, washer, and nut on the threaded end of the brake cable (Fig. 179). Fig. 179 Fig.
CHASSIS 5. Engage the parking brake. Measure the overall length of the compression spring (Fig. 180). The correct length should be between 1-1/2” and 1-9/16” (3.8 and 4.9cm). If the spring length is within this range, no adjustment is needed. If it is not, proceed. A BC D 3 6. Hold the end of the threaded rod with a tool, and adjust the lock nut until the spring length is between 1-1/2” and 1-9/16” (3.8 and 4.0cm) (Fig. 181). Note: DO NOT allow the cable to turn when the nuts are being turned.
CHASSIS Motion Control Damper Replacement 3. Remove the nut securing the damper to the motion control assembly (Fig. 183). Note: There is a right and left motion control damper. The following removal and installa tion procedures are on the left damper. The procedure is the same for the right damper. Motion Control Damper Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition OFF and remove the key. 3 2. Remove the nut securing the damper ball joint to the frame.
CHASSIS Motion Control Damper Installation Adjusting the Motion Control Damper Motion Control Damper (Fig. 185) Note: The top damper mounting bolt can be adjust ed to obtain a more desired motion control lever resistance. See Figure 187 for mounting options. A B C 3 A Fig. 185 DSCN-4452a E D A. Belleville washer 1. Install the damper with ball joint end that has the Belleville washer into the frame. Torque the lock nut to 200 in-lbs. (16.7 ft-lbs. or 22.6 Nm) (Fig. 186). Fig. 186 Fig. 187 fig.
CHASSIS Adjusting the Motion Control Neutral Lock Pivot Adjusting the Control Handle Position Note: The flanged nut can be adjusted to obtain a more desired motion control lever resistance when moving it to the neutral lock position. See Figure 188 for adjustment options. Note: There are two height positions for the control levers; high and low. Remove the bolts to adjust the height for the operator. A B 1.
CHASSIS 4. Align the levers front to rear position by bringing the levers together to the neutral position and slide them until they are aligned, then tighten the bolts (Fig. 190). Motion Control Assembly Replacement Motion Control Assembly Removal Note: This procedure is performed on the left hand motion control assembly; follow the same procedure for the right hand side. 1. Park the machine on a level surface, disengage the PTO, turn the ignition key to OFF position and remove the key. 3 2.
CHASSIS 3. Remove the two bolts and nuts retaining the LH steering handle assembly to the LH lever-control motion (Fig. 192). 5. Remove the plug connector to the neutral switch (Fig. 194). 3 Fig. 194 Fig. 192 4. Remove the lock nut from the damper motion control from the LH motion control assembly (Fig. 193). 6. Remove the wire harness from the wire anchor on the LH motion control assembly (Fig. 195). Fig. 195 Fig.
CHASSIS 7. Remove screw, flat washer and nut retaining the front pump linkage to the LH motion control assembly (Fig. 196). 9. Remove the pivot hub from the LH motion control (Fig. 198). 3 Fig. 198 Fig. 196 8. Remove the bolt securing the pivot hub and the LH motion control to the frame (Fig. 197). 10. Remove the wire harness anchor from the LH motion control (Fig. 199). Fig. 199 Fig.
CHASSIS 11. Remove the neutral switch from the LH motion control (Fig. 200). 13. Remove the jam nut from the LH motion control lever (Fig. 202). 3 Fig. 200 Fig. 202 DSCN-4476a 12. Remove the carriage bolt and nut retaining the leaf spring to the LH motion control (Fig. 201). 14. Remove the nut, two spring washers, flat washer and LH motion control lever from the LH motion control (Fig. 203). AB C C D Fig. 201 DSCN-4480 E F DSCN-4492b Fig. 203 A. Jam nut B. Nut C.
CHASSIS Motion Control Assembly Installation 3. Install flat washer on motion control lever (Fig. 206). 1. Install 4 new flange bushings in the LH motion control (Fig. 204). 3 Fig. 206 Fig. 204 DSCN-4487a DSCN-4489a 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 Fig.
CHASSIS 5. Install the nut and tighten so it is snug (Fig. 208). 7. Install the neutral switch to the motion control lever (Fig. 210). 3 Fig. 208 DSCN-4491a Fig. 210 6. Install the spring leaf with carriage bolt and nut (Fig. 209). Fig. 209 DSCN-4495a 8. Install the wire harness anchor to the motion control lever (Fig. 211). DSCN-4492a Fig.
CHASSIS 9. Secure the LH control assembly to the frame with a bolt and the pivot tube (Fig. 212). 11. Install the wiring harness in the wire anchor located on the LH motion control assembly (Fig. 214). 3 Fig. 212 DSCN-4473a 10. Install the plug connector to the neutral switch (Fig. 213). Fig. 213 3-60 DSCN-4500a Fig. 214 DSCN-4502a 12. Install the lock nut from the damper motion control to the LH motion control assembly (Fig. 215). Fig.
CHASSIS 13. Secure the front pump linkage assembly to the LH motion control assembly with a bolt, washer and nut. 16. Install the 2 screws retaining the LH motion control cover assembly (Fig. 218). Note: The washer must be installed between the LH motion control assembly and the ball joint on the front pump linkage assembly (Fig. 216). 3 Fig. 218 Fig. 216 DSCN-4470a 14. Install the two bolts and nuts retaining the LH steering handle assembly to the LH motion control lever (Fig. 217). Fig.
CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
ENGINE Engine Replacement 3. Raise the machine in the rear and support it with jack stands (Fig. 220). Note: The following procedure for removing and installing the engine was performed on a Kohler 29 HP EFI engine. You can follow the same procedures for removing other engines from the Z Master G3, 3000, 5000, and 6000 Series units. Engine Removal 1. Remove the battery negative and positive cables. Remove the battery from the frame. 2.
ENGINE 5. Remove the 3 carriage bolts and nuts retaining the LH bumper to the frame and rear guard (Fig. 222). 4 Fig. 222 DSCN-0004a 6. Remove the 2 nuts retaining the rear guard to the frame and 1 carriage bolt and nut retaining the muffler guard to the rear guard (Fig. 223). 7. Loosen the cable clamp and remove the throttle cable (Fig. 224). Fig. 224 8. Remove the z-bend end of the cable from the throttle arm assembly (Fig. 225). Fig. 225 Fig.
