LCE Products Z580-D / Z593-D / Z595-D Diesel 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 Z593-D & Z595-D ..................................................................................................2-1 Configurations ................................
TABLE OF CONTENTS CHASSIS cont. Deck Lift Lever Replacement .....................................................................................................3-39 Deck Lift Lever Removal ......................................................................................................3-39 Deck Lift Lever Installation ...................................................................................................3-43 Motion Control Assembly Replacement...............................................
TABLE OF CONTENTS ENGINE cont. Cooling Fan Replacement ..........................................................................................................5-49 Cooling Fan Removal ..........................................................................................................5-49 Cooling Fan Installation .......................................................................................................5-50 Air Cleaner Replacement ..........................................................
TABLE OF CONTENTS ELECTRICAL cont. Delay Module................................................................................................................................6-9 Purpose ..................................................................................................................................6-9 Location .................................................................................................................................6-9 How It Works ....................................
TABLE OF CONTENTS MOWER DECKS Mower Belt Replacement .............................................................................................................7-1 Mower Deck Removal ............................................................................................................7-3 Mower Deck Installation .........................................................................................................7-6 Mower Spindle Replacement.........................................................
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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-D, Z593-D and Z595-D.
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SPECIFICATIONS Specifications Z593-D & Z595-D Configurations Z593-D Pro Performance Z595-D Pro Performance 23 hp Kubota® 3 Cyl Diesel 52”/60” Turbo Force 25 hp Kubota® 3 Cyl Diesel 2 52”/60”/72” Turbo Force Power System Z593-D Pro Performance Z595-D Pro Performance Heavy Duty Canister Air Cleaner Standard Standard Clutch 200 ft-lbs. (271 Nm) Electromagnetic 200 ft-lbs.
SPECIFICATIONS Specifications Z593-D & Z595-D cont. Mowing Deck 2 Z593-D Pro Performance Z595-D Pro Performance Type TURBO FORCE™ TURBO FORCE™ Deck Construction Fabricated, 7-ga Steel w/Bull-Nose bumper Fabricated, 7-ga Steel w/Bull-Nose bumper Deck Material High-Strength Steel High-Strength Steel Deck Depth 5-1/2” (13.97cm) 5-1/2” (13.97cm) Adjustable Discharge Baffle Standard Standard Spindle Housings 9-3/8” (23.8cm) Diameter Cast Iron 9-3/8” (23.
SPECIFICATIONS Specifications Z593-D & Z595-D cont. Operator Zone Z593-D Pro Performance Z595-D Pro Performance Steering Controls 1-5/8” (1.625cm) Diameter Grips, Adjustable, Dampened 1-5/8” (1.
SPECIFICATIONS Specifications Z580-D Configurations Z580-D 2 25 hp Kubota Liquid-Cooled Diesel 52”/60”/72” Turbo Force Power System Z580-D Heavy Duty Canister Air Cleaner Standard Clutch Adjustable .015” - .021” (0.35mm - 0.65mm) Ogura 150 ft-lbs. (203.37 Nm) Hydraulic Pump Tandem Hydro-Gear® variable displacement 16cc, w/shock valves Hydraulic Oil System Capacity 4.2 quarts (4.0 liters) Wheel Motors(2) Twin Hydro-Gear® 18E, positive displacement 1.25” (3.
SPECIFICATIONS Specifications Z580-D cont. Mowing Deck Z580-D Type TURBO FORCE™ Deck Construction Fabricated, 7-ga Steel w/Bull-Nose bumper Deck Material High-Strength Steel Deck Depth 5-1/2” (13.97cm) Adjustable Discharge Baffle Standard Spindle Housings 9-3/8” (23.8cm) Diameter Cast Iron Spindle Shaft / Bearings 1” (2.54cm) Steel Shaft/Tapered Roller Blades (3) 1/4” (.635cm) Heat Treated Steel Blade Tip Speed 18,500 ft/min (5,638.
SPECIFICATIONS Specifications Z580-D cont. Dimensions Z580-D 2 Model 74266 74267 74274 Wheel Base 54.3” / 137.9cm 56.1” / 142.5cm 59.3” / 150.6cm Overall Length 82.4” / 209.3cm 84.2” / 213.9cm 87.4” / 221.9cm Width Outside Tires 49.5” / 126cm 53.2” / 135cm 57.2” / 145cm Overall Width (outside deck) 68” / 173cm 76” / 193cm 88” / 224cm Gate Width 54” / 137cm 62” / 157.
SPECIFICATIONS Torque Specifications Torque Specifications 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 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 Wheel Bolts and Lug Nuts SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Recommended Torque** Thread Size 2 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 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 Decimals mm 0.015625 0.397 0.03125 0.794 3/64 0.046875 1.191 0.0625 1.588 5/64 0.078125 1.984 1/64 1/32 1/16 3/32 1/8 9/64 5/32 11/64 3/16 13/64 7/32 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 0.21875 5.556 15/64 0.234375 5.953 0.2500 6.350 17/64 0.265625 6.747 0.28125 7.
SPECIFICATIONS U.S. totoMetric U.S. Metric Conversions Conversions 2 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.
CHASSIS Castor Fork Assembly Replacement 4. Slide the castor fork assembly out of the frame (Fig. 003). 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 003 IMG_7700 Castor Bearing Replacement 1. Remove the 3 Belleville washers (Fig. 004). Fig 001 IMG_7694a 3. Remove the locknut (Fig. 002).
CHASSIS 2. Remove the top tapered bearing (Fig. 005). 4. Remove the bottom tapered bearing (Fig. 007). 3 Fig 005 IMG_7706 3. Remove the bottom grease seal (Fig. 006). Fig 006 Fig 007 5. Drive the top and bottom tapered bearing cups out of the caster fork hub (Fig. 008).
CHASSIS 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. The bearing cups should seat against the shoulder inside the frame. 7. Pack the upper and lower tapered bearings with grease (No. 2 general purpose lithium base or molybdenum grease) (Fig. 010). Section view of caster fork hub (Fig. 009): A B 3 C Fig 010 IMG_7719a A Fig 009 tapered bearing cup install 8.
CHASSIS 9. Install the grease seal into the caster fork hub (Fig. 012). Castor Fork Assembly Installation 1. Install 3 Bellville washers as shown (Fig. 014): A 3 Fig 012 IMG_7725a Fig 014 10. Install the upper bearing into the caster fork hub (Fig. 013). fig. 49 G001297 A. Belleville washers 2. Slide the castor fork assembly into the hub (Fig. 015).
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. 016). 5. Remove the grease fitting and install the grease plug. 6. Install the dust cap onto the frame (Fig. 018). 3 Fig 016 IMG_7874a 4. Remove the plug located on the side of the castor hub. Install a grease fitting. Apply grease (No.
CHASSIS 3. Remove the wheel assembly from the fork (Fig. 020). 5. Remove both bearing spacers (one on each side) from the wheel assembly (Fig. 022). 3 Fig 020 IMG_7878 4. Remove the castor spacer from the wheel assembly (Fig. 021). Fig 021 Fig 022 6. Drive the bearing cup, bearing and bearing seal out of the wheel assembly. Repeat on the opposite side (Fig. 023).
CHASSIS Wheel Assembly (Fig. 024). 8. Pack both tapered bearings with grease (No. 2 general purpose lithium base or molybdenum grease) (Fig. 026). E A B CD DCBA F H Fig 024 A. B. C. D. Bearing spacer (2) Grease seal (2) Tapered bearing (2) Tapered bearing cup (2) 3 G IMG_7880a E. Wheel and tire assembly F. Caster spacer G. Wheel assembly axle bolt H. Nut Fig 026 IMG_7718a 9. Install the tapered bearings into each side of the wheel hub (Fig. 027). 7.
CHASSIS 10. Install the grease seals into each side of the wheel hub (Fig. 028). 12. Install the castor spacer into the wheel hub (Fig. 030). 3 Fig 028 IMG_7883a 11. Install a bearing spacer into each side of the wheel hub (Fig. 029). Fig 029 3-8 IMG_7884a Fig 030 IMG_7885a 13. Position the wheel assembly into the caster fork (Fig. 031).
CHASSIS 14. Install the axle bolt and nut securing the wheel assembly to the fork (Fig. 032). Fuel Tank Replacement Right Side Fuel Tank Removal 1. Raise the seat and remove the front engine shield (Fig. 034). 3 Fig 032 IMG_7736 15. Apply grease (No. 2 general purpose lithium base or molybdenum grease) to the wheel assembly grease fitting (Fig. 033). Fig 034 IMG_7751 2. Turn the fuel shut-off valve to the OFF position (Fig. 035).
CHASSIS 3. Disconnect the negative battery cable. 4. Remove the right rear wheel assembly (Fig. 036). 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 and drain the fuel from the fuel line (Fig. 038). 3 Fig 036 IMG_7753a Fig 038 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 fuel tank (Fig. 037).
CHASSIS 8. Remove the bolt and washers securing the left front corner of the fuel tank to the frame (Fig. 040). Right Side Fuel Tank Installation 1. Position the fuel tank onto the frame (Fig. 042). 3 Fig 040 IMG_7764 Fig 042 IMG_7768 9. Lift the fuel tank off the frame (Fig. 041). 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. 043).
CHASSIS 3. Position the hose clamp and tighten (Fig. 044). 5. Loosely install a bolt, lock-washer, and washer through the frame and into the front left corner of the fuel tank (Fig. 046). 3 Fig 044 IMG_7783 Fig 046 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. 045). IMG_7788 6.
CHASSIS 7. Tighten the 3 nuts until three threads protrude past the nut. Do not over-tighten (Fig. 048). 9. Install the right rear wheel assembly (Fig. 050). 3 Fig 050 Fig 048 IMG_7753a PICT-3290 10. Install the negative battery cable. 8. Tighten the bolt located in the front left corner of the tank to the frame (Fig. 049). Fig 049 11. Install the front engine shield (Fig. 051). Fig 051 IMG_7764 IMG_7751 12. Lower the seat.
CHASSIS Left Side Fuel Tank Removal 3. Disconnect the negative battery cable. 1. Raise the seat and remove the front engine shield (Fig. 052). 4. Remove the left rear wheel assembly (Fig. 054). 3 Fig 054 Fig 052 IMG_7751 2. Turn the fuel shut-off valve to the OFF position (Fig. 053). 5. Remove the 4 screws and washers securing the control panel to the fuel tank (Fig. 055).
CHASSIS 6. Remove the cable tie securing the throttle cable to the fuel fitting (Fig. 056). 8. Remove the hose clamp from the fuel return line and fitting located on the operator’s side of the fuel tank (Fig. 058). 3 Fig 056 IMG_7799 Fig 058 7. Move the control panel assembly away from the fuel tank (Fig. 057). Fig 057 10. Remove the return fuel line from the fuel fitting (Fig. 059).
CHASSIS 11. Remove the hose clamp from the fuel intake line and fitting located on the underside of the fuel tank (Fig. 060). 10. Remove the nuts, springs and washers from the 3 fuel tank mounting studs located on the underside of the fuel tank (Fig. 062). A B 3 C C C Fig 060 IMG_7809a Fig 062 A. Fuel tank B. Frame lh fuel tank fasteners a C. Mounting stud fastener assembly (3) 9. Remove the fuel line from the fuel fitting and drain the fuel from the fuel tank (Fig. 061). 11.
CHASSIS 12. Remove the fuel tank from the frame (Fig. 064). 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. 066). 3 Fig 064 IMG_7823 Fig 066 IMG_7828 Left Side Fuel Tank Installation 1. Position the fuel tank onto the frame (Fig. 065). Fig 065 3. Slide a hose clamp onto the fuel intake hose.
CHASSIS 4. Loosely install a bolt, lockwasher, and washer into the right front corner of the fuel tank securing it to the frame (Fig. 068). 6. Tighten the 3 nuts until three threads protrude past the nut. Do not over-tighten the nuts (Fig. 070). 3 Fig 070 Fig 068 PICT-3290 IMG_7863 5. Loosely install a washer, spring and nut onto each of the three studs on the underside of the fuel tank (Fig. 069). 7. Tighten the bolt, located on the right front corner of the fuel tank (Fig. 071).
CHASSIS 8. Install 4 screws and washers securing the control panel to the fuel tank (Fig. 072). 10. Install the left rear tire assembly and lower the machine to the ground. 11. Install the negative battery cable. 12. Install the front engine shield (Fig. 074). 3 Fig 072 IMG_7797 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. 073). Fig 074 IMG_7751 13. Lower the seat.
CHASSIS 2. Using a magnet, remove the fitting from the inside of the fuel tank (Fig. 077). Fuel Tank Fitting Replacement 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. 075). 3 Fig 077 Fig 075 IMG_7771 IMG_7774a 3. Using a magnet, install a fuel tank fitting by inserting it through the fuel tank opening (Fig. 078). 1. Remove the nut and washer securing the fitting to the fuel tank (Fig. 076).
CHASSIS 4. Loosely install a washer and nut to secure the fuel tank fitting to the fuel tank (Fig. 079). Right side fuel tank operator’s side fitting 3 Fig 081 Fig 079 IMG_7779 IMG_7772 Left side fuel tank operator’s side fitting 5. Position the fuel tank fittings as shown (Fig. 080, Fig. 081 and Fig. 082): Right and left fuel tank bottom fitting Fig 082 Fig 080 Z580/Z593/Z595 Diesel Service Manual IMG_7781a PICT-2952 6. Tighten the fitting nut.
CHASSIS 3. Lift the hood and remove it from the machine (Fig. 085). Hood Assembly Replacement Hood Assembly Removal 1. Unhook the rubber latch that is located on the rear of the hood (Fig. 083). 3 Fig 085 Fig 083 IMG_7836 IMG_7848 Hood Assembly Installation 1. Align the hood pivot brackets with holes in the pivot bracket on the frame (Fig. 086). 2. Remove the two hairpins, clevis pins, and washers located in the left and right hinges (Fig. 084).
CHASSIS Note: Check the clearance between the hood screen and the radiator cap. If there is any interference, the hood can be adjusted using the slotted holes in the hood mounting brackets: 2. Install a clevis pin, washer and hairpin into each of the pivot brackets (Fig. 089). Hood Hinge Plate adjustment slots (Fig. 087). 3 Fig 089 Fig 087 PICT-4215 IMG_7844 3. Lower the hood down and hook the rubber latch located at the rear of the hood (Fig. 090). Hood Pivot Plate adjustment slots (Fig. 088).
