Service Manual

ManualsBrandsToro ManualsRiding ProductsGroundsmaster 580-D

NOTE:

Model 30581: Use this book along with Part No. 95866SL Mitsubishi S4S --DT Engine Service Manual.

Model 30582 and 30583: Use this book along with Part No. 04131SL Mitsubishi S4S--Y2DT61TG Engine Ser-

vice Manual.

Part No. 90743SL, Rev. G

Service Manual

Groundsmaster

580--D

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing,

and repair of major systems and components on the

Groundsmaster 580--D, Model 30580, 30581, 30582,

and 30583 (see NOTE above).

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR’S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC-

TIONS. Space is provided in Chapter 2 of this book to

insert the Operator’s Manuals and Parts Catalogs for

your machine. Replacement Operator’s Manuals are

available on the internet at www.toro.com or by sending

complete Model and Serial Number to:

The Toro Company

8111 Lyndale Avenue South

Minneapolis, MN 55420

TheToroCompanyreservesthe right to changeproduct

specifications or this publication without notice.

This safety symbol means DANGER, WARN-

ING, or CAUTION, PERSONAL SAFETY

INSTRUCTION. When you see this symbol,

carefully read the instructions that follow.

Failure to obey the instructions may result in

personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

E The Toro Company -- 1989, 1997, 1999, 2003, 2004, 2005, 2007

Summary of content (329 pages)