ENGINE 9. Remove the fuel line from the fuel filter (Fig. 226). Fig. 226 11. Remove the vent line from the air filter assembly (Fig. 228). DSCN-0013a Fig. 228 10. Remove the fuel hose from the hose clamp and pull the hose forward away from the engine (Fig. 227). Fig. 227 DSCN-0018a 12. Lift and remove the floor pan; then, with a 3/8” breaker bar in the hole for the idler arm, turn clockwise to loosen the mower deck drive-belt and remove it from the electric PTO clutch (Fig. 229). DSCN-0011a Fig.
ENGINE 13. Using a 1/2” drive breaker bar installed in the square hole in the pump idler assembly, rotate the pump idler arm counter-clockwise to relieve tension on the v-belt (Fig. 230). Remove the v-belt from around the engine drive pulley. 4 15. Remove the bolt, spring washers, and washer retaining the electric PTO to the engine crankshaft (Fig. 232). Slide the clutch off the crankshaft. Fig. 232 Fig. 230 DSCN-0025a 14. Unplug the wire plug from the electric PTO clutch (Fig. 231). 16.
ENGINE 17. Remove the key from the engine crankshaft (Fig. 234). Fig. 234 DSCN-0034a 18. Remove the 4 engine bolts and Belleville washers retaining the engine to the frame (Fig. 235). Fig. 235 19. With a hoist raise the engine approximately 6” above the frame (Fig. 236). Fig. 236 DSCN-0047a 20. Remove the starter motor bolt at the top of the starter, then remove the battery ground wire and the wiring harness ground wire (Fig. 237). DSCN-0038a Fig.
ENGINE 21. Unplug the wiring harness plug from the engine harness plug (Fig. 238). 23. Remove the engine from the frame (Fig. 240). Fig. 240 4 Fig. 238 DSCN-0053a DSCN-0049a 22. On the bottom of the starter solenoid disconnect the red wire and red positive cable (Fig. 239). Fig.
ENGINE Engine Installation 4. Plug the wiring harness plug into the engine wiring harness plug connector (Fig. 243). 1. Place the engine approximately 6” above the frame in the engine bay area. 2. Install the battery ground cable and wiring harness ground wire to the starter motor bolt (Fig. 241). Fig. 243 DSCN-0049a 5. Lower the engine to the frame. Fig. 241 DSCN-0043a 6. Align the four holes of the engine base to the frame using 4 bolts and Belleville washers. Torque the bolts to 30 ± 3 ft-lbs.
ENGINE 7. Install the key to the engine crankshaft (Fig. 245). 9. Install the bolt, spring washers (with crown of the washers facing the bolt head), and washer (Fig. 247). C B A Fig. 245 4 DSCN-0034a Fig. 247 8. Install the engine sheave on the crankshaft (Fig. 246). A. Bolt B. Spring Washer (2) DSCN-0060a C. Washer 10. Install the electric PTO clutch on the crankshaft, make sure the slot on the clutch fits on the clutch anchor.
ENGINE 11. Plug the clutch wire plug into the electric PTO clutch (Fig. 249). Fig. 249 13. Using a 3/8” breaker bar, install the mower idler arm assembly and relieve the tension on the idler arm assembly. Install the mower drive belt around the electric PTO clutch (Fig. 251). DSCN-0028a Fig. 251 12. Using a 1/2” drive breaker bar installed in the square hole in the pump idler assembly, rotate the pump idler arm counter-clockwise to allow room to install the v-belt around the engine pulley (Fig. 250).
ENGINE 16. Route the fuel line and the throttle cable through the hose clamp located on the right hand side of the frame next to the battery box (Fig. 253). 18. Slide the throttle cable through the hose clamp located next to the engine (Fig. 255). Fig. 255 4 Fig. 253 17. Install the fuel line and fuel clamp on the fuel filter (Fig. 254). 19. Install the z-bend of the throttle cable into the middle hole in the throttle arm assembly (Fig. 256). Fig. 256 Fig.
ENGINE 20. Install the throttle cable in the cable clamp (Fig. 257). Fig. 257 22. Move the throttle arm assembly to the low-idle position and tighten the throttle cable clamp (Fig. 259). DSCN-4253a Fig. 259 21. Move the throttle control to the slow idle position (Fig. 258). DSCN-4281a 23. Move the throttle control back and forth, checking the operation of the throttle arm assembly. 24.
ENGINE 25. Install 3 carriage bolts and nuts retaining the LH bumper to the frame and rear guard (Fig. 261). 4 Fig. 261 DSCN-0004a 26. Install the 3 carriage bolts and nuts retaining the RH bumper to the frame and rear guard (Fig. 262). Fig. 262 DSCN-4637a 27. Turn the fuel shut off valve to the “On” position; for tilt seats, lift the seat; for non-tilt seats, slide the seat forward to access the fuel shut off valve. 28.
HYDRAULIC SYSTEM Hydrostatic Pump Removal 4. Remove the negative battery cable from the battery (Fig. 263). Note: Cleanliness is a key factor in a successful repair of any hydrostatic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts by using a solvent wash and air-drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
HYDRAULIC SYSTEM 6. Lower the mower deck to the lowest position. Lift the floor pan up and remove it (Fig. 265). 8. Remove the mower deck drive belt from the center mower spindle pulley (Fig. 267). Note: On international models, unbolt the floor pan. Fig. 267 Fig. 265 5 PICT-8543 7. With a 3/8” drive breaker bar installed in the square hole of the idler bracket, rotate the idler bracket clockwise to relieve belt tension (Fig. 266). 9.
HYDRAULIC SYSTEM 10. Raise the rear of the unit and support it with 2 jack stands placed under the right and left tie down loops (Fig. 269). Note: Tires should be at least 6” (15.2cm) off the floor. 12. Using a 1/2” drive breaker bar installed in the square hole in the pump idler assembly, rotate the pump idler arm counter-clockwise to relieve tension on the v-belt (Fig. 271). Fig. 271 Fig. 269 PICT-8548 13.
