LCE Products Z580/Z589 DFI Z Master Service Manual
ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.
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TABLE OF CONTENTS SAFETY INFORMATION General Information.......................................................................................................................1-1 Think Safety First....................................................................................................................1-1 SPECIFICATIONS Specifications................................................................................................................................2-1 Configurations....................
TABLE OF CONTENTS CHASSIS cont. Motion Control Assembly Replacement......................................................................................3-48 Motion Control Assembly Removal.......................................................................................3-48 Right Hand Motion Control Assembly Removal....................................................................3-50 Left Hand Motion Control Assembly Removal......................................................................
TABLE OF CONTENTS ELECTRICAL General..........................................................................................................................................6-1 Relays...........................................................................................................................................6-1 Purpose...................................................................................................................................6-1 Location...................................
TABLE OF CONTENTS ELECTRICAL cont. Engine High Temperature & Malfunction Indicator Light Cluster.................................................6-15 Purpose.................................................................................................................................6-15 Location................................................................................................................................6-15 How It Works....................................................................
TABLE OF CONTENTS MOWER DECKS cont. Gearbox Rebuild.........................................................................................................................7-63 Pinion Shaft Teardown..........................................................................................................7-66 Cross Shaft Teardown...........................................................................................................7-69 Open End Cap Teardown..................................................
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SAFETY INFORMATION General Information ! This symbol means WARNING or PERSONAL SAFETY INSTRUCTION - read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Z Master Z580/Z589 with liquid-cooled DFI Kawasaki engine.
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SPECIFICATIONS Specifications Configurations Model Engine Deck 74253 29 hp Kawasaki Liquid Cool DFI 60” (152.4cm) Turbo Force SD Mower 74254 29 hp Kawasaki Liquid Cool DFI 72” (182.8cm) Turbo Force SD Mower 74253CP 29 hp Kawasaki Liquid Cool DFI 60” (152.4cm) Turbo Force SD Mower 74254CP 29 hp Kawasaki Liquid Cool DFI 72” (182.8cm) Turbo Force SD Mower 2 Power System Engine Kawasaki FD791D-AS07 High Idle 3800 ± 100 RPM Low Idle 2250 ± 150 RPM Engine Oil Capacity 2.1 qt. (1.
SPECIFICATIONS Electrical 2 Engine Charging Coil 40 Amp Voltage 12 volt, negative ground Battery BCI group 26, 540 CCA Gauges and Alarms • • • • Fuses Blade type, 30 Amp ignition, 30 Amp cooling fan and 10 Amp engine Top panel mounted hour meter Audio alarm for excess engine temperature Lighted indicators for engine malfunction and excess engine temperature Push/pull PTO switch Mowing Deck 60” (152.4cm) 72” (182.
SPECIFICATIONS Operator Zone 60” (152.4cm) 72” (182.8cm) Steering Levers Dual, wrap-around hydraulically dampened, with cushioned grips Dual, wrap-around hydraulically dampened, with cushioned grips Parking Brake Left hand operated lever with cushioned grip Left hand operated lever with cushioned grip Folding ROPS Standard Standard Deck Lift Assist Pedal Standard Standard Arm Rests Standard Standard Seat Belt Retractable Retractable Z Stand Optional Optional 2 Dimensions 60” (152.
SPECIFICATIONS Torque Specifications Torque Specifications 2 Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, & Sems with Regular Studs, & Sems with Regular Studs, & Sems with Regular Height Nuts Height Nuts (SAE J995 Height Nuts (SAE J995 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) Grade 2 or Stronger Nuts) Grade 2 or Stronger Nu
SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size 2 Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts ( Class 10 or Strong Nuts) M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm M8 X 1.
SPECIFICATIONS Other Torque Specifications Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.
SPECIFICATIONS Equivalents and Conversions Equivalents and Conversions Decimal Equivalents Decimal and and Millimeter Millimeter Equivalents Fractions 2 Decimals 1/64 1/32 3/64 1/16 5/64 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 0.140625 3.572 0.15625 3.969 0.171875 4.366 0.1875 4.762 0.203125 5.159 0.
SPECIFICATIONS U.S. totoMetric U.S. Metric Conversions Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0.7646 0.02832 16.39 Weight Tons (Short) Pounds Ounces Metric Tons Kilograms Grams 0.
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CHASSIS Castor Fork Assembly Replacement 3. Remove the locknut (Fig. 002). Castor Fork Assembly Removal 1. Raise the front of the machine off the ground leaving enough clearance to remove the castor fork from the carrier frame. 2. Remove the grease cap from the frame (Fig. 001). 3 Fig 002 IMG-7874a 4. Slide the castor fork assembly out of the frame (Fig. 003).
CHASSIS Castor Bearing Replacement 3. Remove the bottom grease seal (Fig. 006). 1. Remove the 3 Belleville washers (Fig. 004). 3 Fig 006 Fig 004 IMG-7709a IMG-7703a 4. Remove the bottom tapered bearing (Fig. 007). 2. Remove the top tapered bearing (Fig. 005).
CHASSIS 5. Drive the top and bottom tapered bearing cups out of the caster fork hub (Fig. 008). 7. Pack the upper and lower tapered bearings with grease (No. 2 general purpose lithium base or molybdenum grease). 8. Install the lower bearing into the caster fork hub (Fig. 010). 3 Fig 008 IMG-7714a 6. Install new tapered bearing cups by pressing each bearing cup into the caster fork hub so that the thicker part of the taper is pressed in first.
CHASSIS 10. Install the upper bearing into the caster fork hub (Fig. 012). Castor Fork Assembly Installation 1. Install 3 Bellville washers as shown (Fig. 013): A 3 Fig 012 IMG-7731a Fig 013 fig. 49 G001297 A. Belleville washers 2. Slide the castor fork assembly into the hub (Fig. 014).
CHASSIS 3. Install the locknut. Tighten the locknut until the Belleville washers are flat, then back the nut off 1/4 turn to properly set the preload on the bearings (Fig. 015). 5. Remove the grease fitting and install the grease plug. 6. Install the dust cap onto the frame (Fig. 017). 3 Fig 015 IMG-7874a Fig 017 IMG-7734a 4. Remove the plug located on the side of the castor hub. Install a grease fitting. Apply grease (No.
CHASSIS Front Wheel Bearing Replacement 4. Remove the castor spacer from the wheel assembly (Fig. 020). 1. Raise the front of the machine off the ground. 2. Remove the wheel axle bolt and nut (Fig. 018). 3 Fig 020 Fig 018 IMG-7736a IMG-7742a 5. Remove both bearing spacers (one on each side) from the wheel assembly (Fig. 021). 3. Remove the wheel assembly from the fork (Fig. 019).
CHASSIS 6. Drive the bearing cup, bearing and bearing seal out of the wheel assembly. Repeat on the opposite side (Fig. 022). 7. Install a new tapered bearing cup into the wheel assembly by pressing each bearing cup into the wheel hub so that the thicker part of the taper is pressed into the wheel hub first. The bearing cups should seat against the shoulder divots inside the wheel hub (Fig. 024). 3 Fig 022 IMG-7748a Fig 024 Wheel Assembly (Fig. 023) 8. Pack both tapered bearings with grease (No.
CHASSIS 10. Install the grease seals into each side of the wheel hub (Fig. 026). 12. Install the castor spacer into the wheel hub (Fig. 028). 3 Fig 026 IMG-7883a 11. Install a bearing spacer into each side of the wheel hub (Fig. 027). Fig 027 3-8 IMG-7884a Fig 028 IMG-7885a 13. Position the wheel assembly into the caster fork (Fig. 029).
CHASSIS 14. Install the axle bolt and nut securing the wheel assembly to the fork (Fig. 030). Fuel Tank Replacement Right Side Fuel Tank Removal 1. Raise the seat and remove the front engine shield (Fig. 032). 3 Fig 030 IMG-7736a 15. Apply grease (No. 2 general purpose lithium base or molybdenum grease) to the wheel assembly grease fitting (Fig. 031). Fig 032 IMG-0303a 2. Turn the fuel shut-off valve to OFF position (Fig. 033).
CHASSIS 3. Disconnect the negative battery cable. 4. Remove the right rear wheel assembly (Fig. 034). 6. Remove the clamp securing the return fuel line to the fitting on the operator’s side of the fuel tank. Slide the fuel hose off the fitting (Fig. 036). 3 Fig 034 Fig 036 IMG-0307a 5. Remove the clamp securing the fuel line to the fitting on the bottom of the fuel tank. Slide the fuel hose off the fitting and drain the fuel from the tank (Fig. 035). IMG-0309a 7.
CHASSIS 8. Remove the bolt, lockwasher and washer securing the left front corner of the fuel tank to the frame (Fig. 038). Right Side Fuel Tank Installation 1. Position the fuel tank onto the frame (Fig. 040). 3 Fig 038 IMG-0310a 9. Lift the fuel tank off the frame (Fig. 039). Fig 039 Fig 040 2. Slide a hose clamp onto the return fuel line. Slide the return fuel line onto the fitting located on the operator’s side of the fuel tank (Fig. 041).
CHASSIS 3. Position the hose clamp and tighten (Fig. 042). 5. Loosely install a bolt, lock washer, and washer through the frame and into the front left corner of the fuel tank (Fig. 044). 3 Fig 042 IMG-0320a Fig 044 4. Slide a hose clamp onto the intake fuel line. Slide the intake fuel line onto the fitting located on the bottom of the fuel tank. Position the hose clamp and tighten (Fig. 043). IMG-0310a 6.
CHASSIS 7. Tighten the 3 nuts until three threads protrude past the nut. Do not over-tighten (Fig. 046). 9. Install the right rear wheel assembly (Fig. 048). 3 Fig 048 Fig 046 8. Tighten the bolt located in the front corner of the tank to frame (Fig. 047). Fig 047 Z580/Z589 DFI Z Master Service Manual IMG-0307a PICT-3290a IMG-0310a 10. Install the negative battery cable. 11. Install the front engine shield (Fig. 049).
CHASSIS Left Side Fuel Tank Removal 3. Disconnect the negative battery cable. 1. Raise the seat and remove the front engine shield (Fig. 050). 4. Remove the left rear wheel assembly (Fig. 052). 3 Fig 052 Fig 050 IMG-0303a 2. Turn the fuel shut-off valve to the “OFF” position (Fig. 051). 5. Remove the 4 screws and washers securing the control panel to the fuel tank (Fig. 053).
CHASSIS 6. Remove the cable tie securing the throttle cable to the fuel fitting (Fig. 054). 8. Remove the hose clamp from the fuel return line and fitting located on the operator’s side of the fuel tank (Fig. 056). 3 Fig 054 IMG-0328a Fig 056 7. Move the control panel assembly away from the fuel tank (Fig. 055). Fig 055 9. Remove the return fuel line from the fuel fitting (Fig. 057).
CHASSIS 10. Remove the hose clamp from the fuel intake line and fitting located on the underside of the fuel tank (Fig. 058). 12. Remove the nuts, springs and washers from the 3 fuel tank mounting studs located on the underside of the fuel tank (Fig. 060). A 3 B C C Fig 058 IMG-0338a 11. Remove the fuel line from the fuel fitting and drain the fuel from the fuel tank (Fig. 059). Fig 060 C LH fuel tank fasteners a A. Fuel tank C. Mounting stud fastener B. Frame assembly (3) 13.
CHASSIS 14. Remove the bolt and washers securing the right front corner of the fuel tank to the frame (Fig. 062). Left Side Fuel Tank Installation 1. Position the fuel tank onto the frame (Fig. 064). 3 Fig 062 IMG-0350a Fig 064 IMG-0345a 15. Remove the fuel tank from the frame (Fig. 063). 2. Slide a hose clamp onto the return fuel hose. Install the fuel return hose onto the fuel-fitting barb located on the operator’s side of the fuel tank. Slide the hose clamp into position and tighten (Fig. 065).
CHASSIS 3. Slide the hose clamp onto the fuel intake hose. Install the fuel intake hose onto the fuel-fitting barb located on the underside of the fuel tank. Slide the hose clamp into position and tighten (Fig. 066). 5. Loosely install a washer, spring and nut onto each of the three studs on the underside of the fuel tank (Fig. 068). A 3 B C C Fig 068 Fig 066 IMG-0338a 4. Install a bolt, lock washer, and washer into the right front corner of the fuel tank securing it to the frame (Fig. 067).
CHASSIS 7. Install the fuel shut-off valve to the fuel valve bracket with a washer and nut (Fig. 070). 9. Install a cable tie securing the throttle cable to the fuel tank fitting located on the operator’s side of the fuel tank (Fig. 072). 3 Fig 070 IMG-0351a Fig 072 8. Install 4 screws and washers securing the control panel to the fuel tank (Fig. 071). IMG-0416a 10. Install the left rear tire assembly and lower the machine to the ground. 11. Install the negative battery cable. 12.
CHASSIS Fuel Tank Fitting Replacement 2. Using a magnet tool, remove the fitting from the inside of the fuel tank (Fig. 076). There are 2 fuel fittings located on each of the fuel tanks. The following procedure can be used to replace any of the fittings (Fig. 074). 3 Fig 076 Fig 074 IMG-7771a IMG-7774a 3. Using a magnet tool, install a fuel tank fitting by inserting it through the fuel tank opening (Fig. 077). 1. Remove the nut and washer securing the fitting to the fuel tank (Fig. 075).
CHASSIS 4. Loosely install a washer and nut to secure the fuel tank fitting to the fuel tank (Fig. 078). Right side fuel tank operator’s side fitting 3 Fig 080 Fig 078 DSC-4856a IMG-7772a 5. Position the fuel tank fittings as shown (Fig. 079, Fig. 080 and Fig. 081): Left side fuel tank operator’s side fitting Right and left fuel tank bottom fitting Fig 081 Fig 079 Z580/Z589 DFI Z Master Service Manual IMG-7781a DSC-4854a 6. Tighten the fitting nut.