CHASSIS 4. Remove the knob from the throttle control assembly (Fig. 092). Throttle Control Assembly Replacement The hood assembly has been removed for photo purposes. Throttle Control Assembly Removal 1. Raise the seat. 3 2. Disconnect the negative battery cable from the battery terminal. 3. Remove the 4 screws securing the control panel to the left hand fuel tank (Fig. 091). Fig 092 IMG_7888 5. Remove the cable tie securing the throttle cable to the fuel tank fitting (Fig. 093).
CHASSIS 6. Remove the 2 locknuts and carriage bolts securing the throttle control to the control panel (Fig. 094). 8. Loosen the swivel clamp at the end of the throttle cable located on the engine throttle linkage (Fig. 096). 3 Fig 094 IMG_7894 Fig 096 IMG_7899 7. Remove the front engine shield assembly (Fig. 095). 9. Remove the nut securing the throttle cable to the throttle bracket (Fig. 097).
CHASSIS 10. Slide the throttle cable out of the throttle bracket and swivel clamp (Fig. 098). 12. Slide the cable out of the slot in the bottom of the control panel (Fig. 100). Note: The loose nut will slide off the cable upon sliding it out of the throttle linkage bracket. 3 Fig 100 Fig 098 IMG_7911 IMG_7906 Throttle Control Assembly Installation 11. Remove the throttle control assembly from the control panel (Fig. 099). 1.
CHASSIS 2. Install the throttle control assembly into the slot in the control panel (Fig. 102). 4. Route the throttle cable back toward the engine so that it is routed under the right hand fuel tank fuel lines where they connect to the fuel shut off valve, under the air cleaner intake hose, along side the fuel intake hose, up to the throttle linkage bracket. 5. Slide the throttle cable into the throttle linkage bracket. Slide the nut onto the cable. Slide the throttle cable into the swivel clamp (Fig.
CHASSIS 7. Slide the end of the throttle cable into the swivel clamp (Fig. 106). 9. Push the speed control lever toward the back of the engine (Fig. 108). 3 Fig 106 IMG_7899 8. Position the throttle control into the slow position (Fig. 107). Fig 107 3-28 IMG_7913 Fig 108 IMG_7914 10. Secure the throttle cable by tightening the swivel (Fig. 109).
CHASSIS 11. Install the front engine shield assembly (Fig. 110). 13. Install the knob onto the throttle control assembly (Fig. 112). 3 Fig 110 IMG_7895 Fig 112 12. Install a cable tie securing the throttle cable to the fuel tank inlet fitting. Trim the excess (Fig. 111). Fig 111 IMG_7888 14. Install 4 screws securing the control panel to the left hand fuel tank (Fig. 113). IMG_7835 Fig 113 IMG_7887 15. Connect the negative battery cable to the battery terminal. 16. Lower the seat.
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. 115). Brake Lever Removal 1. Raise the seat. 3 2. Disconnect the negative battery cable from the battery terminal. 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. 114). Fig 115 IMG_7922a 8.
CHASSIS 9. With a hammer and punch tap out the two pivot bushings (Fig. 117). Brake Lever Installation 1. Raise the floor pan assembly. 2. Install the two bushings into the brake lever pivot mounting hole (Fig. 119). 3 Fig 117 PICT-2883 10. Inspect the brake shaft and bushings for excessive wear. Replace any worn or damaged components (Fig. 118). Fig 119 PICT-2891 3. Slide the brake lever assembly pivot through the bushings (Fig. 120).
CHASSIS 4. Install a cotter pin into the pivot shaft (Fig. 121). Brake Band Replacement 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. 123). 3 Fig 121 IMG_7922a 5. Lower the floor pan assembly. 6. Move the parking brake lever into the released (forward) position. 7. Position the brake linkage yoke to the brake lever. Install a clevis and cotter pin to secure (Fig. 122).
CHASSIS 2. Remove the 3 bolts, spacer and retainer from the brake band assembly (Fig. 124). 4. Remove the brake band from the wheel and hub assembly (Fig. 126). 3 Fig 124 PICT-2920 3. Remove the 2 spacers from the brake band (Fig. 125). Fig 126 PICT-2933 5. Inspect the brake band. Replace if worn or damaged. Brake Band Assembly (Fig. 127) A B C D Fig 125 PICT-2935 Fig 127 A. Shoulder bolt (3) B. Spacer (3) Z580/Z593/Z595 Diesel Service Manual PICT-2926 C. Retainer D.
CHASSIS Brake Band Installation 1. Slide the brake band onto the wheel hub assembly (Fig. 128). 3. Position the brake band retainer and loosely install 2 bolts through the retainer, brake band spacers and into the brake bracket (Fig. 130). 3 Fig 130 Fig 128 PICT-2933 2. Slide a spacer into each end of the brake band (Fig. 129). Fig 129 4. Position the 3rd spacer between the retainer and the brake bracket. Loosely install the 3rd bolt through the retainer and spacer and into the brake bracket (Fig.
CHASSIS 5. Tighten the 3 brake band retainer bolts (Fig. 132). Brake Cross Shaft Replacement Note: The front engine shield has been removed for photo purposes. Brake Cross Shaft Removal 1. Raise the seat. 2. Remove the negative battery cable from the battery. 3. Raise the rear tires off the ground and remove the left and right tires (Fig. 134). Fig 132 PICT-2942 Note: To prevent the unit from rolling, block the front tires. 6. Install the rear tire (Fig. 133).
CHASSIS 4. Remove the clevis spring pins securing the brake rod linkage yokes to the left side of the brake cross shaft (Fig. 135). 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. 137). 3 Fig 135 PICT-2954 5. Remove the clevis spring pin securing the brake rod linkage yoke to the right side of the brake cross shaft (Fig. 136). Fig 136 3-36 PICT-2956 Fig 137 PICT-2958a 7.
CHASSIS 8. Remove brake cross shaft (Fig. 139). Brake Cross Shaft Installation 1. Slide the brake cross shaft into position (Fig. 141). Note: The end of the cross shaft with two tabs is installed on the left side of the machine. 3 Fig 139 PICT-2964 9. Inspect brake cross shaft and bearings. Replace if worn or damaged (Fig. 140). B B D A C C Fig 140 Fig 141 PICT-2964 2. Position a flange bearing onto each end of the cross shaft with the flange facing outward (Fig. 142). A PICT-2968a A.
CHASSIS 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. 143). 5. Ensure the brake cross shaft rotates freely in the flange bearings. 6. Install the clevis spring pin securing the brake rod linkage yoke to the right side of the brake cross shaft (Fig. 145). 3 Fig 143 PICT-2958a Fig 145 PICT-2956 4.
CHASSIS 8. Install the left and right rear tires and lower the machine to the ground (Fig. 147). 4. Place the mower deck in the transport position. Position wood blocks under each corner of the mower deck (Fig. 148). 3 Fig 147 PICT-2919 Fig 148 PICT-2971 9. Lower the seat. 10. Adjust the parking brake. Refer to “Adjusting the Parking Brake” on page 3-63. 5. Lower the mower deck onto the blocks to remove tension from the deck lift chains (Fig. 149).
CHASSIS 6. Remove the lower stop bolt from the deck lift plate (Fig. 150). 8. Remove the hex nut from the back end of the right and left deck lift assemblies (Fig. 152). 3 Fig 150 PICT-2978 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. 151). Fig 151 Fig 152 9. Lower the deck lift lever to its lowest position. The rear deck swivel mounts should clear the deck lift rods on both sides.
CHASSIS 10. Remove the bolt, nut and lift lever bushing that secures the inner deck lift plate to the frame (Fig. 154). 12. Loosen the inner hex head flange nut. Pivot the inner deck lift plate up (Fig. 156). 3 Fig 156 Fig 154 PICT-2991a PICT-2987 13. Raise the floor pan. 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. 155). Fig 155 14.
CHASSIS 15. Remove the E-clip from the deck lift arm pivot (Fig. 158). Note: There may be interference between the lift lever assembly and the floor pan hinge when trying to remove the lift lever assembly (Fig. 160). 3 Fig 158 PICT-3002 Fig 160 PICT-3005 16. Remove the deck lift lever assembly from the pivot (Fig. 159). 17.
CHASSIS Deck Lift Lever Assembly (Fig. 162) A B C 2. Install an E-clip onto the deck lift lever pivot (Fig. 164). E 3 D Fig 162 PICT-3015a Fig 164 A. Bolt B. Bushing C. Deck lift arm (2) PICT-3018 D. Nut E. Lift Lever Assembly 3. Slide the bushing into the hole in the cross shaft assembly tab (Fig. 165). Deck Lift Lever Installation 1. Slide the deck lift lever assembly pivot into the pivot mount on the frame (Fig. 163).
CHASSIS 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. 166). 6. Lower the floor pan assembly. 7. Tighten the nut on the bolt at the top of the inner deck lift plate (Fig. 168). 3 Fig 166 PICT-3000 Fig 168 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. 167). 8.
CHASSIS 9. Install a second nut onto the bolt securing the hitch pin lanyard in place (Fig. 170). 11. Lower the lift lever. The deck lift lever rods should run through the rear swivels (Fig. 172). 3 Fig 170 PICT-3028 10. Lift up on the lift lever an install the lower stop bolt into the deck lift plate (Fig. 171). Fig 171 Z580/Z593/Z595 Diesel Service Manual PICT-2978 Fig 172 PICT-3029a 12. Install a hex nut onto the back end of the right and left deck lift assemblies (Fig. 173).
CHASSIS 13. Raise the mower deck to the transport position. Remove the wood blocks. Tighten the adjusting nut on the deck lift assemblies so that the following length is achieved between the two large washers (Fig. 174): 14. Check the deck level adjustment. Refer to “Leveling the Mower” on page 7-82. 15. Apply grease to the grease fitting on the deck lift lever pivot (Fig. 175). A. 52” Mower Deck: 11.0” + .25” (27.9 + .6cm) B. 60” Mower Deck: 10.5” + .25” (26.7 + .6cm) C. 72” Mower Deck: 11.5” + .25” (29.
CHASSIS 5. Remove the floor pan assembly (Fig. 177). Motion Control Assembly Replacement 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. 176). Fig 177 PICT-3053 6. Remove the 2 top pocket mounting bolts, washer and nuts and the 2 bottom pocket mounting bolts and nuts (Fig. 178).
CHASSIS 7. Remove the pocket (Fig. 179). 9. Remove the outside nut from the bolt that secures the motion control damper to the right hand motion control assembly (Fig. 181). 3 Fig 179 PICT-3057 Fig 181 PICT-3066 Right Hand Motion Control 8. Remove the 2 bolts and washers securing the right lever to the control shaft arm. Remove the right lever (Fig. 180). Fig 180 3-48 PICT-3064 10. Disconnect the harness from the neutral switch located under the right side of the traction frame assembly (Fig. 182).
CHASSIS 11. Remove the bolt, washer and nut that secure the right hand control rod assembly to the right hand motion control assembly (Fig. 183). 13. Loosen the jam nut on the right hand neutral return spring assembly. Remove the yoke from the neutral return bolt (Fig. 185). 3 Fig 183 PICT-3079 12. Remove the cotter pin and clevis pin that secure the neutral return yoke to the right hand motion control assembly (Fig. 184).
CHASSIS 15. Remove the 2 bolts and nuts securing the side flange bearing to the left hand motion control assembly (Fig. 187). 17. Inspect the side flange bearings. Replace if worn or damaged (Fig. 189). B 3 A C D Fig 189 Fig 187 A PICT-3091a PICT-3086 16. Remove the right hand motion control assembly and right hand control shaft arm assembly (Fig. 188). A. B. C. D. Side flange bearing (2) Control shaft arm Right hand motion control assembly Neutral switch Left Hand Motion Control 18.
CHASSIS 19. Raise the seat and remove the outside nut from the bolt that secures the motion control damper to the left hand motion control assembly (Fig. 191). 22. Remove the cotter pin and clevis pin that secure the neutral return yoke to the left hand motion control assembly (Fig. 193). 3 Fig 191 PICT-3102 20. Disconnect the harness from the neutral switch located under the traction frame assembly. Fig 193 PICT-3124 23. Loosen the left hand neutral return assembly jam nut.
CHASSIS 24. Remove the nut, bolt and washer securing the left hand control rod ball joint to the hydrostatic pump control arm (Fig. 195). 26. Remove the 2 bolts and nuts securing the side flange bearing to the inside of the traction frame (Fig. 197). 3 Fig 195 PICT-3131 25. Remove the left hand control rod assembly (Fig. 196). Fig 196 3-52 PICT-3133 Fig 197 PICT-3128 27. Remove the left hand motion control assembly and left hand control shaft arm assembly (Fig. 198).
CHASSIS 28. Inspect the side flange bearings. Replace if worn or damaged (Fig. 199). 2. Position the left hand motion control assembly and control shaft arm assembly into the traction frame (Fig. 201). D 3 A B A C Fig 199 PICT-3137a Fig 201 A. Side flange bearing (2) B. Left hand motion control assembly C. Neutral switch (reverse side of motion control assembly) D. Control shaft arm PICT-3134 3. Install 2 bolts and nuts securing the side flange bearing to the inside of the traction frame (Fig.
CHASSIS 4. Position the left hand control rod assembly into the traction frame (Fig. 203). 6. Install the neutral return yoke onto the neutral return bolt (Fig. 205). 3 Fig 203 PICT-3133 5. Install a bolt, washer and nut securing the left hand control rod ball joint to the hydrostatic pump control arm (Fig. 204). Fig 205 PICT-3126 7. Position the left hand neutral return yoke to the left hand motion control tab and install a clevis pin and cotter pin (Fig. 206).
CHASSIS 8. Tighten the jam nut to secure the neutral adjustment yoke (Fig. 207). 10. Position the right hand motion control assembly and control shaft arm assembly into position under the traction frame (Fig. 209). 3 Fig 207 PICT-3142 Fig 209 PICT-3088 Right Hand Motion Control 9. Slide a side flange bearing onto each end of the right motion control assembly (Fig. 208). Fig 208 11.
CHASSIS 12. Position the side flange bearing to the inside of the traction control frame and loosely install 2 bolts and nuts securing the side flange bearing (Fig. 211). 14. Position the neutral return yoke to the right hand motion control tab and install a clevis pin. Install a cotter pin into the clevis pin to secure (Fig. 213). 3 Fig 211 PICT-3084a 13. Thread the yoke onto the neutral return bolt (Fig. 212). Fig 213 15. Tighten the jam nut to secure the yoke (Fig. 214).