HYDRAULIC SYSTEM 14. On the side of the machine being serviced, remove the bolt and washer securing the hydro control arm to the hydro drive control shaft (Fig. 273). Fig. 273 5 PICT-8563 15. On the side of the machine being serviced, pry the control arm off the square tapered shaft (Fig. 274). 16. On the side of the machine being serviced, remove the cotter pin securing the castle nut to the wheel hub (Fig. 275). Fig. 275 PICT-8578 17.
HYDRAULIC SYSTEM 18. Release the parking brake. 19. Remove the nut securing the brake swivel to the brake caliper arm (Fig. 277). 21. Remove the caliper assembly from the wheel hub (Fig. 279). Fig. 279 Fig. 277 PICT-8582a 20. Remove the 2 bolts and washers securing the brake caliper to the UHT (Fig. 278). Note: There is a spacer washer on each bolt between the caliper bracket and the UHT. 22. Repeat steps 19 – 21 on the opposite side of the machine. 23.
HYDRAULIC SYSTEM 24. Squeeze the tabs on the brake cable and pull the brake cable out of the slot in the cable anchor bracket (Fig. 281). Fig. 281 26. Release the brake cable retainer holding the brake cable to the cradle. Pull the retainer toward the end of the cable and push the cable through the routing holes so the slack is on the front side (Fig. 283). PICT-8655 Fig. 283 5 25. Pull back the rubber boot, exposing the brake cable, and slide the cable out of the cable anchor bracket slot (Fig. 282).
HYDRAULIC SYSTEM 29. On the side of the machine being serviced, remove the bottom carriage bolt and nut securing the UHT to the cradle (Fig. 285). Fig. 285 PICT-8605a 30. On the side of the machine being serviced, loosen the 2 carriage bolts and nuts located on either side of the UHT securing it to the cradle (Fig. 286). Fig. 286 PICT-8607a Toro Z Master G3 3000/5000/6000 Series Service Manual 31.
HYDRAULIC SYSTEM 33. On the side of the machine being serviced, remove the 2 bolts securing the UHT to the frame (Fig. 289). 35. Remove the 2 nuts from the bolts securing the UHT to the cradle (Fig. 291). Caution: The UHT weighs approximately 80 lbs. (36.29kg). Fig. 289 PICT-8619a Fig. 291 5 34. Lower the UHT/cradle assembly from the frame by lowering the floor jack. Take care that the brake cables and UHT fan are clear of the frame (Fig. 290). PICT-8623a 36. Remove the UHT from the cradle (Fig.
HYDRAULIC SYSTEM G3 UHT Transmission Installation (2009 2011 models) 1. Using the top 2 bolts as guides, position the UHT into the cradle and slide the unit onto the 2 bolts (Fig. 293). 3. Lift the UHT/cradle assembly up to the frame with a floor jack. Align the UHT mounting holes with the holes in the frame (Fig. 295). On the opposite side, ensure the cradle mounting holes align with the mounting holes on the UHT (Fig. 296). Note: Be careful not to damage the UHT drive pulley.
HYDRAULIC SYSTEM 4. Raise the mower deck to the 3” (7.6cm) height-of-cut position. 5. On the side of the machine that was serviced, loosely install 2 mounting bolts, coming from the top down, through the frame and into the UHT (Fig. 297). 7. On the side of the machine being serviced, tighten the 3 bolts securing the cradle to the UHT and the 2 bolts securing the UHT to the frame (Fig. 299). B B A A A Fig. 299 PICT-8640a A. Cradle to UHT nuts B. UHT mounted to frame bolts Fig. 297 5 PICT-8638a 6.
HYDRAULIC SYSTEM 9. Remove the floor jack. 10. Apply thread locking compound to control arm bolt (Fig. 301). 12. Install the left hand brake cable retainer into the cradle so that the retainer tab is installed in the slot on the cradle (Fig. 303). Fig. 303 Fig. 301 11. Install the control arm bolt and washer securing the control arm linkage to the UHT. Torque the bolt to 10 ft-lbs. (13.55 Nm) (Fig. 302). 13. Route the left hand brake cable around the cradle and into the cable retainers (Fig. 304). Fig.
HYDRAULIC SYSTEM 14. Pull the boot back and slide the brake cable into the slot in the cable anchor bracket. Slide the boot up and over the end of the cable retainer to ensure water is sealed out (Fig. 305). 17. Slide the brake cable swivel through the brake caliper and loosely install a nut onto the swivel (Fig. 307). Fig. 307 Fig. 305 5 PICT-8663a PICT-8659a 15. Repeat steps 12 and 14 to install the right hand brake cable. 16.
HYDRAULIC SYSTEM 19. Repeat step 18 to install the other brake mounting bolt. 20. Tighten the brake cable swivel nut to secure (Fig. 309). Adjust the Parking Brake: Note: For this example, the left side brake is being adjusted; the right side brake adjustment is the same procedure. 22. Open the valve(s) (vertical position) on the UHTs (Fig. 310). Fig. 309 PICT-8668a Fig. 310 21. Repeat steps 17 thru 20 to install the brake caliper on the opposite wheel hub.
HYDRAULIC SYSTEM 25. While holding the lever, pull the cable threaded end tight through the swivel. Spin the standard nut against the swivel (Fig. 312). 29. Once step 26 is achieved, hold the threaded rod end with a tool and tighten the lock nut against the standard nut. Do not allow the cable to turn when the lock nut is tightened (Fig. 313). A B C DE F G I Fig. 312 5 H PICT-8680a 26. Try to turn the wheel hub in both directions relative to the caliper.
HYDRAULIC SYSTEM 30. Close the drive wheel release valve (horizontal operating position) (Fig. 314). 34. Check the distance from the bottom of the slot in the castle nut to the inside edge of the cross hole in the shaft. Two threads or less should be showing (Fig. 316). A Fig. 314 PICT-8677a B 31. Repeat steps 24 - 30 on the opposite side of the machine. Fig. 316 32. Engage the parking brake. 33. Torque the castle nut to 200 ft-lbs. (271 Nm) (Fig. 315). Fig. 315 fig. 58 G008603 A. 0.