CHASSIS Hood Assembly Replacement 3. Lift the hood and remove from the machine (Fig. 084). Hood Assembly Removal 1. Unhook the rubber latch that is located on the rear of the hood (Fig. 082). 3 Fig 084 Fig 082 IMG-0369a IMG-0361a 2. Remove the two hairpin cotters, clevis pins, and washers in the left and right hinges (Fig. 083).
CHASSIS Hood Assembly Installation 2. Install a clevis pin, washer and hairpin cotter into each of the pivot brackets (Fig. 086). 1. Align the hood pivot brackets with holes in the pivot bracket on the frame (Fig. 085). Note: The hood screen can contact the radiator cap. The pressure on the cap can result in a crack at the cap adapter joint, resulting in loss of radiator pressure and overheating. Check the clearance between the hood screen and the radiator cap.
CHASSIS Hood hinge plate adjustment slots (Fig. 087). 3. Lower the hood and hook the rubber latch located at the rear of the hood (Fig. 089). 3 Fig 087 IMG-0381a Fig 089 IMG-0361a Hood pivot plate adjustment slots (Fig. 088).
CHASSIS Throttle Control Assembly Replacement 4. Remove the 4 screws securing the control panel to the left hand fuel tank (Fig. 091). Throttle Control Assembly Removal 1. Raise the seat. 2. Disconnect the negative battery cable from the battery terminal. 3. Remove the knob from the throttle control assembly (Fig. 090). 3 Fig 091 IMG-0385a 5. Remove the locknuts and carriage bolts securing the throttle control to the control panel (Fig. 092).
CHASSIS 6. Remove the front engine panel shield assembly (Fig. 093). 8. Remove the cable tie securing the throttle cable to the bracket located behind the voltage regulator (Fig. 095). 3 Fig 093 IMG-0303a Fig 095 7. Remove the cable tie securing the throttle cable to the fuel tank fitting (Fig. 094). Fig 094 9. Loosen the cable clamp and remove the throttle cable (Fig. 096).
CHASSIS 10. Remove the z-bend end of the cable from the throttle arm assembly (Fig. 097). Throttle Control Assembly Installation 1. Slide the throttle cable through the slot in the side of the control panel (Fig. 098). 3 Fig 097 11. Remove the throttle cable from the unit. IMG-0390a Fig 098 IMG-0392a 2. Install the throttle cable assembly into the slot in the control panel (Fig. 099).
CHASSIS 3. Install the carriage bolts and locknuts securing the throttle control assembly to the control panel (Fig. 100). 5. Route the throttle cable behind the engine breather tube (Fig. 102). 3 Fig 102 Fig 100 4. Route the throttle cable behind the fuel tank fitting (Fig. 101). 6. Then route the cable back on the right side of the engine to the throttle linkage (Fig. 103).
CHASSIS 7. Insert the z-bend of the throttle cable into the throttle arm assembly (Fig. 104). 9. Install the 4 screws securing the control panel to the left hand fuel tank. Install the knob for the throttle control assembly. Move the throttle control to the low idle speed setting (Fig. 106). 3 Fig 104 IMG-0406a Fig 106 8. Install the throttle cable into the cable clamp on the engine throttle linkage (Fig. 105). Fig 105 10. Adjust the throttle linkage on the engine.
CHASSIS 11. Install a cable tie securing the throttle cable to the bracket located behind the voltage regulator (Fig. 108). 13. Install the front engine shield assembly (Fig. 110). 3 Fig 110 Fig 108 IMG-0303a IMG-0414a 14. Connect the negative battery cable. 12. Install a cable tie securing the throttle cable to the fuel tank fitting located on the operator’s side of the fuel tank (Fig. 109). Fig 109 3-30 15.
CHASSIS Brake Lever Replacement 6. Lift the floor pan assembly. The left fuel tank and hood have been removed for photo purposes. 7. Remove the brake lever pivot shaft cotter pin (Fig. 112). Brake Lever Removal 1. Raise the seat. 2. Disconnect the negative battery cable from the battery terminal. 3 3. Lower the seat. 4. Release the parking brake (forward position). 5. Remove the cotter pin and clevis pin securing the brake linkage yoke to the brake lever assembly (Fig. 111). Fig 112 IMG-7922a 8.
CHASSIS 9. With a hammer and punch tap out the two pivot bushings (Fig. 114). 3 Fig 114 PICT-2883a 10. Inspect the brake shaft and bushings for excessive wear. Replace any worn or damaged components (Fig. 115).
CHASSIS Brake Lever Installation 4. Install a cotter pin into the pivot shaft (Fig. 118). 1. Raise the floor pan assembly. 2. Install the two bushings into the brake lever pivot mounting hole (Fig. 116). 3 Fig 118 IMG-7922a 5. Lower the floor pan assembly. Fig 116 PICT-2891a 3. Slide the brake lever assembly pivot through the bushings (Fig. 117). Fig 117 Z580/Z589 DFI Z Master Service Manual PICT-2892a 6. Move the parking brake lever into the released (forward) position. 7.
CHASSIS Brake Band Replacement 2. Remove the 3 bolts, spacer and retainer from the brake band assembly (Fig. 121). Note: The following procedures can be followed for both right and left brake band removal and installation. Brake Band Removal 1. Remove the rear tire (Fig. 120). 3 Fig 121 PICT-2920a 3. Remove the 2 spacers from the brake band (Fig. 122).
CHASSIS 4. Remove the brake band from the wheel and hub assembly (Fig. 123). Brake Band Installation 1. Slide the brake band onto the wheel hub assembly (Fig. 125). 3 Fig 123 PICT-2933a Fig 125 PICT-2933a 5. Inspect the brake band. Replace if worn or damaged. 2. Slide a spacer into each end of the brake band (Fig. 126). Brake Band Assembly (Fig. 124) A B C D Fig 124 A. Shoulder bolt (3) B. Spacer (3) PICT-2926a Fig 126 PICT-2935a C. Retainer D.
CHASSIS 3. Position the brake band retainer and loosely install 2 bolts through the retainer, brake band spacers and into the brake bracket (Fig. 127). 5. Tighten the 3 brake band retainer bolts (Fig. 129). 3 Fig 129 Fig 127 PICT-2942a PICT-2941a 6. Install the rear tire (Fig. 130). 4. Position the third spacer between the retainer and the brake bracket. Loosely install the third bolt through the retainer and spacer and into the brake bracket (Fig. 128).
CHASSIS Brake Cross Shaft Replacement Note: The front engine shield has been removed for photo purposes. 4. Remove the two clevis spring pins securing the brake rod linkage yokes to the left side of the brake cross shaft (Fig. 132). Brake Cross Shaft Removal 1. Raise the seat. 2. Remove the negative battery cable from the battery. 3 3. Raise the rear tires off the ground and remove the left and right tires (Fig. 131). Note: To prevent the unit from rolling, block the front tires. Fig 132 PICT-2954a 5.
CHASSIS 6. Remove the 2 bolts and nuts securing the right side flange bearing to the frame. Remove the flange bearing from the cross shaft (Fig. 134). 8. Remove brake cross shaft (Fig. 136). 3 Fig 136 Fig 134 PICT-2964a PICT-2958a 7. Remove the 2 bolts and nuts securing the left side flange bearing to the frame. Remove the flange bearing from the cross shaft (Fig. 135). 9. Inspect brake cross shaft and bearings. Replace if worn or damaged (Fig. 137).
CHASSIS Brake Cross Shaft Installation 1. Slide the brake cross shaft into position (Fig. 138). 3. Position the flange bearing on the right end of the cross shaft and install 2 bolts and nuts securing the flange bearing to the frame (Fig. 140). Note: The end of the cross shaft with two tabs is installed on the left side of the machine. 3 Fig 140 Fig 138 PICT-2964a PICT-2958a 4.
CHASSIS 5. Ensure the brake cross shaft rotates freely in the flange bearings. 8. Install the left and right rear tires and lower the machine to the ground (Fig. 144). 6. Install the clevis spring pin securing the brake rod linkage yoke to the right side of the brake cross shaft (Fig. 142). 3 Fig 144 Fig 142 PICT-2956a 7. Install the two clevis spring pins securing the brake rod linkage yokes to the left side of the brake cross shaft (Fig. 143). Fig 143 3-40 PICT-2919a 9. Lower the seat. 10.
CHASSIS Deck Lift Lever Replacement 5. Lower the mower deck onto the blocks to remove tension from the deck lift chains (Fig. 146). Deck Lift Lever Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Place the mower deck in the transport position. Position wood blocks under each corner of the mower deck (Fig. 145). 3 Fig 146 PICT-2973a 6.
CHASSIS 7. Loosen the jam nut and hex nut on the right hand and left hand deck lift rods until the deck support springs are fully extended (Fig. 148). 9. Lower the deck lift lever to its lowest position. The rear deck swivel mounts should clear the deck lift rods on both sides. The mower deck lift linkage should now be fully unloaded (Fig. 150). 3 Fig 148 PICT-2980a Fig 150 8. Remove the hex nut from the back end of the right and left deck lift assemblies (Fig. 149). Fig 149 10.
CHASSIS 11. Remove the outside hex head flange nut at the top of the inner deck lift plate. Remove the hitch pin assembly from the bolt (Fig. 152). 13. Raise the floor pan. 14. Remove the front bolt and nut that secure the 2 deck lift arms to the deck lift cross shaft assembly. Pivot the deck lift arms away from the cross shaft assembly and remove the bushing from the hole in the cross shaft assembly tab (Fig. 154). 3 Fig 152 PICT-2988a 12. Loosen the inner hex head flange nut.
CHASSIS 16. Remove the deck lift lever assembly from the pivot (Fig. 156). 17. If there is interference between the lift lever assembly and the floor pan hinge, loosen the right hand floor pan hinge mounting hardware, push the hinge upward and re-tighten the floor pan hinge mounting hardware (Fig. 158). 3 Fig 156 PICT-3014a Note: There may be interference between the lift lever assembly and the floor pan hinge when trying to remove the lift lever assembly (Fig. 157).
CHASSIS Deck Lift Lever Installation 3. Slide the bushing into the hole in the cross shaft assembly tab (Fig. 162). 1. Slide the deck lift lever assembly pivot into the pivot mount on the frame (Fig. 160). 3 Fig 162 Fig 160 PICT-3011a 2. Install an E-clip onto the deck lift lever pivot (Fig. 161). 4. Rotate the deck lift arms forward to align them with the bushing in the cross shaft assembly tab. Install a bolt and nut to secure (Fig. 163).
CHASSIS 5. Rotate the inner deck lift plate down to the mounting hole in the frame. Position a spacer in between the inner and outer plates. Install a bolt and nut to secure (Fig. 164). 8. Slide the hitch pin lanyard onto the bolt (Fig. 166). 3 Fig 166 Fig 164 PICT-3027a PICT-3022a 9. Install a second nut onto the bolt securing the hitch pin lanyard in place; do not tighten nut against the lanyard (Fig. 167). 6. Lower the floor pan assembly. 7.
CHASSIS 10. Lift up on the lift lever and install the lower stop bolt into the deck lift plate (Fig. 168). 12. Install a hex nut onto the back end of the right and left deck lift assemblies (Fig. 170). 3 Fig 168 PICT-2978a 11. Lower the lift lever. The deck lift lever rods should run through the rear swivels (Fig. 169). Fig 170 PICT-2982a 13. Raise the mower deck to the transport position. Remove the wood blocks.
CHASSIS 14. Check the deck level adjustment. Refer to “Leveling the Mower” on page 7-79. Motion Control Assembly Replacement 15. Apply grease to the grease fitting on the deck lift lever pivot (Fig. 172). Motion Control Assembly Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 3 4. Remove both floor pan assembly hinge bolts and nuts (Fig. 173). Fig 172 PICT-3035a 16.
CHASSIS 5. Remove the floor pan assembly (Fig. 174). 7. Remove the pocket (Fig. 176). 3 Fig 174 PICT-3053a Fig 176 PICT-3057a 6. Remove the 2 top pocket mounting bolts, washers and nuts and the 2 bottom pocket mounting bolts and nuts (Fig. 175). Note: Raise the seat to remove the top two bolts and nuts. A A B B Fig 175 A. Bolt, washer, nut PICT-3055a B.
CHASSIS Right Hand Motion Control Assembly Removal 10. Disconnect the harness from the neutral switch located under the right side of the traction frame assembly (Fig. 179). 8. Remove the 2 bolts and washers securing the right lever to the control shaft arm. Remove the right lever (Fig. 177). 3 Fig 179 Fig 177 PICT-3064a PICT-3075a 11. Remove the bolt, washer and nut that secure the right hand control rod assembly to the right hand motion control assembly (Fig. 180). 9.
CHASSIS 12. Remove the cotter pin and clevis pin that secure the neutral return yoke to the right hand motion control assembly (Fig. 181). 14. Remove the 2 bolts and nuts securing the side flange bearing to the inside of the traction frame (Fig. 183). 3 Fig 181 PICT-3081a 13. Loosen the jam nut on the right hand neutral return spring assembly. Remove the yoke from the neutral return bolt (Fig. 182). Fig 182 Z580/Z589 DFI Z Master Service Manual PICT-3087a Fig 183 PICT-3084a 15.
CHASSIS 16. Remove the right hand motion control assembly and right hand control shaft arm assembly (Fig. 185). Left Hand Motion Control Assembly Removal 18. Remove the 2 bolts, and washers securing the left lever to the control shaft arm. Remove the left lever (Fig. 187). 3 Fig 185 PICT-3088a 17. Inspect the side flange bearings. Replace if worn or damaged (Fig. 186). B A Fig 186 A. B. C. D.
CHASSIS 20. Disconnect the harness from the neutral switch located under the traction frame assembly. Note: Access the switch from under the seat area. 23. Loosen the left hand neutral return assembly jam nut. Remove the yoke from the neutral return bolt (Fig. 191). 21. Remove the bolt, washer and nut that secure the left hand control rod assembly to the left hand motion control assembly (Fig. 189). 3 Fig 191 Fig 189 PICT-3109a PICT-3126a 24.
