Form No. 3328–909 Groundsmaster 580-D Traction and Cutting Units Model No.
Page Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Diagnostic ACE Display . . . . . . . . . . . . . . . . . . . . 26 Checking the Interlock Switches . . . . . . . . . . . . . . 26 Checking the Warning Indicator Lights . . . . . . . . . 30 Pushing or Towing the Machine . . . . . . . . . . . . . . 30 Operating Characteristics . . . . . . . . . . . . . . . . . . . . 30 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Recommended Maintenance Schedule .
Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Introduction Read this manual carefully to learn how to operate and maintain your product properly.
• EU (European Union) standard EN836 requires a maximum slope usage angle statement. This stated angle is 50% of the smallest angle recorded during the of stability test. For this product this statement is; Do not use on slopes of more than 10°. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. Preparation • Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
• Disengage drives, lower the cutting units, set parking brake, stop engine and remove key and disconnect spark plug wire (gas engine only). Wait for all movement to stop before adjusting, cleaning or repairing. – before clearing blockages; – before checking, cleaning or working on the mower; – after striking a foreign object or if an abnormal vibration occurs. Inspect the mower for damage and make repairs before restarting and operating the equipment.
• Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine. After every two years, replace all interlock switches in the safety system, whether they are working properly or not. Maintenance and Storage • Before starting the engine, sit on the seat. • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 72-4080 95-0831 1. 15 amp. fuse for flasher 2. 15 amp. fuse for horn 3. 15 amp. fuse for headlights 4. 15 amp. fuse for taillights 98-1487 95-0821 1. 2. 3. 4. 1. Read the operator’s manual for information on hydraulic oil. 2. View the hydraulic level oil through the sight glass.
98-4387 1. Warning—wear hearing protection. 43-8480 1. Cutting hazard of hands and fingers 76-8750 1. Cutting hazard of hands and fingers 69-0940 1. Step on the traction pedal to operate forward or reverse.
67-5360 95-0815 95-0818 1. Throttle fast 2. Throttle slow 3. Raises and lowers the left-hand cutting unit 1. Warning—torque the blade bolt to 140–165 ft.-lb. (190–224 N⋅m). Read the operator’s manual for further instructions. 4. Raises and lowers the front cutting unit 5. Raises and lowers the right-hand cutting unit 95-0819 1. Belt routing for left-hand cutting unit 95-0825 1. 2. 3. 4.
99-1900 1. Read the operator’s manual for maintenance procedures. 2. Traction reverse test port 3. 4. 5. 6. Traction forward test port Charge pump test port Steering circuit test port Deck lift test port 98-3040 1. 2. 3. 4. 5. 6. 7. 8. 9. 95-0845 1. Height-of-cut settings 10. 11. 12. 13. 14. 95-0820 1.
66-1340 95-0817 1. Low range height-of-cut settings 2. High range height-of-cut settings 106-0044 105-0739 1. Read the Operator’s Manual. 2. Grease every 50 hours. 3. Add grease (9 grease points).
Specifications Note: Specifications and design subject to change without notice. Traction Unit Engine Air Cleaner Cooling System Fuel System Mitsubishi, Model s4s-DT 4 cycle, four cylinder, overhead valve, 203.3 cu. in. (3331 cc) displacement, water cooled diesel. Rated 80 HP @2750 RPM. 17:1 compression ratio, direct injected and turbo-charged. Crankcase capacity: 8.5 qt. (8 l). Heavy duty, centrifugal air type w/replaceable element Radiator w/wide-spaced fins (5 per in.).
Traction Unit (continued) Traction System Hydrostatic closed loop system driving gear reduction wheel drives. Has bypass valve for towing. Adjustable foot pedal with speed stop controls forward/reverse ground speed. Switch engaged cruise control, disengaged by service brake or ON/OFF switch. Cruise speed changeable without disengagement. All Cutting Units Cutting Unit Drive System All hydraulic drive. Initial cutting drive engagement via electric switch.
Outboard Cutting Units Type Trimming Ability Height-of-Cut Adjustment Cutter Drive Castor Wheels Cutting Unit Suspension Two, three spindle, side mounted rotary cutting units each with a 57 in. (145 cm) width of cut Trims to either side. 58 in. (147 cm) cutting unit offset from outside of wheel to trim side of side cutting unit on either side 1/2 in. (12.7 mm) increments by spacers on all castor shafts Hydraulic gear motor. Three “B” section belts to spindles Four 10.50 x 3.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Description Qty. Deck tilt link 1 Klik pin 2 Securing the front cutting unit in a vertical position for service (shipped in the tool box) Diagnostic ACE with overlay 1 Troubleshooting aid Parts Catalog 1 Ordering service parts. Operator’s manual 2 Read and understand before operating the machine. Operator Video 1 View and understand before operating the machine.
