Toro 476 - User Manual - manualsarea.com

Page 2 - ABOUT THIS MANUAL; The Toro Company

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 syst...

Page 4 - TABLE OF CONTENTS; - Safety Information

TABLE OF CONTENTS i Toro Z Master G3 3000/5000/6000 Series Service Manual 1 - Safety Information General Information .........................................................................................................................................1-1 Think Safety First...........................

Page 8 - SAFETY INFORMATION; General Information; Think Safety First

SAFETY INFORMATION 1-1 Toro Z Master G3 3000/5000/6000 Series Service Manual 1 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...

Page 10 - SPECIFICATIONS; Torque Specifications; Inch Series bolts and Screws

SPECIFICATIONS 2-1 Toro Z Master G3 3000/5000/6000 Series Service Manual 2 Torque Specifications Inch Series bolts and Screws (A) Grade 1 & 2 (B) Grade 5 (C) Grade 8 Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either th...

Page 13 - Other Torque Specifications; SAE Grade 8 Steel Set Screws

SPECIFICATIONS 2-4 Toro Z Master G3 3000/5000/6000 Series Service Manual 2 Other Torque Specifications Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Cutting Screws (Zinc Plated Steel) Conversion Factors in-lb X 11.2985 = N-cm ft-lb X 1.3558 = N-m Wheel Bolts and Lug Nuts ** For ste...

Page 14 - Equivalents & Conversions; Decimal & Millimeter Equivalents; Equivalents and Conversions; Decimal and Millimeter Equivalents

SPECIFICATIONS 2-5 Toro Z Master G3 3000/5000/6000 Series Service Manual 2 Equivalents & Conversions Decimal & Millimeter Equivalents Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03...

Page 18 - Voltage

SPECIFICATIONS 2-9 Toro Z Master G3 3000/5000/6000 Series Service Manual 2 G3 3000/5000/6000 Series Specifications cont. Electrical System: Voltage 12 volt, negative ground Battery Type Wet-Battery Fuses Blade Type Hourmeter with Service Indicator Standard Equipment Controls: Steering Levers Dual, w...

Page 19 - Dimensions

SPECIFICATIONS 2-10 Toro Z Master G3 3000/5000/6000 Series Service Manual 2 Dimensions Overall Length Overall Height Model # 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...

Page 22 - CHASSIS; Caster Fork Assembly Replacement; Caster Fork Assembly Removal

CHASSIS 3-1 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Caster Fork Assembly Replacement Caster Fork Assembly Removal 1. Raise the front of the machine off the ground, leaving enough clearance to remove the caster fork from the frame. 2. Remove the grease cap from the frame (Fig. 001). F...

Page 23 - Caster Bearing Replacement

CHASSIS 3-2 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Caster Bearing Replacement 3. Remove the bottom grease seal (Fig. 006). Fig. 004 PICT-0359a 2. Remove the top tapered bearing (Fig. 005). Fig. 005 PICT-0361a Fig. 006 PICT-0364a 4. Remove the bottom tapered bearing (Fig. 007). Fig. ...

Page 25 - Caster Fork Assembly Installation

CHASSIS 3-4 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Caster Fork Assembly Installation 1. Install 3 Belleville washers as shown (Fig. 013). Fig. 012 PICT-0372a Fig. 013 fig. 69 G001297 A. Spring washer (3) C. Dust Cap B. Lock nut 2. Slide the caster fork assembly into the hub (Fig. 01...

Page 26 - Front Wheel Bearing Replacement; Front Wheel Bearing Removal

CHASSIS 3-5 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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). 1. Raise the front of the machine off the ground. 2. Remove th...

Page 28 - Front Wheel Bearing Installation

CHASSIS 3-7 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Front Wheel Bearing Installation 8. Remove the 2 tapered bearings from the wheel assembly (Fig. 023). 1. Install a new tapered bearing cup into the wheel assembly by pressing each bearing cup into the wheel hub so that the thicker p...

Page 30 - Fuel Tank Replacement; Fuel Tank Removal; Note: The only recommended way to remove the

CHASSIS 3-9 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Fuel Tank Replacement Fuel Tank Removal 1. Turn the fuel valve to the “Off” position. 2. Siphon the fuel from the fuel tank. Note: The only recommended way to remove the fuel from the tank is by using a siphon pump. 3. Remove the 4 ...