CHASSIS 25. Remove the left hand control rod assembly (Fig. 193). 27. Remove the left hand motion control assembly and left hand control shaft arm assembly (Fig. 195). 3 Fig 193 Fig 195 PICT-3133a 26. Remove the 2 bolts and nuts securing the side flange bearing to the inside of the traction frame (Fig. 194). PICT-3135a 28. Inspect the side flange bearings. Replace if worn or damaged (Fig. 196). D A B C Fig 196 Fig 194 3-54 PICT-3128a A. B. C. D.
CHASSIS Left Hand Motion Control Assembly Installation 3. Install 2 bolts and nuts securing the side flange bearing to the inside of the traction frame (Fig. 199). 1. Slide a side flange bearing onto each end of the left hand motion control assembly (Fig. 197). 3 Fig 199 Fig 197 PICT-3138a PICT-3128a 4. Position the left hand control rod assembly into the traction frame (Fig. 200). 2. Position the left hand motion control assembly and control shaft arm assembly into the traction frame (Fig. 198).
CHASSIS 5. Install a bolt, washer and nut securing the left hand control rod ball joint to the hydrostatic pump control arm (Fig. 201). 7. Position the left hand neutral return yoke to the left hand motion control tab and install a clevis pin and cotter pin (Fig. 203). Note: The washer is installed between the ball joint and the control arm. 3 Fig 203 Fig 201 PICT-3131a 6. Install the neutral return yoke onto the neutral return bolt (Fig. 202). Fig 202 8.
CHASSIS Right Hand Motion Control Assembly Installation 9. Slide a side flange bearing onto each end of the right motion control assembly (Fig. 205). 11. Position the side flange bearing to the left hand motion control assembly and loosely install 2 bolts and nuts to secure the side flange bearing (Fig. 207). 3 Fig 207 Fig 205 PICT-3092a 10. Position the right hand motion control assembly and control shaft arm assembly into position under the traction frame (Fig. 206). 12.
CHASSIS 13. Thread the yoke onto the neutral return bolt (Fig. 209). 15. Tighten the jam nut to secure the yoke (Fig. 211). Note: The neutral return spring may need adjust ment after the motion contol levers are instal led. The motion control lever, when moved to reverse position, should spring back to the neutral postions when the handles are let go. 3 Fig 209 PICT-3145a 14. Position the neutral return yoke to the right hand motion control tab and install a clevis pin.
CHASSIS 17. Install a bolt, washer and nut securing the left hand control rod assembly to the left hand motion control assembly (Fig. 213). Note: The washer is installed between the ball joint and motion control assembly tab. 19. Connect the harness to the 2 neutral switches located under the seat, behind the left hand and right and sides of the traction control frame under the traction frame assembly. Right hand neutral switch (Fig. 215) 3 Fig 213 PICT-3109a 18.
CHASSIS 20. Tighten all 6 bolts and nuts securing the 4 side flange bearings: C. Flange bearing mounted to the inside (left) of the traction frame (Fig. 219). A. Flange bearing mounted to the inside (right) of the traction control frame (Fig. 217). 3 Fig 219 Fig 217 PICT-3084a B. Flange bearings mounted to the left hand motion control assembly (Fig. 218). Fig 218 3-60 PICT-3086a PICT-3161a 21. Position the left hand control lever to the left hand control shaft arm.
CHASSIS 22. Position the right hand control lever to the right hand control shaft arm. Install 2 bolts, and washers securing the right hand lever to the control shaft arm (Fig. 221). Motion Control Assembly Installation 25. Insert the pocket into the traction frame (Fig. 222). 3 Fig 221 Fig 222 PICT-3064a 23. Adjust the control handle neutral position. Refer to “Adjusting the Control Handle Neutral Position” on page 4-27. 24. Adjust the hydrostatic pump neutral.
CHASSIS Motion Control Damper Replacment 27. Position the floor pan assembly (Fig. 224). There is a right and a left motion control damper. The following removal and installation procedures are done on the right damper. The procedure is the same for the left damper. Motion Control Damper Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 3 2. Raise the seat. 3. Remove the negative battery cable from the battery. Fig 224 PICT-3053a 4.
CHASSIS 5. Remove the outer nut from the bolt on the upper end of the damper (Fig. 227). Damper Assembly (Fig. 229) 3 Fig 227 PICT-3173a Fig 229 PICT-3181a 6. Remove the damper assembly (Fig. 228).
CHASSIS Motion Control Damper Installation 4. Insert the lower damper bolt into the frame and install a nut to secure the lower end of the damper (Fig. 232). 1. Raise the seat. 2. Position the damper assembly with the rod end down (Fig. 230). 3 Fig 232 Fig 230 PICT-3178a PICT-3171 5. Install the negative battery cable to the battery. 6. Lower the seat. 3. Insert the upper damper bolt into the motion control assembly arm. Install a nut to secure the upper end of the damper (Fig. 231).
CHASSIS Adjusting the Parking Brake 1. Engage the parking brake, (lever up). 2. Measure the length of the spring. Measurement should be 2-1/2” (64mm) between the washers (Fig. 233). A 3 C B Fig 233 A. Brake lever in engaged position fig. 57 G001294 B. Spring 2-1/2” (64mm) C. Adjusting nut & jam nut 3. If adjustment is necessary, release the parking brake, loosen the jam nut below the spring and ad just the nut directly below the spring (Fig. 233).
CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
HYDRAULIC SYSTEM Hydrostatic Tandem Pump Replacement 5. Remove the pump idler arm spring using a spring tool (Toro p/n: 92-5771) (Fig. 235). Note: Cleanliness is a key factor in a successful repair of any hydrostatic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts with a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
HYDRAULIC SYSTEM 7. Remove the 2 pump pulley set screws (Fig. 237). 4 Fig 237 IMG-0433a Fig 239 IMG-0434a Fig 240 4-2 IMG-0439a 10. Remove the bolt, nut and washer securing the right hand control rod assembly to the pump control arm (Fig. 240). 8. Remove the pump pulley (Fig. 238). Fig 238 9. Remove the key from the keyway (Fig. 239).
HYDRAULIC SYSTEM 11. Remove the bolt, nut and washer securing the left hand control rod assembly to the pump control arm (Fig. 241). 13. Unplug the harness from the PTO clutch connector (Fig. 243). Fig 243 Fig 241 12. Remove the cable tie securing the 2 RH wheel motor hydraulic hoses to the frame (Fig. 242). 14. Remove the cable tie securing the PTO clutch wire to the frame (Fig. 244).
HYDRAULIC SYSTEM 15. Remove the hose clamp located on the hydraulic suction hose coming from the oil filter (Fig. 245). 17. Raise the rear of the unit and remove both right and left rear tires. 18. Mark or tag the wheel motor hydraulic hoses and fittings to ensure they are reconnected correctly. 19. Remove the two hydraulic hoses from the RH wheel motor (Fig. 247). 4 Fig 245 PICT-3202a 16. Remove the hydraulic suction hose from the fitting on top of the hydrostatic pump (Fig. 246).
HYDRAULIC SYSTEM 21. Remove the two hydraulic hoses from the LH wheel motor (Fig. 249). Fig 249 23. Remove the hose clamp located on the hydraulic hose routed from the oil cooler to the left side of the hydrostatic pump (Fig. 251). PICT-3208a Fig 251 22. Cap the hydraulic hoses and fittings (Fig. 250). Fig 250 24. Remove the hydraulic hose from the fitting barb (Fig. 252).
HYDRAULIC SYSTEM 25. Remove the two bolts, washers and nuts securing the front of the hydrostatic pump (by the input shaft) to the frame (Fig. 253). 4 27. Remove the two bolts, washers, and nuts holding the pump bracket to the frame of the unit (Fig. 255). Fig 255 Fig 253 PICT-3257a 26. Remove the pump shield plate from the hydrostatic pump input shaft (Fig. 254). 28. Position the mower deck in the lowest height-of-cut position (Fig. 256).
HYDRAULIC SYSTEM 29. Carefully lower the hydrostatic pump from the frame (Fig. 257). Fig 257 PICT-3271a 30. Mark the wheel motor hose and pump fitting locations (Fig. 258). Fig 259 PICT-3300a 32. Remove the 2 bolts, washers and nuts securing the pump mounting bracket to the pump. Remove the mounting bracket (Fig. 260). B A D C Fig 258 A. B. C. D. 31. Remove all 4 wheel motor hoses from the pump fittings (Fig. 259).
HYDRAULIC SYSTEM 33. Remove the set screw securing the control arm to the pump control shaft. Remove the control arm from the pump control shaft (Fig. 261). 4 Fig 261 Hydrostatic Tandem Pump Installation 1. Apply thread locking compound to the pump control arm set screw (Fig. 263). PICT-3302a Fig 263 34. Repeat step 33 to remove the opposite control arm from the pump. 35. For tandem pump service, refer to the Hydro-Gear P Series Pumps Service and Repair Manual (form BLN-52503) PICT-3307a 2.
HYDRAULIC SYSTEM 3. Repeat steps 1 and 2 to install the other control arm to the opposite pump control shaft. 7. Align the pump mounting bracket to the frame and loosely install 2 bolts, washers and nuts (Fig. 267). 4. Position the pump mounting bracket to the pump. Loosely install 2 bolts, washers and nuts securing the pump mounting bracket to the pump (Fig. 265). Fig 267 Fig 265 PICT-4204a 5. Lower the mower deck to the lowest height-of-cut position. PICT-3312a 8.
HYDRAULIC SYSTEM 9. Tighten the 2 bolts securing the pump mounting bracket to the bracket on the frame. Tighten the 2 bolts securing the mounting bracket to the pump (Fig. 269). 4 11. Install the LH wheel motor hoses. Note the location of each of the hoses by the markings on the hoses and wheel motor fittings (Fig. 271). Fig 271 Fig 269 PICT-3324a PICT-3259a 10. Loosely install the 4 wheel motor hoses to the bottom of the pump.
HYDRAULIC SYSTEM 14. Tighten the RH wheel motor hose fittings at the pump and at the wheel motor. 17. Slide a hose clamp over the hydraulic suction hose (Fig. 275). 15. With the hose clamp on the oil cooler hose, slide the hose onto the pump fitting (Fig. 273). Fig 275 Fig 273 PICT-3331a PICT-3333a 18. Slide the hydraulic suction hose onto the pump fitting on top of the hydrostatic pump (Fig. 276). 16. Position the hose clamp over the hose and fitting barb (Fig. 274).
HYDRAULIC SYSTEM 19. Position the hose clamp and tighten (Fig. 277). 4 Fig 277 21. Install a cable tie securing the PTO clutch wire to the frame (Fig. 279). PICT-3337 Fig 279 20. Plug the harness plug into the PTO clutch connector (Fig. 278). Fig 278 22. Install a cable tie securing the 2 RH wheel motor hydraulic hoses to the frame (Fig. 280).
HYDRAULIC SYSTEM 23. Position the left hand control rod ball joint to the pump control arm. Install a bolt, washer and nut securing the left hand control rod assembly to the pump control arm (Fig. 281). 25. Apply anti-seize compound onto the pump input shaft (Fig. 283). Note: The washer is installed between the ball joint and the control arm. Fig 283 IMG-0444a 26. Install the key into the pump shaft keyway (Fig. 284). Fig 281 PICT-3196a 24.
HYDRAULIC SYSTEM 27. Apply thread locking compound to the 2 pump pulley set screws (Fig. 285). 4 Fig 285 PICT-3307a 28. Loosely install the 2 set screws into the pump pulley (Fig. 286). 29. Slide the pump pulley onto the pump shaft (Fig. 287). Fig 287 Belt Alignment Tool (Toro p/n: 110-0876) (Fig.
HYDRAULIC SYSTEM 30. Hook the belt alignment tool (Toro p/n: 110-0876) onto the engine drive sheave. Align the hydro pump drive pulley so that the tool lies squarely within the outer sheaves (Fig. 289). Fig 289 31. Rotate the too so that it faces to the right side of the machine. Hook the end into the hydro pump drive pulley on the front of the engine. There is a raised contact area on the tool.
HYDRAULIC SYSTEM 32. Tighten the 2 pump pulley set screws. Torque to 12.1 + 1.6 in-lbs. (1.37 + 0.18 Nm) (Fig. 291). 4 Fig 291 IMG-0447a 33. Install the pump drive belt (Fig. 292). 34. Using a spring tool (Toro p/n: 92-5771), install the pump idler arm spring (Fig. 293). Fig 293 IMG-0595a 35. Install the right and left rear wheels. 36. Install the front engine shield (Fig. 294).
HYDRAULIC SYSTEM 37. Install the negative battery cable. Wheel Motor Replacement 38. Lower the seat. The following procedures are the same for the left and right wheel motor. 39. Purge the hydraulic system. Refer to “Purging the Hydraulic System” on page 4-26. 40. Adjust the control handle neutral position. Refer to “Adjusting the Control Handle Neutral Position” on page 4-27. 41. Adjust the hydrostatic pump neutral. Refer to “Setting the Hydrostatic Pump Neutral” on page 4-28. Wheel Motor Removal 1.
HYDRAULIC SYSTEM 6. Remove the castle nut securing the wheel hub to the wheel motor (Fig. 296). 4 Fig 296 9. Remove the 3 bolts, spacers and the retainer from the brake band assembly and remove the brake band (Fig. 298). PICT-3351a 7. Using a Wheel Hub Puller (Toro p/n: TOR4097), remove the wheel hub from the wheel motor shaft (Fig. 297). Fig 297 8. Release the parking brake. Fig 298 10. Mark or tag the wheel motor hoses and fittings to ensure they are reconnected correctly (Fig. 299).