Warning Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery. Ambient Temperature Proper Viscosity –20° to 20° F (–28.9° to –6.7° C) SAE 10 20° to 105° F (–6.7° to 40.6° C) SAE 30 105° F (40.6° C) and higher SAE 40 Note: Do not use multi-viscosity oils. 5. When batteries are fully charged, disconnect charger from electrical outlet and battery posts. 1. Be sure machine is positioned on a level surface. 6.
Checking the Hydraulic System Fluid Important Check oil after every 5 hours operation or daily. Change oil and filter after the first 50 hours, then change both every 100 hours operation thereafter. Change oil and filter more frequently when engine is operated in extremely dusty or dirty conditions. 1. Fluid level should be checked daily through sight glass at rear of hydraulic reservoir (Fig. 6).
Checking Cutting Unit Mismatch 2. Fill tank to about 1 in. (25 mm) below bottom of filler neck with No. 2 diesel fuel. Install cap. To ensure all cutting units are at the same height-of-cut: 1. Adjust all cutting units to the highest height–of–cut. 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.
Figure 8 Figure 10 1. Lynch pin 2. Spacers 1. Start engine, position the machine on a level surface, lower cutting units to a point where castor wheels can be removed from arms, set lift levers in neutral, set parking brake and shut engine off. Remove ignition key to prevent accidental startup. 3. Washers Adjusting the Skids 2. Position castor wheel axles on all cutting units in the same hole in the castor forks. After initial set up or if height-of-cut is changed, deck skids should also be adjusted.
Seat height adjusts vertically to three positions. To raise, lift seat to first or second click stop; to lower, lift seat to highest position, then lower to lowest position. Arm rests pivot up and down. Operation Note: Determine the left and right sides of the machine from the normal operating position. The use of protective equipment, such as but not limited to, for eyes, ears, feet, and head is recommended.
Coolant Temperature Warning Hydraulic Oil Level Warning If engine coolant temperature exceeds 215 F (101.7 C), a warning indicator light illuminates (Fig. 14) and audible signal sounds. If coolant temperature exceeds 230 F (110 C), the engine automatically shuts down. Switch resets automatically when system and engine cools down. A warning indicator light (Fig. 15) and audible signal warn of low hydraulic oil level. If oil level drops further, the engine will automatically be stopped.
Cruise Control Indicator Cruise Control Switches The cruise control indictor, on steering column (Fig. 16), alerts operator the cruise control is engaged. There are two cruise control switches on panel to right of operator (Fig. 17)—one for ON/OFF control, the other for cruise engagement. Cruise control operation, when in either high range or low range mode, is disengaged either by actuating the brake pedal or turning the switch to OFF position.
Engine Override Switch upon high range/low range ground speed mode(slower in low than high range) and proportionate to how far pedal is depressed. If engine has overheated and been shut–down by the safety switch, depressing button (Fig. 17 and 18) will allow engine operation. Use button only for emergencies and only at short intervals. Steering/Parking Brake Pedals The left and right turn pedals are connected to the front wheel brakes (Fig. 20).
7 5 6 4 1 2 3 2 Figure 21 1. Hinged floor plate 2. Removable tool tray Figure 22 Important The fuel system must be bled if any of the following have occurred: 1. 2. 3. 4. • Initial start-up of a new machine. PTO Switch Cruise control switches High/Low range switch Cutting unit lift controls 5. Throttle lever 6. Ignition key switch 7. Glow plug indicator light • Engine has ceased running due to lack of fuel. • Maintenance has been performed upon fuel system components; i.e.
Bleeding the Fuel System 1. Unlatch, raise and prop engine hood open and remove left side panel (Fig. 23). 1 Figure 25 1. Fuel filter air bleed plug 5. Loosen air vent plug on injection pump about 1-1/2 turns (Fig. 26). Operate priming pump until solid stream of fuel flows from the vent hole (Fig. 26), then tighten air vent plug. Figure 23 1. Engine hood 2. Left side panel 6. Push priming pump down to compress spring and rotate clockwise to lock closed. 3. Hood latches 4. Side panel latch 7.