Page 33 - Fuel Tank Installation

CHASSIS 3-12 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Fuel Tank Installation 4. Plug the fuel sender plug to the wiring harness (Fig. 044). Fig. 042 PICT-0426a 2. Install the fuel clamp around the fuel line to the fuel valve. 3. Connect the vapor line retainers to the fuel manifold (F...

Page 35 - Throttle Control Assembly; Throttle Control Assembly Removal

CHASSIS 3-14 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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). Fig. ...

Page 37 - Throttle Control Assembly Installation

CHASSIS 3-16 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Throttle Control Assembly Installation 1. Slide the throttle cable through the hose clamp next to the frame brace for the ROPS assembly (Fig. 058). Fig. 057 DSCN-4260a Fig. 058 DSCN-4260a 2. Slide the throttle cable through the hos...

Page 39 - Park Brake Handle Assembly

CHASSIS 3-18 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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). Fig. 064 DSCN-4279a Park Brake Handle Assembly Replacement (2012 & Later) Park Brak...

Page 42 - Park Brake Cable Replacement (2011

CHASSIS 3-21 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Park Brake Cable Replacement (2011 & Prior) 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 ...

Page 43 - Note: The cable is routed around the cradle.

CHASSIS 3-22 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 6. Release the brake cable retainer holding the brake cable to the cradle. Push the cable through the routing hole and remove (Fig. 079). Fig. 079 PICT-8974a 7. Remove the tie strap securing the brake cable to the cradle (Fig. 080)...

Page 45 - Left Park Brake Cable Installation (2011 &

CHASSIS 3-24 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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). Fig. 089 PICT-9001a 4. Install a cotter pin through the clevis pin to secu...

Page 50 - Right Park Brake Cable Installation (2011 &

CHASSIS 3-29 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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). Fig. 106 PICT-9092a Right Park Brake Cable Installation (2011 & Prior) Fig. 107 PICT-9092a 2. Po...

Page 53 - Adjusting the Parking Brake; Note: The left side brake is being adjusted in the

CHASSIS 3-32 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Adjusting the Parking Brake 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. 1. Open the push valve (vertical positi...

Page 55 - Park Brake Cable Replacement (2012

CHASSIS 3-34 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Park Brake Cable Replacement (2012 & Later) Left 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 u...

Page 58 - Left Park Brake Cable Installation (2012 &

CHASSIS 3-37 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Left Park Brake Cable Installation (2012 & Later) 1. Install brake cable with the clevis end out toward the park brake handle (Fig. 134). Fig. 134 DSCN-4358a 2. Install the brake cable grooved fitting into the slot on the botto...

Page 60 - A F

CHASSIS 3-39 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 9. Install the L-bracket, spring, washer, and nut on the threaded end of the brake cable (Fig. 142). Fig. 142 DSCN-4336a 10. Install the L-Bracket with brake pin, washer, and e-ring to the brake caliper (Fig. 143). Fig. 143 DSCN-43...

Page 61 - Note: Do not allow the cable to turn when the nut

CHASSIS 3-40 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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). Note: Do not allow the cable to turn when the nut are being turned. Fig. 145...

Page 65 - Right Park Brake Cable Installation (2012 &

CHASSIS 3-44 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Right Park Brake Cable Installation (2012 & Later) 1. Install brake cable with the clevis end out toward the park brake handle (Fig. 159). Fig. 159 DSCN-4385a 3. Install the clevis and cotter pin to the right side of the park b...

Page 67 - Note: DO NOT allow the cable to turn when the nuts

CHASSIS 3-46 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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 spr...

Page 68 - Brake Caliper Replacement; Brake Caliper Removal; Note: The left side is being removed use the same

CHASSIS 3-47 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 14. Plug the wire harness to the park brake switch (Fig. 169). Fig. 169 DSCN-2617a 15. Install the two screws retaining the right hand motion-control cover assembly to the frame (Fig. 170). Fig. 170 DSCN-2614a 16. Install the rear ...

Page 70 - Brake Caliper Installation

CHASSIS 3-49 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Brake Caliper Installation 1. Install the brake mount plate to the caliper (Fig. 176). Fig. 176 DSCN-4398a 2. Apply thread locker to the 2 bolts that retain the brake mount plate (Fig. 177). Fig. 177 DSCN-4400a Fig. 178 DSCN-4402a ...

