FORM NO. 3324-616 Rev A MODEL NO. 30581—80001 & UP ® OPERATOR’S MANUAL GROUNDSMASTER® 580-D To understand this product, and for safety and optimum performance, read this manual before starting operation. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol.
FOREWORD This operator’s manual has instructions on safety, proper set-up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual. This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, understand the safety message that follows. For complete safety instructions, read pages 3–5.
Safety Instructions Training • Store fuel in containers specifically designed for this purpose. 1. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. • Refuel outdoors only and do not smoke while refueling. 2. Never allow children or people unfamiliar with these instructions to use the lawn mower. Local regulations may restrict the age of the operator. • Add fuel before starting the engine.
Safety Instructions • lawn mower; never mow across the face of the slope, unless the lawn mower is designed for this purpose. • 6. Use care when pulling loads or using heavy equipment. • Use only approved drawbar hitch points. • Limit loads to those you can safely control. • Do not turn sharply. Use care when reversing. • Use counterweight(s) or wheel weights when suggested in the instruction handbook. 7. Watch out for traffic when crossing or near roadways. 15.
Safety Instructions Vibration Levels This unit has a vibration level of 2.5 m/s2 at the posterior, based on measurements of identical machines per ISO 5349 procedures. This unit does not exceed a vibration level of 0.5 m/s2 at the posterior based on measurements of identical machines per ISO 2631 procedures.
Symbol Glossary Caustic liquids, Poisonous Electrical shock, chemical burns to fumes or toxic electrocution fingers or hand gases, asphyxiation Crushing of whole body, applied from above High pressure High pressure Crushing of Crushing of spray, erosion of spray, erosion of fingers or hand, toes or foot, force flesh flesh force applied from applied from above above Crushing of Crushing of fingers Crushing of leg, Crushing of torso, force or hand/, force force applied whole body applied from side applied
Safety Instructions Consult technical Fasten seat manual for proper belts service procedures Safety alert triangle Outline safety alert symbol Head protection Hearing Caution, toxic must be worn protection must risk be worn First aid Flush with water Engine Transmission Hydraulic system Exhaust gas Level indicator Liquid level Brake system Filter Oil Temperature Coolant (water) Intake air Failure/ Malfunction Start switch/ mechanism On/start Read operator’s Fire, open light manual and sm
Symbol Glossary, continued n/min Engine start Engine stop Engine failure/ malfunction Engine rotational Choke speed/frequency Primer (start aid) Electrical preheat Transmission (low temperature oil start aid) NH L F Transmission oil pressure Transmission oil temperature Transmission Clutch failure/malfunction Neutral High Low Forward RP 1 2 3 Reverse Park First gear Hydraulic oil filter Hydraulic oil temperature Hydraulic oil Parking brake failure/malfunction Fuel Unleaded fuel Headligh
Specifications CUTTING UNITS OUTBOARD CUTTING UNITS Cutting Unit Drive System: All hydraulic drive. Initial cutting drive engagement via electric switch. Drive shuts off or engages individually as cutting units are raised or lowered. Type: Two, three-spindle, side-mounted rotary cutting units, each with a 145 cm width of cut. Automatic Weight Transfer: Patented automatic weight transfer from decks to traction unit under demanding traction situations for improved traction and deck floatation.
Specifications Leaf Mulcher Cold Start Kit Foam Filled Castor Tires Extra Traction Drive TireSpecifications and design subject to change without notice.
Before Operating 5. When the batteries are fully charged, disconnect the charger from the electrical outlet and battery posts. 6. Install the negative (–) cable ends, slide the tray back in place, secure it with capscrews and install the side panel. CAUTION Wear safety goggles and rubber gloves when working with the batteries. Charge batteries in a well-ventilated place so the gases produced while charging can dissipate.
Before Operating CHECK THE COOLING SYSTEM (DAILY) The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check the coolant level at the beginning of each day before starting the engine. Capacity of the cooling system is 14.7 L. CAUTION Figure 3 1. Dipstick The engine uses any high-quality detergent oil having the American Petroleum Institute—API—“service classification” CD. Oil viscosity recommendations are: AMBIENT TEMPERATURE –28.9° to –6.7°C –6.
Before Operating CHECK HYDRAULIC SYSTEM FLUID (DAILY) 1. Fluid level should be checked daily through the sight glass at the rear of the hydraulic reservoir (Fig. 6). When oil is cold, the level will be slightly below center, but it should be in the middle of the sight glass when the oil is warm. Figure 7 1. Fuel Tank Cap CHECK TIRE PRESSURE (DAILY) Since the Groundsmaster 580-D can be operated under many different turf conditions, proper tire pressure is important. Use the following as a guide: 1.