CHASSIS 16. Install the bolt, washer and nut securing the right hand control rod assembly to the right hand motion control assembly (Fig. 215). Note: The washer is installed between the ball joint and motion control assembly tab. 18. Raise the seat and insert the right and left damper bolts into the right and left motion control assembly tabs. Install a nut onto each of the damper bolts to secure the motion control dampers to the motion control assemblies (Fig. 217). 3 Fig 217 Fig 215 17.
CHASSIS Left hand neutral switch - access by raising seat. 3 B. Flange bearings mounted to the left hand motion control assembly (Fig. 221). A Fig 219 PICT-4221a Fig 221 PICT-3086 A. Left hand neutral switch located under the traction frame front console. C. Flange bearing mounted to the inside (left) of the traction frame (Fig. 222). 20. Tighten all 6 bolts and nuts securing the 4 side flange bearings: A. Flange bearing mounted to the inside (right) of the traction control frame (Fig. 220).
CHASSIS 21. Position the left hand control lever to the left hand control shaft arm. Install 2 bolts, and washers securing the left lever to the control shaft arm (Fig. 223). 23. Adjust the control handle neutral position. Refer to “Adjusting the Control Handle Neutral Position” on page 4-25. 24. Adjust the hydrostatic pump neutral. Refer to “Setting the Hydrostatic Pump Neutral” on page 4-27. 25. Insert the pocket into the traction frame (Fig. 225). 3 Fig 223 PICT-3098 22.
CHASSIS 26. Install 2 top pocket mounting bolts, washers and nuts and 2 bottom pocket mounting bolts and nuts (Fig. 226). 28. Install both floor pan assembly hinge bolts and nuts (Fig. 228). Note: Raise the seat to install the top 2 bolts washer and nuts. A A 3 B B Fig 228 Fig 226 A. Bolt, washer, nut PICT-3055 B. Bolt, nut PICT-3052 29. Install the negative battery cable from the battery. 30. Lower the seat. 27. Position the floor pan assembly (Fig. 227).
CHASSIS Motion Control Damper Replacment 5. Remove the outer nut from the bolt on the upper end of the damper (Fig. 230). There is a right and a left motion control damper. The following removal and installation procedures are done on the right damper. The procedures are 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.
CHASSIS Damper Assembly (Fig. 232) 3. Insert the upper damper bolt into the motion control assembly arm. Install a nut to secure the upper end of the damper (Fig. 234). 3 Fig 232 PICT-3181a Fig 234 PICT-3173 Motion Control Damper Installation 1. Raise the seat. 2. Position the damper assembly with the rod end down (Fig. 233). 4. Insert the lower damper bolt into the frame and install a nut to secure the lower end of the damper (Fig. 235). Fig 235 Fig 233 PICT-3171 PICT-3178 5.
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. 236). A 3 C B Fig 236 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 adjust the nut directly below the spring (Fig. 057). Turn the nut until the correct measurement is obtained.
CHASSIS 3 THIS PAGE INTENTIONALLY LEFT BLANK.
HYDRAULIC SYSTEM 5. Using a spring removal tool (Toro part no. 92-5771), remove the pump idler arm spring (Fig. 238). Hydrostatic Tandem Pump Replacement 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. 240). Fig 240 4 PICT-3188a Fig 242 PICT-3190a Fig 243 4-2 PICT-3192a 10. Remove the bolt, nut and washer securing the right hand control rod assembly to the pump control arm (Fig. 243). 8. Remove the pump pulley (Fig. 241). Fig 241 9. Remove the key from the keyway (Fig. 242).
HYDRAULIC SYSTEM 11. Remove the bolt, nut and washer securing the left hand control rod assembly to the pump control arm (Fig. 244). 13. Unplug the harness from the PTO clutch connector (Fig. 246). Fig 246 Fig 244 12. Remove the cable tie securing the 2 right wheel motor hydraulic hoses to the frame (Fig. 245). 14. Remove the cable tie securing the PTO clutch wire to the frame (Fig. 247).
HYDRAULIC SYSTEM 15. Remove the hose clamp located on the hydraulic suction hose coming from the oil filter (Fig. 248). 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 right wheel motor (Fig. 250). 4 Fig 248 PICT-3202 16. Remove the hydraulic suction hose from the fitting on top of the hydrostatic pump (Fig. 249).
HYDRAULIC SYSTEM 21. Remove the two hydraulic hoses from the left wheel motor (Fig. 252). Fig 252 23. Remove the hose clamp located on the hydraulic hose routed from the oil cooler to the left side of the hydrostatic pump (Fig. 254). PICT-3208 Fig 254 PICT-3211 22. Cap the hydraulic hoses and fittings (Fig. 253). 24. Remove the hydraulic hose from the fitting barb (Fig. 255).
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. 256). 4 27. Remove the two bolts, washers, and nuts holding the pump bracket to the frame of the unit (Fig. 258). Fig 258 Fig 256 PICT-3257 26. Remove the pump shield plate from the hydrostatic pump input shaft (Fig. 257). 28. Position the mower deck in the lowest height-of-cut position (Fig. 259).
HYDRAULIC SYSTEM 29. Carefully lower the hydrostatic pump from the frame (Fig. 260). Fig 260 PICT-3271 30. Mark the wheel motor hose and pump fitting locations (Fig. 261). 31. Remove all 4 wheel motor hoses from the pump fittings (Fig. 262). Fig 262 PICT-3300 32. Remove the 2 bolts, washers and nuts securing the pump mounting bracket to the pump. Remove the mounting bracket (Fig. 263). B A D C Fig 261 PICT-3298 Fig 263 A. B. C. D.
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. 264). 4 Fig 264 Hydrostatic Tandem Pump Installation 1. Apply thread locking compound to the pump control arm set screw (Fig. 266). PICT-3302 Fig 266 34. Repeat steps 29 and 30 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. 270). 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. 268). Fig 270 Fig 268 PICT-4204 PICT-3312 8. Position the pump shield plate over the pump shaft, against the frame.
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. 272). 4 11. Install the left wheel motor hoses. Note the location of each of the hoses by the markings on the hoses and wheel motor fittings (Fig. 274). Fig 274 Fig 272 PICT-3324 PICT-3259 10. Loosely install the 4 wheel motor hoses to the bottom of the pump.
HYDRAULIC SYSTEM 14. Tighten the right hand wheel motor hose fittings at the pump and at the wheel motor. 17. Slide a hose clamp over the hydraulic suction hose (Fig. 278). 15. With the hose clamp on the oil cooler hose, slide the hose onto the pump fitting (Fig. 276). Fig 278 Fig 276 PICT-3333a PICT-3331a 18. Slide the hydraulic suction hose onto the pump fitting on top of the hydrostatic pump (Fig. 279). 16. Position the hose clamp over the hose and fitting barb (Fig. 277).
HYDRAULIC SYSTEM 19. Position the hose clamp and tighten (Fig. 280). Fig 280 4 21. Install a cable tie securing the PTO clutch wire to the frame (Fig. 282). PICT-3337 Fig 282 20. Plug the harness plug into the PTO clutch connector (Fig. 281). Fig 281 22. Install a cable tie securing the 2 right wheel motor hydraulic hoses to the frame (Fig. 283).
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. 284). 25. Apply anti-seize compound onto the pump input shaft (Fig. 286). Note: The washer is installed between the ball joint and the control arm. Fig 286 PICT-3340a 26. Install the key into the pump shaft keyway (Fig. 287). Fig 284 PICT-3196 24.
HYDRAULIC SYSTEM 27. Apply thread locking compound to the 2 pump pulley set screws (Fig. 288). 4 Fig 288 PICT-3307a 28. Loosely install the 2 set screws into the pump pulley (Fig. 289). 29. Slide the pump pulley onto the pump shaft (Fig. 290). Fig 290 Belt Alignment Tool (Toro p/n: 110-0876) (Fig.
HYDRAULIC SYSTEM 30. Hook the belt alignmentn 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. 292). 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. 294). 4 Fig 294 PICT-3349a 33. Install the pump drive belt (Fig. 295). 34. Using a spring removal tool (Toro part no. 92-5771), install the pump idler arm spring (Fig. 296). Fig 296 PICT-3185 35. Install the right and left rear wheels. 36. Install the front engine shield (Fig. 297).
HYDRAULIC SYSTEM 37. Install the negative battery cable. 5. Apply the parking brake. Remove the cotter pin from the wheel motor shaft (Fig. 298). 38. Lower the seat. 39. Purge the hydraulic system. Refer to “Purging the Hydraulic System” on page 4-24. 40. Adjust the control handle neutral position. Refer to “Adjusting the Control Handle Neutral Position” on page 4-25. 41. Adjust the hydrostatic pump neutral. Refer to “Setting the Hydrostatic Pump Neutral” on page 4-27.
HYDRAULIC SYSTEM 7. Using a Wheel Hub Puller (Toro p/n: TOR4097), remove the wheel hub from the wheel motor shaft (Fig. 300). 4 10. Mark or tag the wheel motor hoses and fittings to ensure they are reconnected correctly (Fig. 302). Fig 302 Fig 300 11. Disconnect the wheel motor hoses from the wheel motor fittings (Fig. 303). 8. Release the parking brake. 9. Remove the 3 bolts, spacers and the retainer from the brake band assembly and remove the brake band (Fig. 301).
HYDRAULIC SYSTEM 12. Remove the wheel motor fittings from the wheel motor (Fig. 304). Fig 304 PICT-3367 13. Loosen all 4 wheel motor mounting bolts (Fig. 305). Fig 305 14. Remove the front 2 wheel motor mounting bolts, spacers and nuts (Fig. 306). Fig 306 15. Swing the brake linkage forward away from the wheel motor (Fig. 307).
HYDRAULIC SYSTEM 16. Remove the 2 rear wheel motor mounting bolts, spacers and nuts (Fig. 308). 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. Note: There are two different spacers used on the wheel motors (Fig. 310). The short spacers are used in the front of the wheel motor (with the brake linkage) and the long spacers are used to retain the back of the wheel motor.
HYDRAULIC SYSTEM 1. Insert the wheel motor into the frame. Loosely install the 2 rear wheel motor mounting bolts, long spacers and nuts (Fig. 311). 3. Loosely install the 2 front wheel motor mounting bolts, short spacers and nuts (Fig. 313). Fig 313 Fig 311 2. Swing the brake linkage into position (Fig. 312). Fig 312 Z580/Z593/Z595 Diesel Service Manual PICT-3376 PICT-3377 PICT-3374 4. Torque the 4 wheel motor mounting bolts to 100 + 8 ft-lbs. (136 + 11 Nm) (Fig. 314).
HYDRAULIC SYSTEM 5. Install the wheel motor fittings. Note the location markings (Fig. 315). 4 Fig 315 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. 317). PICT-3367 Fig 317 6. Install the wheel motor hoses onto the wheel motor fittings. Note the location markings (Fig. 316). PICT-3358 8. Make sure the parking brake is released. 9. Make sure the woodruff key is in place in the motor shaft.
HYDRAULIC SYSTEM 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. 319). 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. 321). b. If necessary, tighten the nut until the next set of slots line up with the hole in the shaft (Fig. 321). D A C B Fig 319 4 PICT-3385 12.
HYDRAULIC SYSTEM 13. Install a cotter pin into the wheel motor shaft (Fig. 322). 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. 1. Raise rear of the machine so the wheels are off the ground and support it with jack stands (Fig. 323). 4 Fig 322 PICT-3350 14. Install the rear wheel. 15. Install the negative battery cable. Fig 323 PICT-3464 16. Lower the seat.
HYDRAULIC 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. 324). 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.
HYDRAULIC SYSTEM 4. Begin with either the left or right motion control lever. 8. If adjustment is needed, loosen the nut and jam nut against the yoke (Fig. 327). 5. Move the lever to the neutral position but not locked (Fig. 326). A B D F B C G C A 4 Fig 327 Fig 326 A. Neutral locked position B. Control lever fig. 62 G001046 C. Neutral position 6. Pull the lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Fig.
HYDRAULIC SYSTEM Setting the Hydrostatic Pump Neutral 1. Raise the machine and support with jack stands so that the rear tires are off the ground (Fig. 328). 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. 330). B A C Fig 330 Fig 328 PICT-3464 A. Bolt B. Nut PICT-5324 C. Seat rod 2. Raise the seat (Fig. 329). 4. Disconnect the wire harness terminals from the seat switch.
HYDRAULIC SYSTEM Setting the Right Hydraulic Pump Neutral Position Setting the Left Hydraulic Pump Neutral Position 5. Place the motion control levers in the neutral position. 10. Place the motion control levers in the neutral position. 6. Start the engine, open the throttle 1/2 way and release parking brake. 11. Loosen the jam nuts at the ball joints on the pump control rod (Fig. 333). 7.
HYDRAULIC SYSTEM 12. Start the engine, open the throttle 1/2 way and release the parking brake. 16. Tighten the jam nuts at the ball joints (Fig. 335). 13. Adjust the pump rod length by rotating double nuts on rod, in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 334). Note: The front nut on the pump rod has left-hand threads. Fig 335 PICT-3486a 17. After both pump neutrals are set, shut off the machine. Fig 334 PICT-3489a 18.
HYDRAULIC SYSTEM 6. To make the machine go left, turn the knob towards the left side of the machine (Fig. 338). Adjusting the Tracking The machine has a knob located under the seat to adjust the tracking. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to “Adjusting the Control Handle Neutral Position” on page 4-25 and “Setting the Hydrostatic Pump Neutral” on page 4-27. 1. Start the engine. 2. Push both control levers forward the same distance. 3.
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. 341). 5. Unplug the wire harness clutch wire from the electric PTO clutch to prevent accidental engagement of the mower deck (Fig. 342). 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 Fig 342 Fig 341 PICT-3507 PICT-3513 6.
HYDRAULIC SYSTEM 7. Verify the restrictor valve on the hydraulic flow tester is in the fully “Opened” position (Fig. 344). Fig 344 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. 345). 4 PICT-3497 Fig 345 PICT-3509a 8. Start the machine.
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 5. Unplug the harness connector from the electric PTO clutch (Fig. 351). Traction Pump Drive Belt Replacement 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. 350). Fig 351 PICT-3513 6. Remove the 2 carriage bolts and nuts securing the clutch stop bracket to the frame (Fig. 352).
HYDRAULIC SYSTEM 7. Remove the clutch stop bracket (Fig. 353). Fig 353 4 9. With tension released from the gearbox idler, remove the PTO clutch belt from the clutch and gearbox pulleys (Fig. 355). PICT-3515 Fig 355 PICT-3519 8. Release tension from the gearbox idler arm pulley (Fig. 354). 10. Using a spring removal tool (Toro p/n: 92-5771), remove the pump idler assembly spring (Fig. 356).