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Part No. 90743SL, Rev. G Service Manual GroundsmasterR 580--D Preface NOTE: Model 30581: Use this book along with Part No. 95866SL Mitsubishi S4S--DT Engine Service Manual. Model 30582 and 30583: Use this book along with Part No. 04131SL Mitsubishi S4S--Y2DT61TG Engine Service Manual.
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Table Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4 Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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9. Since diesel fuel is highly flammable, handle it carefully: A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and only to within an inch (25 mm) from the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel. 10.
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Maintenance and Service 21. Before servicing or making adjustments, stop engine and remove key from the switch. 27. For major repairs or other assistance, contact your local Toro Distributor. 22. Assure entire machine is properly maintained and in good operating condition. Frequently check all nuts, bolts and screws. 28. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt. 23. Frequently check all hydraulic line connectors and fittings.
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Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 580--D. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor. Safety Page 1 -- 4 Rev.
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Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . 1 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 3 Capscrew Markings and Torque Values -- U.S. . . .
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Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Groundsmaster 580–D
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Torque Specifications Groundsmaster 580–D Page 2 – 3 Product Records and Maintenance
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Chapter 3 Engine (Model 30580) Table of Contents NOTE: This Chapter provides engine information for TORO Model 30580. See Chapter 3A for Model 30581 or Chapter 3B for Model 30582. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 3 Engine Serial Number Location. . . . . . . . . . . . . . 3 Engine External Views. . . . . . . . . . . . . . . . . . . . . 4 Engine Sectional Views . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .
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Stopping the Engine Important: Before stopping the engine after mowing or full load operation, cool the turbocharger by allowing the engine to idle at low speed for 5 minutes. Failure to do so may lead to turbocharger failure. Rev.
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Cone removing Tool For removing crankshaft pulley 34791-01100 Rev.
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NOTE: The crankshaft pulley uses a tapered cone to secure the pulley to the crankshaft. Use Mitsubishi Special Tool 34791-01100 for pulley removal. Rev.
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Chapter 3A Engine (Model 30581) Table of Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Information The engine used in the Groundsmaster 580–D mower is manufactured by Mitsubishi Heavy Industries Limited. Service and repair parts for Mitsubishi engines are supplied through TORO Distributors. Repair parts may be ordered by TORO part number.
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Specifications Item Description Make / Designation Mitsubishi Model S4S–DT 4 cycle, 4 cylinder Diesel Engine Number of Cylinders 4 Total Displacement 3331 cc (203.3 cu. in.) Fuel Diesel Fuel No. 2–D Fuel Capacity 28 U.S.
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Chapter 3B Engine (Models 30582 and 30583) Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MITSUBISHI S4S--Y2DT61TG SERVICE MANUAL General Information The engine used in the Groundsmaster 580--D Models 30582 and 30583 mower is manufactured by Mitsubishi Heavy Industries Limited. Service and repair parts for this Mitsubishi engine are supplied through TORO Distributors.
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Specifications Item Description Make / Designation Mitsubishi Model S4S–DT 4 cycle, OHV, Liquid Cooled, Turbocharged Diesel Engine Number of Cylinders 4 Total Displacement 3331 cc (203.3 cu. in.) Fuel Diesel Fuel No. 2–D Fuel Capacity 28 U.S. gallon (106 liter) Idle Speed (no load) 1100 + 50 RPM High Idle (no load) 2700 + 50 RPM Engine Oil See Operator’s Manual for Oil Recommendations Oil Capacity Specifications 10.5 U.S. quart (10 liter) with filter Page 3B – 2 Rev.
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Chapter 4 Hydraulic System Table of Contents NOTE: See Chapter 9 -- Foldout Diagrams for Hydraulic Schematics SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Pushing or Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Draining and Refilling System . . . . . .
