Toro Z580 DFI Z Master Service Manual
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Toro Z580 DFI Z Master Service Manual

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Summary of Contents for Toro Z580 DFI Z Master

  • Page 1 LCE Products Z580/Z589 DFI Z Master Service Manual...
  • Page 2 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.
  • Page 3 THIS PAGE INTENTIONALLY LEFT BLANK.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION General Information ........................1-1 Think Safety First ........................1-1 SPECIFICATIONS Specifications ..........................2-1 Configurations ........................2-1 Power System ........................2-1 Electrical ..........................2-2 Mowing Deck .........................2-2 Operator Zone ........................2-3 Dimensions ..........................2-3 Torque Specifications ........................2-4 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) ........2-5 Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) ........2-6 Other Torque Specifications ......................2-7 Equivalents and Conversions .......................2-8...
  • Page 5 TABLE OF CONTENTS CHASSIS cont. Motion Control Assembly Replacement..................3-48 Motion Control Assembly Removal ..................3-48 Right Hand Motion Control Assembly Removal ..............3-50 Left Hand Motion Control Assembly Removal ..............3-52 Left Hand Motion Control Assembly Installation ..............3-55 Right Hand Motion Control Assembly Installation ..............3-57 Motion Control Assembly Installation ...................3-61 Motion Control Damper Replacment ..................3-62 Motion Control Damper Removal ..................3-62...
  • Page 6 TABLE OF CONTENTS ELECTRICAL General ............................6-1 Relays............................6-1 Purpose ..........................6-1 Location ..........................6-1 How It Works ..........................6-2 Testing ............................6-2 PTO Switch ...........................6-3 Purpose ..........................6-3 Location ..........................6-3 How It Works ..........................6-3 Testing ............................6-4 Ignition Switch ..........................6-5 Purpose ..........................6-5 Location ..........................6-5 How It Works ..........................6-5 Testing ............................6-6 Neutral Safety Switch ........................6-6 Purpose ..........................6-6...
  • Page 7 TABLE OF CONTENTS ELECTRICAL cont. Engine High Temperature & Malfunction Indicator Light Cluster ..........6-15 Purpose ..........................6-15 Location ..........................6-15 How It Works ........................6-15 Testing ..........................6-16 Hour Meter..........................6-16 Purpose ..........................6-16 Location ..........................6-16 How It Works ........................6-17 Testing ..........................6-17 Electric PTO Clutch ........................6-17 Purpose ..........................6-17 Location ..........................6-17 How It Works ........................6-18...
  • Page 8 TABLE OF CONTENTS MOWER DECKS cont. Gearbox Rebuild.........................7-63 Pinion Shaft Teardown ......................7-66 Cross Shaft Teardown ......................7-69 Open End Cap Teardown .....................7-70 Closed End Cap Teardown ....................7-70 Closed End Cap Rebuild ......................7-71 Open End Cap Rebuild ......................7-71 Cross Shaft Rebuild ......................7-72 Pinion Shaft Rebuild ......................7-73 Gearbox Assembly .......................7-75 Leveling the Mower ........................7-79...
  • Page 9 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. Z580/Z589 DFI Z Master Service Manual...

  • Page 10: Safety Information

    - read the instruction because it has to operating practices. Operator’s manuals are available do with your safety. Failure to comply online at www.toro.com, through your Toro parts source with the instruction may result in personal injury or even death.
  • Page 11 SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK. Z580/Z589 DFI Z Master Service Manual...

  • Page 12: Specifications Specifications

    SPECIFICATIONS Specifications Configurations Model Engine Deck 74253 29 hp Kawasaki Liquid Cool DFI 60” (152.4cm) Turbo Force SD Mower 74254 29 hp Kawasaki Liquid Cool DFI 72” (182.8cm) Turbo Force SD Mower 74253CP 29 hp Kawasaki Liquid Cool DFI 60” (152.4cm) Turbo Force SD Mower 74254CP 29 hp Kawasaki Liquid Cool DFI 72”...

  • Page 13: Electrical

    SPECIFICATIONS Electrical Engine Charging Coil 40 Amp Voltage 12 volt, negative ground Battery BCI group 26, 540 CCA Gauges and Alarms • Top panel mounted hour meter • Audio alarm for excess engine temperature • Lighted indicators for engine malfunction and excess engine temperature •...