HYDRAULIC SYSTEM 35. If more than two threads (0.1”/25mm) are showing, remove the nut and install a washer between the hub and the castle nut. 36. If a washer was added, re-torque the slotted nut to 200 ft-lbs. (271 Nm) (Fig. 317). 39. Using a 1/2” drive breaker bar installed in the square hole in the pump idler assembly, rotate the idler arm counter-clockwise, tensioning the spring to allow room to install the belt (Fig. 319). Fig. 319 Fig. 317 5 PICT-8557a PICT-8687a 37.
HYDRAULIC SYSTEM 41. Route the mower deck drive belt around the electric PTO clutch (Fig. 321). Fig. 321 43. Route the mower deck drive belt around the mower deck pulleys. Refer to the mower deck routing decal (Fig. 323). PICT-8693a 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 Fig.
HYDRAULIC SYSTEM 44. Install rear wheels and torque lug nuts to 90 - 95 ft-lbs. (122 - 129 Nm). 48. Install the floor pan (Fig. 326). 45. Lower the machine to the ground. 46. Connect the negative battery cable to the battery (Fig. 324). Fig. 326 Fig. 324 5 PICT-8543 PICT-8541a 47. Reinstall the guard above the UHT (Fig. 325). Fig.
HYDRAULIC SYSTEM Check the hydraulic fluid level: 49. Raise the seat up. 50. Clean the area around the dipsticks of UHT reservoirs (Fig. 327). 51. Remove one dipstick from the UHT reservoir (Fig. 327). 52. Wipe the dipstick off and thread the dipstick into the reservoir. 53. Remove the dipstick and look at the metal end (Fig. 327). The level needs to be within knurled section. If oil level is low, slowly pour only enough oil into the UHT reservoir to raise the level to the knurled section. 58.
HYDRAULIC SYSTEM Burnishing the Brake 3. Clear the area of any flammable material before starting the burnishing process. 1. Raise the rear of the machine and support it with 2 jack stands placed under the right and left tie down loops (Fig. 328). 4. Rotate the drive wheel release valve to the “operating” position (Fig. 330). A Fig. 328 5 B PICT-8548 Fig. 330 2. Remove the two rear wheels (Fig. 329). fig. 36 G008957 A. Vertical: “released” B.
HYDRAULIC SYSTEM 7. Start the mower while in the operating position. 15. Ensure the parking brake is disengaged. 8. Release the parking brake so the handle rests on the 1/2” x 6” rod or bolt. 16. Using your thumb, push the caliper lever arm for ward to engage the brake pads on the wheel hub until the lever stops (Fig. 333). 9. Move the throttle over to the full throttle position. 10. Move both motion control levers to the full forward position and hold for 15 seconds.
HYDRAULIC SYSTEM 17. While holding the lever, pull the cable threaded end tight through the swivel. Spin the standard nut against the swivel (Fig. 334). 21. Once step 18 is achieved, hold the end of the threaded rod with a tool and tighten the lock nut against the standard nut. Do not allow the cable to turn when the nuts are turned (Fig. 335). A B C DE F G I Fig. 334 5 H PICT-8680a 18. Try to turn the wheel hub in both directions relative to the caliper.
HYDRAULIC SYSTEM 22. Close the drive wheel release valve (horizontal operating position) (Fig. 336). UHT Transmission Replacement (2012 & later models) UHT Transmission Removal (2012 & later models) Note: The following procedures cover replacing the left hand UHT transmission. The same procedures can be followed to remove the right hand UHT Transmission. 1. Position the machine on a level surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position. Apply the park brake.
HYDRAULIC SYSTEM 6. Using a 1/2” drive breaker bar installed in the square hole in the pump idler assembly, rotate the pump idler arm counter-clockwise to relieve tension on the v-belt (Fig. 338). 8. On the side of the machine being serviced, remove the bolt and washer securing the hydro drive control shaft (Fig. 340). Fig. 340 Fig. 338 5 7. With the tension removed from the belt, remove the v-belt from around the left side transmission pulley (Fig. 339). Fig. 339 9.
HYDRAULIC SYSTEM 10. On the side of the machine being serviced, remove the locknut from the wheel hub (Fig. 342). Fig. 342 13. Hold the end of the threaded rod with a tool. With a socket wrench, remove the lock nut and washer from the end of the cable (Fig. 344). Remove the washer and spring. DSCN-4516a Fig. 344 DSCN-4315a 11. Disengage the park brake lever. 12. Remove the e-ring, washer, and brake pin from the L-Bracket (Fig. 343). Fig. 343 14.
HYDRAULIC SYSTEM 15. Pull the brake cable out of the cable anchor on the transmission and slide it out of the slot (Fig. 346). Fig. 346 17. On the side of the machine not being serviced, remove the three carriage bolts and nuts securing the UHT transmission to the cradle (Fig. 348). DSCN-4325a Fig. 348 5 16. On the side of the machine being serviced, use a wheel hub puller (Toro part number TOR6006) to remove the wheel hub from the UHT wheel shaft (Fig. 347). Fig.
HYDRAULIC SYSTEM 19. Position a floor jack under the cradle on the side of the machine being serviced. Raise the floor jack to contact the cradle (Fig. 350). 21. Lower the UHT transmission/cradle assembly from the frame by lowering the floor jack. Take care that the UHT transmission fan clears the frame. Note: Ensure the control arm shaft clears the frame, and the control arm linkage doesn’t get caught between the frame and the UHT transmission, as it is being lowered. 22.
HYDRAULIC SYSTEM UHT Transmission Installation (2012 & later models) 1. Using the top two bolts as guides, position the UHT transmission into the cradle and slide the unit onto the two bolts (Fig. 354). 3. Lift the UHT transmission/cradle assembly up to the frame with a floor jack. On the side of the machine that was serviced, loosely install two mounting bolts, coming from the top down, through the frame and into the UHT transmission (Fig. 356).
HYDRAULIC SYSTEM 5. Loosely install three bolts and nuts securing the cradle to the UHT transmission that was not servic ed. The floor jack might have to be repositioned to align holes (Fig. 358). Fig. 358 DSCN-4551a 7. On the side of the machine being serviced, tighten the 3 bolts and nuts securing the cradle to the UHT transmission and the 2 bolts securing the UHT transmission to the frame, torque the nuts and bolts to 75 ± 8 ft-lbs. (101.7 ± 10.8 Nm) (Fig. 359). B 8.