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Specifications Item Description Traction Drive Pump Variable displacement axial piston pump with servo assisted manual displacement control (MDC) 5000 + 250 psi (344.8 + 7.2 bar) 230 + 10 psi (15.9 + .7 bar) 285 + 10 psi (15.9 + .7 bar) Main relief pressure Charge relief pressure (Pump S/N below A--96--01--XXXXX) Charge relief pressure (Pump S/N above A--96--01--XXXXX) Front Wheel Motor (2 used) Variable displacement axial piston motor Mow/Transport speed, elec./hyd.
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Deck drive test ports on newer models at deck motor Older model shown 3. Start the engine and adjust throttle so engine speed is 2,500 rpm. Rev.
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TEST NO. 2: Traction Circuit Charge Pressure 1. Hydraulic oil must be at operating temperature. Deck drive test ports on newer models at deck motor. Older model shown. 2. Connect a 1,000 psi gauge onto charge pressure test port (Fig. 10). 3. Start the engine and put throttle at idle position (approx. 1,200 rpm) with no load on the system. TESTER READING TO BE: 230 ± 10 PSI (Pump S/N Below A-96-01-XXXXX) 285 ± 10 PSI (Pump S/N A-96-01-XXXXX & Up) 4.
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Deck drive test ports on newer models at deck motor Older model shown 3. Start the engine and adjust throttle so engine speed is 2,500 rpm. Rev.
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TEST NO. 4: Lift Circuit Working Pressure and Relief Pressure WORKING Pressure Test NOTE: Always set counterbalance pressure to correct amount before attempting to adjust lift relief pressure (see TEST 5). 1. Connect a 5,000 psi gauge to the LIFT test port. a. On machines with serial number below 250000000, the LIFT test port is located on the outside of the control console (Fig. 12). b.
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TEST NO. 5: Counterbalance Pressure IMPORTANT: To prevent damage to test gauge, raise all decks before connecting 1,000 psi gauge to LIFT test port. NOTE: Hydraulic oil must be at operating temperature for these tests or pressure reading will be too high. COUNTERBALANCE Pressure Test 2 1 1. Connect a 1,000 psi gauge to the LIFT test port. a. On machines with serial number below 250000000, the LIFT test port is located on the outside of the control console (Fig. 13).
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“TRACTION PLUS” SHIFT Pressure Test 1. Connect a 1,000 psi gauge to the LIFT test port. Connect a 5,000 psi gauge to TRACTION FORWARD test port. a. On machines with serial number below 250000000, the LIFT and TRACTION FORWARD test ports are located on the outside of the control console (Fig. 13). b. On machines with serial number above 250000000, the LIFT and TRACTION FORWARD test ports are located underneath the center of the machine (Figs. 14 and 14A). 2.
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Diagnosing Cutting Performance Problems Over a period of time, the seals in the deck motors can deteriorate and wear from heat and contamination. A leaking motor seal will by--pass oil to the case drain line and make the motor less efficient. Eventually enough oil loss will occur and cause the deck motor to stall in heavy cutting conditions.
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Deck Motor Internal Leakage Test NOTE: Test only one deck at a time. Decks not being tested should be in the raised position so the deck will not operate when the PTO is engaged. 3. Start the engine and engage the PTO for exactly 15 seconds at full throttle, then disengage the PTO and stop the engine. 1. Determine which deck motor is turning slow. The left and right decks are powered in series by the same circuit, therefore one deck could affect the other. 4. Measure the amount of oil in the container.
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Deck drive test ports on newer models at deck motor Older model shown Rev.
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NOTE: The Traction Control Neutral Adjustment information listed is for models 30580 and 30581. For model 30582 and 30583 neutral adjustment, steps 5 to 7 are not relevent. Refer to Variable Pump Neutral Start Switch Spool Replacement Procedure in the Sauer/ Danfoss Traction Pump and Motor Service Manual included at the end of this chapter. Rev.
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NOTE: Machines with serial numbers above 90001 do not use a jam nut and setscrew. On these machines, locate collar so there is from .060 to .120 inch (1.5 to 3.0 mm) clearance between cruise control coil and clutch plate. Rev.
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NOTE: Refer to the Sauer/Sundstrand M46-Axial Piston Pumps and Motors Service Manual at the end of this chapter for traction pump service procedures. Rev.
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NOTE: For Service and Repair Procedures of the front wheel motors used on the Groundsmaster 580-D, see the Sundstrand Sauer M46-Axial Piston Pumps and Motors Repair Manual that follows this Chapter. Rev.