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. 357). 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. 359): Fig 359 Fig 357 fig. 108-5955 PICT-3523 3. Using a spring removal tool (Toro p/n: 92-5771), install the pump idler assembly spring (Fig. 360).
HYDRAULIC SYSTEM 4. With tension released from the gearbox idler, install the PTO clutch belt around the electric PTO clutch and gearbox pulleys as shown (Fig. 361): 4 6. Install 2 carriage bolts and nuts to secure the clutch stop bracket to the frame (Fig. 363). Fig 363 Fig 361 7. Plug the harness connector into the electric PTO clutch (Fig. 364). 5. Position the clutch stop bracket (Fig. 362). Fig 362 4-38 PICT-3514 fig.
HYDRAULIC SYSTEM 8. Install the front engine panel (Fig. 365). Hydraulic Oil Cooler 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 hood assembly. 5. Remove the 3 bolts, washers and nuts securing right side top frame brace. Remove the top brace (Fig. 366). Fig 365 IMG_7862 4 9. Install the negative battery cable from the battery.
HYDRAULIC SYSTEM 6. Remove the nut securing the right side guard strap to the frame and radiator support. Remove the right hand fan guard (Fig. 367). 4 Fig 367 PICT-3432 7. Remove the 2 bolts, washers and nut securing right side guard strap to the frame and radiator support. Remove the guard strap (Fig. 368). 8. Remove the 2 bolts, washers and nuts securing the left hand top brace and guard strap to the radiator support (Fig. 369). Fig 369 9. Remove the radiator support (Fig. 370).
HYDRAULIC SYSTEM 10. Remove the 4 bolts and nuts securing the oil cooler to the frame (Fig. 371). 12. Remove the 2 hoses from the oil cooler (Fig. 373). Fig 373 Fig 371 11. Slide the 2 hose clamps off the oil cooler hoses (Fig. 372). 13. Remove the 4 r-clamps and transfer them to the new oil cooler (Fig. 374).
HYDRAULIC SYSTEM 3. Position the oil cooler and install 4 bolts and nuts securing the oil cooler to the frame (Fig. 377). Hydraulic Oil Cooler Installation 1. Install the 2 hoses onto the oil cooler (Fig. 375). 4 Fig 377 Fig 375 PICT-3454 2. Slide the 2 hose clamps into position (Fig. 376). Fig 376 4-42 PICT-3447 PICT-3452 4. Position the radiator support between the left hand top guard strap and frame (Fig. 378).
HYDRAULIC SYSTEM 5. Install 2 bolts, washers and nuts securing the left hand top brace and guard strap to the radiator support and frame (Fig. 379). Fig 379 PICT-3437 6. Position the right side guard strap. Install a bolt, washer and nut to secure the end of the guard strap (closest to the operator) to the frame. Position the right hand fan guard. Install a bolt, washer and nut securing the guard strap, fan guard and radiator support to the frame (Fig. 380).
HYDRAULIC SYSTEM 5. Remove the left hand mower deck belt cover (Fig. 383). Hydraulic Reservoir Tank Replacement 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. 382). 4 Fig 383 PICT-3389 6. Unhook the idler spring from the mower deck idler arm and spring post (Fig. 384).
HYDRAULIC SYSTEM 7. Remove the mower deck belt from the PTO drive pulley (Fig. 385). Fig 385 PICT-3393 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. 386). 10. Slide the hose clamp down the oil cooler hose, off the tank fitting barb (Fig. 387). Fig 387 11. Remove the oil cooler hose from the tank fitting. Allow the hydraulic fluid to drain into the drain pan (Fig. 388).
HYDRAULIC SYSTEM 12. Remove the 2 bolts, washers and nuts securing the reservoir to the hydraulic tank bracket (Fig. 389). Hydraulic Reservoir Tank Installation 1. Transfer the 2 hydraulic tank fittings to the new hydraulic reservoir tank (Fig. 391). 4 Fig 389 PICT-3409 Fig 391 PICT-3416 13. Remove the hydraulic reservoir (Fig. 390). 2. Position the hydraulic reservoir onto the tank bracket (Fig. 392).
HYDRAULIC SYSTEM 3. Install 2 bolts, washers and nuts to secure the reservoir to the hydraulic tank bracket (Fig. 393). 5. Position the hose clamp to secure the oil cooler hose to the tank fitting barb (Fig. 395). Fig 393 Fig 395 PICT-3409 4. Install the oil cooler hose onto the tank fitting on the bottom of the hydraulic reservoir (Fig. 394). Fig 394 Z580/Z593/Z595 Diesel Service Manual PICT-3397a PICT-3396a 6.
HYDRAULIC SYSTEM 7. Route the mower deck belt around the PTO drive pulley (Fig. 397). 4 Fig 397 PICT-3393 8. Hook the idler spring from the mower deck idler arm to the spring post (Fig. 398). 9. Install the left hand mower deck belt cover (Fig. 399). Fig 399 10. Lower the floor pan assembly (Fig. 400).
HYDRAULIC SYSTEM 11. Install the negative battery cable. Pushing the Machine by Hand 12. Lower the seat. 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. 13. Fill the reservoir to the cold oil level (Fig. 401). 2. Raise the seat. B A 3. Rotate the by-pass valves counterclockwise 1 turn. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 402).
HYDRAULIC SYSTEM Switching from Pushing the Machine Back to Machine Operation 1. Engage the parking brake. 2. Raise the seat. 3. Rotate the by-pass valves clockwise 1 turn to operate machine (Fig. 403). Note: Do not over-tighten the by-pass valves. 4 Fig 403 PICT-3524a 4. Lower the seat.
ENGINE 5. Remove the Hood Assembly. Refer to “Hood Assembly Removal” on page 3-22. Engine Replacement Engine Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 6. Remove the bolt, washer and nut securing the hose clamp to the left hand guard strap (Fig. 405). 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4. Remove the front engine panel (Fig. 404). Fig 405 PICT-3527a 7.
ENGINE 8. Remove the 3 bolts, washers and nuts securing right side top brace frame and radiator support. Remove the right side top brace (Fig. 407). Fig 407 5 PICT-3421 9. Repeat previous step to remove the left side top brace. 11. Remove the 2 bolts, washers and nut securing right side guard strap to the frame and radiator support. Remove the guard strap (Fig. 409). Fig 409 PICT-3775 12. Remove the oil cooler shield (Fig. 410). 10.
ENGINE 13. Remove the bolt, washer and nut securing the left hand guard strap to the frame. Remove the left hand guard strap (Fig. 411). Fig 411 PICT-3533 DANGER! Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns. 15. Remove the radiator cap. Place a funnel below the radiator drain plug located on the lower right hand corner of the radiator. Remove the plug (Fig. 412). Fig 412 PICT-3534 16. Allow the coolant to drain from the radiator. 5 17.
ENGINE 18. Loosen the hose clamp securing the left hand radiator hose to the lower left hand corner of the radiator (Fig. 413). 21. Remove the cable tie securing the overflow hose to the radiator cap barb (Fig. 415). Fig 415 Fig 413 5 PICT-3542a PICT-3539a 19. Place a drain pan under the left hand rear corner of the radiator. 22. Slide the overflow hose from the barb on the radiator cap flange (Fig. 416). 20. Remove the left hand radiator hose from the lower left hand corner of the radiator.
ENGINE 23. Pull the over flow hose out and away from the radiator (Fig. 417). Fig 417 25. Remove the 2 R-clamps located on the inside of the front panel of the bottom radiator plate assembly (Fig. 419). PICT-3544 Fig 419 24. Disconnect the harness from the fan connector (Fig. 418). Fig 418 26. Loosen the hose clamp securing the right hand radiator hose to the water pump (Fig. 420).
ENGINE 27. Slide the right hand radiator hose off the water pump (Fig. 421). Fig 421 5 PICT-3685 28. Remove the 10 bolts, nuts and 2 washers securing the radiator assembly to the frame (Fig. 422). 29. Remove the radiator assembly from the frame (Fig. 423). Fig 423 PICT-3554 30. Remove the 2 bolts and flange nuts securing the rear radiator support to the frame (Fig. 424).
ENGINE 31. Move the oil cooler assembly away from the engine area of the machine to prevent damage to oil cooler and hoses. 34. Loosen the hose clamp on the lower end of the left hand radiator hose (Fig. 427). 32. Remove the 2 bolts securing the fan and retainer plate to the engine (Fig. 425). Fig 427 Fig 425 PICT-3563a PICT-3565 35. Slide the left hand radiator hose off the flange on the engine (Fig. 428). 33. Remove the fan and retainer plate (Fig. 426).
ENGINE 36. Remove the nut and bolt securing the wire harness R-clamp to the muffler bracket (Fig. 429). Fig 429 5 PICT-3567 37. Remove the 2 muffler mounting bolts and lock washers (Fig. 430). 38. Remove the 4 muffler manifold mounting bolts and lock washers (Fig. 431). Fig 431 39. Remove the muffler and manifold gasket (Fig. 432).
ENGINE 40. Remove the cable tie securing the harness to the oil switch located under the oil filter (Fig. 433). Fig 433 PICT-3578 41. Remove the cable tie securing the harness to the solenoid wires (Fig. 434). Fig 434 Z580/Z593/Z595 Diesel Service Manual PICT-3576a 42. Remove the screw and lock washer securing the harness terminal to the oil switch (Fig. 435). Fig 435 PICT-3581 43. Unplug the harness connector from the alternator (Fig. 436).
ENGINE 44. Slide the rubber boot off the alternator connection and remove the nut securing the harness terminal to the alternator. Remove the harness terminal (Fig. 437). 46. Remove the bolts and washers securing 2 R-clamps to the engine block (Fig. 439). B A Fig 439 Fig 437 5 PICT-3587 PICT-3590 A. Bolt, nut and washer securing the negative battery cable and fuel lines B. Bolt and 2 washers securing fuel lines 45. Remove the following connections from the starter solenoid (Fig. 438): 47.
ENGINE 48. Unplug the harness terminal from the engine thermoswitch (Fig. 441). Fig 441 PICT-3595 49. Remove the nut securing the harness terminal to the front glow plug cord terminal (Fig. 442). Fig 442 Z580/Z593/Z595 Diesel Service Manual PICT-3596 50. Remove the cable tie securing the harness to the engine stop solenoid wire (Fig. 443). Fig 443 PICT-3598 51. Unplug the harness from the stop solenoid connector (Fig. 444).
ENGINE 52. Loosen the swivel clamp and rearmost nut holding the throttle cable into the throttle support bracket (Fig. 445). 54. Remove the 2 hose clamps securing the fuel lines to the fuel injection pump and fuel return (Fig. 447). Fig 447 Fig 445 5 PICT-3601a 53. Remove the throttle cable from the throttle support bracket (Fig. 446). 55. Slide the fuel line off the fuel injection pump (Fig. 448).
ENGINE 56. Slide the fuel line off the fuel return (Fig. 449). 58. Remove the traction pump drive belt. Refer to “Traction Pump Drive Belt Removal” on page 4-35. Machines with a Warner clutch: a. Unplug the harness connector from the electric PTO clutch (Fig. 451). Fig 449 PICT-3611 57. Loosen the hose clamp securing the air cleaner hose to the engine (Fig. 450). Fig 451 PICT-3933 b. Unhook the spring from the gearbox idler arm assembly (Fig. 452).
ENGINE c. Remove the gearbox drive belt from around the electric PTO clutch pulley (Fig. 453). Fig 453 5 PICT-3934a d. Remove the center clutch bolt, 2 cupped washers and clutch retainer securing the electric PTO clutch to the stub shaft (Fig. 454). Fig 454 e. Remove the electric PTO clutch from the stub shaft (Fig. 455). Fig 455 Machines with an Ogura Clutch: a. Remove the tie strap holding the electric PTO clutch wire to the frame crossbar (Fig. 456).
ENGINE b. Unplug the harness connector from the electric PTO clutch (Fig. 457). Fig 457 c. PICT-3979a Remove the carriage bolts, washers and nuts holding the clutch stop to the frame. Remove the clutchstop (Fig. 458). d. Loosen the bolt holding the electric PTO clutch to the stub shaft (Fig. 459). Fig 459 e. Remove the bolt, 2 curved washers, flat washer and retainer (Fig. 460).
ENGINE f. Remove the electric PTO clutch from the stub shaft (Fig. 461). Fig 461 PICT-3998 g. Remove the key from the stub shaft (Fig. 462). 5 h. Remove the clutch adapter from the stub shaft (Fig. 463). Fig 463 PICT-3954a 59. Remove the 3 engine mounting bolts, washers and nuts (Fig. 464 and Fig. 465): Rear engine mounting bolt.
ENGINE Front right and front left engine mounting bolts. Fig 465 61. Remove the large washer off the top of the rear engine mount (Fig. 467). PICT-3621 Fig 467 60. Attach a properly rated hoist to the 2 engine hooks. Lift the engine out of the frame (Fig. 466). Fig 466 62. Remove the 3 sets of engine isolation mounts and the 3 isolation mount spacers (Fig. 468).
ENGINE 63. Inspect the 3 sets of engine isolation mounts and spacers. Replace if damaged or worn (Fig. 469). 65. Remove the stub shaft from the flywheel (Fig. 471). Note: The engine isolation mounts come in pairs. If one half of the pair is damaged, the whole mount should be replaced. A B Fig 469 5 C Fig 471 PICT-3631a PICT-3642 66. Remove the rear engine mount bracket from the engine by removing the 4 bolts and lock washers securing it to the engine (Fig. 472). A.
ENGINE 67. Remove the right side engine mount by removing the 2 bolts and lock washers securing it to the engine (Fig. 473). Fig 473 Engine Installation 1. Apply thread locking compound to the 8 engine mounting bracket bolts (Fig. 475). PICT-3643a Fig 475 68. Remove the left side engine mount by removing the 2 bolts and lock washers securing it to the engine (Fig. 474). Fig 474 Z580/Z593/Z595 Diesel Service Manual PICT-3644 PICT-3648a 2.
ENGINE 3. Install the right side engine mount bracket to the engine with 2 mounting bolts and lock washers (Fig. 477). 5. Torque all 8 engine mount bracket mounting bolts to 29 ft-lbs. (39 Nm) (Fig. 479). Fig 479 Fig 477 5 PICT-3643a 4. Install the left side engine mount bracket to the engine with 2 mounting bolts and lock washers (Fig. 478). 6. Apply thread locking compound to the 5 stub shaft mounting bolts (Fig. 480).