HYDRAULIC SYSTEM 11. Install the control arm bolt and washer securing the control arm linkage to the UHT transmission. Torque the bolt to 10 ft-lbs. (13.55 Nm) (Fig. 362). 13. Slide the brake cable into the cable anchor slot on the transmission (Fig. 364). Fig. 364 Fig. 362 5 DSCN-4325a DSCN-4554a 12. Slide the wheel hub onto the UHT transmission shaft aligning the keyway in the wheel hub with the key in the UHT shaft. Loosely install the nut (Fig. 363). 14.
HYDRAULIC SYSTEM 15. Install the L-Bracket, spring, washer, and nut on the threaded end of the brake cable (Fig. 366). 17. Engage the parking brake. Measure the overall length of the compression spring (Fig. 368). The correct length should be between 1-1/2” and 1-9/16” (3.8 and 4.9cm). If the spring length is within this range, no adjustment is needed. If it is not, proceed. A BC D AF Fig. 366 DSCN-4336a HG E 16. Install the L-Bracket with brake pin, washer, and e-ring to the brake caliper (Fig. 367).
HYDRAULIC SYSTEM 18. Hold the end of the threaded rod with a tool and adjust the lock nut until the spring length is between 1-1/2” and 1-9/16” (3.8 and 4.0cm) (Fig. 369). Note: DO NOT allow the cable to turn when the nut is being turned. Wheel Hub Slotted Nut Installation 22. Installing the wheel Hub slotted nut • Style A (black finish): (Fig. 370) Torque the slotted nut to 211 - 260 ft-lbs. (286 - 352 Nm). Note: Do Not use anti-seize on wheel hub. A Fig. 369 5 DSCN-4315a 19.
HYDRAULIC SYSTEM a. Torque the slotted nut to 200 ft-lbs. (271 Nm). b. Check distance from bottom of slot in nut to inside edge of hole. Two threads (0.1” / 0.0cm) or less should be showing. c. 23. Using a 1/2” drive breaker bar installed in the square hole in the pump idler assembly, rotate the idler arm counter-clockwise to relieve tension and install the v-belt around the engine pulley, UHT transmission pulleys and the idler pulley (Fig. 372). If more than two threads (0.1” / 0.
HYDRAULIC SYSTEM Adjusting the Motion Control Linkage (Neutral Adjustment) 1. Prior to starting the engine, push the deck lift pedal and remove the height of cut pin. Lower the deck to the ground. The adjustment nuts are located on either side of the fuel tank, below the seat on the pump control linkages (Fig. 373). Rotating the pump linkage nuts with a 1/2” wrench allows fine tuning adjustments so that the machine does not move in neutral.
HYDRAULIC SYSTEM 5. Start engine. Note: Brake must be engaged and motion control levers out to start the engine. Operator does not have to be in the seat because of the jumper wire being used. 6. Run engine at full throttle and release the brake. 7. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature. Note: The motion control lever needs to be in neutral while making any necessary adjustments. 8.
HYDRAULIC SYSTEM Checking the Hydraulic Oil 6. Clean the area around the dipsticks of hydraulic system reservoirs (Fig. 377). Service Interval: Every 50 hours - check the hydraulic oil level 1. Position the machine on a level surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. AC B 4.
HYDRAULIC SYSTEM Flow Test Instructions Note: The Flow Test Kit allows the dealer to easily determine if the UHT transmission pump is faulty by isolating the pump section from the wheel motor (Fig. 378). 1. Raise the rear end of the unit and install jack stands under the tie down loops on the frame. Remove the RH and LH wheels from the unit (Fig. 379). The following information describes how to test the pump by installing the Flow Test Kit and simulating a wheel motor load.
HYDRAULIC SYSTEM 3. Unplug the seat switch and temporarily install a jumper wire across the terminals in the connector of the main wiring harness (Fig. 381). 4. Isolate the pump from the wheel motor by removing the two plugs from the top of the wheel motor assembly and installing the flow test kit. Install the Diagnostic Plug in port “A”, and the Straight Fitting into port “B” (Fig. 382). Take precautions to ensure no debris gets into the wheel motor system ports. A Fig. 381 B DSCN-4620a Fig.
HYDRAULIC SYSTEM 5. Completely open the restriction valve on the flow tester. 6. Start the engine. 7. Slowly bring engine up to maximum operating speed. 8. Move the vehicle’s motion control lever on the side that is being tested all the way into the forward position. Have someone hold the motion control lever to prevent false readings. 9. Continue to operate without any load to allow the system oil temperature to rise. Note: Raising the temperature of the oil will make a difference in your readings.
HYDRAULIC SYSTEM Hydraulic Pump Drive Belt Replacement 5. Use a ratchet or breaker bar in the square hole of the idler arm to remove the idler spring (Fig. 385). A 1. Disengage the PTO and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. B C G F 3. Remove the mower belt. Refer to “Mower Belt Removal” on page 6-1. 4. Raise the rear of the machine and support it with jack stands (Fig. 384). D E Fig. 385 A. B. C. D.
HYDRAULIC SYSTEM Using the Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Stop the engine, remove the key, and allow all moving parts to stop before accessing the drive wheel release valves. 2. Rotate the release valve levers vertically to push the machine. This allows hydraulic oil to by-pass the pump enabling the wheels to turn (Fig. 386).
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MOWER DECKS Mower Belt Replacement 5. Lift the floor pan. Mower Belt Removal 6. With a 3/8” ratchet or breaker bar in the square hole in the idler arm, release tension on the idler-spring (Fig. 388). 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Lower the mower to the 3” (76mm) height-of-cut. 4.
MOWER DECKS 8. Remove the belt guide on the spring-loaded idler arm shown in (Fig. 390). Mower Belt Installation 1. Install the new belt around the mower deck pulleys and the clutch pulley under the engine (Fig. 391). A Fig. 390 9. Remove the existing belt. BC D E DSCN-0069a G F Fig. 391 A. Clutch pulley E. B. Mower belt C. Spring-loaded idler F. pulley G. D. Ratchet 6 fig. 81 G009038 Square hole in the idler arm for the ratchet Idler grease zerk Belt guide 2.