For the electronic controller to control the machine as desired, each of the input switches, output solenoids and relays must be connected and functioning properly. The Diagnostic ACE display is a tool to help the user verify correct electrical functions of the machine. Checking the Interlock Switches 1 Caution Figure 27 If safety interlock switches are disconnected or damaged the machine could operate unexpectedly, causing personal injury. 1.
Verifying Output Function 3. Connect the Diagnostic ACE display connector (Fig. 28) to the harness connector. Make sure correct overlay decal is positioned on Diagnostic ACE display. 1. Park machine on a level surface, lower the cutting units, stop the engine and engage the parking brake. 2. Open control panel cover. Locate wire harness and connectors near controller. Carefully unplug loopback connector from harness connector. 3. Connect the Diagnostic ACE connector to the harness connector.
Indications that this is the cause of the problem include: Important The Diagnostic ACE display should not be left connected to the machine. It is not designed to withstand the environment of the machine’s every day use. When done using Diagnostic ACE, disconnect it from the machine and reconnect loopback connector to harness connector. Machine will not operate without loopback connector installed on harness. Store Diagnostic ACE in dry, secure location in shop, not on machine.
LOGIC GRID 1) Start X 2) Hi Range Engage X 3) Run (no operator) X X Run (with operator) 4) Cruise Engage O B X XX O X O B X X X X X 5) Front Deck Engage O X X O MO X 6) Right Deck Engage O X X O MO 7) Left Deck Engage O X X O MO X O X O 17 16 Service Brake (x=off) 15 Cruise Control Engage 14 Hyd.
Checking the Warning Indicator Lights Each day, before operating assure all warning lights are functioning: 1. Sit on seat and apply parking brake. Turn ignition key ON and push TEST button. All lights should illuminate. 2. If a light fails to illuminate, replace the bulb and test again. Pushing or Towing the Machine Figure 30 In an emergency, the machine can be moved by the following methods: 1.
Note: We recommend HIGH RANGE ground speed be used for road travel only (with cutting units up). normal configuration. Be sure to inspect the cutting unit for damage and repair as necessary before resuming operation. Points to consider while operating the traction unit, cutting units or other implements are the hydrostatic transmission, engine speed, load on the cutting blades or other implement components and the importance of the brakes.
If it is an emergency and it becomes necessary to stop suddenly while in cruise control, depress the service brake pedal, this breaks the electrical circuit, returns the traction pedal to neutral and stops the machine. deck lift controls to neutral. Switch cruise control to OFF, set the parking brake and turn ignition key to OFF. Remove the key if the machine is to be left unattended. Stopping the Machine To stop the machine and cease operation, take foot off traction pedal and apply the brakes.
Maintenance Service Interval Every 800 hours Every 1000 hours or every 2 years, whichever occurs first Important Maintenance Procedure • Change the planetary gear drive fluid. • Check the rear wheel toe-in. • • • • • • • Change the brake fluid. Change the fuel filter. Change the thermostat. Replace the safety switches. Flush the cooling system and replace the hoses. Drain/flush the fuel tank. Change the hydraulic oil. Refer to your engine operator’s manual for additional maintenance procedures.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Check safety interlock operation. Check brake operation. Check engine oil level. Check cooling system fluid level. Drain water/fuel separator. Check air filter/pre-cleaner condition. Check radiator and screen for debris. Check unusual engine noises. Check unusual operating noises. Check height of cut. Check hydraulic system oil level. Check hydraulic hoses for damage. Check fluid leaks.
Lubrication operating conditions. However, lubricate more frequently under extreme conditions. The left column numbers correspond with numbers in Fig. 31. 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 Component No.
1 1 2 2 3 3 4 2 3 3 2 9 4 9 16 8 2 22 8 7 7 5 7 5 8 5 5 13 13 6 6 15 6 15 15 18 12 12 6 6 6 13 24 14 14 10 13 14 14 10 17 5 11 11 5 12 12 5 5 21 21 24 25 23 20 25 19 19 Figure 32 Engine Oil and Filter The engine uses any high quality detergent oil having the American Petroleum Institute – API – “service classification” CD. Oil viscosity recommendations are: Ambient Temperature Proper Viscosity –20° to 20° F (–28.9° to –6.