  • Page 14: Operator Zone

    SPECIFICATIONS Operator Zone 60” (152.4cm) 72” (182.8cm) Steering Levers Dual, wrap-around hydraulically Dual, wrap-around hydraulically dampened, with cushioned grips dampened, with cushioned grips Parking Brake Left hand operated lever with Left hand operated lever with cushioned grip cushioned grip Folding ROPS Standard Standard Deck Lift Assist Pedal...

  • Page 15: 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.

  • Page 16: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 8 with Thin Studs, &...

  • Page 17: Standard Torque For Dry, Zinc, And Steel Fasteners (Metric Fasteners)

    SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Regular Height Nuts Regular Height Nuts ( (Class 8 or Strong Nuts) Class 10 or Strong Nuts)

  • Page 18: Other Torque Specifications

    SPECIFICATIONS Other Torque Specifications Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 - 20 UNF 65 ± 10 ft-lb 88 ± 14 N-m Grade 5 1/4 - 20 UNC 140 ±...

  • Page 19: Equivalents And Conversions

    SPECIFICATIONS Equivalents and Conversions Equivalents and Conversions Decimal and Millimeter Equivalents Decimal and Millimeter Equivalents Fractions Decimals Fractions Decimals 1/64 0.015625 0.397 33/64 0.515625 13.097 1/32 0.03125 0.794 16/32 0.53125 13.484 3/64 0.046875 1.191 35/64 0.546875 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288...

  • Page 20: U.s. To Metric Conversions

    SPECIFICATIONS U.S. to Metric Conversions U.S. to Metric Conversions To Convert Into Multiply By 1.609 Miles Kilometers Yards Meters 0.9144 Feet Meters 0.3048 Linear Feet Centimeters 30.48 Measurement Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters...
  • Page 21 SPECIFICATIONS THIS PAGE INTENTIONALLY LEFT BLANK. 2-10 Z580/Z589 DFI Z Master Service Manual...

  • Page 22: Chassis

    CHASSIS Castor Fork Assembly Replacement 3. Remove the locknut (Fig. 002). Castor Fork Assembly Removal 1. Raise the front of the machine off the ground leaving enough clearance to remove the castor fork from the carrier frame. 2. Remove the grease cap from the frame (Fig. 001). Fig 002 IMG-7874a 4.

  • Page 23: Castor Bearing Replacement

    CHASSIS Castor Bearing Replacement 3. Remove the bottom grease seal (Fig. 006). 1. Remove the 3 Belleville washers (Fig. 004). Fig 006 IMG-7709a Fig 004 IMG-7703a 4. Remove the bottom tapered bearing (Fig. 007). 2. Remove the top tapered bearing (Fig. 005). Fig 007 IMG-7711a Fig 005...
  • Page 24 CHASSIS 5. Drive the top and bottom tapered bearing cups out of 7. Pack the upper and lower tapered bearings with the caster fork hub (Fig. 008). grease (No. 2 general purpose lithium base or molybdenum grease). 8. Install the lower bearing into the caster fork hub (Fig. 010).

  • Page 25: Castor Fork Assembly Installation

    CHASSIS Castor Fork Assembly Installation 10. Install the upper bearing into the caster fork hub (Fig. 012). 1. Install 3 Bellville washers as shown (Fig. 013): Fig 012 IMG-7731a Fig 013 fig. 49 G001297 A. Belleville washers 2. Slide the castor fork assembly into the hub (Fig. 014).
  • Page 26 CHASSIS 3. Install the locknut. Tighten the locknut until the 5. Remove the grease fitting and install the grease Belle ville washers are flat, then back the nut off 1/4 plug. turn to properly set the preload on the bearings (Fig. 015).

  • Page 27: Front Wheel Bearing Replacement

    CHASSIS Front Wheel Bearing Replacement 4. Remove the castor spacer from the wheel assembly (Fig. 020). 1. Raise the front of the machine off the ground. 2. Remove the wheel axle bolt and nut (Fig. 018). Fig 020 IMG-7742a Fig 018 IMG-7736a 5.
  • Page 28 CHASSIS 6. Drive the bearing cup, bearing and bearing seal out 7. Install a new tapered bearing cup into the wheel of the wheel assembly. Repeat on the opposite side assembly by pressing each bearing cup into the (Fig. 022). wheel hub so that the thicker part of the taper is pressed into the wheel hub first.
  • Page 29 CHASSIS 10. Install the grease seals into each side of the wheel 12. Install the castor spacer into the wheel hub (Fig. hub (Fig. 026). 028). Fig 026 IMG-7883a Fig 028 IMG-7885a 11. Install a bearing spacer into each side of the wheel 13.

