Form No. 3353–642 Rev. A Groundsmaster) 580-D Traction and Cutting Units Model No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . . Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic ACE Display . . . . . . . . . . . . . . . . . . . Checking the Interlock Switches . . . . . . . . . . . . . Checking the Warning Indicator Lights . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.
• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning: • lack of awareness of the effect of ground conditions, especially slopes. • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property.
• Use care when checking the blades. Wear gloves and use caution when servicing them. • Reduce the throttle setting before stopping the engine and, if the engine is provided with a fuel shut-off valve, turn the fuel off at the conclusion of mowing. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path.
• If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts. – Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine. • When operating a machine on slopes, by banks, or drop offs, always have ROPS (roll–over protection system) installed.
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 108-8078 1. Read the Operator’s Manual. 67-5360 95-0818 1. Warning—torque the blade bolt to 140–165 ft.-lb. (190–224 N⋅m). Read the operator’s manual for further instructions.
9-1900 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 106-0390 1. 2. 3. 4. Parking brake High speed Cruise control locked To lock the parking brake, press the brake pedal and pull out the parking brake knob. 5. To unlock the parking brake, press the brake pedal. 6. Read the Operator’s Manual. 95-0845 1. Height-of-cut settings 95-0820 1.
6-0392 1. Engine—preheat 2. Fast 3. Continuous variable setting 4. Slow 5. Lower the cutting unit 6. Raise the cutting unit 7. Left cutting unit 8. Center cutting unit 9. Right cutting unit 95-0817 1. Low range height-of-cut settings 2. High range height-of-cut settings 105-0739 1. Read the Operator’s Manual. 2. Grease every 50 hours. 106-0044 10 3. Add grease (9 grease points).
106-0393 1. Press the button to silence the alarm. 2. Press the button to test the warning lights.
106-0391 1. 2. 3. 4. 5. 6. 7. 8. Engine—stop Engine—run Engine—start Flow divider Forward Reverse Engine—preheat Engage the power take-off (PTO). 9. Disengage the power take-off (PTO) 10. Transmission—high speed 11. Transmission—low speed 12. Forward machine speeds 13. Press the button to set the cruise control 14. Cruise control 15. On 16. Off 17. Headlights 18. Push the button to over-ride an overheated engine shutdown. 19.
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. 19:1 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 Adjusting screw 1 Nut 1 Height gauge 1 Use when replacing front cutting unit blade drive belt 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.
3. Check both batteries for charge with a hydrometer. If batteries check acceptably, slide tray back in place, secure with capscrews and lockwashers and install side panel. If batteries require charging, proceed to step 4. Warning Charging the battery produces gasses that can explode. Warning Never smoke near the battery and keep sparks and flames away from the battery. Charge batteries in a open well ventilated area. Incorrect battery cable routing could damage the tractor and cables, causing sparks.
Before Operating 3. Remove dipstick (Fig. 5), wipe with a clean rag, and insert into tube until fully seated. Remove dipstick from tube and check oil level. If oil level is low, remove filler cap (Fig. 6). Add proper type of oil until level is between the upper and lower holes on the dipstick (Fig. 7). Do not overfill. Note: Determine the left and right sides of the machine from the normal operating position. Checking the Engine Oil The engine is shipped with 8.5 qt. (8 l) of oil in the crankcase.
Checking the Cooling System The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check coolant level at beginning of each day before starting the engine. Capacity of cooling system is approximately 3.9 gal. (14.7 l). Caution 1 If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Do not open the radiator cap when the engine is running.
Filling the Fuel Tank • When turf is dry and harder than normal, use higher tire pressure: 18 psi (120 kPa) front and rear. The engine runs on ASTM No. 2-D diesel fuel. Castor Wheel Tires • All conditions use 50 psi (340 kPa) castors. Danger Checking Systems Operation Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. Start engine.
Adjusting the Height of Cut 4 The height-of-cut is adjustable from 1 to 5-1/2 in. (25 to 140 mm) in 1/2 in. (13 mm) increments. Positioning the castor wheel axles in the top holes of the castor forks (Fig. 12) allows Low range height-of-cut settings from 1 to 4 in. (25 to 102 mm); positioning the castor wheel axles in the lower holes of the castor forks (Fig. 12) allows High range height-of-cut settings from 2-1/2 to 5-1/2 in. (63.5 to 140 mm). 1 3 2 Figure 13 1. Hairpin cotter 2. Clevis pin 3.