ENGINE 7. Position the stub shaft to the flywheel (Fig. 481). Fig 481 9. Install the 3 sets of engine isolation mounts and the 3 isolation mount spacers (Fig. 483). PICT-3642 Fig 483 8. Install the 5 mounting bolts securing the stub shaft to the flywheel. Torque the mounting bolts to 145 + 20 in-lbs. (196 + 27 Nm) (Fig. 482). Fig 482 Note: The frame bracket is sandwiched between the engine isolation mounts with the spacer running through the middle (Fig. 484).
ENGINE 10. Place a large washer on the top of the rear engine isolation mount (Fig. 485). 12. Install 3 engine mounting bolts, washers and nuts (Fig. 487 and Fig. 488): Rear engine mounting bolt. Fig 485 PICT-3629a Fig 487 5 11. Attach a properly rated hoist to the 2 engine hooks. Position the engine into the frame aligning it with the engine isolation mounts (Fig. 486). Fig 486 5-22 PICT-3626 PICT-3617 Front right and front left engine mounting bolts.
ENGINE Machines with a Warner clutch: c. Apply thread locking compound to the center clutch bolt (Fig. 491). a. Apply anti-seize compound to the stub shaft (Fig. 489) Fig 491 Fig 489 PICT-3957a PICT-3656 d. Install the center clutch bolt, two spring washers, and the clutch retainer (Fig. 492). b. Install the electric PTO clutch to the stub shaft (Fig. 490). Note: The direction of the spring washers. A Fig 490 Fig 492 PICT-3615 A. Clutch bolt B.
ENGINE e. Torque the center clutch bolt to 50 ft-lbs. (67.8 Nm) (Fig. 493). Fig 493 f. 5 PICT-4006 Install the gearbox belt around the electric PTO clutch pulley (Fig. 494). Fig 494 5-24 PICT-3934a g. Hook the spring up from the gearbox idler assembly to the frame (Fig. 495). Fig 495 PICT-3872 h. Connect the harness connector to the electric PTO clutch (Fig. 496).
ENGINE Machines with an Ogura Clutch: c. Install the key onto the stub shaft (Fig. 499). a. Apply anti-seize compound on the engine crankshaft (Fig. 497). Fig 499 Fig 497 PICT-3955 PICT-3656 d. Align the key with the clutch and slide the clutch onto the stub shaft (Fig. 500). 5 b. Install the clutch adapter onto the stub shaft (Fig. 498). Note: Ensure it is installed as shown.
ENGINE e. Apply thread locking compound to the bolt (Fig. 501). g. Torque the bolt to 50 ft-lbs. (67.8 Nm) (Fig. 503). Fig 503 Fig 501 f. 5 Secure the clutch to the stub shaft with retainer, flat washer, 2 curved washers (note the direction of the curved washers), and bolt (Fig. 502). A B h. Install the PTO drive belt onto the clutch. Install the spring for the idler arm (Fig. 504). C Fig 504 Fig 502 A. Clutch bolt B.
ENGINE i. Install the clutch stop on the machine with 2 carriage bolts, 2 flat washers, and 2 locknuts (Fig. 505). k. Install a tie strap around the wire on the electric PTO clutch (Fig. 507). Note: Make sure there is a twist in the clutch stop. Fig 507 Fig 505 PICT-3988a PICT-3974 13. Install the traction pump drive belt. Refer to “Traction Pump Drive Belt Installation” on page 4-37. j. Connect the harness connector to the electric PTO clutch (Fig. 506). Fig 506 14.
ENGINE 15. Slide the fuel line onto the fuel return barb (Fig. 509). Fig 509 17. Slide the 2 hose clamps up the fuel line, onto the fitting barbs and tighten (Fig. 511). PICT-3611 Fig 511 16. Slide the fuel line onto the fuel injection pump (Fig. 510). 5 Fig 510 18. Slide the throttle cable into the throttle support bracket and swivel clamp. Tighten the swivel clamp and rearmost nut securing the throttle cable into the throttle support bracket (Fig. 512).
ENGINE 19. Plug the harness into the stop solenoid connector (Fig. 513). Fig 513 PICT-3599 20. Install the cable tie securing the harness to the engine stop solenoid wire (Fig. 514). Fig 514 Z580/Z593/Z595 Diesel Service Manual cabletie a 21. Slide the harness terminal onto the front glow plug cord terminal and install a nut to secure (Fig. 515). Fig 515 PICT-3596 22. Plug the harness terminal into the engine thermoswitch (Fig. 516).
ENGINE 23. Apply thread locking compound to the engine block grounding bolt (Fig. 517). 25. Position the 2 harness R-clamps to the front of the engine and install the bolts and washers to secure (Fig. 519). B A Fig 517 PICT-3669a Fig 519 5 24. Position the ground wire and negative battery cable terminal to the engine block and install the engine block grounding bolt and washer (Fig. 518). PICT-3590 A. Bolt, nut and washer securing the negative battery cable and fuel lines B.
ENGINE 27. Slide the harness terminal onto the alternator terminal and install a nut. Slide the rubber boot up over the connection (Fig. 521). 29. Position the harness terminal to the oil switch and install a screw and lock washer to secure (Fig. 523). Fig 523 Fig 521 28. Plug the harness connector into the alternator (Fig. 522). 30. Install a cable tie securing the harness to the solenoid wires (Fig. 524).
ENGINE 31. Install a cable tie securing the harness to the oil switch located under the oil filter (Fig. 525). Fig 525 5 PICT-3578 32. Position the muffler to the engine with a new manifold gasket installed between the engine and exhaust manifold plates (Fig. 526). 33. Apply thread locking compound to the 4 muffler manifold mounting bolts (Fig. 527). Fig 527 34. Loosely install 4 muffler manifold mounting bolts and lock washers (Fig. 528).
ENGINE 35. Apply thread locking compound to the 2 lower muffler mounting bolts (Fig. 529). 37. Tighten the top 4 muffler mounting bolts (Fig. 531). Fig 531 Fig 529 36. Loosely install 2 muffler mounting bolts and lock washers on the lower muffler mounting bracket (Fig. 530). 38. Torque the 2 lower muffler mounting bolts to 29 ftlbs. (39 Nm) (Fig. 532).
ENGINE 39. Position the wire harness R-clamp to the underside of the muffler mounting bracket. Install a bolt and nut to secure (Fig. 533). 41. Slide the hose clamp into position and tighten (Fig. 535). Fig 535 Fig 533 5 PICT-3567 40. Slide the lower end of the left hand radiator hose onto the flange on the engine (Fig. 534). 42. Position the fan and retainer plate to the engine (Fig. 536).
ENGINE 43. Install 2 bolts securing the fan and retainer plate to the engine (Fig. 537). Fig 537 PICT-3563a 44. Position the oil cooler assembly to the rear of the engine aligning the lower mounting bracket holes with the holes in the frame (Fig. 538). 45. Loosely install 2 bolts and flange nuts securing the rear radiator support to the frame (Fig. 539). Fig 539 46. Position the radiator assembly onto the frame (Fig. 540).
ENGINE 47. Loosely install 10 bolts, nuts and 2 washers securing the radiator assembly to the frame (Fig. 541). 49. Slide the right hand radiator hose onto the water pump (Fig. 542). Note: There are 8 bolts and nuts securing the front end of the radiator and 2 bolts, washers and nuts securing the rear end of the radiator. Fig 542 Fig 541 PICT-3553 5 PICT-3685 50. Slide the hose clamp into position and tighten (Fig. 543). 48. Tighten (in the following order): a.
ENGINE 51. Position the 2 harness R-clamps to the inside of the front panel on the bottom radiator plate assembly. Install a bolt and nut securing each R-clamp (Fig. 544). 53. Route the overflow hose up, through the front right hand corner of the radiator frame assembly, to the coolant fill overflow barb (Fig. 546). Fig 546 Fig 544 52. Plug the harness into the fan connector (Fig. 545). Fig 545 Z580/Z593/Z595 Diesel Service Manual PICT-3544a PICT-3549 PICT-3547 54.
ENGINE 55. Install a cable tie securing the overflow hose to the barb (Fig. 548). 57. Position the hose clamp and tighten (Fig. 550). Fig 550 Fig 548 5 PICT-3539a PICT-3692 56. Slide the left hand radiator hose onto the flange located on the lower left hand corner of the radiator (Fig. 549). 58. Slide the left hand guard strap between the frame and radiator support bracket. Insert a bolt (with a washer) and position the fuel pump bracket onto the bolt.
ENGINE 59. Position the cooler shield to the rear radiator support (Fig. 552). 61. Position the left hand radiator hose R-clamp to the left hand fan guard and install a bolt, washer and nut to secure (Fig. 554). Note: The cooler shield is installed between the left hand guard strap and the rear radiator support. Fig 554 Fig 552 PICT-3696 60. Position the left fan guard behind the rear radiator support.
ENGINE 5 63. Align the left hand top frame brace, cooler shield and left fan guard with the rear radiator brace and loosely install a bolt, washer and nut to secure (Fig. 556). 65. Slide the front end of the right hand guard strap between the right hand radiator brace and the frame. Loosely install a bolt and nut to secure (Fig. 558). Fig 556 Fig 558 PICT-3717 64. Position the oil cooler hydraulic hose R-clamp to the inside of the left hand guard strap. Install a bolt, washer and nut to secure (Fig.
ENGINE 67. Position the front end of the right hand top frame brace to the inside of the right hand radiator brace. Loosely install 2 bolts, washers and nuts to secure (Fig. 560). 69. Tighten all the fasteners securing the right and left guard straps and frame braces to the frame and rear support. 70. Install the Hood Assembly. Refer to “Hood Assembly Installation” on page 3-22. 71. Check and fill the engine oil per specifications. 72. Connect the negative battery cable to the battery. 73.
ENGINE 76. Check the coolant level in the overflow bottle and add as necessary. Radiator Replacement Radiator Removal 77. Install the front engine panel (Fig. 563). 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 5. Place a drain pan under the lower right hand corner of the radiator. 9. Loosen the hose clamp securing the left hand radiator hose to the lower left hand corner of the radiator (Fig. 566). 6. Remove the radiator cap. Place a funnel below the radiator drain plug located on the lower right hand corner of the radiator. Remove the plug located on the lower right hand corner of the radiator (Fig. 565). Fig 566 Fig 565 7. Allow the coolant to drain from the radiator. PICT-3731 PICT-3539a 10.
ENGINE 12. Remove the cable tie securing the overflow hose to the radiator cap barb (Fig. 568). Fig 568 5 PICT-3542a 13. Slide the overflow hose from the barb on the radiator cap flange (Fig. 569). Fig 569 5-44 PICT-3690 14. Pull the overflow hose out and away from the radiator (Fig. 570). Fig 570 PICT-3544a 15. Remove the 6 bolts and washers securing the top radiator plate to the radiator (Fig. 571).
ENGINE 16. Remove the top radiator plate (Fig. 572). Fig 572 18. 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. 574). PICT-3747 Fig 574 PICT-3767 17. Remove the 6 bolts and washers (3 on the left and 3 on the right) securing the radiator to the bottom radiator plate and cooling shroud (Fig. 573). 19. Slide the right hand radiator hose off the flange (Fig. 575).
ENGINE 20. Remove the radiator (Fig. 576). Fig 576 2. Lift up the front end of the radiator and slide the right hand radiator hose onto the radiator flange (Fig. 578). PICT-3753 Fig 578 PICT-3765a Radiator Installation 5 1. Position the radiator onto the bottom radiator plate and cooling shroud (Fig. 577). Fig 577 5-46 PICT-3753 3. Slide the hose clamp into position and tighten (Fig. 579).
ENGINE 4. Install 6 bolts and washers (3 on the left and 3 on the right) securing the radiator to the bottom radiator plate and cooling shroud (Fig. 580). 6. Install 6 bolts and washers to secure the top radiator plate to the radiator (Fig. 582). Fig 582 Fig 580 PICT-3769 5. Position the top radiator plate onto the radiator (Fig. 581). Fig 581 Z580/Z593/Z595 Diesel Service Manual PICT-3745 PICT-3747 7.
ENGINE 8. Slide the overflow hose onto the barb onto the radiator filler neck barb fitting (Fig. 584). Fig 584 5 PICT-3690 9. Install a cable tie to secure the overflow hose to the radiator filler neck barb fitting (Fig. 585). Fig 585 5-48 PICT-3692a 10. Slide the left hand radiator hose onto the lower left hand corner of the radiator (Fig. 586). Fig 586 PICT-3734 11. Slide the hose clamp into position and tighten to secure (Fig. 587).
ENGINE 12. Ensure the drain plug is installed and tight. Cooling Fan Replacement 13. Fill the radiator with a 50/50 mix of extended life antifreeze/Dex-Cool and water. Cooling Fan Removal 14. Install the radiator cap (Fig. 588). 1. Remove the Radiator. Refer to “Radiator Removal” on page 5-42. 2. Unplug the cooling fan connector from the harness connector (Fig. 589). Fig 588 PICT-3771a 5 15. Check the antifreeze overflow bottle and make sure it is up to indicator line.
ENGINE 4. Remove the 4 bolts, washers and nuts securing the cooling fan to the shroud (Fig. 591). Cooling Fan Installation 1. Position the cooling fan to the back side of the shroud. Position the fan onto the shroud as shown (Fig. 593). A C Fig 591 PICT-3756 B 5. Remove the cooling fan from the shroud (Fig. 592). Fig 593 PICT-3760a A. Front of the machine side with large flange and cutout B. Rear of the machine C. Fan plug location 5 2.
ENGINE 3. Position the cooling fan and shroud assembly into the bottom radiator plate (Fig. 595). Air Cleaner Replacement Air Cleaner 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. 597). Fig 595 PICT-3755 4. Plug the cooling fan connector into the harness connector (Fig. 596). 5 Fig 597 Fig 596 IMG_7895 PICT-3754 5.
ENGINE 5. Raise the hood assembly (Fig. 598). Fig 598 7. Remove the 2 bolts, washers and nuts securing the air cleaner mounting bracket to the frame (Fig. 600). PICT-3729 Fig 600 6. Remove the bottom cover and air cleaner element from the air cleaner assembly (Fig. 599). 5 Fig 599 8. Loosen the hose clamp securing the engine intake hose to the air cleaner (Fig. 601).