  • Page 30: Fuel Tank Replacement

    CHASSIS Fuel Tank Replacement 14. Install the axle bolt and nut securing the wheel as- sembly to the fork (Fig. 030). Right Side Fuel Tank Removal 1. Raise the seat and remove the front engine shield (Fig. 032). Fig 030 IMG-7736a 15.
  • Page 31 CHASSIS 3. Disconnect the negative battery cable. 6. Remove the clamp securing the return fuel line to the fitting on the operator’s side of the fuel tank. 4. Remove the right rear wheel assembly (Fig. 034). Slide the fuel hose off the fitting (Fig. 036). Fig 034 IMG-0307a Fig 036...

  • Page 32: Right Side Fuel Tank Installation

    CHASSIS Right Side Fuel Tank Installation 8. Remove the bolt, lockwasher and washer securing the left front corner of the fuel tank to the frame (Fig. 038). 1. Position the fuel tank onto the frame (Fig. 040). Fig 038 IMG-0310a Fig 040 IMG-0313a 9.
  • Page 33 CHASSIS 3. Position the hose clamp and tighten (Fig. 042). 5. Loosely install a bolt, lock washer, and washer through the frame and into the front left corner of the fuel tank (Fig. 044). Fig 042 IMG-0320a Fig 044 IMG-0310a 4.
  • Page 34 CHASSIS 7. Tighten the 3 nuts until three threads protrude past 9. Install the right rear wheel assembly (Fig. 048). the nut. Do not over-tighten (Fig. 046). Fig 048 IMG-0307a Fig 046 PICT-3290a 10. Install the negative battery cable. 8. Tighten the bolt located in the front corner of the tank to frame (Fig.

  • Page 35: Left Side Fuel Tank Removal

    CHASSIS Left Side Fuel Tank Removal 3. Disconnect the negative battery cable. 4. Remove the left rear wheel assembly (Fig. 052). 1. Raise the seat and remove the front engine shield (Fig. 050). Fig 052 IMG-0322a Fig 050 IMG-0303a 5. Remove the 4 screws and washers securing the control panel to the fuel tank (Fig.
  • Page 36 CHASSIS 6. Remove the cable tie securing the throttle cable to 8. Remove the hose clamp from the fuel return line and the fuel fitting (Fig. 054). fitting located on the operator’s side of the fuel tank (Fig. 056). Fig 054 IMG-0328a Fig 056 IMG-0333a...
  • Page 37 CHASSIS 10. Remove the hose clamp from the fuel intake line and 12. Remove the nuts, springs and washers from the 3 fitting located on the underside of the fuel tank (Fig. fuel tank mounting studs located on the underside of 058).

  • Page 38: Left Side Fuel Tank Installation

    CHASSIS Left Side Fuel Tank Installation 14. Remove the bolt and washers securing the right front corner of the fuel tank to the frame (Fig. 062). 1. Position the fuel tank onto the frame (Fig. 064). Fig 062 IMG-0350a Fig 064 IMG-0345a 15.
  • Page 39 CHASSIS 3. Slide the hose clamp onto the fuel intake hose. 5. Loosely install a washer, spring and nut onto each Install the fuel intake hose onto the fuel-fitting barb of the three studs on the underside of the fuel tank located on the underside of the fuel tank.
  • Page 40 CHASSIS 7. Install the fuel shut-off valve to the fuel valve bracket 9. Install a cable tie securing the throttle cable to the with a washer and nut (Fig. 070). fuel tank fitting located on the operator’s side of the fuel tank (Fig.

  • Page 41: Fuel Tank Fitting Replacement

    CHASSIS Fuel Tank Fitting Replacement 2. Using a magnet tool, remove the fitting from the inside of the fuel tank (Fig. 076). There are 2 fuel fittings located on each of the fuel tanks. The following procedure can be used to replace any of the fittings (Fig.
  • Page 42 CHASSIS 4. Loosely install a washer and nut to secure the fuel Right side fuel tank operator’s side fitting tank fitting to the fuel tank (Fig. 078). Fig 080 DSC-4856a Fig 078 IMG-7772a Left side fuel tank operator’s side fitting 5.

  • Page 43: Hood Assembly Replacement

    CHASSIS Hood Assembly Replacement 3. Lift the hood and remove from the machine (Fig. 084). Hood Assembly Removal 1. Unhook the rubber latch that is located on the rear of the hood (Fig. 082). Fig 084 IMG-0369a Fig 082 IMG-0361a 2.