HYDRAULIC SYSTEM 11. Disconnect the wheel motor hoses from the wheel motor fittings (Fig. 300). 13. Loosen all 4 wheel motor mounting bolts (Fig. 302). Note: Cap the hoses and fittings to prevent debris from entering the system. Fig 302 Fig 300 PICT-3366a PICT-3370a 14. Remove the front 2 wheel motor mounting bolts, spacers and nuts (Fig. 303). 12. Remove the wheel motor fittings from the wheel motor (Fig. 301).
HYDRAULIC SYSTEM 15. Swing the brake linkage forward away from the wheel motor (Fig. 304). 4 17. Remove the wheel motor (Fig. 306). Fig 306 Fig 304 16. Remove the 2 rear wheel motor mounting bolts, spacers and nuts (Fig. 305). Fig 305 4-20 PICT-3378a PICT-3374a 18. For wheel motor service, refer to Parker/Ross Wheel Motor Service Manual (form no. 492-4753).
HYDRAULIC SYSTEM Wheel Motor Installation Note: As a reminder, prior to connecting the hydraulic lines, the o-rings should be replaced with new ones and lightly lubricated with petroleum jelly. 1. Insert the wheel motor into the frame. Loosely install the 2 rear wheel motor mounting bolts, long spacers and nuts (Fig. 308). Note: There are two different spacers used on the wheel motors (Fig. 307).
HYDRAULIC SYSTEM 3. Loosely install the 2 front wheel motor mounting bolts, short spacers and nuts (Fig. 310). 4 Fig 310 PICT-3376a 4. Torque the 4 wheel motor mounting bolts to 100 + 8 ft-lbs. (136 + 11 Nm) (Fig. 311). Fig 311 4-22 PICT-3382a 5. Install the wheel motor fittings. Note the location markings (Fig. 312). Fig 312 PICT-3367a 6. Install the wheel motor hoses onto the wheel motor fittings. Note the location markings (Fig. 313).
HYDRAULIC SYSTEM 7. Slide the brake band assembly over the wheel motor hub. Install the 3 spacers, the retainer and 3 brake band bolts into brake bracket (Fig. 314). Fig 314 10. Apply the parking brake. 11. Install a castle nut onto the wheel motor shaft. Torque the castle nut to 125 ft-lbs (170 Nm) (Fig. 316). 4 PICT-3358a Fig 316 PICT-3385a 8. Make sure the parking brake is released. 9. Make sure the woodruff key is in place in the motor shaft.
HYDRAULIC SYSTEM 12. Check the distance from bottom of the slot in the nut to the inside edge of the hole. Two threads or less should be showing (Fig. 317). A C B Note: If more than two threads are showing remove nut and install washer between hub and nut and then: a. Torque the slotted nut to 125 ft-lbs. (170 Nm) (Fig. 318). b. If necessary, tighten the nut until the next set of slots line up with the hole in the shaft (Fig. 318). D A C B 4 Fig 317 A. Slotted nut B.
HYDRAULIC SYSTEM 13. Install a cotter pin into the wheel motor shaft (Fig. 319). Fig 319 4 PICT-3350a 14. Install the rear wheel. 15. Install the negative battery cable. 16. Lower the seat. 17. Purge the hydraulic system. Refer to “Purging the Hydraulic System” on page 4-26. 18. Adjust the tracking. See “Adjusting the Tracking” on page 4-32.
HYDRAULIC SYSTEM Purging the Hydraulic System The hydraulic system is normally self-bleeding however; it may be necessary to bleed the system if fluid is changed, or after work is performed on the system. 2. Start the engine and run it at low idle speed. Engage the motion control lever on one side and spin the wheel by hand (Fig. 321). 1. Raise rear of the machine so the wheels are off the ground and support it with jack stands (Fig. 320). 4 Fig 321 Fig 320 IMG-0448a PICT-3465a 3.
HYDRAULIC SYSTEM Adjusting the Control Handle Neutral Position If the motion control levers do not align or do not move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Begin with either the left or right motion control lever. 5.
HYDRAULIC SYSTEM 8. If adjustment is needed, loosen the nut and jam nut against the yoke (Fig. 324). 1. Raise the machine and support with jack stands so that the rear tires are off the ground (Fig. 325). A D F B C G 4 Fig 324 A. B. C. D. Height-of-cut lever Nut against yoke Jam nut Clevis pin in slot Setting the Hydrostatic Pump Neutral E fig. 63 G001155 E. Adjustment bolt F. Yoke G. Spring Fig 325 IMG-0448a 2. Raise the seat (Fig. 326). 9.
HYDRAULIC SYSTEM 3. Remove the bolt and nut securing the seat rod to the seat. Rotate the seat rod up and out of the way of the hydrostatic pump (Fig. 327). 5. Place the motion control levers in the neutral position. B A 6. Start the engine, open the throttle 1/2 way and release parking brake. 7. Adjust the pump rod length by rotating the knob, in the appropriate direction, until the right wheel is stopped or slightly creeping in reverse (Fig. 329). C Fig 327 A. Bolt B.
HYDRAULIC SYSTEM Setting the Left Hydraulic Pump Neutral Position 12. Start the engine, open the throttle 1/2 way and release the parking brake. 10. Place the motion control levers in the neutral position. 13. Adjust the pump rod length by rotating double nuts on rod, in the appropriate direction, until wheel is stopped or slightly creeps in reverse (Fig. 331). 11. Loosen the jam nuts at the ball joints on the pump control rod (Fig. 330). Note: The front nut on the pump rod has left-hand threads.
HYDRAULIC SYSTEM 16. Tighten the jam nuts at the ball joints (Fig. 332). Fig 332 4 PICT-3486a 17. After both pump neutrals are set, shut off the machine. 18. Remove the jumper wire from the wire harness terminals and plug the terminals into the seat switch (Fig. 333). Fig 333 PICT-3491a 19. Install the seat rod and lower the seat into position. 20. Lower the machine.
HYDRAULIC SYSTEM Adjusting the Tracking 6. To make the machine go left, turn the knob towards the left side of the machine (Fig. 335). The machine has a knob located under the seat to adjust the tracking. Important: Adjust the handle neutral and hydrostatic pump neutral before adjusting the tracking. Refer to “Adjusting the Control Handle Neutral Position” on page 4-27 and “Setting the Hydro static Pump Neutral” on page 4-28. 1. Start the engine.
HYDRAULIC SYSTEM Hydraulic Flow Testing The following procedure was performed on the right hand wheel motor hoses. It can be performed on either the right or left side of the machine. Note: Cleanliness is a key factor in successful flow testing of the hydraulic system. Thoroughly clean all exposed surfaces prior to any type of maintenance. Cleaning all parts with a solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign material and chemicals.
HYDRAULIC SYSTEM 3. Connect the hydraulic hose fittings to the hydraulic flow tester (Fig. 338). Note: The flow tester shown is bidirectional so it does not matter which order the hoses are connected to the flow tester. If using a directional flow tester, be sure to correctly connect hoses. 4 5. Unplug the wire harness clutch wire from the electric PTO clutch to prevent accidental engagement of the mower deck (Fig. 339). Fig 339 Fig 338 PICT-3507a IMG-0456a 6.
HYDRAULIC SYSTEM 7. Verify the restrictor valve on the hydraulic flow tester is in the fully “Opened” position (Fig. 341). Fig 341 10. Stroke the left hand hydrostatic lever fully forward. Very slowly, rotate the “T” handle of the adjustable flow tester restrictor valve until the pressure gauge reaches 500 PSI (3447 kPa). The measured flow should be 13 to 15 gpm (49 to 56.8 lpm) (Fig. 342). 4 PICT-3497a 8. Start the machine. Run it for approximately 5 minutes to warm the oil in the hydrostatic system.
HYDRAULIC SYSTEM 12. Record the difference or “flow droop” of the pump. For the Hydro-Gear PR Series pump, maximum allowable “flow droop” is 2.5 gpm (9.46lpm). Any droop greater than 2.5 gpm (9.46lpm) is considered unacceptable and the pump should be repaired/ replaced barring any other potential causes. 17. Reinstall the rear tire and lower the unit to the ground. 18. Remove the temporary jumper cable from the wire harness seat switch terminals. Plug the wire harness terminals into the seat switch (Fig.
HYDRAULIC SYSTEM Traction Pump Drive Belt Replacement 5. Unplug the harness connector from the electric PTO clutch (Fig. 348). Traction Pump Drive Belt Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Remove the front engine panel (Fig. 347). Fig 348 IMG-0456a 6. Remove the 2 carriage bolts and nuts securing the clutch stop bracket to the frame (Fig. 349).
HYDRAULIC SYSTEM 7. Remove the clutch stop bracket (Fig. 350). 4 Fig 350 9. With tension released from the gearbox idler, remove the PTO clutch belt from the clutch and gearbox pulleys (Fig. 352). IMG-0461a Fig 352 8. With a spring tool (Toro p/n: 92-5771), remove the gear box idler assembly spring (Fig. 351). Fig 351 10. Using a spring tool (Toro p/n: 92-5771), remove the traction pump idler assembly spring (Fig. 353).
HYDRAULIC SYSTEM 11. Remove the traction pump drive belt from the pump pulley. Lift up on the gearbox idler pulley and remove the belt by sliding it out around the electric PTO clutch (Fig. 354). Fig 354 PICT-3523a Traction Pump Drive Belt Installation 1. Slide the traction pump drive belt over the electric PTO clutch (Fig. 355). 4 Fig 355 PICT-3523a 2. While lifting up on the gearbox idler pulley, route the traction pump drive belt around the pump pulley and the engine pulley as shown (Fig.
HYDRAULIC SYSTEM 3. Using a spring tool (Toro p/n: 92-5771), install the traction pump idler assembly spring (Fig. 357). 4 5. Position the clutch stop bracket (Fig. 359). Fig 359 Fig 357 4. With tension released from the gearbox idler, install the PTO clutch belt around the electric PTO clutch and gearbox pulleys as shown (Fig. 358): 6. Using a spring tool (Toro p/n: 92-5771) install the gear box idler assembly spring (Fig. 360). Fig 360 Fig 358 4-40 IMG-0461a IMG-0421a IMG-0463a fig.
HYDRAULIC SYSTEM 7. Install 2 carriage bolts and nuts to secure the clutch stop bracket to the frame (Fig. 361). Fig 361 9. Install the front engine panel (Fig. 363). Fig 363 IMG-0460a IMG-0303a 10. Install the negative battery cable from the battery. 8. Plug the harness connector into the electric PTO clutch (Fig. 362). Fig 362 Z580/Z589 DFI Z Master Service Manual 11. Lower the seat.
HYDRAULIC SYSTEM Hydraulic Oil Cooler Replacement 4. Lift the hydraulic cooler from the radiator top plate (Fig. 366). Hydraulic Oil Cooler Removal 1. Park the machine on a level surface, disengage the PTO, engage the parking, turn the ignition OFF and remove the key. 2. Raise the seat and hood assembly (Fig. 364). 4 Fig 366 IMG-0467a 5. Remove the right hose clamp and hose on the right side of cooler over a drain pan (Fig. 367). Fig 364 IMG-0465a 3.
HYDRAULIC SYSTEM Hydraulic Oil Cooler Installation 1. Install R-clamps on the right and left side of the hydraulic oil cooler (Fig. 368). 3. Install carriage bolt through the right side radiator top plate and R-clamp and then a washer and nut (Fig. 370). Fig 370 Fig 368 IMG-0471a IMG-0469a 2. Install the two hydraulic hoses and hose clamps to the hydraulic oil cooler (Fig. 369). 4. Install a washer and nut on the other 2 carriage bolts and tighten. 5.
HYDRAULIC SYSTEM Hydraulic Reservoir Tank Replacement 5. Remove the left hand mower deck belt cover (Fig. 372). Hydraulic Reservoir Tank Removal 1. Park the machine on a level surface, disengage the PTO, engage the parking brake, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 371). 4 Fig 372 PICT-3389a 6.
HYDRAULIC SYSTEM 7. Remove the mower deck belt from the PTO drive pulley (Fig. 374). Fig 374 IMG-0627a 8. Place a drain pan under the hydraulic reservoir tank. 9. Remove the hydraulic filter hose from the fitting on the bottom of the hydraulic reservoir (Fig. 375). Fig 375 Z580/Z589 DFI Z Master Service Manual PICT-3401a 10. Slide the hose clamp down the oil cooler hose, off the tank fitting barb (Fig. 376). Fig 376 PICT-3396a 11. Remove the oil cooler hose from the tank fitting.
HYDRAULIC SYSTEM 12. Remove the 2 bolts, washers and nuts securing the reservoir to the hydraulic tank bracket (Fig. 378). 4 Fig 378 PICT-3409a 13. Remove the hydraulic reservoir (Fig. 379).
HYDRAULIC SYSTEM Hydraulic Reservoir Tank Installation 3. Install 2 bolts, washers and nuts to secure the reservoir to the hydraulic tank bracket (Fig. 382). 1. Transfer the 2 hydraulic tank fittings to the new hydraulic reservoir tank (Fig. 380). Fig 382 Fig 380 PICT-3409a PICT-3416a 4. Install the oil cooler hose onto the tank fitting on the bottom of the hydraulic reservoir (Fig. 383). 2. Position the hydraulic reservoir onto the tank bracket (Fig. 381).
HYDRAULIC SYSTEM 5. Position the hose clamp to secure the oil cooler hose to the tank fitting barb (Fig. 384). 4 Fig 384 PICT-3396a 6. Install the hydraulic filter hose to the fitting on the bottom of the hydraulic reservoir (Fig. 385). Fig 385 7. Route the mower deck belt around the PTO drive pulley (Fig. 386). Fig 386 8. Hook the idler spring from the mower deck idler arm to the spring post using a spring tool (Toro p/n: 925771) (Fig. 387).
HYDRAULIC SYSTEM 9. Install the left hand mower deck belt cover (Fig. 388). 11. Install the negative battery cable. 12. Lower the seat. 13. Fill the reservoir to the cold oil level (Fig. 390). B A D Fig 388 C 4 PICT-3389a Fig 390 10. Lower the floor pan assembly (Fig. 389). A. Cap B. Baffle fig 55 line art C. Cold fluid level - full D. Hot fluid level - full 14. Purge the hydraulic system. Refer to “Purging the Hydraulic System” on page 4-26.