Page 72 - Motion Control Damper Replacement; Note: There is a right and left motion control; Motion Control Damper Removal; Note: You will need a T40 Torx wrench to hold the

CHASSIS 3-51 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Motion Control Damper Replacement 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 Dam...

Page 73 - Motion Control Damper Installation; Adjusting the Motion Control Damper; Note: The top damper mounting bolt can be adjust; A B C

CHASSIS 3-52 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Motion Control Damper Installation Motion Control Damper (Fig. 185) A. Belleville washer Fig. 185 DSCN-4452a Adjusting the Motion Control Damper Note: The top damper mounting bolt can be adjust ed to obtain a more desired motion c...

Page 74 - Adjusting the Motion Control Neutral; Adjusting the Control Handle

CHASSIS 3-53 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Adjusting the Motion Control Neutral Lock Pivot 1. Loosen the jam nut. 2. Tighten or loosen the flanged nut to the desired feel. For more resistance, tighten the flange nut. For less resistance, loosen the flange nut. 3. Tighten ja...

Page 75 - Motion Control Assembly; Motion Control Assembly Removal; Note: This procedure is performed on the left hand

CHASSIS 3-54 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 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). Fig. 190 fig. 85 G009195 Motion Control Assembly Replaceme...

Page 78 - A B C C D

CHASSIS 3-57 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 11. Remove the neutral switch from the LH motion control (Fig. 200). Fig. 200 DSCN-4476a 12. Remove the carriage bolt and nut retaining the leaf spring to the LH motion control (Fig. 201). Fig. 201 DSCN-4492b 14. Remove the nut, tw...

Page 79 - Motion Control Assembly Installation

CHASSIS 3-58 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 Motion Control Assembly Installation 1. Install 4 new flange bushings in the LH motion control (Fig. 204). Fig. 204 DSCN-4487a 2. Install motion control lever in the LH motion control (Fig. 205). Fig. 205 DSCN-4488a 3. Install flat...

Page 82 - Note: The washer must be installed between the LH

CHASSIS 3-61 Toro Z Master G3 3000/5000/6000 Series Service Manual 3 13. Secure the front pump linkage assembly to the LH motion control assembly with a bolt, washer and nut. Note: The washer must be installed between the LH motion control assembly and the ball joint on the front pump linkage assemb...

Page 84 - ENGINE; Engine Replacement; Note: The following procedure for removing and; Engine Removal

ENGINE 4-1 Toro Z Master G3 3000/5000/6000 Series Service Manual 4 Engine Replacement 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 6...

Page 90 - Engine Installation

ENGINE 4-7 Toro Z Master G3 3000/5000/6000 Series Service Manual 4 Engine Installation 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. 241 DSCN-0043a 4. Plug the...

Page 96 - HYDRAULIC SYSTEM; Hydrostatic Pump Removal

HYDRAULIC SYSTEM 5-1 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 Hydrostatic Pump Removal 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...

Page 99 - Note: Be careful to not damage the trunnion shaft

HYDRAULIC SYSTEM 5-4 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 16. On the side of the machine being serviced, remove the cotter pin securing the castle nut to the wheel hub (Fig. 275). Fig. 273 PICT-8563 15. On the side of the machine being serviced, pry the control arm off the square ...

Page 100 - Note: There is a spacer washer on each bolt be-

HYDRAULIC SYSTEM 5-5 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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. 277 PICT-8582a 20. Remove the 2 bolts and ...

Page 101 - Note: Only the left hand brake cable is installed in

HYDRAULIC SYSTEM 5-6 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 25. Pull back the rubber boot, exposing the brake cable, and slide the cable out of the cable anchor bracket slot (Fig. 282). 26. Release the brake cable retainer holding the brake cable to the cradle. Pull the retainer tow...

Page 102 - not

HYDRAULIC SYSTEM 5-7 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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). 32. Position a floor jack under the cradle on the side of the machi...

Page 103 - Caution: The UHT weighs approximately 80 lbs.; Note: Ensure the control arm shaft clears the frame

HYDRAULIC SYSTEM 5-8 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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 34. Lower the UHT/cradle assembly from the frame by lowering the f...

Page 104 - G3 UHT Transmission Installation (2009 -; Note: Be careful not to damage the UHT drive

HYDRAULIC SYSTEM 5-9 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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). Note: Be careful not to damage the UHT drive pulley....