  • Page 44: Hood Assembly Installation

    CHASSIS Hood Assembly Installation 2. Install a clevis pin, washer and hairpin cotter into each of the pivot brackets (Fig. 086). 1. Align the hood pivot brackets with holes in the pivot Note: The hood screen can contact the radiator cap. bracket on the frame (Fig.
  • Page 45 CHASSIS Hood hinge plate adjustment slots (Fig. 087). 3. Lower the hood and hook the rubber latch located at the rear of the hood (Fig. 089). Fig 087 IMG-0381a Fig 089 IMG-0361a Hood pivot plate adjustment slots (Fig. 088). Fig 088 IMG-0382a 3-24 Z580/Z589 DFI Z Master Service Manual...

  • Page 46: Throttle Control Assembly Replacement

    CHASSIS Throttle Control Assembly 4. Remove the 4 screws securing the control panel to the left hand fuel tank (Fig. 091). Replacement Throttle Control Assembly Removal 1. Raise the seat. 2. Disconnect the negative battery cable from the battery terminal. 3.
  • Page 47 CHASSIS 6. Remove the front engine panel shield assembly (Fig. 8. Remove the cable tie securing the throttle cable to 093). the bracket located behind the voltage regulator (Fig. 095). Fig 093 IMG-0303a Fig 095 IMG-0387a 7. Remove the cable tie securing the throttle cable to 9.

  • Page 48: Throttle Control Assembly Installation

    CHASSIS Throttle Control Assembly Installation 10. Remove the z-bend end of the cable from the throttle arm assembly (Fig. 097). 1. Slide the throttle cable through the slot in the side of the control panel (Fig. 098). Fig 097 IMG-0390a Fig 098 IMG-0392a 11.
  • Page 49 CHASSIS 3. Install the carriage bolts and locknuts securing the 5. Route the throttle cable behind the engine breather throttle control assembly to the control panel (Fig. tube (Fig. 102). 100). Fig 102 IMG-0397a Fig 100 IMG-0386a 6. Then route the cable back on the right side of the 4.
  • Page 50 CHASSIS 7. Insert the z-bend of the throttle cable into the throttle 9. Install the 4 screws securing the control panel to the arm assembly (Fig. 104). left hand fuel tank. Install the knob for the throttle control assembly. Move the throttle control to the low idle speed setting (Fig.
  • Page 51 CHASSIS 11. Install a cable tie securing the throttle cable to the 13. Install the front engine shield assembly (Fig. 110). bracket located behind the voltage regulator (Fig. 108). Fig 110 IMG-0303a Fig 108 IMG-0414a 14. Connect the negative battery cable. 15.

  • Page 52: Brake Lever Replacement

    CHASSIS Brake Lever Replacement 6. Lift the floor pan assembly. 7. Remove the brake lever pivot shaft cotter pin (Fig. The left fuel tank and hood have been removed for photo 112). purposes. Brake Lever Removal 1. Raise the seat. 2.
  • Page 53 CHASSIS 9. With a hammer and punch tap out the two pivot bushings (Fig. 114). Fig 114 PICT-2883a 10. Inspect the brake shaft and bushings for excessive wear. Replace any worn or damaged components (Fig. 115). Fig 115 PICT-2887a 3-32 Z580/Z589 DFI Z Master Service Manual...

  • Page 54: Brake Lever Installation

    CHASSIS Brake Lever Installation 4. Install a cotter pin into the pivot shaft (Fig. 118). 1. Raise the floor pan assembly. 2. Install the two bushings into the brake lever pivot mounting hole (Fig. 116). Fig 118 IMG-7922a 5. Lower the floor pan assembly. Fig 116 PICT-2891a 6.

  • Page 55: Brake Band Replacement

    CHASSIS Brake Band Replacement 2. Remove the 3 bolts, spacer and retainer from the brake band assembly (Fig. 121). Note: The following procedures can be followed for both right and left brake band removal and installation. Brake Band Removal 1. Remove the rear tire (Fig. 120). Fig 121 PICT-2920a 3.

  • Page 56: Brake Band Installation

    CHASSIS Brake Band Installation 4. Remove the brake band from the wheel and hub assembly (Fig. 123). 1. Slide the brake band onto the wheel hub assembly (Fig. 125). Fig 123 PICT-2933a Fig 125 PICT-2933a 5. Inspect the brake band. Replace if worn or damaged.
  • Page 57 CHASSIS 3. Position the brake band retainer and loosely install 2 5. Tighten the 3 brake band retainer bolts (Fig. 129). bolts through the retainer, brake band spacers and into the brake bracket (Fig. 127). Fig 129 PICT-2942a Fig 127 PICT-2941a 6.