ENGINE 9. Push the air cleaner intake hose out of the R-clamp (Fig. 602). Fig 602 PICT-3845 10. Remove the air cleaner/hose assembly (Fig. 603). Fig 603 11. Loosen the hose clamp securing the intake hose to the air cleaner (Fig. 604). Fig 604 12. Remove the air cleaner intake hose from the air cleaner (Fig. 605).
ENGINE 3. Position the upper half of the air cleaner and hose assembly up to the left side of the engine (Fig. 608). Air Cleaner Installation 1. Slide the air cleaner intake hose onto the air cleaner (Fig. 606). Fig 608 Fig 606 5 PICT-3848 PICT-3868 4. Slide the air cleaner intake hose into the R-clamp located behind the seat (Fig. 609). 2. Position the hose clamp and tighten (Fig. 607).
ENGINE 5. Slide the engine intake hose onto the air cleaner. Position the hose clamp and tighten (Fig. 610). Fig 610 7. Install the air cleaner element and bottom cover onto the air cleaner assembly (Fig. 612). PICT-3825 6. Install 2 bolts, washers and nuts securing the air cleaner mounting bracket to the frame (Fig. 611). Fig 612 PICT-3866 8. Install the negative battery cable to the battery. 5 9. Install the front engine panel (Fig. 613).
ENGINE 5. Remove the nut from the bolt securing the right guard strap to the frame and radiator support. Remove the right fan guard (Fig. 615). Alternator Belt Replacement Alternator 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 3 bolts, washers and nuts securing right side top brace frame and radiator support. Remove the right side top brace (Fig.
ENGINE 7. Remove the 2 bolts, washers and nuts securing the left side of the cooler shield to the rear radiator support (Fig. 617). Fig 617 PICT-3808 8. Remove the cooler shield (Fig. 618). Fig 618 9. Remove the 4 bolts, washers and nuts securing the oil cooler to the rear radiator support. Lower the oil cooler out of the way of the alternator belt (Fig. 619). Fig 619 10. Remove the 2 bolts securing the fan and retainer plate to the engine (Fig. 620).
ENGINE 11. Remove the retainer and fan (Fig. 621). Fig 621 13. Rotate the belt cover to the side and remove the belt from the pulleys and alternator (Fig. 623). PICT-3795a Fig 623 12. Loosen the bottom bolt and remove the upper bolt securing the alternator and belt cover (Fig. 622). 5 PICT-3799 Alternator Belt Installation 1. Route the alternator belt around the pulley and the alternator (Fig. 624).
ENGINE 2. Position the belt cover and install the upper bolt to secure. Tighten the bottom bolt (Fig. 625). Fig 625 PICT-3797 3. Check the alternator belt tension. Refer to “Checking Alternator Belt Tension” on page 5-61. 5. Install 2 bolts securing the fan and retainer plate to the engine (Fig. 627). Fig 627 PICT-3794 6. Position the oil cooler assembly to the rear radiator support. Install 4 bolts, washers and nuts to secure oil cooler to the rear radiator support (Fig. 628). 4.
ENGINE 7. Position the cooler shield so the left flange is between the left hand straps and the rear radiator support (Fig. 629). Fig 629 5 PICT-3781 9. Position the right hand guard strap. Install 2 bolts, washers and nuts securing right side guard strap to the frame and radiator support (Fig. 631). Fig 631 PICT-3775 8. Install 2 bolts, washers and nuts securing the left side of the cooler shield and left fan guard to the rear radiator support (Fig. 630). 10.
ENGINE 11. Position the right hand top brace. Install 3 bolts, washers and nuts securing the right hand top brace to the frame and rear radiator support (Fig. 633). Checking Alternator Belt Tension 1. Check the tension of the alternator belt. There should be 1/4” to 11/32” deflection in the belt between the engine and alternator pulleys with 22.1 lbs. of force (10kgf) (Fig. 634). E Fig 633 D A PICT-3421 12. Install the negative battery cable to the battery. 5 13. Lower the seat. B C Fig 634 A.
ENGINE Tensioning the Alternator Belt 1. Slightly loosen the bottom alternator bolt. Loosen the top alternator bolt (Fig. 635). 2. Using a wooden handle or pry bar to pivot the alternator away, from the engine block, tension the drive belt until there is 1/4” to 11/32” (7 to 9mm) deflection in the belt between the engine and the alternator pulleys with 22.1 lbs. of force (10 kgf) (Fig. 636). E Fig 635 D A PICT-3797 5 B C Fig 636 A. Alternator B. Alternator belt C.
ENGINE 3. Tighten the top and bottom alternator bolt (Fig. 637). Fuel Filter Service Models through 2007: the fuel system includes 2 replaceable, in-line fuel filters (15 micron). Both fuel filters should be replaced at the same time. 2008 and later Models: the fuel system includes 1 replaceable, in-line fuel filter and one fuel/water separator. Models through 2007: 2 replaceable in-line fuel filters (Fig. 638). Fig 637 PICT-3797 4. Check the deflection in the belt again.
ENGINE Note: Arrow on filter shows direction of fuel flow (Fig. 639). Fuel Filter Replacement 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. Allow the machine to cool down. 4. Close the fuel shut-off valve (Fig. 641).
ENGINE 5. Loosen the two hose clamps and disconnect the fuel lines from the fuel filter (Fig. 642). Fig 642 7. Connect the fuel lines to the fuel filter so that the fuel flows through the filter in the direction of the arrow on the side of the filter housing. Slide the hose clamps into position and tighten (Fig. 644). PICT-3812 Fig 644 PICT-3812 6. Install a new filter. Note directional arrow embossed in the side of the filter (Fig. 643). 5 8. Repeat process for second filter (2007 and prior models).
ENGINE Draining the Water Separator Checking the Radiator Coolant 1. Position the machine on a level surface. Note: Do not open the radiator cap. Doing this may introduce air into the cooling system. 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. Locate the water separator at the back left of the machine. 5.
ELECTRICAL General Relays Note: Interactive Electrical Troubleshooting DVD, Form No. 492-9171 is also available. There are 3 relays: 1. Glow Relay (furthest forward) 2. Start Relay 3. Fan Relay Engine Starting Turn the ignition switch to the RUN position, push the glow plug switch for 10 seconds. The light will turn on. Release the switch after 10 seconds. The light will turn off. Turn the key to the start position and the glow plug indicator light will come back on.
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. 650). Location The PTO switch is located on the control panel, on the left side of the operator (Fig. 651). Fig 650 xl relay Fig 651 PICT-4133 PTO Switch Purpose How It Works 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. Contacts inside the switch electrically connect various terminals in both “On” and “Off” position.
ELECTRICAL 6. Replace the switch if your test results do not correspond with those given in Fig. PTO switch test. Testing 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. 653). 2. Remove the 4 screws holding the control panel to the fuel tank. Grey 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. 655). The ignition switch provides the proper switching for the starter, accessories, and safety circuits. Location The ignition switch is located on the control panel, to the left side of the operator (Fig. 654).
ELECTRICAL Testing How It Works 1. Disconnect the switch from the wiring harness. 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. 657). 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.
ELECTRICAL Parking Brake Switch How It Works Purpose 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. 659).
ELECTRICAL Testing Seat Switch 1. Disconnect the switch from the wiring harness. Purpose The park brake switch is a double pole switch. When the park brake is in the ON position, a pair of closed terminals is part of the starting safety interlock circuit. When the brake is released after starting, the other pair of terminals closes, bypassing the neutral switches and applying power to the seat switch circuit. The seat switch is in the safety circuit.
ELECTRICAL How It Works Delay Module 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 swtich closes and there should be continuity between the two terminals (Fig. 662). Purpose When operating the unit on rough terrain and the operator comes off the seat, the seat delay module will temporarily delay the engine shutting down, preventing erratic engine operation.
ELECTRICAL How It Works Testing 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. 664). 1. Raise the seat and disconnect the seat switch. Install a jumper wire in place of the seat switch (Fig. 665).
ELECTRICAL Follow the procedure below to test the delay module function. 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. High Temperature Audible Alarm (Solid Tone) Purpose This machine has an audible alarm that alerts the user to turn off the engine or engine damage can occur from overheating. 4. The meter should read approximately 12 volts DC. 5. Disconnect one of the jumper wire leads.
ELECTRICAL How It Works Temperature Sender A continuous tone will sound when the engine temperature switch connects to ground as the engine reaches a certain temperature (Fig. 668). Purpose The temperature sender is a temperature-dependent variable resistor. As the coolant temperature increases, the internal resistance decreases. This causes a change in voltage applied to the water temperature gauge, which indicates a higher temperature.
ELECTRICAL How It Works Oil Pressure Switch When the water temperature reaches an excessive operating temperature the switch will close internally and ground the high temperature audible alarm. This completes the alarm circuit and the alarm sounds (Fig. 670). Purpose The oil pressure switch completes the circuit that activates the hour meter and the radiator fan relay. Location The oil pressure switch is located on the right side of the engine under the alternator (Fig. 671).
ELECTRICAL How It Works When the engine oil pressure builds the switch closes to complete the circuit for both the hour meter and the cooling fan relay (Fig. 672). High Temperature & Glow Plug 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 representation of high temperature. It is a red LED light. 2. The glow plug indicator light turns on when the glow plug switch is engaged.
ELECTRICAL How It Works Glow Plug Switch The high temperature light is connected in parallel with the high temperature audible alarm. The light gives a visual indicator that the engine has reached a high temperature. Purpose The glow plug switch activates the glow plug relay in addition to turning the glow plug indicator light on. The glow plug light comes on when the glow plug relay is activated by the glow plug switch (Fig. 674).
ELECTRICAL How It Works Hour Meter The glow pug switch is manually depressed and held in place for 10 seconds. This activates the relay that closes the circuit which sends current to the glow plugs. Purpose The hour meter keeps track of the actual engine running hours. Testing Location Only terminals 1 and 2 are used in this application. The switch can be tested with an ohmmeter. There should be no continuity between terminals 1 and 2.
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. 678). There are two different electric PTO clutches: • 2007 and prior models have a Warner clutch. • 2008 and later models have an Ogura clutch.
ELECTRICAL How It Works 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 4. Using a continuity tester, touch one tester lead to one of the clutch terminals and the other lead to the clutch housing. How It Works 5. If the tester shows a resistance reading, the field has failed and needs to be replaced. The ignition switch removes power to the stop solenoid when the key is turned to the Off position, the plunger of the solenoid cuts off fuel flow to the fuel injectors and the engine stops.
ELECTRICAL Pull Coil Terminal Test Hold Coil Terminal Test This test checks both the pulling coil and pulling coil timer module (Fig. 684). This test checks the holding coil. 1. Connect a jumper lead from the ground (A) terminal to the negative battery terminal. A B 2. Connect a jumper lead from the holding (B) terminal to the positive battery terminal. 3. Connect a jumper lead from the pull coil (G) terminal to the battery positive terminal. G C D F Fig 684 A. B. C. D.
MOWER DECKS 4. Remove the right hand and left hand belt covers (Fig. 686). Mower Belt Replacement 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. 685). Fig 686 PICT-4012 5. Using a spring removal tool (Toro p/n: 92-5771), remove the mower deck belt idler spring (Fig. 687).
MOWER DECKS 6. Remove the belt guide from the idler arm pulley (Fig. 688). Fig 688 8. Install a new belt around the mower pulleys and the gearbox pulley under the engine. Refer to the belt routing decal (Fig. 690). PICT-4060 Fig 690 fig. 108-5981 7. Remove the existing belt if needed (Fig. 689). 9. Install the belt guide on the spring loaded idler at a 45 degree angle as shown (Fig. 691): BA D E C B 7 Fig 689 BF PICT-4044 Fig 691 A. Mower belt B. Mower spindle pulley C.
MOWER DECKS 10. Install mower deck belt idler spring (Fig. 692). 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. 694). Fig 692 PICT-4013 11. Install the right hand and left hand belt covers (Fig. 693). Fig 694 PICT-4011 5. Remove the left and right mower deck belt covers (Fig. 695). 7 Fig 693 PICT-4012 12.
MOWER DECKS 6. Using a spring removal tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 696). Fig 696 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. 698). PICT-4013 Fig 698 PICT-4019 7. Remove the mower deck belt from the gearbox deck drive pulley (Fig. 697). 9.
MOWER DECKS 10. Remove the outer nut from each of the 4 deck chain assemblies (Fig. 700). Fig 700 PICT-4023 11. Raise the deck lift lever to the transport position (Fig. 701). 12. Remove the bolt and nut securing the strut to the mower deck (Fig. 702). Fig 702 PICT-4036 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 pins (Fig. 703).
MOWER DECKS 15. Tie the struts up, out of the way of the mower deck being removed. 16. Remove the 4 wood blocks from each corner of the mower deck. Mower Deck Installation 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. 706). 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. 704). Fig 706 Fig 704 PICT-4041 PICT-4041 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. 708). 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. 710).
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. 712). 11. Install the left and right mower deck belt covers (Fig. 714). Fig 714 Fig 712 PICT-4012 fig. 108-5981 12. Lower the floor pan assembly (Fig. 715). 10. Install the mower deck idler spring (Fig. 713). 7 Fig 715 Fig 713 PICT-4011 PICT-4013 13. Install the negative battery cable to the battery. 14. Lower the seat.
MOWER DECKS 5. Remove the left and right mower deck belt covers (Fig. 717). Mower Spindle Replacement 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. 716). Fig 717 PICT-4012 6. Using a spring removal tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 718).
MOWER DECKS 7. Remove the mower deck belt from the spindle pulley (Fig. 719). Fig 719 PICT-4044 8. Remove the nuts from the 6 spindle mounting bolts (Fig. 720). 9. 72” mower decks: Remove 3 bolts retaining the pulley to the pulley hub (Fig. 721). Fig 721 CLR DSC-2662 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. 52” mower decks: Remove the 6 spindle mounting bolts securing the spindle housing to the mower deck (Fig. 723). 15. 52” mower decks: Remove the spindle blade bolt and washer (Fig. 725). Fig 725 Fig 723 PICT-4050 PICT-4046 16. 52” mower decks: Remove the blade (Fig. 726). 14. 52” mower decks: Carefully lower the spindle assembly out of the mower deck (Fig. 724).
MOWER DECKS 17. 52” mower decks: Remove the 3 bolts securing the pulley to the spindle hub (Fig. 727). Mower Deck Spindle Rebuild 1. Remove the nut and washer (Fig. 729). Fig 727 PICT-4055 Fig 729 18. 52” mower decks: Remove the pulley from the spindle assembly (Fig. 728). CLR DSC-2669 2. Remove the pulley hub and square key (Fig. 730).