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Torque to 35 Ft-lbs (47.1 N-m) Torque to 35 Ft-lbs (47.1 N-m) Torque to 60 Ft-lbs (81.4 N-m) Torque to 35 Ft-lbs (47.1 N-m) Torque to 65 Ft-lbs (88.1 N-m) Rev.
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PTO Valve Block Service (S/N 50001 & UP) Torque to 35 ft-lbs (47.5 N–m) 2 Torque to 35 ft-lbs (47.5 N–m) 6 4 Torque to 60 ft–lbs (81.4 N–m) Torque to 15 in-lbs (1.7 N–m) 5 1 3 Torque to 65 ft–lbs (88.1 N–m) Torque to 35 ft-lbs (47.5 N–m) Loctite 242 Figure 27A 1. Solenoid valve (SV2 shown) 2. Bypass (main) relief cartridge (R3BY shown) 3. Bypass (main) logic cartridge (BY2 shown) Groundsmaster 580-D Page 4 - 36.1 Rev. E 4. Brake relief cartridge (R2BR shown) 5.
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B. Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas on poppet type valves causing malfunction. PTO Solenoid Valve Service (S/N 50001 & UP) C. If cartridge valve seals appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. 5. Clean and check for proper valve operation: A. Use clean mineral spirits to clean cartridge valve.
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NOTE: When installing solenoid valve into manifold, torque solenoid valve 35 Ft-lbs (47.1 N-m). NOTE: When installing a cartridge valve into manifold, torque valve as specified in Figures 27 and 27A. Rev.
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PTO Pump Repair (Models 30580 and 30581) 11 12 13 14 3 10 4 5 12 8 7 6 5 4 2 15 8 3 9 6 4 5 1 16 3 17 12 10 24 4 7 5 3 23 22 18 21 20 19 Figure 31A 1. Coupler 4. Retainer 7. Center section 10. O--ring 13. Capscrew (4 used) 16. Port section 19. Plug 22. Seal 2. Adapter section 5. Flex plate 8. Idler gear 11. Rear cover 14. Capscrew (4 used) 17. Gear 20. Shaft seal 23. Nut 3. Gland 6. O--ring 9. Gear 12. Lockwasher (16 used) 15. O--ring 18. Shaft end cover 21. Retaining ring 24.
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PTO Pump Repair (Models 30582 and 30583) 9 10 2 3 4 5 11 7 6 12 5 4 3 2 2 3 8 4 5 14 2 1 5 18 20 17 13 15 19 4 21 3 16 Figure 31B 1. Shaft coupling 4. Seal retainer 7. Idler gear 10. Capscrew (4 used) 13. Center section 16. Shaft end cover 19. Stud (8 used) 2. O--ring 5. Wear plate 8. Drive gear 11. Capscrew (4 used) 14. Idler gear 17. Shaft seal 20. Lockwasher (16 used) 3. Seal gland 6. Center section 9. Rear cover 12. Center housing 15. Drive gear 18. Seal 21.
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Deck Motor Repair (P/N 94-4907) Mark before disassembling 7 4 Drive Shaft 4 7 Mounting flange Body Gears 8 5 2 1 3 Torque to 70 + 5 ft-lbs 6 Figure 35A 1. Hex nut 2. Flat washer 3. Shaft seal 4. Load plate 5. O-ring seal 6. Retaining ring Disassembly 1. Use a marker or scribe to make a line across the body and mounting flange for proper reassembly (put mark along drive shaft side of body and flange as shown). 7. Load seal 8. Square key * Seal Kit (Items 3, 5-8) 6.
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Check the shaft seal recess for scoring or damage that could result in oil leakage around the outside diameter of the shaft seal. NOTE: Replacement shaft seals can be refitted with Loctite hydraulic sealant to overcome slight damage to this area. 3. Load Plates: The side faces which are against the gears should be perfectly flat showing no signs of scoring. Typically there are bright polished areas on this surface caused by loading against the gear side faces.
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Wing Deck Hose Replacement (S/N 50001 & Up) Routing of wing deck hoses through the wing arms requires accurate hose positioning or the hoses can be damaged as the wing decks are raised and lowered. In order to reduce hose damage due to incorrect routing, a Hose Routing Kit (P/N 93–9956) is available for previously manufactured products (S/N 80101 – 49999). The kit contains all the parts, hoses and instructions necessary to re–route the wing deck hoses external to the arms.
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Torque all cartridges to 35 Ft-lbs (47.5 N-m) Rev.
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NOTE: When installing cartridge into float/traction assist manifold, torque cartridge to 35 ft-lbs (47.5 N-m). If cartridge is overtightened, cartridge damage may occur. Rev.
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Steering/Auxiliary Pump Repair (Models 30582 and 30583) 10 7 360 to 380 in--lbs (40.7 to 42.9 N--m) 3 5 4 8 9 5 6 2 1 11 13 360 to 380 in--lbs (40.7 to 42.9 N--m) 12 8 14 Figure 39A 1. 2. 3. 4. 5. Cap screw (4 used) Shaft seal Pre--load seal Load seal Sealing ring 6. 7. 8. 9. 10. Front wear plate Drive shaft Dowel Rear wear plate Cap screw (3 used) 11. 12. 13. 14. Rear cover (flow divider) assembly Gear plate Idler gear Front body Disassembly 6. Carefully remove idler gear and drive gear.