Before Operating Position all castor arm height-of-cut spacers to on the underside of the castor arms. Do not move washers. Leave them in their original position. Note: Unless all castor wheel axles are not in the same location, axles do not have to be relocated. All, however, must be in the same holes (Fig. 8). 2. Place a flat sheet of plywood at least 2mm thick and at least 1.2m x 2.4 m on a level surface and lower the cutting unit onto the plywood. 3.
Before Operating Remove the castor fork shaft and spacer assembly from the castor arm (Fig. 10). Place spacers onto the castor spindle to the desired height-of-cut setting and install the castor fork shaft in arm (Fig. 9). Install the remaining spacers onto the shaft and secure the assemblies with the lynch pin (Fig. 10). Figure 11 1. Skid Figure 10 1. Lynch pin 2. Spacers 3. Washers ADJUSTING SKIDS After the initial set up or if height of cut is changed, deck skids should also be adjusted.
Controls Seat (Fig. 12)—Pull the seat adjusting lever (right side) outward, slide the seat fore or aft to the desired position and release the lever to lock the seat in position. The seat moves 15 cm fore and aft in 15mm increments. The knob at the lower center provides variable weight adjustment from 49.9–129.3 kg. Hour Meter (Fig. 13)—Registers accumulated hours of engine operation, which is useful for determining intervals for service maintenance and lubrication. Coolant Temperature Gauge (Fig.
Controls Hydraulic Oil Filter Warning (Fig. 14)—A warning indicator light and audible signal warn the filter is clogged and needs service. Hydraulic Oil Level Warning (Fig. 14)—A warning indicator light and audible signal warn of low hydraulic oil level. If the oil level drops further, the engine will automatically be stopped. The engine cannot be restarted until the oil supply is brought to a safe level. Air Cleaner Warning (Fig.
Controls Cutting Unit Lift Controls (Fig. 16)—The two outside levers raise and lower the outside cutting units; the center lever raises and lowers the front unit. The engine must be running to lower and raise cutting units. Cutting unit blades automatically stop whenever the cutting units are raised. When lowering outside cutting units, keep the control levers actuated until the cutting units pass over the center. Units will then “float” down to the turf.
Controls Figure 19 1. 2. 3. 4. Traction pedal Brake pedal Steering/parking brake pedals Brake latch lever Brake Pedal (Fig. 19)—A pedal operated by the right foot actuates fully enclosed, multiple-disc front brakes. Note: There is dynamic braking through the closed-loop hydrostatic traction drive system. Storage (Fig. 20)—A large removable tool storage tray is located under a hinged floor plate. A small storage and beverage holder is to the operator’s right. Figure 20 1. Hinged floor plate 2.
Operation engine starts and allow it to return to the RUN position. IMPORTANT. The fuel system must be bled if any of the following have occurred: A. Initial start-up of a new machine. B. Note: Do not run the starter motor more than 10 seconds at a time or premature starter failure may result. If the engine fails to start after 10 seconds, turn the key to the OFF position. Recheck controls and procedures, wait 10 additional seconds and repeat starting operation.
Operation Figure 24 1. Fuel filter air bleed plug Figure 22 1. 2. 3. 4. 2. Engine hood Left side panel Glow plug indicator light Side panel latch At the lower left side of the engine, loosen the air bleed screw at the top of the fuel filter/water separator (Fig. 23). 5. Loosen the air vent plug on the injection pump about 1-1/2 turns (Fig. 25). Operate the priming pump until a solid stream of fuel flows from the vent hole (Fig. 25), then tighten the air vent plug. 6.
Operation relays must be connected and functioning properly. The Diagnostic ACE display is a tool to help the user verify the correct electrical functions of the machine. CHECKING INTERLOCK SWITCHES Figure 26 1. Electronic controller light When the controller diagnostic light blinks, one of the following outputs has been detected in the controller: 1. 2. One of the outputs has been shorted. One of the outputs is open circuited.
Operation pedal, etc.), and note that the appropriate LED on Diagnostic ACE will blink on and off when corresponding switch is closed and opened. Repeat on each switch that it is possible to be changed by hand. 7. If the switch is closed and appropriate LED does not blink on and off, check all wiring and connections to the switch and/or check switches with an ohmmeter. Replace any defective switches and repair any defective wiring. Figure 27 1. Wire Harness and Connectors 3. 4.
Operation BUTTON. 6. Sit on the seat and attempt to operate the desired function of the machine. (If you need help verifying the correct input settings for each function, refer to the Logic Chart) The appropriate output LEDs should illuminate to indicate that the ECU is turning on that function. (Refer to the logic chart to be certain of the specified output LEDs).