MOWER DECKS 3. Remove the bearing shield (Fig. 731). Fig 731 5. Remove the seal spacer from the top of the spindle housing (Fig. 733). CLR DSC-2671 Fig 733 4. Remove the spindle housing from the spindle shaft assembly (Fig. 732). CLR DSC-2673 6. Remove the seal spacer from the bottom of the spindle housing (Fig. 734).
MOWER DECKS 7. Remove the top oil seal from the spindle housing (Fig. 735). 9. Remove the spacer (Fig. 737). Fig 737 Fig 735 CLR DSC-2677 CLR DSC-2675 8. Remove the tapered roller bearing from the top of the spindle housing (Fig. 736). 10. Turn the spindle housing over and remove the oil seal from the bottom of the spindle housing (Fig. 738). 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. 739). Fig 739 13. Remove the large spacer in the spindle housing (Fig. 741). CLR DSC-2680 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. 740). Fig 741 CLR DSC-2682 14. This view shows the 2 bearing races and the large spacer in the spindle housing (Fig. 742).
MOWER DECKS 15. Install the spacer through the top of the spindle housing (Fig. 743). 17. Turn the spindle housing over and install the lower bearing race into the spindle housing (Fig. 745). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing. Fig 743 CLR DSC-2688 16. Using a press, install the upper bearing race into the spindle housing (Fig. 744). 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. 747). 21. Install the inner spacer to the spindle assembly (Fig. 749). Note: The open lip of the seal should be facing outward. Fig 749 Fig 747 CLR DSC-2700 CLR DSC-2692 22. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig. 750). 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. 748).
MOWER DECKS 23. Install the seal. Press it flush with the top of the housing (Fig. 751). 25. Lower the spindle housing over the spindle shaft (Fig. 753). Note: The open lip of the seal faces inward. Fig 753 Fig 751 CLR DSC-2703 CLR DSC-2696 26. Install the seal spacer on the top of the spindle housing (Fig. 754). 24. Install the bearing shield and the seal spacer onto the spindle shaft (Fig. 752).
MOWER DECKS 27. Install bearing shield (Fig. 755). Fig 755 29. Install the pulley hub on the spindle shaft (Fig. 757). CLR DSC-2705 28. Install the square key onto the spindle shaft (Fig. 756). Fig 757 CLR DSC-2707 30. Install the heavy washer and nut on the top of the spindle shaft (Fig. 758). 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. 759). 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. 760). Fig 759 CLR DSC-2709 32. Grease the spindle assembly using a grease gun with #2 grease. Fig 760 CLR DSC-2666 2. 72” mower decks: Install the mower blade onto the spindle assembly. 3.
MOWER DECKS 4. 52” mower decks: Position the pulley onto the spindle assembly (Fig. 762). Fig 762 PICT-4056 5. 52” mower decks: Install 3 bolts securing the pulley to the spindle hub. Torque bolts to 23 ft-lbs. (31 Nm) (Fig. 763). 6. 52” mower decks: Position the blade to the spindle shaft retainer (Fig. 764). Fig 764 PICT-4053a 7. 52” mower decks: Install the spindle blade bolt and washer. Torque to 85-110 ft-lbs. (115-149 Nm) (Fig. 765).
MOWER DECKS 8. 52” mower decks: Carefully position the spindle assembly into the mower deck (Fig. 766). Fig 766 10. Install a nut onto each of the 6 spindle mounting bolts (Fig. 768). PICT-4049 9. 52” mower decks: Install 6 spindle mounting bolts securing the spindle housing to the mower deck (Fig. 767). Fig 768 PICT-4045 11. Route the mower deck belt around the spindle pulley. Refer to the belt routing diagram (Fig. 769): BA D E C B 7 BF Fig 769 Fig 767 A. Mower belt B. Mower spindle pulley C.
MOWER DECKS 12. Install the mower deck idler spring (Fig. 770). Fig 770 14. Lower the floor pan assembly (Fig. 772). PICT-4013 13. Install the left and right mower deck belt covers (Fig. 771). Fig 772 PICT-4011 15. Install the negative battery cable to the battery. 16. Lower the seat.
MOWER DECKS 5. Remove the left and right mower deck belt covers (Fig. 774). Mower Deck Idler Assembly Replacement 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. 773). Fig 774 PICT-4012 6. Using a spring removal tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 775).
MOWER DECKS 7. Remove the bolt, belt guide and 2 flat washers securing the idler pulley to the idler arm (Fig. 776). 9. Remove the bolt, nut and 2 washers securing the idler arm assembly to the mower deck (Fig. 778). Note: One of the washers is between the idler arm and mower deck. Fig 776 PICT-4061 Fig 778 PICT-4065 8. Remove the pulley from the idler arm assembly (Fig. 777). 10. Remove the idler arm assembly from the mower deck (Fig. 779).
MOWER DECKS 11. Remove the 2 bushings and 1 spacer from the idler arm (Fig. 780). Mower Deck Idler Assembly Installation 1. Install a grease fitting into the idler arm pivot (Fig. 782). Fig 780 PICT-4073a Fig 782 PICT-4070a 12. Remove the grease fitting from the idler arm pivot (Fig. 781). 2. Press 2 bushings into the idler arm pivot (Fig. 783).
MOWER DECKS 3. Slide a spacer into the idler arm pivot (Fig. 784). Fig 784 5. Position the idler arm assembly onto the mower deck with the pivot placed over the washer (Fig. 786). PICT-4082a Fig 786 PICT-4084 4. Position a washer onto the mower deck in the idler arm pivot location (Fig. 785). 6. Install a bolt, nut and washer to secure the idler arm assembly to the mower deck (Fig. 787).
MOWER DECKS 7. Position the pulley onto the idler arm assembly (Fig. 788). 9. Position the belt guide onto the 2 washers so that it is 45 degrees from the idler arm (Fig. 790). A Fig 788 PICT-4063 Fig 790 belt guide position A. 45º 8. Route the mower deck belt into the pulley and place 2 washers on top of the pulley (Fig. 789). 10. Install a bolt to secure the belt guide to the pulley (Fig. 791).
MOWER DECKS 11. Apply grease to the idler arm pivot grease fitting (Fig. 792). 13. Install the mower deck idler spring (Fig. 794). Fig 794 Fig 792 12. Ensure the mower deck belt is properly routed around the pulleys. Refer to the belt routing decal (Fig. 793). BA D PICT-4013 PICT-4127 E C 14. Install the left and right mower deck belt covers (Fig. 795). B 7 BF Fig 793 A. Mower belt B. Mower spindle pulley C. Mower idler pulley Fig 795 PICT-4012 fig. 55 G001067 D. Belt guide E.
MOWER DECKS 15. Lower the floor pan assembly (Fig. 796). Fixed Pulley Replacement 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. 797). Fig 796 PICT-4011 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. 798). Fig 798 PICT-4012 6. Using a spring removal tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 799). 7. Remove the bolt, washer and nut securing the fixed pulley to the mower deck (Fig. 800). Fig 800 PICT-4090a 8. Remove the pulley from the pulley mount (Fig. 801).
MOWER DECKS 9. Remove the pulley mount (Fig. 802). Fig 802 2. Position the pulley onto the pulley mount (Fig. 804). PICT-4095 Fig 804 PICT-4093 3. Install a bolt, washer and nut securing the fixed pulley to the mower deck (Fig. 805). Fixed Pulley Installation 1. Position the pulley mount onto the mower deck (Fig. 803).
MOWER DECKS 4. Route the mower deck belt. Refer to the belt routing decal (Fig. 806). Fig 806 6. Install the left and right mower deck belt covers (Fig. 808). fig. 108-5981 5. Install the mower deck idler spring (Fig. 807). Fig 808 PICT-4012 7. Lower the floor pan assembly (Fig. 809). 7 Fig 807 PICT-4013 Fig 809 PICT-4011 8. Install the negative battery cable to the battery. 9. Lower the seat.
MOWER DECKS Electric PTO Clutch Replacement 5. Unplug the harness connector from the electric PTO clutch (Fig. 811). Electric PTO Clutch Removal Warner Clutch 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. 810). Fig 811 PICT-3933 6.
MOWER DECKS 7. Remove the gearbox drive belt from around the electric PTO clutch pulley (Fig. 813). Fig 813 PICT-3934a 8. Remove the center clutch bolt, 2 spring washers and clutch retainer securing the electric PTO clutch to the stub shaft (Fig. 814). 9. Remove the electric PTO clutch from the stub shaft (Fig. 815). Fig 815 PICT-3615 Electric PTO Clutch Installation Warner Clutch 1. Apply anti-seize compound to the PTO stub shaft (Fig. 816).
MOWER DECKS 2. Slide the electric PTO clutch onto the stub shaft (Fig. 817). 4. Install the center clutch bolt, two spring washers, and the clutch retainer (Fig. 819). Note: Make sure the clutch stop bracket is in the slot on the clutch. Note: The direction of the spring washers. B A Fig 819 Fig 817 C clutch bolt retainer asm PICT-3615 A. Clutch bolt B. Spring washer (2) C. Clutch retainer 3. Apply thread locking compound to the center clutch bolt threads (Fig. 818). 5.
MOWER DECKS 6. Route the gearbox belt around the electric PTO clutch pulley (Fig. 821). Fig 821 8. Plug the clutch harness into the electric PTO clutch plug (Fig. 823). PICT-4009 7. Hook the gearbox idler spring to the frame (Fig. 822). Fig 823 PICT-3933 9. Install the front engine panel (Fig. 824). 7 Fig 824 Fig 822 IMG_7862 PICT-3872 10. Install the negative battery cable to the battery. 11. Lower the seat.
MOWER DECKS 6. Unplug the harness connector from the electric PTO clutch (Fig. 827). Electric PTO Clutch Removal Ogura Clutch 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. 825). Fig 827 PICT-3979 7. Remove the carriage bolts, washers, and nut holding the clutch stop to the frame (Fig. 828). Fig 825 IMG_7862 5.
MOWER DECKS 8. Using a spring removal tool (Toro p/n: 92-5771), unhook the idler pulley spring from the frame and remove the belt from around the electric PTO clutch (Fig. 829). 10. Remove the bolt, 2 curved washers, flat washer, and retainer (Fig. 831). Fig 831 Fig 829 PICT-3997a PICT-3971 11. Remove the electric PTO clutch from the stub shaft (Fig. 832). 9. Loosen the bolt holding the electric PTO clutch to the stub shaft (Fig. 830).
MOWER DECKS 12. Remove the key from the stub shaft (Fig. 833). Electric PTO Clutch Installation Ogura Clutch 1. Insert a 0.015”–0.021” (0.381–0.533mm) feeler gauge through one inspection slot in the side of the electric PTO clutch. Make sure it is between the armature and the rotor friction surfaces (Fig. 54). 2. Tighten the lock nuts until there is slight binding on the feeler gauge but it can be moved easily within the air gap (Fig. 835). A A Fig 833 PICT-3955 13.
MOWER DECKS 5. Install the clutch stop to the clutch (Fig. 836): 7. Apply anti-seize compound to the stub shaft (Fig. 838). C A E F B B D Fig 836 PICT-3944a Fig 838 A. Nut B. Washer (2) C. Electric PTO clutch PICT-3655 D. Clutch stop E. Spacer F. Bolt 8. Install the key onto the stub shaft (Fig. 839). 6. Slide the clutch adapter onto the stub shaft (Fig. 837).
MOWER DECKS 9. Slide the clutch onto the stub shaft (Fig. 840). 11. Slide the 2 curved washers, a flat washer and a clutch retainer onto the clutch bolt (Fig. 842). Note: Curved washers must be installed as shown. Fig 840 PICT-3956 Fig 842 PICT-3962 10. Apply thread locking compound to the clutch bolt threads (Fig. 841). 12. Torque the clutch bolt to 50 ft-lbs. (68 Nm) (Fig. 843).
MOWER DECKS 13. Route the PTO drive belt onto the clutch pulley. Install the idler arm spring (Fig. 844). Fig 844 PICT-3969 14. Twist the clutch stop and install the end to the frame bracket with 2 carriage bolts, 2 flat washers, and 2 locknuts (Fig. 845). 15. Plug the clutch harness into the electric PTO clutch plug (Fig. 846). Fig 846 PICT-3979 16. Secure the electric PTO clutch plug and wires to the frame crossbar with a cable tie (Fig. 847). Note: Make sure there is a twist in the clutch stop.
MOWER DECKS 17. Install the front engine panel (Fig. 848). Gearbox Assembly Replacement 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. 849). Fig 848 IMG_7862 18. Install the negative battery cable to the battery. 19. Lower the seat.
MOWER DECKS 5. Remove the right rear wheel and tire assembly (Fig. 850). Fig 850 IMG_7753a 6. Using a spring removal tool (Toro p/n: 92-5771) unhook the spring from the gearbox idler assembly (Fig. 851). 7. Remove the gearbox drive belt from the drive pulley (Fig. 852). Fig 852 PICT-3876 8. Raise the floor pan assembly (Fig. 853).
MOWER DECKS 9. Remove the left hand mower deck belt cover (Fig. 854). Fig 854 PICT-3879 10. Using a spring removal tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 855). 11. Remove the deck drive belt from the gearbox pulley (Fig. 856). Fig 856 PICT-3881 12. Remove the 4 mounting bolts and lock washers securing the gearbox assembly to the frame (Fig. 857).
MOWER DECKS 13. Remove the gearbox assembly (Fig. 858). Fig 858 15. Remove the pulley (Fig. 860). PICT-3898 14. Remove the 2 set screws from the gearbox driven pulley (Fig. 859). Fig 860 PICT-3909a 16. Remove the key from the keyway (Fig. 861).
MOWER DECKS 17. Remove the 2 set screws from the gearbox drive pulley (Fig. 862). 19. Remove the key from the keyway (Fig. 864). Fig 864 Fig 862 PICT-3912a PICT-3908 20. Inspect the keys, gearbox shafts and pulleys. Replace if worn or damaged. 18. Remove the pulley (Fig. 863). 21. Check the gearbox oil level. Refer to “Checking the Gearbox Oil Level” on page 7-54.
MOWER DECKS Gearbox Assembly Installation 1. Apply anti-seize compound to both gearbox assembly shafts (Fig. 865). 3. Apply thread locking compound to all 4 pulley set screws. Start the set screws into the pulley hubs (Fig. 867). Fig 867 Fig 865 PICT-3917a PICT-3913a 2. Install a key into the gearbox drive shaft keyway (Fig. 866). Slide the gearbox drive pulley onto the gearbox drive shaft (Fig. 868). Note: Install the pulley so that the pulley hub is flush + .03” (0.