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4. Inspect drive shaft gear and idler gear (Fig. 39C): SCRIBE MARK A. Drive shaft spline should be free of twisted or broken teeth. B. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces or wear on gear shafts indicates need for replacement. C. Gear teeth should be free of excessive scoring and wear. Any broken or nicked gear teeth must be replaced. Figure 39B D. Inspect gear face edge for sharpness.
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(Models 30580 and 30581) Rev.
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Steering Control Unit Repair (Models 30580 and 30581) For service of the steering control unit on Models 30580 and 30581, see the Eaton Char--Lynn Steering Control Units Repair Information at the end of this chapter. Steering Control Unit Repair (Model 30582 and 30583) 8 1 3 24 2 5 19 23 20 7 4 6 19 22 21 150 in--lb (17 N--m) 9 10 13 12 11 14 18 17 16 140 to 160 in--lb (16 to 18 N--m) 15 Figure 49A 1. 2. 3. 4. 5. 6. 7. 8.
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9. Carefully slide the spool out of the sleeve. The centering springs and spring retaining ring will stay with the spool as it is removed. 7. Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals. 8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 49B). CAUTION The centering springs are under tension. Remove the retaining ring carefully. 10.Remove the spring retaining ring and centering springs from the spool.
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Chapter 5 Electrical System (Model 30580, S/N Below 30101) Table of Contents ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 2 Controller Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . 2 Logic Grid (with Controller Update Kit) . . . . . . . . . . 3 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wiring Diagram -- Gauge Package . . . . . . . . . . . . . 5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TROUBLESHOOTING . . . . .
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Groundsmaster 580–D Page 5 – 3 Rev.
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Electrical Schematic Wiring Schematics and Diagrams Page 5 - 4 Rev.
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Groundsmaster 580 - D Page 5 - 5 Rev.
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Note: If machine is equipped with Controller Update Kit, refer to Chapter 8 - Electrical System (S/N 30101 & Up). Page 5 - 21 Rev.
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Note: For machines with serial numbers 30101 & up, refer to updated information in Chapter 8 - Electrical System. Page 5 - 32 Rev.
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Older model shown. Note: For models 30581 and 30582, starter repair information is included in the appropriate Mitsubishi Diesel Engine Service Manual found after chapter 3A (model 30581) or chapter 3B (model 30582). Page 5 - 37 Rev.
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Note: For models 30581 and 30582, starter repair information is included in Chapter 8 - Electrical System (S/N 30101 & Up) and in the Mitsubishi Diesel Engine Service Manual found after chapter 3A (model 30581). Page 5 - 44 Rev.
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Specifications Planetary Wheel Drive Weight: Approx. 95 lb. Planetary Wheel Drive Oil Capacity: Fill to bottom of check/drain plug hole when check/drain plug is at either 3 or 9 o’clock position (Fig. 1). Planetary Wheel Drive Lubricant: API GL-5, SAE 80W or 90W Gear Lubricant. Brake System: Enclosed, multiple hydraulic disc service brakes operated by right foot pedal. Mechanical steering brakes with two pedals which lock together for parking brake function.
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NOTE: Refer to Operator's Manual for additional information regarding Cutting Unit service procedures. Rev.
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Belt Tension Adjustment IMPORTANT: After first ten hours of operation, check new belts for proper tension; thereafter, check tension every 50 hours. 5 3 2 Front Cutting Unit (S/N below 220000000) Note: Belts for wing unit spindles are tensioned by spring loaded idlers and normally do not require tensioning. 1. Position machine on level surface, lower cutting unit to shop floor, engage parking brake, shut engine off and remove key from ignition switch. 4 2. Remove deck covers. 1 3.
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Outboard Cutting Units 1 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. 2 2. To tension belts, loosen flange locknut at top of idler pulley (Fig. 10). Slide pulley against belt until proper tension is reached. Hold pulley in position and tighten locknut. New belt: 3.060 in. (77.
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Note: If machine is equipped with a cab enclosure, take care when pivoting front cutting unit to prevent deck motor from contacting cab windshield. Rev.