HYDRAULIC SYSTEM Pushing the Machine by Hand 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked position and apply parking brake. Remove the key. Switching from Hand Pushing the Machine to Machine Operation 1. Engage the parking brake. 2. Raise the seat. 2. Raise the seat. 3. Rotate the by-pass valves counterclockwise 1 turn. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 391). 3.
ENGINE Engine Replacement 7. Remove the 2 bolts and nuts retaining the air clean er bracket to the bottom radiator plate (Fig. 394). Engine Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition OFF and remove the key. 2. Raise the seat. 3. Remove the battery negative cable from the battery. 4. Remove the front engine panel (Fig. 393). Fig 394 IMG-0505a 8. Remove the 2 bolts, washers, and nuts retaining the ECM mount plate to the bottom radiator plate (Fig. 395).
ENGINE 9. Remove the 4 bolts, washers and nuts retaining the bottom radiator plate to the right hand and left hand radiator brace assemblies (Fig. 396). Fig 396 5 IMG-0509a 10. Remove the 2 bolts, washers and nuts retaining the left side of the bottom radiator plate to the LH radiator brace assembly (Fig. 397). Fig 397 5-2 IMG-0510a 11. Remove the rear 2 bolts, washers and nuts retaining the rear guard assembly to the bottom radiator plate (Fig. 398). Fig 398 IMG-0511a 12.
ENGINE 13. Remove the bottom radiator plate from the radiator brace assemblies (Fig. 400). Fig 400 IMG-0514a 14. Loosen the hose clamp for the air filter, located on the engine (Fig. 401). Fig 401 15. Remove the air cleaner assembly from the engine (Fig. 402). Fig 402 16. Loosen and remove the 2 bolts, washers, and nuts located on top rib of the RH support bracket assem bly. Remove 1 bolt, washer and nut retaining the lower strap guard to the frame (Fig. 403).
ENGINE 17. Remove 1 bolt, washer and nut retaining the R-clamp to the left side strap guard (Fig. 404). Re move the R-clamp. 19. Remove the 2 bolts and nuts retaining the rear guard assembly to the frame (Fig. 406). Fig 406 Fig 404 5 18. Loosen and remove the 2 bolts, washers and nuts located on the top rib of the LH support bracket assembly. Remove 1 bolt, washer and nut retaining the strap guard to the frame (Fig. 405). 20.
ENGINE 21. Remove the electric PTO clutch. Refer to “Electric PTO Clutch Removal” on page 7-34. 22. Using a spring tool (Toro P/N 92-5771), remove the hydraulic pump idler arm spring (Fig. 408). 24. Remove the cable tie securing the throttle cable to on the bracket behind the voltage regulator (Fig. 410). Fig 410 Fig 408 IMG-0595a 23. Remove the belt from the hydraulic pump pulley (Fig. 409). Z580/Z589 DFI Z Master Service Manual 5 25.
ENGINE 26. Remove the Z-bend of the throttle cable from the engine throttle linkage (Fig. 412). Fig 412 5 IMG-0539a 27. Remove the throttle cable from the engine (Fig. 413). Fig 413 5-6 IMG-0541a 28. Pull the radiator overflow tube forward, away from the engine (Fig. 414). Fig 414 IMG-0542a 29. Loosen the hose clamp located on the fuel line next to the fuel filter and remove the fuel line (Fig. 415).
ENGINE 30. At the return fuel line “T” fitting, remove the hose clamp and fuel line that runs to the fuel shutoff valve (Fig. 416). 32. Remove the plug connector to the starter solenoid (Fig. 418). Fig 418 Fig 416 31. Remove the bolt and washer retaining the ground wire terminals to the engine block (Fig. 417). Fig 417 Z580/Z589 DFI Z Master Service Manual IMG-0551a IMG-0548a IMG-0550a 33.
ENGINE 34. Unplug the orange to white wire plug that goes to the voltage regulator (Fig. 420). Fig 420 5 IMG-0554a 36. Cut the cable tie retaining the wires going to the starter solenoid (Fig. 422). Fig 422 IMG-0560a 35. Unplug the connector from the wiring harness to the ECU unit (Fig. 421). 37. Unplug the engine connector harness from the main harness (Fig. 423).
ENGINE 38. From the bottom of the frame, remove the 4 engine bolts and Belleville washers securing the engine (Fig. 424). Engine Installation 1. Lower the engine onto the frame. Install 4 bolts and Belleville washers through the frame and into the base of the engine. Tighten the bolts. 2. Plug the engine connector to the harness (Fig. 426). Fig 424 IMG-0567a 39. Remove the engine from the frame (Fig. 425). Fig 426 IMG-0562a 3. Plug the connector from the wiring harness to the ECU unit (Fig. 427).
ENGINE 4. Plug the orange and wire plug that goes to the voltage regulator (Fig. 428). Fig 428 5 IMG-0554a 5. Install the 3 red wire terminals on the starter solenoid stud with a washer and nut (Fig. 429). Fig 429 5-10 IMG-0574a 6. Install the plug connector to the starter solenoid (Fig. 430). Fig 430 IMG-0575a 7. Install a cable tie around the wires going to the starter solenoid (Fig. 431).
ENGINE 8. Install the ground wires on the bolt and washer (Fig. 432). Fig 432 IMG-0580a 9. Install the bolt and ground wires to the engine block (Fig. 433). Fig 433 10. Install the fuel line from the fuel valve to the joint connecting two fuel lines and tighten the hose clamp (Fig. 434). Fig 434 11. Install the fuel line to the fuel filter and tighten the hose clamp (Fig. 435).
ENGINE 12. Route the radiator overflow tube toward the rear of the engine between the fuel lines (Fig. 436). Fig 436 5 IMG-0581a 13. Continue routing the radiator overflow tube back, placing it under the fuel line at the top of the engine (Fig. 437). Fig 437 5-12 IMG-0585a 14. Route the engine throttle cable behind the engine breather tube (Fig. 438). Fig 438 IMG-0541a 15. The throttle cable routes back to the throttle linkage on the engine.
ENGINE 16. Install the throttle cable into the throttle cable clamp. Place the throttle lever in the Slow (idle) position (Fig. 440). Fig 440 IMG-0587a 17. With slight pressure pushing on the throttle cable towards the throttle linkage, tighten the throttle cable clamp (Fig. 441). 18. Secure the throttle cable to the engine bracket located behind the voltage regulator with a cable tie (Fig. 442). Fig 442 19. Install the hydraulic pump belt around the engine pulley and the pump pulley (Fig. 443).
ENGINE 20. Connect the hydraulic pump idler spring to the pin on the idler arm, using a spring tool (Fig. 444). Fig 444 5 IMG-0595a 21. Install the electric PTO clutch. Refer to “Electric PTO Clutch Installation” on page 7-36. 22. Install the rear guard assembly with the top strap, rib top, and the guards attached (Fig. 445). 23. Install the 2 bolts and nuts retaining the bottom of the rear guard assembly to the frame (Fig. 446). Fig 446 24.
ENGINE 25. Install a bolt through LH support bracket through the strap guard and a nut (Fig. 448). Fig 448 27. Install the air cleaner inlet hose through the R-clamp located on the LH radiator brace assembly (Fig. 450). IMG-0603a Fig 450 26. Install 2 bolts with washers through the RH bracket support assembly and the top rib and install a nut and tighten. Install a bolt with washer through the frame, strap guard, and the RH bracket support assembly. Install a nut and tighten (Fig. 449). 28.
ENGINE 29. With the cooling fan located on the bottom radiator plate, connect the cooling fan electrical plug to the wiring harness (Fig. 452). Fig 454 Fig 452 5 IMG-0512a IMG-0608a 31. Install 2 bolts, washers and nuts retaining the rear guard assembly to the bottom radiator plate (Fig. 455). 30. Install the bottom radiator plate on the right and left radiator brace assemblies (Fig. 453) and on the rear guard assembly (Fig. 454).
ENGINE 32. Install 2 bolts, washers, and nuts retaining the left side of the bottom radiator plate to the LH radiator brace assembly (Fig. 456). Fig 456 34. Install 2 bolts with washers through two holes on the bottom radiator plate, through the right and left radiator brace assemblies and install 2 nuts and tighten (Fig. 458). IMG-0510a Fig 458 33.
ENGINE 36. Install 2 bolts through the air cleaner bracket and then through the bottom radiator plate and install 2 nuts and tighten (Fig. 460). Fig 460 39. Install the hood assembly. Refer to “Hood Assembly Installation” on page 3-23. 40. Install the front engine panel (Fig. 462). IMG-0505a Fig 462 5 37. Install the radiator. Refer to “Radiator Installation” on page 5-22. 38.
ENGINE Radiator Replacement 3. Raise the seat and remove the negative battery cable from the battery. Radiator Removal 4. Raise the hood assembly (Fig. 464). DANGER! Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns. • Do not remove radiator cap or open drain petcock when the engine is hot.
ENGINE 7. Allow the coolant to drain from the radiator. 8. Turn the radiator petcock to the off position. 11. Remove the 6 bolts and washers retaining the top radiator plate to the radiator (Fig. 468). 9. Remove the cable tie securing the overflow hose to the radiator cap barb (Fig. 466). Fig 468 5 Fig 466 IMG-0473a IMG-0477a 12. Remove the top radiator plate, along with the hydraulic oil cooler, and carefully lay it on the floor (Fig. 469). 10.
ENGINE 13. Remove the 6 bolts and washers retaining the radi ator to the bottom radiator plate; 3 are located in back of the radiator (Fig. 470) and 3 are located in the front. 15. Loosen and remove the hose clamp securing the left hand radiator hose to the lower left hand corner of the radiator (Fig. 472). Fig 472 Fig 470 14. Raise the front end of the radiator and loosen the hose clamp securing the right hand radiator hose to the flange on the upper right hand corner of the radiator (Fig. 471).
ENGINE 18. Remove the radiator from the bottom radiator plate (Fig. 474). Radiator Installation 1. Install the radiator on the bottom radiator plate (Fig. 475). Fig 474 IMG-0504a Fig 475 5 IMG-0504a 2. Install the left hand radiator hose on the lower left hand corner of the radiator and tighten the hose clamp (Fig. 476).
ENGINE 3. Install the right hand radiator hose to the right hand corner of the radiator and tighten the hose clamp (Fig. 477). 5. Install the top radiator plate, along with the hydraulic cooler, on top of the radiator (Fig. 479). Fig 479 Fig 477 4. Install 6 bolts with washers retaining the radiator to the bottom radiator plate; 3 are located in the back of the radiator (Fig. 478) and 3 are located in the front. 6. Install 6 bolts with washers retaining the top radiator plate to the radiator (Fig. 480).
ENGINE 7. Slide the overflow hose through the slot located on the top radiator plate and onto the barb on the radiator cap flange (Fig. 481). 9. With a pair of pliers, make sure the radiator petcock is closed (Fig. 483). Fig 483 Fig 481 5 IMG-0472a IMG-0612a 8. Install a cable tie securing the overflow hose to the radiator cap barb (Fig. 482). 10. Fill the radiator with 50/50 mix of extended life antifreeze/Dec-Cool® and water. Note: Cooling System capacity: 156 ounces (4.6 liters) 11.
ENGINE 12. Check the anti-freeze overflow bottle and make sure it is up to indicator line (Fig. 485). 13. Lower the hood assembly (Fig. 486). A B A Fig 486 IMG-0616a 14. Install the negative battery cable to the battery and lower the seat. 15. Start the machine a check for any fluid leaks. Top off cooling system as needed. Fig 485 fig. 51 G001103 A. Coolant overflow B.
ENGINE Cooling Fan Replacement 3. Remove the rear guard assembly from the unit (Fig. 488). Cooling Fan Removal 1. Remove the radiator. Refer to “Radiator Removal” on page 5-19. 2. Remove the 6 bolts, washers, nuts on the top of the rear guard assembly and the 2 bolts and nuts at the bottom of the rear guard assembly (Fig. 487). Note: The 2 top bolts and the 2 bottom bolts are different lengths than the 4 center bolts. Fig 488 IMG-0496a 4.
ENGINE 5. Lower the cooling fan and unplug the cooling fan connector from the harness connector (Fig. 490). Cooling Fan Installation 1. Slide the fan under the bottom radiator plate (Fig. 492). Fig 490 IMG-0499a Fig 492 IMG-0500a 6. Remove the cooling fan from under the bottom radiator plate (Fig. 491). 2. Connect the cooling fan electrical connector to the wiring harness connector (Fig. 493).
ENGINE 3. Install the 4 bolts, washers and nuts retaining the fan assembly to the bottom radiator plate (Fig. 494). Tighten the bolts and nuts. Fig 494 5 IMG-0497a 4. Install the rear guard assembly to the unit (Fig. 495). Fig 495 5-28 5. Install 2 bolts, washers, and nuts on the top of the rear guard and the bottom radiator plate and then install 4 bolts, washer and nuts through the 4 guard straps and rear guard. Install 2 bolts and nuts through the bottom of the rear guard and the frame (Fig. 496).
ENGINE Fuel Pump Replacement 5. Remove the cable tie around the fuel pump wires and the wiring harness (Fig. 498). Fuel Pump Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition switch OFF and remove the key. 2. Raise the seat. 3. Remove the battery negative cable from the battery. 4. Turn the fuel valve to the OFF position (Fig. 497). Fig 498 IMG-0635a 6. Unplug the fuel pump from the wiring harness (Fig. 499).
ENGINE 7. Remove 2 bolts and nuts retaining the fuel pump to the frame (Fig. 500). Fig 500 9. Loosen the hose clamp on the fuel line from the fuel pump to the engine (Fig. 502). Remove the fuel line from the pump. IMG-0639a Fig 502 5 8. Loosen the hose clamp on the fuel line from the pump to the filter (Fig. 501). Remove the fuel line from the pump. 10. Remove the fuel pump (Fig. 503).