  • Page 58: Brake Cross Shaft Replacement

    CHASSIS Brake Cross Shaft Replacement 4. Remove the two clevis spring pins securing the brake rod linkage yokes to the left side of the brake cross shaft (Fig. 132). Note: The front engine shield has been removed for photo purposes. Brake Cross Shaft Removal 1.
  • Page 59 CHASSIS 6. Remove the 2 bolts and nuts securing the right side 8. Remove brake cross shaft (Fig. 136). flange bearing to the frame. Remove the flange bearing from the cross shaft (Fig. 134). Fig 136 PICT-2964a Fig 134 PICT-2958a 9.

  • Page 60: Brake Cross Shaft Installation

    CHASSIS Brake Cross Shaft Installation 3. Position the flange bearing on the right end of the cross shaft and install 2 bolts and nuts securing the flange bearing to the frame (Fig. 140). 1. Slide the brake cross shaft into position (Fig. 138). Note: The end of the cross shaft with two tabs is installed on the left side of the machine.
  • Page 61 CHASSIS 5. Ensure the brake cross shaft rotates freely in the 8. Install the left and right rear tires and lower the flange bearings. machine to the ground (Fig. 144). 6. Install the clevis spring pin securing the brake rod linkage yoke to the right side of the brake cross shaft (Fig.

  • Page 62: Deck Lift Lever Replacement

    CHASSIS Deck Lift Lever Replacement 5. Lower the mower deck onto the blocks to remove tension from the deck lift chains (Fig. 146). Deck Lift Lever Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2.
  • Page 63 CHASSIS 7. Loosen the jam nut and hex nut on the right hand 9. Lower the deck lift lever to its lowest position. The and left hand deck lift rods until the deck support rear deck swivel mounts should clear the deck lift springs are fully extended (Fig.
  • Page 64 CHASSIS 11. Remove the outside hex head flange nut at the top 13. Raise the floor pan. of the inner deck lift plate. Remove the hitch pin assembly from the bolt (Fig. 152). 14. Remove the front bolt and nut that secure the 2 deck lift arms to the deck lift cross shaft assembly.
  • Page 65 CHASSIS 16. Remove the deck lift lever assembly from the pivot 17. If there is interference between the lift lever assemb- (Fig. 156). ly and the floor pan hinge, loosen the right hand floor pan hinge mounting hardware, push the hinge upward and re-tighten the floor pan hinge mounting hardware (Fig.

  • Page 66: Deck Lift Lever Installation

    CHASSIS Deck Lift Lever Installation 3. Slide the bushing into the hole in the cross shaft assembly tab (Fig. 162). 1. Slide the deck lift lever assembly pivot into the pivot mount on the frame (Fig. 160). Fig 162 PICT-3019a Fig 160 PICT-3011a 4.
  • Page 67 CHASSIS 5. Rotate the inner deck lift plate down to the mounting 8. Slide the hitch pin lanyard onto the bolt (Fig. 166). hole in the frame. Position a spacer in between the inner and outer plates. Install a bolt and nut to secure (Fig.
  • Page 68 CHASSIS 10. Lift up on the lift lever and install the lower stop bolt 12. Install a hex nut onto the back end of the right and into the deck lift plate (Fig. 168). left deck lift assemblies (Fig. 170). Fig 168 PICT-2978a Fig 170...

  • Page 69: Motion Control Assembly Replacement

    CHASSIS Motion Control Assembly 14. Check the deck level adjustment. Refer to “Leveling the Mower” on page 7-79. Replacement 15. Apply grease to the grease fitting on the deck lift Motion Control Assembly Removal lever pivot (Fig. 172). 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key.
  • Page 70 CHASSIS 5. Remove the floor pan assembly (Fig. 174). 7. Remove the pocket (Fig. 176). Fig 174 PICT-3053a Fig 176 PICT-3057a 6. Remove the 2 top pocket mounting bolts, washers and nuts and the 2 bottom pocket mounting bolts and nuts (Fig. 175). Note: Raise the seat to remove the top two bolts and nuts.