Operation may occur. The by-pass valve must be open whenever the machine is pushed or towed by this method. TORO does not recommend this process be used as standard procedure. 1. 2. The by-pass valve is located on the left side of the pump (Fig. 29). Rotate the valve 1/2 to 1 turn counter- clockwise to open it and allow oil to bypass internally. Because fluid is bypassed, the machine can be moved—slowly—without damaging the transmission.
Operation disengage the cruise control (if used), move the PTO switch to DISENGAGE and release it (the switch returns to neutral), then fully raise the cutting units. Figure 30 1. Engine over-ride button Mowing—When approaching the area to mow, position the ground speed selector in LOW RANGE and release it. The switch lever will return to neutral and the High Range light will go out. Move the throttle lever to FAST and lower the cutting units.
Maintenance Maintenance LUBRICATION The following must be lubricated regularly with No. 2 general purpose lithium or molybdenum base grease. The chart below lists service intervals based upon normal operating conditions. However, lubricate more frequently under extreme conditions. The left column numbers correspond with numbers in Fig. 31. Component Center Cutting Unit 1. Castor Fork Shaft Bushings 2. Spindle Shaft Bearings 3. Idler Pulley Bushings 4.
Maintenance Figure 31 Figure 31 28
Maintenance DAILY MAINTENANCE CHECKLIST Hydraulic Hoses for Damage Fluid Leaks Tire Pressure Instrument Operation Condition of Blades Lubricate All Grease Fittings2 Touch-up Damaged Paint = Immediately after every washing, regardless of the interval listed.
Maintenance Maintenance Schedule Maintenance Procedure Lubricate All Grease Fittings Inspect Air Filter, Dust Cup, and Baffle Clean Under Cutting Unit Belt Covers Check Cutting Unit Drive Belt Adjustment Maintenance Interval & Service Every 50 hours Every 100 hours Every 200 hours Every 400 hours Every 800 hours ‡Change Engine Oil and Replace Filter ✝Check Fan and Alternator Belt Tension Inspect Cooling System Hoses Service Air Filter Replace Fuel/Water Separator Filter ✝Torque Wheel Lug Nuts Check B
Maintenance Figure 33 1. Dipstick Figure 35 1. Engine oil drain plug 3. Remove the drain plug and allow oil to drain into the pan. Remove and replace the oil filter (Fig. 36); refer to the parts catalog for the replacement number. Apply a coating of oil to the filter O-ring and tighten the filter by hand. Figure 34 1. Engine oil fill cap Changing Engine Oil and Filter The engine holds approximately 10 L of oil.
Maintenance ENGINE COOLING SYSTEM The cooling system holds approximately 14.7 L of a 50/50 solution of ethylene glycol anti-freeze and water. To properly maintain the system, use the following procedures: 1. Check coolant level each day before starting the engine; refer to Check Cooling System in Before Operating section. CAUTION Check coolant level before the engine has been started because the coolant system will not be pressurized.
Maintenance needed. Check and adjust tension as follows: A. Use procedures instep 2, items a-c. B. Unlatch the latch handles on both sides and remove the radiator cowl and grille support (Fig. 40). A. Unlatch and raise the hood and prop it open. Unlatch and remove the right side panel. B. Proper tension will allow 13mm deflection when a force of 14 Nm is applied on the belt midway between the pulleys.
Maintenance SERVICING THE AIR CLEANER 1. Washing Method A. Prepare a solution of filter cleaner and water and soak the filter element about 15 minutes. Refer to directions on the filter cleaner carton for complete information. Release the latches securing the air cleaner cover to the air cleaner body. Separate the cover from the body. Clean the inside of the air cleaner cover. B. After soaking the filter for 15 minutes, rinse it with clear water.
Maintenance Phillips Standard Sun Union Magnus A 68 Energol HLP 68 Sunvis 831 WR Unax AW 68 IMPORTANT. Use only hydraulic oils specified. Other fluids could cause system damage. Note: A red dye additive for the hydraulic system oil is available in 20 ml bottles. One bottle is sufficient FOR 115123 1 of hydraulic oil. Order Part No. 44-2500 from your Authorized Toro Distributor. Figure 46 1. Hydraulic Oil Filter Check Oil Level 1. 2. Visually check hydraulic oil level daily through sight glass (Fig.
Maintenance Drain Water From Hydraulic Reservoir Every 500 hours operation, drain water from the reservoir at three (3) locations. 1. Place drain pan under reservoir. 2. Locate plugs at right rear behind front wheel, at rear center and front center of reservoir (Fig. 47). the sight glass (Fig. 45). 4. Install the reservoir cap. Start the engine and use all hydraulic controls to distribute oil throughout the system. Check for leaks. If repairs are needed, shut off the engine before beginning. 5.