Adjusting the Skids After initial set up or if height-of-cut is changed, deck skids should also be adjusted. Adjust skids by loosening flange lock nuts (Fig. 15), positioning skid at specified height (see chart) and re-tightening flange lock nuts. Front Cutting Unit All H.O.C.—3/8 to 1/2 in. above level surface Outboard Cutting Units 1 in. H.O.C.—Skid positioned all the way up 1-1/2 to 3 in. H.O.C.—Skid positioned 1/2 to 1 in. above level surface 3 in. and above H.O.C.
Operation 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. 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. 18) 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. 19) 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. 20), alerts operator the cruise control is engaged. There are two cruise control switches on panel to right of operator (Fig. 21)—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. 21 and 22) 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. 24).
2 7 1 5 6 4 1 2 2 Figure 25 1. Hinged floor plate 3 2. Removable tool tray Figure 26 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 6. Try to start engine. If engine starts, install left side panel, lower hood and resume operation. If engine does not start, repeat steps 2–6. 1. Unlatch, raise and prop engine hood open and remove left side panel (Fig. 27). 1 1 2 2 4 3 Figure 27 1. Engine hood 2. Left side panel Figure 29 3. Hood latches 4. Side panel latch 1. Priming pump 2. At lower left side of engine, loosen air bleed screw at top of fuel filter/water separator (Fig. 28). 1 2.
• One of the outputs is open circuited. The purpose of the interlock switches are to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL, to ensure cutting units disengage when raised or when operator leaves the seat. In addition, the engine will stop when the traction pedal is depressed with operator off the seat. Using the diagnostic display, determine which output is malfunctioning; refer to Checking the Interlock Switches, page 29.
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.
X X O O 6) Right Deck Engage 7) Left Deck Engage 8) Gauges ON X O 5) Front Deck Engage 4) Cruise Engage X X 3) Run (no operator) Run (with operator) X 2) Hi Range Engage 1) Start ACTIONS LOGIC GRID X X O X O X O X X XX O X O B X X O B X X M O MO MO X O X O O O M X O O O MX X B= MUST BE CLOSED ONLY IF HI TEMP SWITCH IS CLOSED.
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. 1 Pushing or Towing the Machine Figure 33 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. Stopping the Machine To stop the machine and cease operation, take foot off traction pedal and apply the brakes. Move the throttle lever to SLOW, ground speed selector to LOW RANGE and deck lift controls to neutral.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • Check the fan and alternator belt adjustment. • Torque the wheel lug nuts. • Check the cutting unit drive belt adjustment. After first 50 hours • • • • • Change the engine oil and replace the filter. Replace the hydraulic filter. Torque cylinder head bolts and adjust valves.
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.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any 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. Use the above chart and figure 35 to determine the areas to lubricate and number of fittings involved. The left column numbers correspond with numbers in Fig. 35.
Component No.
Engine Oil and Filter 3. If level is low, remove filler cap (Fig. 38). Add proper type of oil until level is between the holes on the dipstick (Fig. 39). Do not overfill. The engine uses any high quality detergent oil having the American Petroleum Institute – API – “service classification” CF–4 or higher. Use the following chart to select the appropriate oil viscosity according to the ambient temperature. 1 Recommended oil viscosity is SAE 15W–40 for all seasons.
Changing the Engine Oil and Filter Engine Fuel System 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. However, change oil more frequently when engine is operated in dusty or sandy conditions. If possible, run engine just before changing oil because warm oil flows better and carries more contaminants than cold oil. 1. Locate fuel filter/water separator on lower left side of engine and drain daily (Fig. 42). 2.
C. Use compressed air to clean the grilles and remove debris from grille mounting areas. Important Following the maintenance steps listed above will, under normal conditions, keep the system trouble-free. However, if the indicator light on the control panel and audible warning signal activate during operation, the engine should be stopped and the fuel system serviced before operation is resumed. This can prevent serious engine damage from occurring. D.
D. Unlatch and raise hood and prop it open. Use compressed air from the engine fan side to clean the radiator and oil cooler fins. 2. Service the air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions). E. Assemble components after cleaning is completed. 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.
Cleaning the Filter Shell Sunoco Texaco 1. Blow compressed air from inside to the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element. Group 2 Hydraulic Fluid (Hot Climate—Heavy Duty) 2. Keep air hose nozzle at least 2 in. from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light. Note: The fluids within this group are interchangeable.
Inspecting the Lines and Fittings 2. If oil needs to be added, clean area thoroughly around the fill cap before removing cap (Fig. 50). Add oil until proper level is indicated in sight glass. Every 100 hours operation inspect all hoses, lines and fittings for signs of leakage or damage (blisters, cut hoses, etc.) 2 Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Draining the Hydraulic Reservoir Hydraulic System Test Ports Every 1000 hours operation, or yearly, drain and replace hydraulic fluid in reservoir. Total system capacity is approximately 40 gal. (151 l); reservoir capacity is approximately 32 gal. (121 l). The test ports (Fig. 54) are used for testing the hydraulic circuits. Contact your local Toro distributor for assistance on use of these components. 1 Note: If oil becomes contaminated (oil appears milky or black), the system must be flushed.