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Belt Replacement Front Cutting Unit (S/N below 220000000) 5 1. Position machine on level surface, lower cutting unit to shop floor, engage parking brake, shut engine off and remove key from ignition switch. 3 2 Note: Wing spindle drive belts must be removed before removing center section belt. 2. Remove belt covers. Lift each wing to release idler pulley tension and slip belt off pulleys (Fig. 20). 4 3. Loosen jam nuts securing tension arm until compression spring on idler assembly is relaxed (Fig.
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9. Check and adjust the drive pulley height as follows: 1 A. Slide the height gauge under the drive pulley (not under the hub). 2 3 B. Loosen jam nuts on three (3) motor mount adjusting screws. Equally tighten or loosen adjusting screws until bottom of pulley rests on height gauge (approximately 1 1/2 in. (38.1 mm)). 4 C. Tighten jam nuts to secure adjustment. Remove height gauge. 10. Adjust belt tension (See Belt Tension Adjustment in the Adjustments section of this chapter). Figure 21B 1.
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Spindle Service Removing Spindle Housing Assembly 2 1 1. Lower cutting unit to ground and engage parking brake. Turn engine off and remove key from ignition switch. 3 4 2. Remove belt cover from top of spindle housing to be serviced. Loosen belt tension and remove belt from spindle. 140 to 160 ft--lb (190 to 217 N--m) 5 6 3. Raise cutting unit to transport position, turn engine off and remove key from ignition switch. Make sure that parking brake is engaged. 7 4.
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2. Using an arbor press, push outer bearing spacer into top of spindle housing; tightly against snap ring. The spacer must contact the snap ring to be sure of the correct assembly of components. 3. Thoroughly oil the bearing cups. Use an arbor press to push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the spacer that was installed in step 2, and the bottom bearing cup must contact the snap ring.
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Chapter 8 Models 30580 (S/N 30101 & Up), 30581, 30582 and 30583 Electrical System Table of Contents ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 2 (See Chapter 9 -- Foldout Diagrams for additional electrical diagrams) Controller Logic Grid . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wire Harness Diagram: Console Gauge Panel . . . 3 Wiring Diagram: Console Gauge Panel . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Electrical System (S/N 30101 & Up) (Rev. E) Page 8 -- 2 Groundsmaster 580--D 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 X MO MO X O X X O X O X X XX O X O B X X O B X M OX O X O O O M X O O O MX X P KEY: X = CLOSED, O = OPEN, P = OUTPUT ON, M = MOMENTARILY CLOSED, B= MUST BE CLOSED ONLY IF HI TEMP SWITCH IS CLOSED.
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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 9 14 19 10 11 12 9 4 24 AUDIO ALARM 15 20 24 GROUND ENG. COOLANT TEMP. OIL FILTER PLUGGED ENGINE TEMP.
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WIRING DIAGRAM: CONSOLE GAUGE PANEL Electrical System (S/N 30101 & Up) (Rev.
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Special Tools Order special tools from your Toro Distributor. Some tools may be listed in the Parts Catalog for the Groundsmaster 580--D. Some tools may also be available from a local supplier. Digital Multimeter The Digital Multimeter can test electrical components and circuits for current, resistance, or voltage drop. Obtain Digital Multimeter from a local supplier. Note: Toro recommends the use of a DIGITAL multimeter when testing electrical circuits.
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Diagnostic ACE Display The diagnostic display is connected to the wiring harness connector located under the control panel to help the user verify correct electrical functions of the machine. Decal Diagnostic ACE Display Diagnostic ACE Display, Toro P/N 85--4750 Decal, V1.0, Toro P/N 88--1860 (S/N Below 30101 with Controller Update Kit) Decal, V2.0, Toro P/N 92--4087 (S/N 30101 & Up) Figure 3 Figure 4 Electrical System (S/N 30101 & Up) (Rev.
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Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 v (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F (16o to 38o C). The ignition key should be in the OFF position and all accessories turned off.
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Troubleshooting For all electrical problems, use of the Quick Reference Troubleshooting Guide is recommended. Using the Diagnostic ACE Display allows you to quickly find the source of the electrical problem. See Chapter 5 -- Electrical System (S/N Below 30101) for additional Troubleshooting information. Only components that are different or new information is provided in this Chapter. If the machine has any interlock switches by--passed, they must be reconnected for proper troubleshooting and safety.