Page 107 - Note: Do not use anti-seize compound on the wheel

HYDRAULIC SYSTEM 5-12 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 17. Slide the brake cable swivel through the brake caliper and loosely install a nut onto the swivel (Fig. 307). Fig. 305 PICT-8659a 15. Repeat steps 12 and 14 to install the right hand brake cable. 16. Slide the wheel hub...

Page 108 - Note: If a brake component or wheel hub is being

HYDRAULIC SYSTEM 5-13 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 21. Repeat steps 17 thru 20 to install the brake caliper on the opposite wheel hub. Note: If a brake component or wheel hub is being replaced, follow the “Burnishing the Brake” procedure on page 5-20. 19. Repeat step 18 to...

Page 114 - Important: Do not overfill the UHT with oil as dam-

HYDRAULIC SYSTEM 5-19 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 Check the hydraulic fluid level: 49. Raise the seat up. 50. Clean the area around the dipsticks of UHT reser- voirs (Fig. 327). 51. Remove one dipstick from the UHT reservoir (Fig. 327). 52. Wipe the dipstick off and threa...

Page 115 - Burnishing the Brake

HYDRAULIC SYSTEM 5-20 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 Burnishing the Brake 3. Clear the area of any flammable material before starting the burnishing process. 4. Rotate the drive wheel release valve to the “operating” position (Fig. 330). Fig. 328 PICT-8548 2. Remove the two ...

Page 118 - UHT Transmission Replacement; Note: The following procedures cover replacing

HYDRAULIC SYSTEM 5-23 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 23. Install the rear wheels. Torque the lug nuts to 90 - 95 ft-lbs. (122 - 129 Nm). 24. Remove the jack stands and lower the machine to the ground. 22. Close the drive wheel release valve (horizontal operating position) (F...

Page 123 - UHT Transmission Installation (2012 & later; Note: Be careful not to damage the UHT transmis-

HYDRAULIC SYSTEM 5-28 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 UHT Transmission Installation (2012 & later models) 4. On the opposite side, ensure the cradle mounting holes align with the mounting holes on the UHT transmission (Fig. 357). 3. Lift the UHT transmission/cradle assemb...

Page 127 - Note: DO NOT allow the cable to turn when the nut; Wheel Hub Slotted Nut Installation

HYDRAULIC SYSTEM 5-32 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 19. Disengage the parking brake. Rotate the drive wheel release handle to the released position. Turn the wheel hub by hand in both directions relative to the caliper; no drag of the caliper pad on the wheel hub is desired...

Page 129 - Warning; Adjusting the Motion Control Linkage

HYDRAULIC SYSTEM 5-34 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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 ...

Page 131 - Checking the Hydraulic Oil; Note: The oil level on the dipstick will be incorrect

HYDRAULIC SYSTEM 5-36 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 Checking the Hydraulic Oil 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 an...

Page 132 - Flow Test Instructions

HYDRAULIC SYSTEM 5-37 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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). The following information describes...

Page 133 - Caution: All fittings and hoses must be securely

HYDRAULIC SYSTEM 5-38 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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” ...

Page 135 - Hydraulic Pump Drive Belt

HYDRAULIC SYSTEM 5-40 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 Hydraulic Pump Drive Belt Replacement 6. Unhook the idler spring from the frame (Fig. 385). 7. Remove the belt from the hydraulic unit drive pulleys and the engine pulley. 8. Install the new belt around engine pulley and t...

Page 136 - Using the Drive Wheel Release Valves; WARNING; Note: Make sure the release valves are in fully

HYDRAULIC SYSTEM 5-41 Toro Z Master G3 3000/5000/6000 Series Service Manual 5 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 par...

Page 138 - MOWER DECKS; Mower Belt Replacement; Mower Belt Removal

MOWER DECKS 6-1 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Mower Belt Replacement Mower Belt Removal 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 ...

Page 139 - Mower Belt Installation

MOWER DECKS 6-2 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Mower Belt Installation Fig. 391 fig. 81 G009038 1. Install the new belt around the mower deck pulleys and the clutch pulley under the engine (Fig. 391). A. Clutch pulley E. Square hole in the idler B. Mower belt arm for the rat...

Page 140 - Mower Deck Replacement; Mower Deck Removal; Note: Before servicing or removing the mower deck,

MOWER DECKS 6-3 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 4. Install the RH and LH belt covers (Fig. 392). Fig. 392 DSCN-0064a 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-...