Maintenance 3. Add gear oil, if necessary, to bring oil up to the proper level and install the plug. 4. Repeat steps 1–3 on the opposite gear assembly. To Drain Gear Oil: 1. With the machine on level surface, position the wheel so the check/drain plug is at the lowest position. 2. Place the drain pan under the hub, remove the plug and allow oil to drain. 3. When the oil has drained, position the wheel so the plug hole is at the three or nine o’clock position (Fig. 50). 4. Add approximately 1.
Maintenance 2. Remove the capscrews securing the battery tray to the machine and slide the tray out (Fig. 51). 3. Check both batteries for charge with a hydrometer. If the batteries check acceptably, slide the tray back in place, secure with capscrews and install the side panel. If the batteries require charging, proceed to step 4. 4. Remove the negative (–) battery cable connectors from the batteries (Fig. 51). Connect a 3- to 4-amp battery charger to the posts.
Maintenance CUTTING UNIT LUBRICATION Follow guidelines in the Lubrication Chart to properly maintain the units. To gain access to the center and inner spindle shaft fittings on each outboard unit, proceed as follows: Note: To grease spindle bearings, apply 2–3 pumps with a hand grease gun for each spindle. 1. Position the machine on a level surface, lower the cutting units to the shop floor, engage the parking brake, shut the engine off and remove the key from the ignition switch. 2.
Maintenance the engine and remove the key from the ignition switch. 5. Fit the deck tilt link over the weldment on the right side of the traction unit and secure with a klik pin. Position a link so it clears when the cutting unit is raised. Keep the remaining klik pin handy to secure the opposite end of the link to the cutting unit arm weldment (Fig. 58). Figure 56 To Pivot (Tilt) the Cutting Unit Upright: 1.
Maintenance 3. Sit on the seat, start the engine and lower the cutting unit so the castor wheels just clear the floor. 4. Remove the height-of-cut pin from the right castor wheel arm. Insert it and the left height-of-cut pin in the proper height-of-cut holes in the castor arms and cutting unit. BLADE BOLT TORQUE Check blade bolt torque daily or after blade strikes a solid object.
Maintenance loaded idlers and normally do not require tensioning. CAUTION If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Fig. 60C)). Part of the blade may eventually break off and be thrown from under the housing, possibly resulting in serious injury to yourself or bystanders. 3. 1. Position the machine on level surface, lower the cutting unit to the shop floor, engage the parking brake, shut the engine off and remove the key from the ignition switch.
Maintenance compression spring (Fig. 62) will be approximately 11.3 cm. 4. Tighten jam nuts to secure adjustment. Replace the covers. Front Cutting Unit Note: To remove the center section belt, wing spindle drive belts must first be removed. 1. Remove deck covers. Lift each wing to release the idler pulley tension and slip the belt off the pulleys. 2. Loosen the jam nuts securing the tension plate until the compression spring on the idler assembly is relaxed (Fig. 64). 3.
Maintenance 4. Remove belt(s). Position the new belt(s) in pulleys and assemble the gear box and plate assembly to the deck. 5. Adjust belt tension; refer to Adjusting Cutting Unit Belt Tension. SEPARATING CUTTING UNITS FROM TRACTION UNIT Front Cutting Unit 1. 2. 3. 4. Figure 66 1. 2. 3. 4. 5. Position the machine on a level surface, lower the cutting unit to the shop floor, engage the parking brake, shut the engine off and remove the key from the ignition switch. 4.
Maintenance recommended standards, add shims between the cutting deck and spindle housing; proceed to step 6. If the measurements meet standards, proceed to step 5. Figure 67 1. High-range height of cut 2. Move to highest height-of-cut setting 2. 5. Rotate the blades so the tips lineup with one another. Tips of adjacent blades must be within 3 mm of each other. If tips are not within 3 mm of one another, add shims between the spindle housing and the bottom of cutter deck; proceed to step 6. 6.
Maintenance Figure 69 Figure 70 1. Winglet stabilizer brackets 3. Start the engine and raise the front deck completely, then stop the engine. 4. Move the stabilizer brackets inward until the rollers contact the skirt of the machine, then tighten the capscrews locking adjustment. TRACTION CONTROL NEUTRAL ADJUSTMENT If the machine moves when the traction pedal and pump lever are in the neutral position, adjustment is required. 1. 2. 3.
Maintenance 4. Connect ball joint to traction pedal. Tighten slotted nut until ball joint it tight against traction pedal then loosen nut until next slot aligns with hole in ball joint and install cotter pin. CYLINDER HEAD BOLTS Figure 71 1. Traction (neutral) switch 2. Adjusting screw 4. Actuate the traction pedal in both FORWARD and REVERSE to assure that switch “clicks” in both directions. TRACTION CONTROL ROD ADJUSTMENT 1.