ENGINE Fuel Pump Installation 3. Install two bolts and nuts and mount the fuel pump to the frame (Fig. 506). 1. Install hose clamp around the fuel line from the engine to the fuel pump and tighten clamp (Fig. 504). Fig 506 Fig 504 IMG-0642a IMG-0639a 4. Plug the fuel pump into the wiring harness (Fig. 507). 5 2. Install hose clamp on the fuel line from the fuel filter to the fuel pump and tighten the clamp (Fig. 505).
ENGINE 5 Install a cable tie around fuel pump wires and the wiring harness (Fig. 508). Checking the Radiator Coolant Note: Do not open the radiator cap. Doing this may introduce air into the cooling system. 1. Position the machine on a level surface, stop the engine, and set the parking brake. 2. Raise the seat. 3. With the engine cool, check the overflow bottle level. The fluid needs to be up to the indicator line (bump) on the outside of the overflow bottle (Fig. 510). 4.
ELECTRICAL General Location Note: Interactive Electrical Troubleshooting DVD, Form No. 492-9171 is also available. The 4 relays are located to the left of the engine attach ed to the top support strap (Fig. 511). A B C D Relays There are four relays in the Z580 and Z589 liquid cooled Kawasaki DFI. Relays have 4 functions in the Z580 and Z590 Liquid Cooled models: • Start Relay • Kill Relay • Fan Relay • Fuel Pump Relay Purpose 1.
ELECTRICAL How It Works Testing A relay is an electrically actuated switch. 1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts to these terminals energizes the coil turning it into an electromagnet. 2. Switch: Terminals 30, 87 and 87a are actually part of a single pole, double throw (SPDT) switch. Terminal 30 is the common lead. The switch is spring loaded so that 30 and 87a are connected when the coil is not energized.
ELECTRICAL 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 514). PTO Switch Purpose The PTO (Power Take Off) switch is typically used to activate the Electric PTO Clutch and to function as part of the safety interlock system. Location The PTO switch is located on the control panel, on the left side of the operator (Fig. 515). Fig 514 xl relay Fig 515 IMG-0648a How It Works Contacts inside the switch electrically connect various terminals in both “On” and “Off” position.
ELECTRICAL Testing 6. Replace the switch if your test results do not correspond with those given in Fig. PTO switch test. 1. Disengage the PTO, set the parking brake, and turn the ignition to OFF and remove the key. 7. Mount the PTO switch back into the control panel and reinstall the wiring harness (Fig. 517). 2. Remove the 4 screws holding the control panel to the fuel tank. Pink/Black 3. Disconnect the wiring harness from the PTO switch. 4.
ELECTRICAL Ignition Switch How It Works Purpose Detents inside the switch give it 3 positions: OFF, RUN and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released (Fig. 519). The ignition switch provides the proper switching for the starter, accessories, and safety circuits. Location A B The ignition switch is located on the control panel, to the left side of the operator (Fig. 518).
ELECTRICAL Testing Neutral Safety Switch 1. Disconnect the switch from the wiring harness. Purpose 2. Verify that continuity exists between the terminals listed for the switch position. Verify that there is NO continuity between terminals not listed for the switch position. Used to ensure the motion control handles are in neutral to start the unit. It is actuated by moving the motion control handles to the neutral position (handles outward).
ELECTRICAL How It Works Parking Brake Switch This single pole plunger (normally open) type switch has two terminals. When the motion control handles are in the neutral position (handles in the out position), it pushes on the plunger, closing the contact and connecting the terminals (Fig. 521). Purpose The purpose of the parking brake switch is to ensure the machine is in neutral and the parking brake is applied before attempting to start the machine.
ELECTRICAL How It Works Testing In the start position it is used to ensure the park brake is in the ON position. At the same time it allows current to flow through for safety circuit. When the park brake is released in the OFF position it bypasses both neutral switches, as long as the operator is in the seat to maintain current for the safety circuit (Fig. 523). 1. Disconnect the switch from the wiring harness. The park brake switch is a double pole switch.
ELECTRICAL Seat Switch How It Works Purpose When the seat is vacated, the switch is open and there should be NO continuity between the two terminals. When the seat is occupied, the switch closes and there should be continuity between the two terminals (Fig. 526). The seat switch is in the safety circuit. If the engine is running and the operator vacates the seat with either the PTO engaged or the parking brake disengaged, the engine will shut down.
ELECTRICAL Delay Module How It Works Purpose The seat delay module circuit board is made up of several different electrical components, such as a transient voltage suppressor, capacitor, transistors, carbon film resistors, diodes and a relay. These all work together to supply seat switch temporary voltage to the circuit to keep the engine running in case of short term voltage interruption (Fig. 528).
ELECTRICAL Testing Follow the procedure below to test the delay module function. 1. Raise the seat and disconnect the seat switch. Install a jumper wire in place of the seat switch (Fig. 529). 1. Disengage the parking brake. 2. Pull the right and left motion control levers out of the neutral position. 3. Turn the ignition key to the RUN position. 4. The meter should read approximately 12 volts DC. 5. Disconnect one of the jumper wire leads.
ELECTRICAL High Temperature Audible Alarm (Solid Tone) Purpose How It Works A continuous tone will sound when the engine temperature switch connects to ground as the engine reaches a certain temperature (Fig. 532). This machine has an audible alarm that alerts the user to turn off the engine or engine damage can occur from overheating. Location The audible alarm is located behind the seal to the left of the front engine access panel (Fig. 531).
ELECTRICAL Temperature Sender How It Works Purpose When the water temperature reaches an excessive operating temperature, the switch will close internally and ground the high temperature audible alarm and the light on the control panel (Fig. 534). The temperature sender is a temperature-dependent variable resistor.
ELECTRICAL Oil Pressure Switch How It Works Purpose When the engine oil pressure builds, the switch closes to complete the circuit for both the hour meter and the cooling fan relay (Fig. 536). The oil pressure switch completes the circuit that activ ates the hour meter and the radiator fan relay. Location The oil pressure switch is located on the lower left side of the engine block, next to the engine oil filter (Fig. 535).
ELECTRICAL Engine High Temperature & Malfunction Indicator Light Cluster Purpose There are two purposes for this light cluster: 1. In addition to the high temperature audible alarm, there is an accompanying light for visual represen tation of high temperature. It is a red light. How It Works The engine high temperature light is connected in par allel with the high temperature audible alarm. The light gives a visual indicator that the engine has reached a high temperature.
ELECTRICAL Testing Hour Meter The indicator lights can be tested with an ohmmeter. There should be continuity between terminals, A - B and C - D (Fig. 539). Purpose The hour meter keeps track of the actual engine running hours. Location A B C D Fig 539 6 The hour meter is positioned on the control panel which is located on the left side of the operator position (Fig. 540).
ELECTRICAL How It Works Electric PTO Clutch The hour meter is made up of an electric “winder” and a mechanical clock movement. When power is applied, a coil is energized to wind the movement. The movement unwinds in about 2 seconds. As it finishes its rotation, it re-energizes the coil so that the cycle can start over (Fig. 541). Purpose The electric clutch controls the engagement and disengagement of the Power Take-off (PTO) pulley.
ELECTRICAL How It Works Testing The PTO clutch is composed of three major components; the field, the clutch plate, and the friction plate. The clutch plate always turns with the engine. The field is a coil of wire wound around an iron core, which acts like an electromagnet when power is applied. The friction plate is the only piece that can slide inward and outward on the crankshaft axis. It is spring loaded away from contact with the clutch plate.
ELECTRICAL Clutch Coil Continuity Test This test can be performed the same way on both the Warner and Orgura clutches. 1. Disengage PTO. 2. Raise the seat and disconnect the negative battery cable from the battery. 3. Unplug the harness connector from the clutch (Fig. 544). Fig 544 PICT-3933a 6 4. Using a continuity tester, touch one tester lead to one of the clutch terminals and the other lead to the clutch housing. 5.
ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK.
MOWER DECKS Mower Belt Replacement 4. Remove the right hand and left hand belt covers (Fig. 546). 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the floor pan (Fig. 545). Fig 546 PICT-4012a 5. Using a spring tool (Toro p/n: 92-5771), remove the mower deck belt idler spring (Fig. 547).
MOWER DECKS 6. Remove the belt guide from the idler arm pulley (Fig. 548). Fig 548 8. Install a new belt around the mower pulleys and the gearbox pulley under the engine. Refer to the belt routing decal (Fig. 550). PICT-4060a Fig 550 7. Remove the existing belt (Fig. 549). fig. 108-5981 9. Install the belt guide on the spring loaded idler at a 45 degree angle as shown (Fig. 551): 7 A Fig 549 PICT-4044a Fig 551 belt guide position_a A.
MOWER DECKS 10. Install mower deck belt idler spring (Fig. 552). Mower Deck Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 554). Fig 552 PICT-4013a 11. Install the right hand and left hand belt covers (Fig. 553). Fig 554 PICT-4011a 5. Remove the left and right mower deck belt covers (Fig. 555). 7 Fig 553 PICT-4012a 12.
MOWER DECKS 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 556). Fig 556 8. Place the mower deck in the transport position. Position wood blocks under each corner of the mower deck. Lower the mower deck onto the blocks to remove tension from the deck lift chains (Fig. 558). PICT-4013a 7. Remove the mower deck belt from the gearbox deck drive pulley (Fig. 557). Fig 558 PICT-4019a 9.
MOWER DECKS 10. Remove the outer nut from each of the 4 deck chain assemblies (Fig. 560). Fig 560 PICT-4023a 11. Raise the deck lift lever to the transport position (Fig. 561). 12. Remove the bolt and nut securing the strut to the mower deck (Fig. 562). Fig 562 PICT-4036a 13. Repeat the above step to remove the bolt and nut securing the opposite strut from the mower deck. 14. Pull both strut pins to free the mower deck from the struts (Fig. 563).
MOWER DECKS 15. Tie the struts up, out of the way of the mower deck. Mower Deck Installation 16. Remove the 4 wood blocks from each corner of the mower deck. 1. Turn the right front wheel so the castor fork is angled forward to allow more clearance for sliding the mower under the frame (Fig. 566). 17. Turn the right front castor wheel so the castor fork is angled forward to allow more clearance for sliding the mower deck out (Fig. 564). Fig 566 Fig 564 PICT-4041a PICT-4041a 2.
MOWER DECKS 3. Slide a wood block under each corner of the mower deck. 4. Push the deck lift handle to the lowest height-of-cut position to overcome the tension of the lift assist springs. Insert the hitch pin above the deck lift handle to lock the handle in the down position (Fig. 568). 6. Place the mower deck in the transport position. Remove the wood blocks from under each corner of the mower deck. 7. Align each strut with the mower deck strut brackets and install the strut pins (Fig. 570).
MOWER DECKS 9. Route the mower deck belt around the mower deck pulleys and gearbox deck drive pulley. Refer to the belt routing decal (Fig. 572). 11. Install the left and right mower deck belt covers (Fig. 574). Fig 574 Fig 572 PICT-4012a fig. 108-5981 10. Install the mower deck idler spring (Fig. 573). 12. Lower the floor pan assembly (Fig. 575). 7 Fig 575 Fig 573 PICT-4011a PICT-4013a 13. Install the negative battery cable to the battery. 14. Lower the seat.
MOWER DECKS Mower Spindle Replacement 5. Remove the left and right mower deck belt covers (Fig. 577). Mower Spindle Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 576). Fig 577 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 578).
MOWER DECKS 7. Remove the mower deck belt from the spindle pulley (Fig. 579). Fig 579 PICT-4044a 8. Remove the nuts from the 6 spindle mounting bolts (Fig. 580). 9. 72” mower decks: Remove 3 bolts retaining the pulley to the pulley hub (Fig. 581). Fig 581 DSC-2662a 10. 72” mower decks: Raise the mower deck to the transport position. 11. 72” mower decks: Remove the mower blade from the spindle assembly. 12. 72” mower decks: Remove the 6 bolts and nuts from the spindle assembly.
MOWER DECKS 13. 60” mower decks: Remove the 6 spindle mounting bolts securing the spindle housing to the mower deck (Fig. 583). 15. 60” mower decks: Remove the spindle blade bolt and washer (Fig. 585). Fig 585 Fig 583 PICT-4050a PICT-4046a 14. 60” mower decks: Carefully lower the spindle assembly out of the mower deck (Fig. 584). 16. 60” mower decks: Remove the blade (Fig. 586).
MOWER DECKS 17. 60” mower decks: Remove the 3 bolts securing the pulley to the spindle hub (Fig. 587). Mower Deck Spindle Rebuild 1. Remove the nut and washer (Fig. 589). Fig 587 PICT-4055a Fig 589 18. 60” mower decks: Remove the pulley from the spindle assembly (Fig. 588). DSC-2669a 2. Remove the pulley hub and square key (Fig. 590).
MOWER DECKS 5. Remove the seal spacer from the top of the spindle housing (Fig. 593). 3. Remove the bearing shield (Fig. 591). Fig 591 DSC-2671a Fig 593 4. Remove the spindle housing from the spindle shaft assembly (Fig. 592). DSC-2673a 6. Remove the seal spacer from the bottom of the spindle housing (Fig. 594).
MOWER DECKS 7. Remove the top oil seal from the spindle housing (Fig. 595). 9. Remove the spacer (Fig. 597). Fig 597 Fig 595 DSC-2677a DSC-2675a 8. Remove the tapered roller bearing from the top of the spindle housing (Fig. 596). 10. Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing (Fig. 598). Note the orientation of the lower oil seal. The open end of the seal faces outwards to help relieve pressure from over-greasing the spindle assembly.
MOWER DECKS 11. Remove the tapered roller bearing from the bottom of the spindle (Fig. 599). Fig 599 13. Remove the large spacer in the spindle housing (Fig. 601). DSC-2680a 12. Using a hammer and a driver with a square edge, drive both the top and bottom bearing races out of the spindle housing (Fig. 600). Fig 601 DSC-2682a 14. This view shows the 2 bearing races and the large spacer in the spindle housing (Fig. 602).