  • Page 71: Right Hand Motion Control Assembly Removal

    CHASSIS Right Hand Motion Control Assembly 10. Disconnect the harness from the neutral switch located under the right side of the traction frame Removal assembly (Fig. 179). 8. Remove the 2 bolts and washers securing the right lever to the control shaft arm. Remove the right lever (Fig.
  • Page 72 CHASSIS 12. Remove the cotter pin and clevis pin that secure the 14. Remove the 2 bolts and nuts securing the side neutral return yoke to the right hand motion control flange bearing to the inside of the traction frame assembly (Fig.

  • Page 73: Left Hand Motion Control Assembly Removal

    CHASSIS Left Hand Motion Control Assembly 16. Remove the right hand motion control assembly and right hand control shaft arm assembly (Fig. 185). Removal 18. Remove the 2 bolts, and washers securing the left lever to the control shaft arm. Remove the left lever (Fig.
  • Page 74 CHASSIS 20. Disconnect the harness from the neutral switch 23. Loosen the left hand neutral return assembly jam located under the traction frame assembly. nut. Remove the yoke from the neutral return bolt (Fig. 191). Note: Access the switch from under the seat area. 21.
  • Page 75 CHASSIS 25. Remove the left hand control rod assembly (Fig. 27. Remove the left hand motion control assembly and 193). left hand control shaft arm assembly (Fig. 195). Fig 195 PICT-3135a Fig 193 PICT-3133a 28. Inspect the side flange bearings. Replace if worn or 26.

  • Page 76: Left Hand Motion Control Assembly Installation

    CHASSIS Left Hand Motion Control Assembly 3. Install 2 bolts and nuts securing the side flange bearing to the inside of the traction frame (Fig. 199). Installation 1. Slide a side flange bearing onto each end of the left hand motion control assembly (Fig. 197). Fig 199 PICT-3128a Fig 197...
  • Page 77 CHASSIS 5. Install a bolt, washer and nut securing the left hand 7. Position the left hand neutral return yoke to the left control rod ball joint to the hydrostatic pump control hand motion control tab and install a clevis pin and arm (Fig.

  • Page 78: Right Hand Motion Control Assembly Installation

    CHASSIS Right Hand Motion Control Assembly 11. Position the side flange bearing to the left hand motion control assembly and loosely install 2 bolts Installation and nuts to secure the side flange bearing (Fig. 207). 9. Slide a side flange bearing onto each end of the right motion control assembly (Fig.
  • Page 79 CHASSIS 13. Thread the yoke onto the neutral return bolt (Fig. 15. Tighten the jam nut to secure the yoke (Fig. 211). 209). Note: The neutral return spring may need adjust­ ment after the motion contol levers are instal­ led. The motion control lever, when moved to reverse position, should spring back to the neutral postions when the handles are let go.
  • Page 80 CHASSIS 17. Install a bolt, washer and nut securing the left hand 19. Connect the harness to the 2 neutral switches control rod assembly to the left hand motion control located under the seat, behind the left hand and right assembly (Fig.
  • Page 81 CHASSIS 20. Tighten all 6 bolts and nuts securing the 4 side C. Flange bearing mounted to the inside (left) of the flange bearings: traction frame (Fig. 219). A. Flange bearing mounted to the inside (right) of the traction control frame (Fig. 217). Fig 219 PICT-3161a Fig 217...

  • Page 82: Motion Control Assembly Installation

    CHASSIS Motion Control Assembly Installation 22. Position the right hand control lever to the right hand control shaft arm. Install 2 bolts, and washers securing the right hand lever to the control shaft arm 25. Insert the pocket into the traction frame (Fig. 222). (Fig.

  • Page 83: Motion Control Damper Replacment

    CHASSIS Motion Control Damper Replacment 27. Position the floor pan assembly (Fig. 224). There is a right and a left motion control damper. The following removal and installation procedures are done on the right damper. The procedure is the same for the left damper.
  • Page 84 CHASSIS 5. Remove the outer nut from the bolt on the upper end Damper Assembly (Fig. 229) of the damper (Fig. 227). Fig 229 PICT-3181a Fig 227 PICT-3173a 6. Remove the damper assembly (Fig. 228). Fig 228 PICT-3178a Z580/Z589 DFI Z Master Service Manual 3-63...

  • Page 85: Motion Control Damper Installation

    CHASSIS Motion Control Damper Installation 4. Insert the lower damper bolt into the frame and install a nut to secure the lower end of the damper (Fig. 232). 1. Raise the seat. 2. Position the damper assembly with the rod end down (Fig.