MOWER DECKS 4. Install the RH and LH belt covers (Fig. 392). Mower Deck Replacement Mower Deck Removal Note: Before servicing or removing the mower deck, the spring loaded deck arms must be locked out. WARNING Deck lift-arm assemblies have stored energy. Removing the deck with out releasing the stored energy can cause serious injury or death. Do not attempt to disassemble the deck from the front frame without locking out the stored energy. Fig. 392 DSCN-0064a 1.
MOWER DECKS 5. Lift up the floor pan and insert a ratchet or breaker bar into the square hole in the deck idler assembly (Fig. 394) A BC D E G F Fig. 394 6 A. Clutch pulley E. B. Mower belt C. Spring-loaded idler F. pulley G. D. Ratchet fig. 81 G009038 Square hole in the idler arm for the ratchet Idler grease zerk Belt guide 6. Rotate the deck idler assembly clockwise and remove the mower drive belt from electric PTO clutch pulley (Fig. 394).
MOWER DECKS 7. Remove and retain the hardware on both sides of the deck (Fig. 395 or Fig. 396). C C B A D D B A C Fig. 396 Fig. 395 fig. 105 G009197 A. Right stabilizer B. Deck strut (right side shown) C. Remove the rear deck lift attachment shoulder bolt & nut D. Remove the front deck lift attachment shoulder bolt & nut Toro Z Master G3 3000/5000/6000 Series Service Manual fig. 106 G010252 A. Right stabilizer B. Deck strut (right side shown) C.
MOWER DECKS Mower Deck Installation Reverse the order of mower deck removal. Extension Spring Adjustment (2010 2012 Models) Fig. 397 DSCN-0136 Fig.
MOWER DECKS Mower Spindle Replacement Mower Spindle Removal (2009 Model G3 Series Units) 4. Lift and remove the floor pan and with a 3/8” ratchet or breaker bar in the square hole for the idler arm, loosen the mower deck drive-belt and remove belt from RH mower spindle-pulley (Fig. 400). The following procedure applies to removing any of the three mower spindles. This example shows removing the right side spindle. 1.
MOWER DECKS 6. Raise the mower deck to the transport position. 7. Remove the mower blade from the spindle assembly. 8. Remove the 5 bolts and nuts retaining the spindle assembly to the mower deck (Fig. 402). Fig. 402 Mower Spindle Installation (2009 Model G3 Series Units) Reverse the order of mower spindle removal (2009 model G3 Series units).
MOWER DECKS Mower Spindle Disassembly (2009 Model G3 Series Units) 4. Remove the bearing shield (Fig. 405). 1. Place the blade saddle in a vise. 2. Remove the nut and washer (Fig. 403). Fig. 405 Fig. 403 DSCN-2669a DSCN-2671a 5. Remove the spindle housing from the spindle shaft assembly (Fig. 406). 3. Remove the pulley hub and square key (Fig. 404). 6 Fig. 406 Fig.
MOWER DECKS 6. Remove the seal spacer from the top of the spindle housing (Fig. 407). Fig. 407 DSCN-2673a 7. Remove the seal spacer from the bottom of the spindle housing (Fig. 408). 8. Remove the top oil seal from the spindle housing (Fig. 409). Fig. 409 DSCN-2675a 9. Remove the bearing from the top of the spindle housing (Fig. 410). 6 Fig. 408 6-10 DSCN-2674a Fig.
MOWER DECKS 10. Remove the spacer (Fig. 411). Fig. 411 12. Remove the bearing from the bottom of the spindle (Fig. 413). DSCN-2677a Fig. 413 11. Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing (Fig. 412). Note the orientation of the lower oil seal. The open end of the seal faces outwards to help relieve pressure from over-greasing the spindle assembly. DSCN-2680a 13.
MOWER DECKS 14. Remove the large spacer in the spindle housing (Fig. 415). Mower Spindle Assembly (2009 Model G3 Series Units) 1. Install the spacer through the top of the spindle housing (Fig. 417). Fig. 415 DSCN-2682a 15. This view shows the 2 bearing races and the large spacer in the spindle housing (Fig. 416). A B 6 Fig. 417 DSCN-2688a 2. Using a press, install the upper bearing race into the spindle housing (Fig. 418).
MOWER DECKS 3. Turn the spindle housing over and install the lower bearing race into the spindle housing (Fig. 419). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing. 5. Install the lower seal (Fig. 421). Note: The open lip of the seal should be facing outward. Fig. 421 Fig. 419 DSCN-2692a DSCN-2690a 4. Pack the bearing with No. 2 grease and install the bearing (Fig. 420). 6.
MOWER DECKS 7. Install the inner spacer to the spindle assembly (Fig. 423). 9. Install the seal. Press it flush with the top of the housing (Fig. 425). Note: The open lip of the faces inward. Fig. 423 DSCN-2700a Fig. 425 8. Pack the bearing with No. 2 grease and install the bearing (Fig. 424). DSCN-2696a 10. Install the bearing shield and the seal spacer onto the spindle shaft (Fig. 426). 6 Fig. 424 DSCN-2694a Fig.
MOWER DECKS 11. Lower the spindle housing over the spindle shaft (Fig. 427). 13. Install bearing shield (Fig. 429). Fig. 429 Fig. 427 DSCN-2705a DSCN-2703a 12. Install the seal spacer on the top of the spindle housing (Fig. 428). 14. Install the square key onto the spindle shaft. 15. Install the pulley hub on the spindle shaft (Fig. 430). 6 Fig. 428 DSCN-2704a Toro Z Master G3 3000/5000/6000 Series Service Manual Fig.
MOWER DECKS 16. Install the heavy washer and nut on the top of the spindle shaft (Fig. 431). Note: The cup side of the washer should be facing down toward the pulley hub. Mower Spindle Replacement (2010 & Later Model G3, 3000/5000/6000 Series Units) Mower Spindle Removal (2010 & Later Model G3, 3000/5000/6000 Series Units) Note: The following procedure applies to removing any of the three mower spindles. This proce dure shows removing the right side spindle. 1.