Page 143 - Mower Deck Installation

MOWER DECKS 6-6 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Mower Deck Installation Reverse the order of mower deck removal. Extension Spring Adjustment (2010 - 2012 Models) Fig. 398 116-5700K12 Fig. 397 DSCN-0136

Page 144 - Mower Spindle Removal (2009 Model G3; Mower Spindle Replacement

MOWER DECKS 6-7 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 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). Fig. 400 DSCN-0020a 5. Remov...

Page 145 - Mower Spindle Installation (2009 Model G3

MOWER DECKS 6-8 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Mower Spindle Installation (2009 Model G3 Series Units) 6. Raise the mower deck to the transport position. 7. Remove the mower blade from the spindle assembly. 8. Remove the 5 bolts and nuts retaining the spindle assembly to the...

Page 146 - Mower Spindle Disassembly (2009

MOWER DECKS 6-9 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Mower Spindle Disassembly (2009 Model G3 Series Units) 4. Remove the bearing shield (Fig. 405). Fig. 403 DSCN-2669a 3. Remove the pulley hub and square key (Fig. 404). Fig. 404 DSCN-2670a Fig. 405 DSCN-2671a 5. Remove the spindl...

Page 149 - Mower Spindle Assembly (2009 Model; Note: The wider inside diameter of the bearing race

MOWER DECKS 6-12 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Mower Spindle Assembly (2009 Model G3 Series Units) 14. Remove the large spacer in the spindle housing (Fig. 415). 1. Install the spacer through the top of the spindle housing (Fig. 417). Fig. 415 DSCN-2682a 15. This view shows...

Page 150 - Note: The open lip of the seal should be facing

MOWER DECKS 6-13 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 4. Pack the bearing with No. 2 grease and install the bearing (Fig. 420). 6. Using a seal driver, drive or press the seal on the lower end of the spindle housing until the seal is flush with the outer edge of the housing (Fig. ...

Page 153 - Note: The cup side of the washer should be facing; Mower Spindle Replacement (2010; Note: The following procedure applies to removing

MOWER DECKS 6-16 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 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. Fig. 431 DSCN-2708a 18. Grease the spindle assembly using a grease g...

Page 154 - Mower Spindle Installation (2010 & Later

MOWER DECKS 6-17 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 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). Fig. 434 DSCN-0020a 5. Raise...

Page 155 - Mower Spindle Disassembly (2010

MOWER DECKS 6-18 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 1. Remove the 3 flange nuts retaining the pulley to the spindle hub (Fig. 436). Fig. 436 DSCN-0082a 2. Remove the top lock nut and washer from the spindle shaft (Fig. 437). Fig. 437 DSCN-0087a Mower Spindle Disassembly (2010 &a...

Page 157 - Note: There is a snap ring located in the spindle

MOWER DECKS 6-20 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 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. Fig. 444 DSCN-0106a Mower Spindle Assembly (2010 ...

Page 160 - Deck Leveling; Note: Ensure the mower deck is leveled before; Leveling the Mower Deck

MOWER DECKS 6-23 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Deck Leveling Note: Ensure the mower deck is leveled before matching the height-of-cut (HOC). 1. Position the mower on a flat surface. 2. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 3. ...

Page 161 - Note: To increase the height, turn the adjustment; C D

MOWER DECKS 6-24 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 A. Adjustment nut C. Rear deck adjustment B. Jam nut D. Front deck adjustment A. Whizlock nut C. Jam nut B. Adjuster screw D. Yoke 11. For mower decks shown below, fine-tune the adjustment nut on the front deck lift-assembly by...

Page 162 - Note: Loosen or tighten the single point adjustment

MOWER DECKS 6-25 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 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...

Page 163 - Note: In most conditions, the back blade tip should

MOWER DECKS 6-26 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 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). 15. Tighten the two bolts at the bottom of the height-of- cut plate ...

Page 164 - Servicing the Cutting Blades; Before Inspecting or Servicing the Blades; DANGER

MOWER DECKS 6-27 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Servicing the Cutting Blades 18. Measure until all four sides are the correct height. Tighten all the jam nuts on the deck lift arm assemblies. 19. Lower discharge chute. 17. Fine-tune the adjustment nut on the front deck lift ...