Checking the Oil Level Check engine oil level after every five hours operation. 1. Unlatch and raise hood and prop it open. Unlatch and remove left side panel (Fig. 33). Make sure hood prop is secured in one of the mounting brackets on hood. 1 Figure 35 1. Engine oil fill cap Changing the Engine Oil and Filter The engine holds approximately 8.5 qt (8 l) of oil. Change oil and filter after the first 50 hours, then change both every 100 hours operation.
4. If fuel system becomes contaminated or machine is to be stored for an extended period, locate drain at bottom of fuel tank and drain and clean tank. Flush tank with clean fuel oil. 3. Remove drain plug and allow oil to drain into pan. Remove and replace oil filter (Fig. 37); refer to parts catalog for replacement number. Apply a coating of oil to the filter O-ring and tighten filter by hand. 1 1 Figure 37 1. Engine oil filter Figure 39 1.
2. Each day after operation, clean debris from the radiator grille. Clean more frequently in dusty and dirty conditions. A. Move seat forward as far as possible. B. Remove upper and lower grille assemblies (Fig. 40). C. Use compressed air to clean the grilles and remove debris from grille mounting areas. D. Install grilles after cleaning, lower and lock seat in position. Figure 41 1. Latch handles 2. Radiator cowl 3. Grille support C.
Removing the Filter 4. Every 100 hours operation, inspect fan belt for condition and proper tension. Replace belt if condition warrants. Check and adjust tension as follows: 1. Release latches securing air cleaner cover to air cleaner body (Fig. 44). Separate cover from body. Clean inside of air cleaner cover. A. Unlatch and raise hood and prop it open. Unlatch and remove right side panel. B. Proper tension will allow 1/2 in. (13 mm) deflection when a force of 10 lb.
Cleaning the Filter Multigrade Hydraulic Fluid – ISO VG 68 1. Washing Method: Mobil DTE 26 Amoco A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes. Refer to directions on filter cleaner carton for complete information. Rykon AW No. 68 Chevron Hydraulic Oil AW ISO 68 Conoco Hydroclear AW 68 Exxon B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the filter element.
Replacing the Hydraulic Filter Draining Water from the Hydraulic Reservoir After 50 hours initial operation, replace the hydraulic filter (Toro Part No. 69–1720). Replace the filter every 500 hours of operation thereafter. Every 500 hours operation, drain water from reservoir at three (3) locations. 1. Place drain pan under filter and remove filter (Fig. 47). 1. Place drain pan under reservoir. 2. Locate plugs at right rear behind front wheel, at rear center and front center of reservoir (Fig. 48).
Servicing the Planetary Gear Drive 5. Check oil level; add if necessary. Hydraulic System Breather Change oil initially after 50 hours operation and every 800 hours, or yearly. Use high quality SAE 80–90 wt. gear lube as replacement. Check oil if leakage is noted. During normal operating conditions, replace the hydraulic system oil breather every 1000 hours operation, or yearly. Replace breather more frequently in extremely dusty, dirty conditions. Checking the Oil Level 1.
Servicing the Battery Warning Warning Incorrect battery cable routing could damage the tractor and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Fuses and Circuit Breaker One 5 amp., two 15 amp. fuses, and a fusible link are incorporated for the protection of the entire wiring circuit. The link can be replaced if total loss of electrical function results. They are located under the control panel to the right of the seat (Fig. 53). If total loss of electrical function occurs, find and correct the malfunction before replacing the fusible link. Figure 54 1. Floor plate 2. Tool tray 2.
Checking the Tire Pressure 3. Use belt to rotate inner and center spindle pulleys until grease fittings can be accessed with a grease gun. Since the machine can be operated under many different types of turf conditions, proper tire pressure is very important. Check tire condition and pressure daily and use the following guide to maintain maximum turf conditions: 4. Grease fittings and replace cover.
Caution Personal injury may occur if only one person tries to pivot the cutting unit up or down. • Use at least one other person to assist in lifting or lowering the unit. • Always use proper lifting techniques and hold the unit securely when pivoting it up or down. GRAPHIC # To Pivot the Cutting Unit Down into the Operating Position 1. With the help of an assistant, hold the unit upright, remove the klik pin securing the link end and remove link end from the weldment. Figure 58 1.
Danger A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. • Inspect the blade periodically for wear or damage. • Replace a worn or damaged blade. Figure 61 3. Examine cutting edges of all blades. Sharpen cutting edges that are dull or nicked. To assure sharpness, sharpen only the top side of the cutting edge while maintaining the original cutting angle (Fig. 62).