MOWER DECKS 4. Lift and remove the floor pan. With a 3/8” ratchet or breaker bar in the square hole for the idler arm, loosen the mower deck belt and remove the belt from the RH mower spindle-pulley (Fig. 434). Mower Spindle Installation (2010 & Later Model G3, 3000/5000/6000 Series Units) Reverse the order of mower spindle removal (2010 & later model G3, 3000/5000/6000 Series units). 1. Install the spindle assembly in the mower deck and tighten the 6 flange nuts. Torque the nuts to 37 ± 4 ft-lbs. (50 ± 5.
MOWER DECKS Mower Spindle Disassembly (2010 & Later Model G3, 3000/5000/6000 Series Units) 3. Remove the spindle hub assembly (Fig. 438). 1. Remove the 3 flange nuts retaining the pulley to the spindle hub (Fig. 436). Fig. 438 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). 6 Fig. 439 Fig.
MOWER DECKS 7. Remove the spacer from the spindle housing (Fig. 442). 5. Remove the top oil seal (Fig. 440). Fig. 440 DSCN-0092a Fig. 442 6. Using a hammer and driver with a square edge, drive the bearing out of the spindle housing (Fig. 441). DSCN-0094a 8. Using a hammer and driver with a square edge, drive the bottom bearing and seal out of the spindle housing (Fig. 443). 6 Fig. 441 DSCN-0093 Fig.
MOWER DECKS Note: There is a snap ring located in the spindle housing (Fig. 444). If replacing the bearings and seals only, there is no need to remove the snap ring, unless it shows damage. Mower Spindle Assembly (2010 & Later Model G3, 3000/5000/6000 Series Units) 1. Install the bottom bearing. Press up against the snap ring (Fig. 445). 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). 6 Fig.
MOWER DECKS 3. Install the spacer in the spindle housing (Fig. 447). Fig. 447 4. Turn the spindle housing over and press the bearing in the bottom of the housing until the bearing seats against the spacer (Fig. 448). DSCN-0116a Fig. 448 DSCN-0111a Note: The open lip of the seal should be facing outward (Fig. 449). 6 Fig.
MOWER DECKS 5. Press seal into the bottom of the spindle housing (Fig. 450). Fig. 450 DSCN-0115a 6. Install spindle shaft in the spindle housing (Fig. 451). 7. Install the spindle hub on the spindle shaft (Fig. 452). Fig. 452 DSCN-0123a 8. Install the washer and lock nut retaining the spindle hub to the spindle shaft. Torque the nut to 120 ± 5 ft-lbs. (162.7 ± 6.8 Nm) (Fig. 453). 6 Fig. 451 DSCN-0122a Fig. 453 DSCN-0125 9.
MOWER DECKS Leveling the Mower Deck 6. Insert the height adjustment pin into the 3” (7.6cm) cutting height location. Deck Leveling 7. Release the transport lock and allow the deck to lower to the cutting height. Note: Ensure the mower deck is leveled before matching the height-of-cut (HOC). 8. Raise the discharge chute. 1. Position the mower on a flat surface. 2. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 9.
MOWER DECKS 10. For mower decks shown below, fine-tune the adjustment nut on the front deck lift-assembly by turning it (Fig. 456). 11. For mower decks shown below, fine-tune the adjustment nut on the front deck lift-assembly by turning it (Fig. 457). Note: To increase the height, turn the adjustment nut clockwise; to decrease, turn counter clockwise. Note: To increase the height, turn the adjustment nut clockwise; to decrease, turn counter clockwise. A B CD CD B A 6 BA Fig. 456 A.
MOWER DECKS 12. If the front deck links do not have enough adjust ment to achieve accurate cut height, the single point adjustment can be utilized to gain more adjustment. 13. To adjust the single point system, loosen the two bolts at the bottom of the height-of-cut plate (Fig. 458). 14. If the deck is too low, tighten the single point adjust ment bolt by rotating it clockwise. If the deck is too high, loosen the single point adjustment bolt by rotating it counterclockwise (Fig. 459).
MOWER DECKS 15. Tighten the two bolts at the bottom of the height-ofcut plate (Fig. 460). Torque to 27-33 ft-lbs. (37-45 Nm). 16. On both sides of the deck, measure from the level surface to the back tip of the blade (Position B). The measurement should read 3-1/4” (8.3cm) (Fig 461). Note: In most conditions, the back blade tip should be adjusted 1/4” (6.4mm) higher than the front. 1 4 2 3 A Fig. 460 6 fig. 96 G017029 Fig. 461 1. 3” (7.6cm) at A is 3. correct 2. 3-1/4” (8.
MOWER DECKS 17. Fine-tune the adjustment nut on the front deck lift assembly by turning it (Fig. 462). Servicing the Cutting Blades Note: To increase the height, turn the adjustment nut clockwise; to decrease, turn counter clockwise. Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.
MOWER DECKS Inspecting the Blades Checking for Bent Blades Service Interval: Before each use or daily 1. Inspect the cutting edges (Fig. 463). 1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake. Note: If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to “Sharpening the Blades” on page 6-30. 2.
MOWER DECKS 4. Rotate the opposite ends of the blades forward. Removing the Blades 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. Blades must be replaced if a solid object is hit, if the blade is out of balance, or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards. 6.
MOWER DECKS Sharpening the Blades Installing the Blades 1. Install the blade onto the spindle shaft (Fig. 468). WARNING When sharpening blade, pieces of blade could be thrown and cause serious injury. Wear proper eye protection when sharpening blade. 1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 466). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.
MOWER DECKS Electric PTO Clutch Replacement 4. Unplug the wire plug from the electric PTO clutch (Fig. 471). Electric PTO Clutch Removal 1. Remove the battery negative cable from the battery. 2. Lift and remove the floor pan. With a 3/8” breaker bar in the hole for the idler arm, loosen the mower deck drive-belt and remove from the electric PTO clutch (Fig. 469). Fig. 471 DSCN-0028a 5.
MOWER DECKS Electric PTO Clutch Installation 3. Plug the clutch wire plug into the electric PTO clutch (Fig. 475). 1. Prepare the clutch bolt, spring washers (with crown of the washers facing the bolt head), and washer (Fig. 473). C BA Fig. 475 Fig. 473 A. Bolt B. Spring Washer (2) 6 DSCN-0060a C. Washer DSCN-0028a 4. Using a 3/8” breaker bar, install the mower idler arm assembly and relieve the tension on the idler arm assembly. Install the mower drive belt around the electric PTO clutch (Fig.