Page 165 - Inspecting the Blades; Note: If the edges are not sharp or have nicks,

MOWER DECKS 6-28 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Inspecting the Blades Checking for Bent Blades 2. Inspect the blades, especially the curved area (Fig. 098). If you notice any damage, wear, or a slot forming in this area (Fig. 463), immediately install a new blade. A. Cutting...

Page 166 - Removing the Blades

MOWER DECKS 6-29 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Removing the Blades 4. Rotate the opposite ends of the blades forward. 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. 6. The difference between the dimensions obtained...

Page 167 - Sharpening the Blades; Important: The curved part of the blade must be

MOWER DECKS 6-30 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Sharpening the Blades Installing the Blades 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 ...

Page 168 - Electric PTO Clutch Replacement; Electric PTO Clutch Removal

MOWER DECKS 6-31 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Electric PTO Clutch Replacement Electric PTO Clutch Removal 5. Remove the bolt, spring washers, and washer retaining the electric PTO to the engine crankshaft and remove from the clutch (Fig. 472). 1. Remove the battery negativ...

Page 169 - Electric PTO Clutch Installation

MOWER DECKS 6-32 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Electric PTO Clutch Installation A. Bolt C. Washer B. Spring Washer (2) 3. Plug the clutch wire plug into the electric PTO clutch (Fig. 475). Fig. 473 DSCN-0060a 2. Install the electric PTO clutch on the crankshaft; make sure t...

Page 170 - Using the Clutch Shim; Removing the Clutch Shim; F G

MOWER DECKS 6-33 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 Using the Clutch Shim Removing the Clutch Shim 3. Check the condition of the wire harness leads, connectors, and terminals. Clean or repair as necessary. 4. Verify that 12V is present at the clutch connector when the PTO switch...

Page 172 - Note: Due to the way the rotor and armature faces; Safety Check

MOWER DECKS 6-35 Toro Z Master G3 3000/5000/6000 Series Service Manual 6 A. Feeler gauge 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). Note: Due to the way the rotor and armature faces ...

Page 174 - ELECTRICAL; General; Note: Interactive Electrical Troubleshooting DVD,; Purpose; Relay; Location

ELECTRICAL 7-1 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 General Note: Interactive Electrical Troubleshooting DVD, Part #492-9193 is also available. Purpose Relay There is one relay on this machine. 1. Start Relay: Functions as an electronic switch. Once the safety connections are met,...

Page 175 - Testing

ELECTRICAL 7-2 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 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 ...

Page 176 - PTO Switch

ELECTRICAL 7-3 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 PTO Switch Purpose Testing 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. How It Works Contacts inside the switch electrically connect...

Page 178 - Ignition Switch; Ignition Switch Wiring Connections; OFF; R A

ELECTRICAL 7-5 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 Ignition Switch Purpose The ignition switch makes the proper connections for the starter, accessories, and safety circuits. Location The ignition switch is located on the control panel, on the right fender (Fig. 490). Fig. 490 DS...

Page 179 - How It Works; Park Brake Switch

ELECTRICAL 7-6 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 How It Works Fig. 493 DSCN-0148a 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 ...

Page 180 - Seat Switch; Note: There is a delay module in the system,

ELECTRICAL 7-7 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 Seat Switch Purpose 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. Note: There is a delay module in ...

Page 181 - Neutral Safety Switch

ELECTRICAL 7-8 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 How It Works Fig. 497 DSCN-0150a 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...

Page 182 - TVS Diode

ELECTRICAL 7-9 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 TVS Diode Purpose 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. 498 DSCN-0005a How It Work...

Page 183 - Fuel Sender

ELECTRICAL 7-10 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 Fuel Sender Purpose How It Works Testing The fuel sender uses an ultrasonic device that measures the level of fuel in the fuel tank. The sender measures the time it takes for and ultrasonic signal to travel from the sender to th...

Page 185 - Coil Resistance Measurement; Electric PTO Clutch

ELECTRICAL 7-12 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 Coil Resistance Measurement 1. Disengage the PTO, set the parking brake, turn the ignition to the “off” position and remove the ignition key. 2. Disconnect the clutch harness from the main harness. 3. Set the multimeter or volt/...

Page 186 - Measuring Clutch Current Draw

ELECTRICAL 7-13 Toro Z Master G3 3000/5000/6000 Series Service Manual 7 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...

Toro 476 - User Manual

Table of Contents:

Other Manuals for Toro 476

Summary

Other Toro Models