Outboard Cutting Units Inspecting and Adjusting the Cutting Unit Belt Tension 1. Remove deck covers. To check belt tension, apply 8 lb. (35.5 N) force at mid-span of belt and check deflection. There should be approximately 5/16 in. (7.9 mm) deflection. If deflection is incorrect, proceed to step 2. If deflection is correct, proceed to step 3. Important After first ten hours of operation, check new belts for proper tension; thereafter, check tension every 50 hours. 2.
6. Position motor mount onto deck while routing belt around drive pulley (Fig. 65). Be careful not to bend, twist, kink or damage flexible hydraulic lines. 8 7. Tighten (4) capscrews securing motor mount to deck. 8. Check the drive pulley (Fig. 65) height as follows: 6 • Slide the height gauge (Fig. 65) under drive pulley (not under hub). 7 9 • Equally tighten or loosen (3) adjusting screws (Fig. 65) until bottom of pulley rests on height gauge (approximately 1–1/2”).
2. Remove deck covers. Loosen flange locknuts on idler pulleys and slide pulleys away from belts. 2. Remove deck covers and relieve belt tension on all belts (Fig. 64). 3. Remove flange head screws securing gearbox plate to deck. To separate plate and drive motor assembly from deck, rotate plate end toward traction unit (Fig. 64). Tip plate, motor and pulley assembly on its side and remove from deck. Be careful not to bend, twist, kink or damage flexible hydraulic lines. 3.
measurements. Maximum difference allowed between any two adjacent blades is 1/4 in. (6 mm). Maximum difference allowed between the highest and lowest blade measurement is 3/8 in. (10 mm). If measurements do not fit recommended standards, add shims between the cutting deck and spindle housing; proceed to step 6. If measurements meet standards, proceed to step 5. outboard units, move all castor shaft spacers to the underside of the castor arms and castor wheel axles to lower castor fork holes. 5.
4. Move stabilizer brackets inward until rollers contacts skirt of machine, then tighten capscrews locking adjustment. 1 2 Adjusting Traction Control Neutral 3 If machine moves when traction pedal and pump lever are in neutral position, adjustment is required. 1. Park machine on a level surface, engage parking brake, raise wing decks completely, lower front deck to the ground and turn the engine OFF. 4 5 2. Actuate pump lever (with foot pedal) to make sure that foot pedal and linkage operate freely.
Adjusting the Traction Control Rod Cylinder Head Bolts Torque initially after 50 operating hours and check every 1000 operating hours or annually thereafter. 1. Park machine on a level surface, engage parking brake, raise wing decks completely, lower front deck to the ground and turn the engine OFF. Engine Valve Clearance 2. Remove cotter pin and slotted nut from ball joint at traction pedal (Fig. 74). Disconnect ball joint from traction pedal.
Electrical Schematic PIN NO. 1 OIL PRESSURE SWITCH AUDIO ALARM 12V + INPUT POWER FROM CONTROLLER 2 BLUE 3 ORANGE 4 YELLOW/RED 5 OIL TEMP. SWITCH 6 GREEN/WHITE AIR CLEANER 7 TAN 8 PINK HYD. OIL LOW 9 11 VOLTMETER GROUND 14 19 10 12 9 4 24 AUDIO ALARM 15 20 24 ENG. COOLANT TEMP. OIL FILTER PLUGGED ENGINE TEMP.
STARTER 56 Y X RUN RUN SOLENOID START 12 VOLTS P2 P1 J3 A2 D1 L3 P3 S3 R3 A3 G2 C1 N2 G3 M2 F2 E2 E3 D2 H2 J2 D3 C2 H3 C3 B2 B3 M3 B1 OUTPUTS F3 LOGIC LOGIC INPUTS N3 E1 F1 R2 G1 H1 N1 K3 CAN CONNECTOR LEFT DECK SOL RIGHT DECK SOL FRONT DECK SOL CRUISE CONTROL SOL ”CRUISE ENGAGED” ”PARKING BRAKE ON” R Y 2–SPEED/HI RANGE Y ”GROUND SPEED/HI RANGE” L1 M1 K2 L2 J1 K1 A1 PARKING BRAKE C RS 232 PORT HI RANGE DISENGAGE HI RANGE ENGAGE LEFT DECK DOWN R
285 100 100 100 Hydraulic Schematic 57
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