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Note: The red text on the overlay decal refers to input switches and the green text refers to output switches. 5. The Inputs Displayed LED on lower right column of the Diagnostic ACE should be lighted. If the Outputs Displayed LED is lighted, press and release Toggle Input/ Output button on Diagnostic ACE to change to the Inputs Displayed LED. Do not hold button down. Note: The Diagnostic ACE will illuminate a LED associated with each input when its associated input switch is closed. 6.
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Retrieving Stored Faults Clearing Fault Memory Note: The machine may require installation of updated software for this function to operate. This required software was installed on machines starting with S/N 70001. Older machines can have new software installed. Contact your Toro Distributor for assistance. Once a fault is repaired, it must be must be cleared from the ECU memory so any future fault can then be stored. 1. Turn ignition switch to OFF.
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Component Identification and Testing See Chapter 5 -- Electrical System (S/N Below 30101) for additional Component Identification and Testing information. Only components that are different or new information is provided in this Chapter. Electronic Control Unit (ECU) The Toro electronic control unit (ECU) senses the condition of various switches, such as the seat switch, cutting unit down switches, traction neutral switch, etc.
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Seat Switch (S/N Between 30101 and 80000) The seat switch is a proximity type, normally open (NO) reed switch that closes when the operator is on the seat. With the operator on the seat, the magnet on the bottom of the seat activates the reed switch causing it to close and complete the circuit. 1. Raise the seat to get access to the seat switch wiring connector. 2. Disconnect the seat switch wiring connector and install a continuity tester or ohm meter between the two leads of the seat switch. 1 3.
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Engine Temperature Switches (S/N 80001 and Up) The high temperature warning and shutdown switches are located near the engine thermostat housing (Fig. 11). The high temperature warning switch has a green/red wire attached it. 3. Check continuity of the switch with a multimeter (ohms setting). The high temperature warning and shutdown switches are both normally open and should close when oil temperature reaches: A. High temperature warning switch should close when oil temperature reaches 212oF (100oC).
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Service and Repairs See Chapter 5 -- Electrical System (S/N Below 30101) for additional Service and Repairs information. Only changed and new information is provided in this Chapter. Circuit Protection On model 30580 (S/N 30101 and up), one 5 Amp fuse and two 15 Amp fuses are used for circuit protection. In addition, a 40 Amp circuit breaker with reset button is used for protection of the entire wiring circuit. The fuses and circuit breaker are located under the control panel to the right of the seat (Fig.
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Battery Service The batteries are the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. Inspection, Maintenance, and Testing 1. Perform the following inspection and maintenance tasks: A. Check for cracks caused by overly tight or loose hold--down clamp. Replace battery if cracked and leaking. Note: Battery information for Model 30580 (S/N below 30101) is included in Chapter 5. B.
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2. Conduct a hydrometer test of the battery electrolyte. A. Check the voltage across the battery terminals prior to testing the battery. If the voltage is less than 12.0 VDC, recharge the battery. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. B. If the battery has been charged, apply a 150 amp load for 15 seconds to remove the surface charge. Use a battery load tester following the manufacturer’s instructions. A.
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Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most shops. Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60o F (15.5o C) before connecting to a charger. Charge the battery in a well--ventilated place to dissipate gases produced from charging.
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Alternator The alternator used on the Groundsmaster 580--D is belt driven and attaches to the engine. If testing determines that alternator is not functioning properly, bench inspection should be performed. Note: For information on disassembly and assembly of the alternator used on models 30581, 30582 and 30583, see the Mitsubishi S4S--DT Service Manual that follows Chapter 3A -- Engine (Model 30581). Resistance should be infinite in one direction and nearly zero in the other.