  • Page 86: Adjusting The Parking Brake

    CHASSIS Adjusting the Parking Brake 1. Engage the parking brake, (lever up). 2. Measure the length of the spring. Measurement should be 2-1/2” (64mm) between the washers (Fig. 233). Fig 233 fig. 57 G001294 A. Brake lever in B. Spring 2-1/2” (64mm) engaged position C.
  • Page 87 CHASSIS THIS PAGE INTENTIONALLY LEFT BLANK. 3-66 Z580/Z589 DFI Z Master Service Manual...

  • Page 88: Hydraulic System

    HYDRAULIC SYSTEM Hydrostatic Tandem Pump 5. Remove the pump idler arm spring using a spring tool (Toro p/n: 92-5771) (Fig. 235). 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.
  • Page 89 HYDRAULIC SYSTEM 7. Remove the 2 pump pulley set screws (Fig. 237). 9. Remove the key from the keyway (Fig. 239). Fig 237 IMG-0433a Fig 239 IMG-0439a 8. Remove the pump pulley (Fig. 238). 10. Remove the bolt, nut and washer securing the right hand control rod assembly to the pump control arm (Fig.
  • Page 90 HYDRAULIC SYSTEM 11. Remove the bolt, nut and washer securing the left 13. Unplug the harness from the PTO clutch connector hand control rod assembly to the pump control arm (Fig. 243). (Fig. 241). Fig 243 IMG-0441a Fig 241 PICT-3196a 14.
  • Page 91 HYDRAULIC SYSTEM 15. Remove the hose clamp located on the hydraulic 17. Raise the rear of the unit and remove both right and suction hose coming from the oil filter (Fig. 245). left rear tires. 18. Mark or tag the wheel motor hydraulic hoses and fittings to ensure they are reconnected correctly.
  • Page 92 HYDRAULIC SYSTEM 21. Remove the two hydraulic hoses from the LH wheel 23. Remove the hose clamp located on the hydraulic motor (Fig. 249). hose routed from the oil cooler to the left side of the hydrostatic pump (Fig. 251). Fig 249 PICT-3208a Fig 251...
  • Page 93 HYDRAULIC SYSTEM 25. Remove the two bolts, washers and nuts securing 27. Remove the two bolts, washers, and nuts holding the front of the hydrostatic pump (by the input shaft) the pump bracket to the frame of the unit (Fig. 255). to the frame (Fig.
  • Page 94 HYDRAULIC SYSTEM 29. Carefully lower the hydrostatic pump from the frame 31. Remove all 4 wheel motor hoses from the pump (Fig. 257). fittings (Fig. 259). Fig 257 PICT-3271a Fig 259 PICT-3300a 30. Mark the wheel motor hose and pump fitting 32.

  • Page 95: Hydrostatic Tandem Pump Installation

    HYDRAULIC SYSTEM Hydrostatic Tandem Pump Installation 33. Remove the set screw securing the control arm to the pump control shaft. Remove the control arm from the pump control shaft (Fig. 261). 1. Apply thread locking compound to the pump control arm set screw (Fig.
  • Page 96 HYDRAULIC SYSTEM 3. Repeat steps 1 and 2 to install the other control arm 7. Align the pump mounting bracket to the frame and to the opposite pump control shaft. loosely install 2 bolts, washers and nuts (Fig. 267). 4. Position the pump mounting bracket to the pump. Loosely install 2 bolts, washers and nuts securing the pump mounting bracket to the pump (Fig.
  • Page 97 HYDRAULIC SYSTEM 9. Tighten the 2 bolts securing the pump mounting 11. Install the LH wheel motor hoses. Note the location bracket to the bracket on the frame. Tighten the 2 of each of the hoses by the markings on the hoses bolts securing the mounting bracket to the pump and wheel motor fittings (Fig.
  • Page 98 HYDRAULIC SYSTEM 14. Tighten the RH wheel motor hose fittings at the 17. Slide a hose clamp over the hydraulic suction hose pump and at the wheel motor. (Fig. 275). 15. With the hose clamp on the oil cooler hose, slide the hose onto the pump fitting (Fig.
  • Page 99 HYDRAULIC SYSTEM 19. Position the hose clamp and tighten (Fig. 277). 21. Install a cable tie securing the PTO clutch wire to the frame (Fig. 279). Fig 277 PICT-3337 Fig 279 PICT-3200a 20. Plug the harness plug into the PTO clutch connector (Fig.
  • Page 100 HYDRAULIC SYSTEM 23. Position the left hand control rod ball joint to the 25. Apply anti-seize compound onto the pump input pump control arm. Install a bolt, washer and nut shaft (Fig. 283). securing the left hand control rod assembly to the pump control arm (Fig.
  • Page 101 (Fig. 285). 287). Fig 285 PICT-3307a Fig 287 PICT-3345a 28. Loosely install the 2 set screws into the pump pulley Belt Alignment Tool (Toro p/n: 110-0876) (Fig. 288): (Fig. 286). Fig 288 alignment tool _a Fig 286 PICT-3342a 4-14...
  • Page 102 HYDRAULIC SYSTEM 30. Hook the belt alignment tool (Toro p/n: 110-0876) 31. Rotate the too so that it faces to the right side of the onto the engine drive sheave. Align the hydro pump machine. Hook the end into the hydro pump drive drive pulley so that the tool lies squarely within the pulley on the front of the engine.
  • Page 103 HYDRAULIC SYSTEM 32. Tighten the 2 pump pulley set screws. Torque to 34. Using a spring tool (Toro p/n: 92-5771), install the 12.1 + 1.6 in-lbs. (1.37 + 0.18 Nm) (Fig. 291). pump idler arm spring (Fig. 293). Fig 291...