MOWER DECKS 15. Install the spacer through the top of the spindle housing (Fig. 603). 17. Turn the spindle housing over and install the lower bearing race into the spindle housing (Fig. 605). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing. Fig 603 DSC-2688a 16. Using a press, install the upper bearing race into the spindle housing (Fig. 604). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing.
MOWER DECKS 19. Install the lower seal (Fig. 607). Note: The open lip of the seal should be facing outward. 21. Install the inner spacer to the spindle assembly (Fig. 609). Fig 609 Fig 607 DSC-2700a DSC-2692a 20. Using a seal driver, drive or press the seal on the lower end of the spindle housing until the seal is flush with the outer edge of the housing (Fig. 608). 22. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig. 610).
MOWER DECKS 23. Install the seal. Press it flush with the top of the housing (Fig. 611). 25. Lower the spindle housing over the spindle shaft (Fig. 613). Note: The open lip of the seal faces inward. Fig 613 Fig 611 DSC-2703a DSC-2696a 24. Install the bearing shield and the seal spacer onto the spindle shaft (Fig. 612). 26. Install the seal spacer on the top of the spindle housing (Fig. 614).
MOWER DECKS 27. Install bearing shield (Fig. 615). Fig 615 29. Install the pulley hub on the spindle shaft (Fig. 617). DSC-2705a 28. Install the square key onto the spindle shaft (Fig. 616). Fig 617 DSC-2707a 30. Install the heavy washer and nut on the top of the spindle shaft (Fig. 618). Note: The cup side of the washer should be facing down toward the pulley hub.
MOWER DECKS 31. Torque the top nut to 100 to 120 ft-lbs. (135.58 to 162.7 Nm) (Fig. 619). Mower Spindle Installation 1. 72” mower decks: Position the spindle assembly into the mower deck. Install the 6 self-tapping bolts securing the spindle assembly to the mower deck (Fig. 620). Fig 619 DSC-2709a 32. Grease the spindle assembly using a grease gun with #2 grease. Fig 620 DSC-2666a 2. 72” mower decks: Install the mower blade onto the spindle assembly. Torque bolt to 85 - 110 ft-lbs. (115149 Nm). 3.
MOWER DECKS 4. 60” mower decks: Position the pulley onto the spindle assembly (Fig. 622). Fig 622 PICT-4056a 5. 60” mower decks: Install 3 bolts securing the pulley to the spindle hub. Torque bolts to 23 ft-lbs. (31 Nm) (Fig. 623). 6. 60” mower decks: Position the blade to the spindle shaft retainer (Fig. 624). Fig 624 PICT-4053a 7. 60” mower decks: Install the spindle blade bolt and washer. Torque to 85-110 ft-lbs. (115-149 Nm) (Fig. 625).
MOWER DECKS 8. 60” mower decks: Carefully position the spindle assembly into the mower deck (Fig. 626). Fig 626 10. Install a nut onto each of the 6 spindle mounting bolts (Fig. 628). Fig 628 PICT-4049a 9. 60” mower decks: Install 6 spindle mounting bolts securing the spindle housing to the mower deck (Fig. 627). PICT-4045a 11. Route the mower deck belt around the spindle pulley. Refer to the belt routing diagram (Fig. 629): BA D 7 E C B BF Fig 629 Fig 627 7-22 PICT-4046a A. Mower belt B.
MOWER DECKS 12. Install the mower deck idler spring (Fig. 630). Fig 630 14. Lower the floor pan assembly (Fig. 632). Fig 632 PICT-4013a 13. Install the left and right mower deck belt covers (Fig. 631). PICT-4011a 15. Install the negative battery cable to the battery. 16. Lower the seat.
MOWER DECKS Mower Deck Idler Assembly Replacement 5. Remove the left and right mower deck belt covers (Fig. 634). Mower Deck Idler Assembly Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 633). Fig 634 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 635).
MOWER DECKS 7. Remove the bolt, belt guide and 2 flat washers securing the idler pulley to the idler arm (Fig. 636). 9. Remove the bolt, nut and 2 washers securing the idler arm assembly to the mower deck (Fig. 638). Note: One of the washers is between the idler arm and mower deck. Fig 636 PICT-4061a Fig 638 PICT-4065a 8. Remove the pulley from the idler arm assembly (Fig. 637). 10. Remove the idler arm assembly from the mower deck (Fig. 639).
MOWER DECKS 11. Remove the 2 bushings and 1 spacer from the idler arm (Fig. 640). Mower Deck Idler Assembly Installation 1. Install a grease fitting into the idler arm pivot (Fig. 642). Fig 640 PICT-4073a Fig 642 PICT-4070a 12. Remove the grease fitting from the idler arm pivot (Fig. 641). 2. Press 2 bushings into the idler arm pivot (Fig. 643).
MOWER DECKS 3. Slide a spacer into the idler arm pivot (Fig. 644). Fig 644 5. Position the idler arm assembly onto the mower deck with the pivot placed over the washer (Fig. 646). PICT-4082a Fig 646 4. Position a washer onto the mower deck in the idler arm pivot location (Fig. 645). PICT-4084a 6. Install a bolt, nut and washer to secure the idler arm assembly to the mower deck (Fig. 647).
MOWER DECKS 7. Position the pulley onto the idler arm assembly (Fig. 648). 9. Position the belt guide onto the 2 washers so that it is 45 degrees from the idler arm (Fig. 650). A Fig 648 Fig 650 PICT-4063a belt guide position_a A. 45º 8. Route the mower deck belt into the pulley and place 2 washers on top of the pulley (Fig. 649). 10. Install a bolt to secure the belt guide to the pulley (Fig. 651).
MOWER DECKS 11. Apply grease to the idler arm pivot grease fitting (Fig. 652). 13. Install the mower deck idler spring (Fig. 654). Fig 654 Fig 652 PICT-4013a PICT-4127a 12. Ensure the mower deck belt is properly routed around the pulleys. Refer to the belt routing decal (Fig. 653). 14. Install the left and right mower deck belt covers (Fig. 655). 7 Fig 655 Fig 653 Z580/Z589 DFI Z Master Service Manual PICT-4012a fig.
MOWER DECKS Fixed Pulley Replacement 15. Lower the floor pan assembly (Fig. 656). Fixed Pulley Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 657). Fig 656 PICT-4011a 16. Install the negative battery cable to the battery. 17. Lower the seat.
MOWER DECKS 5. Remove the left and right mower deck belt covers (Fig. 658). Fig 658 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 659). 7. Remove the bolt, washer and nut securing the fixed pulley to the mower deck (Fig. 660). Fig 660 PICT-4090a 8. Remove the pulley from the pulley mount (Fig. 661).
MOWER DECKS Fixed Pulley Installation 9. Remove the pulley mount (Fig. 662). 1. Position the pulley mount onto the mower deck (Fig. 663). Fig 662 PICT-4095a Fig 663 PICT-4095a 2. Position the pulley onto the pulley mount (Fig. 664).
MOWER DECKS 3. Install a bolt, washer and nut securing the fixed pulley to the mower deck (Fig. 665). 5. Install the mower deck idler spring (Fig. 667). Fig 667 Fig 665 PICT-4013a PICT-4100a 4. Route the mower deck belt. Refer to the belt routing decal (Fig. 666). 6. Install the left and right mower deck belt covers (Fig. 668). 7 Fig 668 Fig 666 Z580/Z589 DFI Z Master Service Manual PICT-4012a fig.
MOWER DECKS Electric PTO Clutch Replacement 7. Lower the floor pan assembly (Fig. 669). Electric PTO Clutch Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition OFF and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Remove the front engine panel (Fig. 670). Fig 669 PICT-4011a 8. Install the negative battery cable to the battery. 9. Lower the seat.
MOWER DECKS 5. Unplug the harness connector from the electric PTO clutch (Fig. 671). Fig 671 IMG-0528a 6. Using a spring tool (Toro p/n: 92-5771) unhook the spring from the gearbox idler arm assembly (Fig. 672). 7. Remove the gearbox drive belt from around the electric PTO clutch pulley (Fig. 673). Fig 673 PICT-3934a 8. Remove the center clutch bolt, spring washers, and clutch retainer (Fig. 674).
MOWER DECKS 9. Remove 2 bolts and nuts retaining the clutch stop strap to the frame (Fig. 675). Electric PTO Clutch Installation 1. Apply anti-seize compound to the stub shaft (Fig. 677). Fig 675 IMG-0532a Fig 677 IMG-0596a 10. Remove the electric PTO clutch from the stub shaft (Fig. 676). 2. Install the electric PTO clutch to the crankshaft (Fig. 678).
MOWER DECKS 3. Apply thread locking compound to the center clutch bolt (Fig. 679). Fig 679 IMG-0599a 4. Install center clutch bolt, spring washers, and clutch retainer. Note the direction of the spring washers (Fig. 680). A B 5. Torque the center clutch bolt to 50 ft-lbs. (67.8 Nm) (Fig. 681). Fig 681 IMG-0600a 6. Install the gearbox drive belt around the electric PTO clutch and the gearbox pulley (Fig. 682). C 7 Fig 682 Fig 680 A. Clutch bolt B.
MOWER DECKS 7. With a spring tool (Toro p/n: 92-7551), hook the spring to the idler arm assembly (Fig. 683). Fig 683 9. Plug the harness connector to the electric PTO clutch (Fig. 685). Fig 685 IMG-0463a 8. Install the clutch stop strap to the frame using 2 bolts, washers, and nuts (Fig. 684). IMG-0528a 10. Install the front engine panel (Fig. 686). 7 Fig 686 Fig 684 IMG-0303a IMG-0532a 11. Install the negative battery cable. 12. Lower the seat.
MOWER DECKS Gearbox Assembly Replacement 5. Remove the right rear wheel and tire assembly (Fig. 688). Gearbox Assembly Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Remove the front engine panel (Fig. 687). Fig 688 IMG-0620a 6. Using a spring tool (Toro p/n: 92-5771) unhook the spring from the gearbox idler assembly (Fig. 689).
MOWER DECKS 7. Remove the gearbox drive belt from the drive pulley (Fig. 690). Fig 690 IMG-0626a 8. Raise the floor pan assembly (Fig. 691). 9. Remove the left hand mower deck belt cover (Fig. 692). Fig 692 PICT-3879a 10. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 693).
MOWER DECKS 11. Remove the deck drive belt from the gearbox pulley (Fig. 694). 13. Remove the gearbox assembly (Fig. 696). Fig 696 Fig 694 IMG-0632a IMG-0627a 12. Remove the 4 mounting bolts and lock washers securing the gearbox assembly to the frame (Fig. 695). 14. Remove the 2 set screws from the gearbox driven pulley (Fig. 697).
MOWER DECKS 15. Remove the pulley (Fig. 698). Fig 698 17. Remove the 2 set screws from the gearbox drive pulley (Fig. 700). PICT-3909a Fig 700 16. Remove the key from the keyway (Fig. 699). PICT-3908a 18. Remove the pulley (Fig. 701).
MOWER DECKS 19. Remove the key from the keyway (Fig. 702). Gearbox Assembly Installation 1. Apply anti-seize compound to both gearbox assembly shafts (Fig. 703). Fig 702 PICT-3912a 20. Inspect the keys, gearbox shafts and pulleys. Replace if worn or damaged. 21. Check the gearbox oil level. Refer to “Checking the Gearbox Oil Level” on page 7-48. To change the gearbox oil, see “Changing Gearbox Oil” on page 7-49. Fig 703 PICT-3913a 2. Install a key into the gearbox drive shaft keyway (Fig. 704).
MOWER DECKS 3. Apply thread locking compound to all 4 pulley set screws. Start the set screws into the pulley hubs (Fig. 705). 4. Tighten the set screws (Fig. 707). Fig 707 Fig 705 PICT-3919a PICT-3917a Slide the gearbox drive pulley onto the gearbox drive shaft (Fig. 706). 5. Torque each set screw to 145 + 20 in-lbs. (16 + 2.25 Nm) (Fig. 708). Note: Install the pulley so that the pulley hub is flush + .03” (0.76mm) with the end of the gearbox shaft.
MOWER DECKS 6. Install a key into the gearbox driven shaft keyway (Fig. 709). Fig 709 Note: Install the pulley so that the hub is .06” (1.5mm) from the end of the gearbox driven shaft. Tighten the set screws (Fig. 711). PICT-3924a Fig 711 7. Slide the driven pulley onto the gearbox driven shaft (Fig. 710). PICT-3925a 8. Torque each set screw to 145 + 20 in-lbs. (16 + 2.25 Nm) (Fig. 712).
MOWER DECKS 9. Position the gearbox assembly to the frame (Fig. 713). Fig 713 IMG-0632a 10. Install 4 mounting bolts and lock washers securing the gearbox assembly to the frame. Torque the 4 mounting bolts to 145 + 20 in-lbs. (16 + 2.25 Nm) (Fig. 714). 11. Install the deck drive belt around gearbox mower deck drive pulley (Fig. 715). Fig 715 IMG-0627a 12. Using a spring tool (Toro p/n: 92-5771), install the mower deck idler spring (Fig. 716).
MOWER DECKS 13. Install the left hand mower deck belt cover (Fig. 717). Fig 717 PICT-3879a 14. Lower the floor pan assembly (Fig. 718). 15. Position the gearbox drive belt around the gearbox drive pulley (Fig. 719). Fig 719 IMG-0626a 16. Using a spring tool (Toro p/n: 92-5771), install the spring to the gearbox idler assembly (Fig. 720).
MOWER DECKS 17. Install the right rear wheel and tire assembly (Fig. 721). Checking the Gearbox Oil Level 1. Park the machine on a level surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Remove the side or rear plug on the gear box (Fig. 723). Note: Gearbox removed from machine for photo clarity. Fig 721 IMG-0620a 18.