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Chapter 9 Models 30580 (S/N 30101 & Up), 30581, 30582, and 30583 Foldout Diagrams Table of Contents HYDRAULIC SCHEMATICS Hydraulic Schematic (2WD Machines) . . . . . . . . . . 3 Hydraulic Schematic (4WD Machines) . . . . . . . . . . 4 ELECTRICAL SCHEMATICS Model 30580 (S/N 30101 and Up) . . . . . . . . . . . . . 5 Models 30581 and 30582 . . . . . . . . . . . . . . . . . . . . . 6 Model 30583 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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This page is intentionally blank. Foldout Diagrams (Rev.
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NOTE: Hydraulic Schematic differences exist as follows: Charge pressure = 230 psi for piston pumps with serial numbers below A--96--01--xxxx RxBR pressure = 600 psi for models with serial numbers below 70000 Groundsmaster 580--D (2WD Machines) Hydraulic Schematic Page 9 -- 3 (Rev.
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Groundsmaster 580--D (4WD Machines) Hydraulic Schematic Page 9 -- 4 (Rev.
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Groundsmaster 580--D Model 30580 (S/N 30101 and Up) Electrical Schematic Page 9 -- 5 (Rev.
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GRAY/WHITE WHITE RED YELLOW RED RED/WHITE GREEN/WHITE BROWN/WHITE BLACK VIOLET BLUE ORANGE BLACK YELLOW/BLUE TAN BLUE/WHITE RED RED ORANGE/BLACK YELLOW/BLUE WHITE/BLACK ORANGE BROWN/WHITE YELLOW (Model 30581 Only) RED BROWN/RED RED/BLUE WHITE/GREEN GREEN/BLACK BLUE WHITE BLUE GREEN RED GREEN GREEN/YELLOW ORANGE/WHITE RED BLUE/WHITE WHITE RED/BLACK BLUE/WHITE YELLOW/RED BROWN/RED WHITE GRAY VIOLET/WHITE GREEN GREEN/RED BLACK YELLOW WHITE BLUE/WHITE BLACK Groundsmaster
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NOTE: The High Range/Low Range Ground Speed Switch on the machine console includes the terminals for both the High Range Engage/Disengage and the High/Low Speed switches.
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Groundsmaster 580--D Wire Harness Drawing Model 30580 (S/N 30101 and up) Page 9 -- 8 (Rev.
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BROWN/ RED/ RED RED WHITE RED PURPLE ORANGE ORANGE YELLOW BROWN BROWN ORANGE YELLOW RED BLUE PURPLE ORANGE/ BROWN RED WHITE RED BROWN PURPLE PURPLE BROWN BLACK/ BLUE BROWN WHITE BROWN BROWN PURPLE BROWN BROWN YELLOW/ RED WHITE/ GREEN BLUE YELLOW/ RED ORANGE BROWN BROWN/ GREEN/ WHITE RED YELLOW RED BLACK RED/ BROWN WHITE TAN GREEN/ WHITE PINK PURPLE BROWN BLACK YELLOW BLACK/ WHITE ORANGE BLACK YELLOW/ BLACK/ WHITE RED/ ORANGE WHITE BLACK GREEN/ WHITE BLUE/ WHITE BROWN/ RED GRE
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Groundsmaster 580--D Wire Harness Drawing Model 30581 Page 9 -- 10 (Rev.
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BROWN/ RED PURPLE ORANGE YELLOW BROWN ORANGE RED BROWN YELLOW RED RED RED PURPLE BLUE RED RED ORANGE/ BROWN WHITE BROWN BLUE PURPLE PURPLE BROWN BROWN BROWN BLACK/ WHITE PURPLE BROWN BROWN BLUE YELLOW/ RED BLUE GREEN/ WHITE PINK WHITE BLACK BROWN GRAY/ BLACK YELLOW/ RED RED TAN GREEN/ RED RED/ YELLOW WHITE ORANGE BLACK PURPLE BROWN ORANGE BLACK/ WHITE BROWN YELLOW BLACK RED/ WHITE BROWN/ RED BLACK GREEN/ WHITE BLUE/ WHITE ORANGE/ BLACK BROWN/ RED ORANGE GREEN/ RED B
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Groundsmaster 580--D Wire Harness Drawing Model 30582 (S/N Below 240999999) Page 9 -- 12 (Rev.
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BROWN/ RED PURPLE ORANGE ORANGE ORANGE/ WHITE BROWN BROWN RED RED RED PURPLE BLUE RED BROWN BLUE BROWN RED BLACK/ WHITE BROWN BROWN PURPLE RED RED PURPLE BROWN BROWN BROWN BLUE PURPLE YELLOW/ RED GRAY/ BLACK BLUE GREEN/ WHITE PINK GREEN/ RED YELLOW WHITE BROWN TAN WHITE BLACK BLACK PURPLE BROWN RED/ WHITE YELLOW ORANGE BLACK/ WHITE BLACK/ WHITE BLACK YELLOW/ RED ORANGE BROWN/ RED BLACK BLUE/ WHITE GREEN/ WHITE BROWN/ RED BLACK RED BROWN ORANGE GREEN/ RED GRA
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Groundsmaster 580--D Wire Harness Drawing Models 30582 (S/N Above 250000000) and 30583 Page 9 -- 14 (Rev.
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YELLOW BLACK BROWN BROWN/RED YELLOW RED RED RED BLACK YELLOW YELLOW YELLOW BLACK BLACK VIOLET RED VIOLET BLUE BROWN ORANGE GRAY ORANGE/ WHITE BLUE/WHITE WHITE RED ORANGE BLUE GREEN BLACK BLACK RED/WHITE BLUE GREEN/RED RED VIOLET VIOLET GREEN/WHITE YELLOW GREEN/WHITE TAN BLACK YELLOW YELLOW PINK BLACK RED BLACK BLACK BLACK YELLOW BLACK BLACK BLACK BLACK BLACK BLACK BLACK VIOLET GREEN BLACK YELLOW GREEN GRAY/WHITE BLUE/WHITE ORANGE/WHITE ORANGE/WHITE BLUE BLUE/WHI
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ORANGE GREEN BLACK BLACK GREEN BLACK WHITE BLACK WHITE YELLOW YELLOW GREEN GREEN GREEN ORANGE YELLOW YELLOW Groundsmaster 580--D 4WD Wire Harness (S/N Below 240999999) Page 9 -- 16 (Rev.
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SWITCH GREEN BLACK BLACK GREEN ORANGE WHITE BLACK BLACK WHITE YELLOW YELLOW YELLOW YELLOW GRAY GREEN GREEN GRAY GREEN GREEN ORANGE Groundsmaster 580--D 4WD Wire Harness (S/N Above 250000000) Page 9 -- 17 (Rev.