MOWER DECKS 4. Tighten the set screws (Fig. 869). Fig 869 6. Install a key into the gearbox driven shaft keyway (Fig. 871). PICT-3919a Fig 871 5. Torque each set screw to 145 + 20 in-lbs. (16 + 2.25 Nm) (Fig. 870). PICT-3924a 7. Slide the driven pulley onto the gearbox driven shaft (Fig. 872).
MOWER DECKS 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. 873). 9. Position the gearbox assembly to the frame (Fig. 875). Fig 875 Fig 873 PICT-3898 PICT-3925 8. Torque each set screw to 145 + 20 in-lbs. (16 + 2.25 Nm) (Fig. 874). 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. 876).
MOWER DECKS 11. Install the deck drive belt around gearbox mower deck drive pulley (Fig. 877). Fig 877 PICT-3881 12. Using a spring removal tool (Toro p/n: 92-5771), install the mower deck idler spring (Fig. 878). 13. Install the left hand mower deck belt cover (Fig. 879). Fig 879 PICT-3879 14. Lower the floor pan assembly (Fig. 880).
MOWER DECKS 15. Position the gearbox drive belt around the gearbox drive pulley (Fig. 881). Fig 881 17. Install the right rear wheel and tire assembly (Fig. 883). PICT-3876 16. Using a spring removal tool (Toro p/n: 92-5771), install the spring to the gearbox idler assembly (Fig. 882). Fig 883 IMG_7753a 18. Install the front engine panel (Fig. 884). 7 Fig 884 Fig 882 IMG_7862 PICT-3872 19. Install the negative battery cable to the battery. 20. Lower the seat.
MOWER DECKS Checking the Gearbox Oil Level Changing Gearbox Oil 1. Park the machine on a level surface. Service Interval: Initial at 100 hours, then yearly. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 1. Remove the gearbox assembly from the machine. Refer to “Gearbox Assembly Removal” on page 7-44. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
MOWER DECKS 3. Drain the oil from the gearbox into a drain pan. Strut Replacement 4. Fill the gearbox assembly with 75W-90 Synthetic Gear Lube until the oil level reaches the plug openings (Fig. 887). Capacity 6 oz. (.177 liters). 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.
MOWER DECKS 5. Remove the left and right mower deck belt covers (Fig. 890). Fig 890 PICT-4012 6. Using a spring removal tool (Toro p/n: 92-5771), remove the mower deck idler spring. Remove the mower deck belt from the gearbox deck drive pulley (Fig. 891). 7. Remove the bolt and nut securing the strut pin to the mower deck strut bracket (Fig. 892). Fig 892 PICT-4108 8. Remove the strut pin (Fig. 893).
MOWER DECKS 9. Remove the nut, lockwasher and bolt securing the strut balljoint to the frame (Fig. 894). 11. Remove the grease fittings from the strut (Fig. 896). Fig 896 Fig 894 PICT-4116a PICT-4105 12. Loosen the balljoint jam nut (Fig. 897). 10. Remove the strut assembly (Fig. 895).
MOWER DECKS 13. Remove the balljoint and jam nut from the strut (Fig. 898). 2. Tighten the jam nut to secure the balljoint position (Fig. 900). Note: Balljoint to be positioned perpendicular to strut. Fig 898 PICT-4121a Fig 900 PICT-4119a Strut Installation 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. 899). 3. Install 2 grease fittings into the strut (Fig.
MOWER DECKS 4. Position the strut assembly balljoint up to the frame. Secure it to the frame with a bolt, lockwasher and nut (Fig. 902). 6. Install a bolt and nut securing the strut pin to the mower deck strut bracket (Fig. 904). Fig 904 Fig 902 PICT-4108 PICT-4105 7. Apply grease to the strut grease fitting (Fig. 905). 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. 903).
MOWER DECKS 8. Route the mower deck belt. Refer to the belt routing decal (Fig. 906). BA D E C 10. Install the left and right mower deck belt covers (Fig. 908). B BF Fig 906 A. Mower belt B. Mower spindle pulley C. Mower idler pulley fig. 55 G001067 D. Belt guide E. Gearbox pulley F. Spring Fig 908 PICT-4012 11. Lower the floor pan assembly (Fig. 909). 9. Install the mower deck idler spring (Fig. 907). 7 Fig 909 Fig 907 PICT-4013 PICT-4011 12.
MOWER DECKS 5. Remove the left and right mower deck belt covers (Fig. 911). 72” Mower Deck Belt Tension Adjustment Plate Replacement 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. 910). Fig 911 PICT-4012 6.
MOWER DECKS 7. Remove the belt from around the adjustment plate pulley. 10. Remove the tension adjustment plate assembly (Fig. 915). 8. Remove the nut from the pivot bolt (Fig. 913). Note: The pivot bolt will fall through to the underside of the deck when the nut is removed. Fig 915 Fig 913 6666a PICT-6668a 11. Remove the 2 spacers from the mower deck (Fig. 916). 9. Remove the nut and washer from the adjustment plate slot bolt (Fig. 914).
MOWER DECKS 12. Remove the nut, washer and bolt securing the pulley to the adjustment plate (Fig. 917). 14. Remove the idler bushing (Fig. 919). Fig 919 Fig 917 6672a 6670a 13. Remove the pulley from the idler bushing (Fig. 918). 72” Mower Deck Belt Tension Adjustment Plate Removal 1. Position the idler bushing onto the tension adjustment plate (Fig. 920).
MOWER DECKS 2. Insert the mounting bolt up through the idler bushing and place the pulley onto the bushing (Fig. 921). 4. Position 2 spacers onto the mower deck (Fig. 923). 6669.jpg add arrows pointing to the spacers Fig 923 Fig 921 6669a 6671a 3. Install a washer and nut onto the pulley bolt securing the pulley to the adjustment plate (Fig. 922). 5. Position the tension adjustment plate assembly onto the mower deck making sure the spacers are in place (Fig. 924).
MOWER DECKS 6. Insert 2 bolts up through the mower deck, spacers and tension adjustment plate. Install a washer and nut onto each bolt (Fig. 925). 8. Install the mower deck idler spring (Fig. 927). Fig 927 Fig 925 PICT-4013 6667a 9. Adjust the mower belt tension. Refer to “72” Mower Deck Mower Belt Tension Adjustment” on page 7-66. 7. Route the belt around the adjustment plate pulley. Refer to the belt routing decal (Fig. 926). 10. Install the left and right mower deck belt covers (Fig. 928).
MOWER DECKS 11. Lower the floor pan assembly (Fig. 929). 4. Measure the mower deck idler spring length (Fig. 000). If the spring length is between 10” and 10-1/4” (25.4 and 26.0cm), from post to post, no adjustment is needed. If it is not between 10” and 10-1/4” (25.4 and 26.0cm), continue: 5. Loosen the bolts holding the idler plate (Fig. 930). A D Fig 929 B PICT-4011 12. Install the negative battery cable to the battery. 13. Lower the seat.
MOWER DECKS 3. Carefully remove the pinion assembly (Fig. 933). Gearbox Rebuild 1. Remove the two gearbox drain plugs and drain the oil from the gearbox (Fig. 931). Fig 933 Fig 931 PICT-5631 PICT-5646 4. Remove the o-ring from the pinion pilot (Fig. 934). 2. Remove the 4 bolts securing the pinion housing to the case (Fig. 932). 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. 935). Fig 937 Fig 935 IMG-8490 PICT-5650 7. Remove the closed end cap (Fig. 938). 6. Remove the 8 end cap screws (4 securing each end cap) (Fig. 936 and Fig. 937). 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. 939). Fig 939 IMG-8491 9. Remove the open end cap and cross shaft assembly (Fig. 940). 10. Remove the o-ring from the cross shaft pilot (Fig. 941). Fig 941 PICT-5664 11. Remove the shim(s) (Fig. 942).
MOWER DECKS 12. Remove the cross shaft from the open end cap (Fig. 943). 15. Remove the washer from the pinion shaft (Fig. 945). Fig 945 Fig 943 IMG-8495 PICT-5667 16. Using a gear puller, remove the cross shaft gear from the pinion shaft (Fig. 946). Pinion Shaft Teardown 13. Secure the pinion shaft in a vise. 14. Remove the lock nut from the pinion shaft (Fig. 944).
MOWER DECKS 17. Remove the key from the shaft keyway (Fig. 947). Fig 947 19. Remove the bearing and shaft assembly from the pinion housing (Fig. 949). IMG-8501 Fig 949 18. Place the pinion shaft assembly in a press, shaft side down. Press the pinion shaft assembly out of the pinion housing (Fig. 948). IMG-8504 20. Remove the grease seal from the shaft (Fig. 950).
MOWER DECKS 21. Place the shaft assembly in a press and press the bearing off the shaft (Fig. 951). Cross Shaft Teardown 23. Place the cross shaft in a press with the pinion gear bearing facing up. 24. Press the pinion gear and bearing off the cross shaft (Fig. 953). Fig 951 IMG-8509 22. Place the pinion housing in a vise and remove the inner and outer bearing races from the housing (Fig. 952). Note: The inner race and housing must be heated to remove the races. Fig 953 IMG-8517 25.
MOWER DECKS 26. Position the cross shaft in the press so the opposite bearing is facing up. Press the bearing off the shaft (Fig. 955). 28. Remove the bearing race form the open end cap (Fig. 957). Note: The inner race and housing must be heated to remove the race. Fig 955 IMG-8520 Fig 957 IMG-8537 Open End Cap Teardown 27. Remove the oil seal from the open end cap (Fig. 956). Closed End Cap Teardown 29. Remove the bearing race from the closed end cap (Fig. 958).
MOWER DECKS 32. Press the bearing race into the open end cap (Fig. 961). Closed End Cap Rebuild 30. Press the bearing race into the open end cap (Fig. 959). Fig 961 Fig 959 IMG-8537 IMG-8537 Cross Shaft Rebuild Open End Cap Rebuild 33. Place the cross shaft in the press and press a new bearing onto the shaft (Fig. 962). 31. Press the oil seal into the open end cap (Fig. 960).
MOWER DECKS 34. Install the key into the shaft keyway (Fig. 963). Fig 963 IMG-8519 35. Place the cross shaft in a press with the installed bearing down. 36. Align the keyway in the pinion gear with the key installed in the shaft. Press the pinion gear onto the shaft (Fig. 964). 37. Press the bearing onto the shaft (Fig. 965). Fig 965 IMG-8530 Pinion Shaft Rebuild 38. Press a new bearing race into the outer end of the pinion housing (Fig. 966).
MOWER DECKS 39. Press a new bearing race into the inner end of the pinion housing (Fig. 967). Fig 967 IMG-8534 40. Place the pinion shaft assembly in a press and press the bearing onto the shaft (Fig. 968). 41. Slide the bearing and shaft assembly into the pinion housing (Fig. 969). Fig 969 IMG-8541 42. Place the assembly into a press and press a new bearing into the pinion housing (Fig. 970).
MOWER DECKS 43. Install the key into the pinion shaft keyway (Fig. 971). 45. Install a washer onto the pinion shaft (Fig. 973). Fig 973 Fig 971 IMG-8547 IMG-8543 46. Install the lock nut onto the pinion shaft (Fig. 974). 44. Align the keyway in the pinion gear with the key installed in the shaft. Press the pinion gear onto the shaft (Fig. 972). Note: Secure the assembly in a vise and tighten the lock nut enough to draw the gear and washer until the bearings bind slightly.
MOWER DECKS 47. Place a protective wrap around the shaft keyway to protect the grease seal on installation. 48. Press the grease seal into the pinion housing (Fig. 975). Fig 975 50. Install 4 new bolts securing the closed end cap to the gearbox housing. Torque the bolts to 280 – 325 in-lbs. (31.6 – 36.7 Nm) (Fig. 977). Note: The bolts are to be tightened in a crisscross pattern. IMG-8550 Fig 977 PICT-6429a Gearbox Assembly 49. Assemble the closed end cap onto the gearbox (Fig. 976). 51.
MOWER DECKS 52. Install .013” (.33mm) thickness of shims onto the open end cap (Fig. 979). Note: The shim color corresponds to its thickness: Blue: .005” (.127mm) thick Green: .003” (.076mm) thick Brown: .010” (.254mm) thick 54. Apply a protective film onto the shaft keyway. 55. Install the open end cap assembly over the cross shaft and onto the gearbox (Fig. 981). Fig 981 Fig 979 IMG-8559 IMG-8561 56. Install 4 new bolts securing the open end cap to the gearbox housing.
MOWER DECKS 57. Check the cross shaft end play measurement, it should be between .004” and .012” (.101 and .305mm). Adjust the open end cap shims to adjust backlash (Fig. 983). 59. Install a new o-ring on onto the pinion housing (Fig. 985). Fig 985 Fig 983 IMG-8569 IMG-8564 58. Install .013” (.33mm) thickness of shims onto the pinion housing (Fig. 984). 60. Insert the pinion shaft assembly into the gearbox assembly seating the pinion gear into the cross shaft gear (Fig. 986).
MOWER DECKS 61. Install 4 new bolts securing the pinion assembly to the to the gearbox housing. Torque the bolts to 280 – 325 in-lbs. (31.6 – 36.7 Nm) (Fig. 987). Note: The bolts are to be tightened in a crisscross pattern. Fig 987 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. 988). Note: Pinion housing shims and open end cap shims should not vary more than .005” (.127mm).
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. 989). 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. 991). 3. Record this measurement. This measurement needs to be 3-1/8” to 3-1/4” (7.9 to 8.3cm). 4. Position the left blade side-to-side (Fig. 991). 5. Measure the left blade at the C location (Fig. 65 m1078) from level surface to cutting edge of the blade tips (Fig. 992). 6. Record this measurement. The measurement needs to 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. 994). 3. Record the measurement. 4. Measure the right blade at the B location (Fig. 991) from a level surface to the cutting edge of the blade tip (Fig. 995). 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. 994). 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. 996 and Fig. 997) to achieve 1/4” to 3/8” (6 to 10mm) lower in front A than in the rear at B (Fig. 994). Adjusting the Compression Spring 1. Raise the mower lift lever to the transport position. 2. Check the distance between the two large washers, it needs to be 11-1/2” (29.2cm) (Fig. 998). 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 998).
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Z580-D / Z593-D / Z595-D Diesel Z Master Service Manual Form No.