MOWER DECKS Using the Clutch Shim Removing the Clutch Shim Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the point where the clutch no longer engages consistently, the shim can be removed to extend the clutch life (Fig. 477). E 1. Stop the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake. Allow the machine to cool completely before starting these instructions. 2.
MOWER DECKS 5. Measure the gap between the rotor and armature. If the gap is greater than 0.04” (1mm), proceed. 7. Using needle nose pliers, or by hand, take hold of the tab and remove the shim (Fig. 480). 6. Loosen both brake mounting-bolts one-half to one full turn (Fig. 479). Note: Do not discard the shim until proper clutch function has been confirmed. Note: Do not remove the brake pole from the field shell/armature.
MOWER DECKS 10. Using a 0.010” thick feeler gauge, verify that a gap is present between the rotor and armature face on both sides of the brake pole (Fig. 481 and Fig. 482). Safety Check Note: Due to the way the rotor and armature faces wear (peaks and valleys) it is sometimes difficult to measure the true gap. 2. Make sure the blades Do Not engage with the PTO switch “off ” and the clutch disengaged.
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ELECTRICAL General How It Works Note: Interactive Electrical Troubleshooting DVD, Part #492-9193 is also available. A relay is an electrically actuated switch. Relay Purpose There is one relay on this machine. 1. Start Relay: Functions as an electronic switch. Once the safety connections are met, the relay will activate completing the circuit to the starter solenoid. 1. Coil: Terminals 85 and 86 are connected to a coil.
ELECTRICAL Testing 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 486). Fig. 485 relay pin diagram Fig. 486 xl relay 1. Disconnect the relay from the harness. 2. Verify the coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be from 70 to 90 ohms. There should be continuity between terminals 87a and 30. 3. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to 85.
ELECTRICAL PTO Switch Testing Purpose 1. Disengage the PTO, set the parking brake, and turn the ignition to OFF and remove the key. The PTO (Power Take Off) switch is typically used to activate the Electric PTO Clutch and to function as part of the safety interlock system. 2. Remove the 4 screws holding the control panel to the fuel tank. 3. Disconnect the wiring harness from the PTO switch. Location 4.
ELECTRICAL 6. Replace the switch if your test results do not corre spond with those given in Fig. PTO switch test. 7. Mount the PTO switch back into the control panel and reinstall the wiring harness (Fig. 489). Pink/Black NC COM NC NC NO NO COM COM Grey Orange Fig.
ELECTRICAL Ignition Switch How It Works Purpose Detents inside the switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the key automatically returns to RUN when released (Fig. 491). The ignition switch makes the proper connections for the starter, accessories, and safety circuits. S Location The ignition switch is located on the control panel, on the right fender (Fig. 490). I B R A Fig. 491 Fig.
ELECTRICAL Park Brake Switch How It Works Purpose When starting, it functions to ensure the park brake is in the ON position. At the same time it allows current to flow through the remainder of the starting safety circuit. When the park brake is released in the OFF position, it bypasses both neutral switches, permitting the control levers to be used, as long as the operator is in the seat to maintain current to the safety circuit (Fig. 493).
ELECTRICAL Seat Switch How It Works Purpose When the seat is vacated, the switch is open and there should be NO continuity between the two terminals. When the seat is occupied, the switch closes and there should be continuity between the two terminals (Fig. 495). The switch is in the safety circuit. If the engine is running and the operator vacates the seat with either the PTO or the parking brake disengaged, the engine will shut down.
ELECTRICAL Neutral Safety Switch How It Works Purpose This single pole plunger (normally open) type switch has two terminals. When the motion control handles are in the neutral position (handles in the out position), it pushes on the plunger, closing the contact and connecting the terminals (Fig. 497). Used to ensure the motion control handles are in neutral to start the unit. It is activated by moving the motion control handles to the neutral position (handles outward).
ELECTRICAL TVS Diode How It Works Purpose This is a surge protector for the electric PTO clutch. It clamps the voltage off of the PTO clutch (Fig. 499). The TVS Diode is a surge protector for the electric PTO clutch. Location The TVS Diode is located on the right hand side of the engine, plugged into the wiring harness (Fig. 498). Fig. 499 DSCN-0149a Testing 1. Check to see if the 10 amp fuse is blown for the PTO clutch. Fig. 498 DSCN-0005a 2. With a multi-tester, check the oms.
ELECTRICAL Fuel Sender How It Works Purpose The sender measures the time it takes for and ultrasonic signal to travel from the sender to the fuel in the fuel tank and back to the sender to determine the fuel level (Fig. 501). The fuel sender uses an ultrasonic device that measures the level of fuel in the fuel tank. Location The fuel sender is located under the seat, on top of the fuel tank (Fig. 500). Fig. 501 Fig.
ELECTRICAL Fuel/Hour Meter How It Works Purpose The solid state multi-function meter which has no serviceable parts. The functions include an hour meter which records the number of hours the engine has operated. A fuel gauge which a light will light up when the fuel is low (about 1 gallon of fuel left) and also has indicator bars to indicate how much fuel is in the fuel tank. Battery light when the battery is low.
ELECTRICAL Electric PTO Clutch Coil Resistance Measurement Purpose 1. Disengage the PTO, set the parking brake, turn the ignition to the “off” position and remove the ignition key. The electric clutch controls the engagement and disengagement of the Power Take Off (PTO) pulley. 2. Disconnect the clutch harness from the main harness. Location 3. Set the multimeter or volt/ohm meter to check resistance (ohms). The electric clutch is located on the PTO end of the engine crankshaft. 4.
ELECTRICAL Measuring Clutch Current Draw 1. Disengage the PTO, set the parking brake, turn the ignition key to OFF, and remove the key. 2. Disconnect the PTO clutch harness from the main harness. 3. Set the multimeter to check amps (10 amp scale). 4. Connect the positive meter lead to terminal (1) of the main harness (Fig. 504). Fig. 504 diag 3-7a 5. Connect the negative meter lead to the clutch harness terminal (3) (Fig. 504). 6. Connect a short jumper lead from terminal (2) to terminal (4) Fig. 000.
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Toro Z Master G3 3000/5000/6000 Series Service Manual Form Number 492-9237