2. Remove plug. Oil should be to bottom of the hole. 3. Add gear oil, if necessary, to bring up to proper level and install plug. 2 4. Repeat steps 1–3 on the opposite gear assembly. Draining the Gear Oil 1. With machine on level surface, position wheel so the check/drain plug is at lowest position. 2. Place drain pan under hub, remove plug and allow oil to drain. 3. When oil has drained, position wheel so plug hole is at three or nine o’clock position (Fig. 55). 1 4. Add approximately 32 oz. (1.
Servicing the Brake System 4. Remove negative (–) battery cable connectors from batteries (Fig. 56). Connect a 3 to 4 amp. battery charger to the posts. Charge the batteries at a rate of 3 to 4 Amperes for 4 to 8 hours. Check brake fluid level every 50 hours operation. Replace fluid every 1000 hours operation, or yearly. Replenish system with DOT 3 hydraulic brake fluid. To check fluid level: Warning 1. Raise floor panel in front of seat (Fig. 58). Remove tool tray.
Wheels and Tires Torque Wheel Nuts After the first ten (10) hours operation, check torque on the wheel nuts and every 200 hours thereafter. 1. Torque lug nuts for front wheels 60–70 ft.-lb. (81–95 N⋅m). 2. Torque lug nuts for rear wheels to 30–35 ft.-lb. (41–47 N⋅m). 1 Figure 60 Checking the Tire Pressure 1. Inner cover Since the machine can be operated under many different types of turf conditions, proper tire pressure is very important.
Tilting the Cutting Unit Upright Caution 1. Position front cutting unit so rear castor wheels just clear the floor, set parking brake and shut engine off. Personal injury may occur if only one person tries to pivot the cutting unit up or down. 2. Remove deck tilt link from tool box under traction unit floor (Fig. 58) and klik pins from weldments on traction unit frame and cutting unit lift arm. • Use at least one other person to assist in lifting or lowering the unit.
Blade Bolt Torque Danger Check blade bolt torque daily or after blade strikes a solid object. However, if solid object causes blade to be damaged or bent to a degree it is unusable, replace it; refer to Removing Cutting Unit Blade, below. 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. 1.
4 SHARPEN AT THIS ANGLE ONLY 1 2 Figure 66 End View 3–1/6”– New belt 3–1/4”– Old belt 4. To check blade for being straight and parallel, remove from cutting unit. Lay blade on level surface and check its ends. Blade ends must be slightly lower than blade center and cutting edge lower than heel of the blade. If so, it will produce good quality–of–cut and require minimal engine power to turn.
Replacing the Blade Drive Belts 3. Locate and remove the adjusting screw and nut from the tool box. 4. Thread the nut onto the adjusting screw and thread the screw into the rear of the motor mount (Fig. 69). Position machine on level surface, lower cutting unit to shop floor, engage parking brake, shut engine off and remove key from ignition switch. 5. Loosen the (4) capscrews securing the slide plate to the motor mount (Fig. 69). Front Cutting Unit 6.
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. 68). 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. 14. Tension the front idler pulleys (Fig. NO TAG) as follows: • Loosen the jam nuts on idler arm spring tension rod. • Thread the jam nuts in or out until the tension spring length is 6.75 .25”. 4.
5 4 3 1 2 2 1 Figure 73 Figure 72 1. Deck cover 2. Gearbox plate 3. Deck pivot shaft 1. High range height-of-cut 4. Deck clevis 5. Lift bar 2. Move to highest height-of-cut setting 2 4. Remove locknut securing deck pivot shaft into deck clevis and lift bar (Fig. 72). 5. Move the cutting unit away from the machine. 3 6. To install cutting unit, assemble in reverse order.
Adjusting the Traction Control Rod 6. Remove locknuts securing spindle housing to deck in area where shims are to be added. To lower a blade, add a shim (Part No. 3256–24), to each mounting bolt, between spindle housing and cutter deck. Repeat step 5. Continue process until blade tips are within the required dimensions. 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.
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 10 24 11 AUDIO ALARM 12 VOLTMETER GROUND 15 20 21 21 19 WHITE 14 BLACK ENG. COOLANT TEMP. OIL FILTER PLUGGED ENGINE TEMP.
Controller Electrical Schematic 59
285 100 100 100 Hydraulic Schematic 60
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 Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