MOWER DECKS Changing Gearbox Oil 3. Drain the oil from the gearbox into a drain pan. Service Interval: Initial at 100 hours, then yearly. 4. Fill the gearbox assembly with 75W-90 Synthetic Gear Lube until the oil level reaches the plug openings (Fig. 725). Capacity 6 oz. (.177 liters). 1. Remove the gearbox assembly from the machine. Refer to “Gearbox Assembly Removal” on page 7-39. Note: The pulleys do not have to be removed from the gearbox. 2.
MOWER DECKS Strut Replacement 5. Remove the left and right mower deck belt covers (Fig. 728). Note: The right rear wheel assembly has been removed for photo purposes. Strut Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 727). Fig 728 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring.
MOWER DECKS 7. Remove the bolt and nut securing the strut pin to the mower deck strut bracket (Fig. 730). Fig 730 PICT-4108a 8. Remove the strut pin (Fig. 731). 9. Remove the nut, lockwasher and bolt securing the strut balljoint to the frame (Fig. 732). Fig 732 PICT-4105a 10. Remove the strut assembly (Fig. 733).
MOWER DECKS 11. Remove the grease fittings from the strut (Fig. 734). Fig 734 13. Remove the balljoint and jam nut from the strut (Fig. 736). PICT-4116a Fig 736 PICT-4121a 12. Loosen the balljoint jam nut (Fig. 735).
MOWER DECKS Strut Installation 2. Tighten the jam nut to secure the balljoint position (Fig. 738). 1. Install the balljoint and jam nut into the strut. The length of the strut should be 17.31” (43.97cm) from the center of the balljoint to the center of the cross shaft of the strut (Fig. 737). Note: Position balljoint perpendicular to strut. D A B C Fig 738 Fig 737 A. Strut B. Jam nut PICT-4119a fig. 108-5969 C. Balljoint D. 17.31” (43.97cm) 3. Install 2 grease fittings into the strut (Fig. 739).
MOWER DECKS 4. Position the strut assembly balljoint to the frame. Secure it to the frame with a bolt, lockwasher and nut (Fig. 740). 6. Install a bolt and nut securing the strut pin to the mower deck strut bracket (Fig. 742). Fig 742 Fig 740 PICT-4108a PICT-4105a 5. Position the front end of the strut between the strut brackets on the rear of the mower deck and install the strut pin (Fig. 741). 7. Apply grease to the strut grease fitting (Fig. 743).
MOWER DECKS 8. Route the mower deck belt. Refer to the belt routing decal (Fig. 744). Fig 744 10. Install the left and right mower deck belt covers (Fig. 746). fig. 108-5981 9. Install the mower deck idler spring (Fig. 745). Fig 746 PICT-4012a 11. Lower the floor pan assembly (Fig. 747). 7 Fig 745 PICT-4013a Fig 747 PICT-4011a 12. Install the negative battery cable to the battery. 13. Lower the seat.
MOWER DECKS 72” Mower Deck Belt Tension Adjustment Plate Replacement 5. Remove the left and right mower deck belt covers (Fig. 749). 72” Mower Deck Belt Tension Adjustment Plate Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 748). Fig 749 PICT-4012a 6.
MOWER DECKS 7. Remove the belt from around the adjustment plate pulley. 10. Remove the tension adjustment plate assembly (Fig. 753). 8. Remove the nut from the pivot bolt (Fig. 751). Note: The pivot bolt will fall through to the underside of the deck when the nut is removed. Fig 753 Fig 751 6666a PICT-6668a 11. Remove the 2 spacers from the mower deck (Fig. 754). 9. Remove the nut and washer from the adjustment plate slot bolt (Fig. 752).
MOWER DECKS 12. Remove the nut, washer and bolt securing the pulley to the adjustment plate (Fig. 755). 14. Remove the idler bushing (Fig. 757). Fig 757 Fig 755 6672a 6670a 13. Remove the pulley from the idler bushing (Fig. 756).
MOWER DECKS 72” Mower Deck Belt Tension Adjustment Plate Installation 3. Install a washer and nut onto the pulley bolt securing the pulley to the adjustment plate (Fig. 760). 1. Position the idler bushing onto the tension adjustment plate (Fig. 758). Fig 760 Fig 758 6672a 6670a 4. Position 2 spacers onto the mower deck (Fig. 761). 2. Insert the mounting bolt up through the idler bushing and place the pulley onto the bushing (Fig. 759).
MOWER DECKS 5. Position the tension adjustment plate assembly onto the mower deck making sure the spacers are in place (Fig. 762). 7. Route the belt around the adjustment plate pulley. Refer to the belt routing decal (Fig. 764). Fig 764 Fig 762 fig. 108-5981 PICT-6668a 6. Insert 2 bolts up through the mower deck, spacers and tension adjustment plate. Install a washer and nut onto each bolt (Fig. 763). 8. Install the mower deck idler spring (Fig. 765).
MOWER DECKS 9. Adjust the mower belt tension. Refer to “72” Mower Deck Belt Tension Adjustment” on page 7-62. 10. Install the left and right mower deck belt covers (Fig. 766). Fig 766 12. Install the negative battery cable to the battery. 13. Lower the seat. PICT-4012a 11. Lower the floor pan assembly (Fig. 767).
MOWER DECKS 72” Mower Deck Belt Tension Adjustment Important: To ensure proper mower belt tension, which will result in longer belt life, check the mower belt tension after the first 8 hours of use and 8 hours after each belt change. 5. Loosen the bolts holding the idler plate (Fig. 768). A D B 1. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 2.
MOWER DECKS Gearbox Rebuild 3. Carefully remove the pinion assembly (Fig. 771). 1. Remove the two gearbox drain plugs and drain the oil from the gearbox (Fig. 769). Fig 771 Fig 769 PICT-5631a PICT-5646a 4. Remove the o-ring from the pinion pilot (Fig. 772). 2. Remove the 4 bolts securing the pinion housing to the case (Fig. 770). Note: The bolts securing the end caps to the gearbox housing are patch lock bolts and must be replaced with new patch lock bolts.
MOWER DECKS 5. Remove the shim(s) (Fig. 773). Fig 775 Fig 773 IMG-8490a PICT-5650a 7. Remove the closed end cap (Fig. 776). 6. Remove the 8 end cap screws (4 securing each end cap) (Fig. 774 and Fig. 775). Note: The bolts securing the end caps to the gearbox housing are patch lock bolts and must be replaced with new patch lock bolts.
MOWER DECKS 8. Remove the o-ring from the closed end cap (Fig. 777). Fig 777 IMG-8491a 9. Remove the open end cap and cross shaft assembly (Fig. 778). 10. Remove the o-ring from the cross shaft pilot (Fig. 779). Fig 779 PICT-5664a 11. Remove the shim(s) (Fig. 780).
MOWER DECKS 12. Remove the cross shaft from the open end cap (Fig. 781). Pinion Shaft Teardown 13. Secure the pinion shaft in a vise. 14. Remove the lock nut from the pinion shaft (Fig. 782). Fig 781 PICT-5667a Fig 782 IMG-8494a 15. Remove the washer from the pinion shaft (Fig. 783).
MOWER DECKS 16. Using a gear puller, remove the cross shaft gear from the pinion shaft (Fig. 784). Fig 784 18. Place the pinion shaft assembly in a press, shaft side down. Press the pinion shaft assembly out of the pinion housing (Fig. 786). IMG-8499 Fig 786 17. Remove the key from the shaft keyway (Fig. 785). IMG-8503 19. Remove the bearing and shaft assembly from the pinion housing (Fig. 787).
MOWER DECKS 20. Remove the grease seal from the shaft (Fig. 788). 22. Place the pinion housing in a vise and remove the inner and outer bearing races from the housing (Fig. 790). Note: The inner race and housing must be heated to remove the races. Fig 788 IMG-8507a 21. Place the shaft assembly in a press and press the bearing off the shaft (Fig. 789).
MOWER DECKS Cross Shaft Teardown 23. Place the cross shaft in a press with the pinion gear bearing facing up. 26. Position the cross shaft in the press so the opposite bearing is facing up. Press the bearing off the shaft (Fig. 793). 24. Press the pinion gear and bearing off the cross shaft (Fig. 791). Fig 793 Fig 791 IMG-8520a IMG-8517a 25. Remove the key from the shaft keyway (Fig. 792).
MOWER DECKS Open End Cap Teardown Closed End Cap Teardown 27. Remove the oil seal from the open end cap (Fig. 794). 29. Remove the bearing race from the closed end cap (Fig. 796). Note: The inner race and housing must be heated to remove the race. Fig 794 IMG-8536a 28. Remove the bearing race from the open end cap (Fig. 795). Fig 796 IMG-8537a Note: The inner race and housing must be heated to remove the race.
MOWER DECKS Closed End Cap Rebuild Open End Cap Rebuild 30. Press the bearing race into the open end cap (Fig. 797). 31. Press the oil seal into the open end cap (Fig. 798). Fig 798 Fig 797 IMG-8538a IMG-8537a 32. Press the bearing race into the open end cap (Fig. 799).
MOWER DECKS Cross Shaft Rebuild 35. Place the cross shaft in a press with the installed bearing down. 33. Place the cross shaft in the press and press a new bearing onto the shaft (Fig. 800). Fig 800 36. Align the keyway in the pinion gear with the key installed in the shaft. Press the pinion gear onto the shaft (Fig. 802). IMG-8525a Fig 802 IMG-8529a 34. Install the key into the shaft keyway (Fig. 801). 37. Press the bearing onto the shaft (Fig. 803).
MOWER DECKS Pinion Shaft Rebuild 40. Place the pinion shaft assembly in a press and press the bearing onto the shaft (Fig. 806). 38. Press a new bearing race into the outer end of the pinion housing (Fig. 804). Fig 806 Fig 804 IMG-8540a IMG-8532a 41. Slide the bearing and shaft assembly into the pinion housing (Fig. 807). 39. Press a new bearing race into the inner end of the pinion housing (Fig. 805).
MOWER DECKS 42. Place the assembly into a press and press a new bearing into the pinion housing (Fig. 808). Fig 808 44. Align the keyway in the pinion gear with the key installed in the shaft. Press the pinion gear onto the shaft (Fig. 810). IMG-8542a Fig 810 43. Install the key into the pinion shaft keyway (Fig. 809). IMG-8546a 45. Install a washer onto the pinion shaft (Fig. 811).
MOWER DECKS 46. Install the lock nut onto the pinion shaft (Fig. 812). Gearbox Assembly Note: Secure the assembly in a vise and tighten the lock nut enough to draw the gear and washer until the bearings bind slightly. Back off the nut approximately 1/8 of a turn. 49. Assemble the closed end cap onto the gearbox (Fig. 814). Fig 812 Note: The end cap is oriented onto the gearbox adjacent to the 2 drain plug holes. IMG-8494a Fig 814 47.
MOWER DECKS 51. Insert the cross shaft into the gearbox. Seat the cross shaft bearing into the closed end cap (Fig. 816). 53. Install a new end cap o-ring (Fig. 818). Fig 818 Fig 816 IMG-8562a IMG-8558a 54. Apply a protective film onto the shaft keyway. 52. Install .013” (.33mm) thickness of shims onto the open end cap (Fig. 817). 55. Install the open end cap assembly over the cross shaft and onto the gearbox (Fig. 819). Note: The shim color corresponds to its thickness: Blue: .005” (.
MOWER DECKS 56. Install 4 new bolts securing the open end cap to the gearbox housing. Torque the bolts to 280 – 325 inlbs. (31.6 – 36.7 Nm) (Fig. 820). Note: Tighten the bolts in a crisscross pattern. Fig 820 58. Install .013” (.33mm) thickness of shims onto the pinion housing (Fig. 822). Note: The shim color corresponds to its thickness: Blue: .005” (.127mm) thick Green: .003” (.076mm) thick Brown: .010” (.254mm) thick IMG-8582a Fig 822 57.
MOWER DECKS 60. Insert the pinion shaft assembly into the gearbox assembly seating the pinion gear into the cross shaft gear (Fig. 824). 62. Check the pinion shaft end play measurement, it should be between .004” and .012” (.101 and .305mm). Adjust the pinion housing shims to adjust backlash (Fig. 826). Note: Pinion housing shims and open end cap shims should not vary more than .005” (.127mm). If they vary more than that, adjust the cross shaft shimming until a better balance is achieved.
MOWER DECKS 63. Fill the gearbox with 6 oz. (.15 liters) of 75W-90 synthetic gear oil with anti-foaming agent until it starts to flow out of the oil plug hole (Fig. 827). Leveling the Mower Setting up the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4.
MOWER DECKS Leveling the Mower Side to Side 1. Position the right blade side-to-side (Fig. 829). 3. Record this measurement. The measurement should be 3-1/8” to 3-1/4” (7.9 to 8.3cm). 4. Position the left blade side-to-side (Fig. 829). 5. Measure the left blade at the C location (Fig. 65 m-1078) from level surface to cutting edge of the blade tips (Fig. 66 m-2539). 6. Record this measurement. The measurement should be 3-1/8” to 3-1/4” (7.9 to 8.3cm). 7.
MOWER DECKS Adjusting the Front to Rear Mower Pitch 1. Position the right blade front-to-rear (Fig. 832). 3. Record the measurement. 4. Measure the right blade at the B location (Fig. 829) from a level surface to the cutting edge of the blade tip (Fig. 833). 5. Record this measurement. 6. The mower blade should be 1/4” to 3/8” (6 to 10mm) lower at position A than at position B (Fig. 832). If it is not correct, proceed to the following steps.
MOWER DECKS 8. Adjust the lift nuts on both the left and the right side of the machine (Fig. 834 and Fig. 835) to achieve 1/4” to 3/8” (6 to 10mm) lower in front A than in the rear at B (Fig. 832). Adjusting the Compression Spring 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, which should be 11-1/2” (29.2cm) (Fig. 836). 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 836).
Z580/Z589 DFI Z Master Service Manual Form No.