  • Page 104: Wheel Motor Replacement

    HYDRAULIC SYSTEM Wheel Motor Replacement 37. Install the negative battery cable. 38. Lower the seat. The following procedures are the same for the left and right wheel motor. 39. Purge the hydraulic system. Refer to “Purging the Hydraulic System” on page 4-26. 40.
  • Page 105 Fig 296 PICT-3351a Fig 298 PICT-3358a 7. Using a Wheel Hub Puller (Toro p/n: TOR4097), remove the wheel hub from the wheel motor shaft (Fig. 297). 10. Mark or tag the wheel motor hoses and fittings to ensure they are reconnected correctly (Fig. 299).
  • Page 106 HYDRAULIC SYSTEM 11. Disconnect the wheel motor hoses from the wheel 13. Loosen all 4 wheel motor mounting bolts (Fig. 302). motor fittings (Fig. 300). Note: Cap the hoses and fittings to prevent debris from entering the system. Fig 302 PICT-3370a 14.
  • Page 107 HYDRAULIC SYSTEM 15. Swing the brake linkage forward away from the 17. Remove the wheel motor (Fig. 306). wheel motor (Fig. 304). Fig 306 PICT-3378a Fig 304 PICT-3374a 18. For wheel motor service, refer to Parker/Ross Wheel Motor Service Manual (form no. 492-4753). 16.

  • Page 108: Wheel Motor Installation

    HYDRAULIC SYSTEM Wheel Motor Installation 1. Insert the wheel motor into the frame. Loosely install the 2 rear wheel motor mounting bolts, long spacers and nuts (Fig. 308). Note: As a reminder, prior to connecting the hy- draulic lines, the o-rings should be replaced with new ones and lightly lubricated with petroleum jelly.
  • Page 109 HYDRAULIC SYSTEM 3. Loosely install the 2 front wheel motor mounting 5. Install the wheel motor fittings. Note the location bolts, short spacers and nuts (Fig. 310). markings (Fig. 312). Fig 310 PICT-3376a Fig 312 PICT-3367a 4. Torque the 4 wheel motor mounting bolts to 100 + 8 6.
  • Page 110 HYDRAULIC SYSTEM 7. Slide the brake band assembly over the wheel motor 10. Apply the parking brake. hub. Install the 3 spacers, the retainer and 3 brake band bolts into brake bracket (Fig. 314). 11. Install a castle nut onto the wheel motor shaft. Torque the castle nut to 125 ft-lbs (170 Nm) (Fig.
  • Page 111 HYDRAULIC SYSTEM 12. Check the distance from bottom of the slot in the nut Note: If more than two threads are showing remove to the inside edge of the hole. Two threads or less nut and install washer between hub and nut should be showing (Fig.
  • Page 112 HYDRAULIC SYSTEM 13. Install a cotter pin into the wheel motor shaft (Fig. 319). Fig 319 PICT-3350a 14. Install the rear wheel. 15. Install the negative battery cable. 16. Lower the seat. 17. Purge the hydraulic system. Refer to “Purging the Hydraulic System”...

  • Page 113: Purging The Hydraulic System

    HYDRAULIC SYSTEM Purging the 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. 321). 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.

  • Page 114: Adjusting The Control Handle Neutral Position

    HYDRAULIC SYSTEM Adjusting the Control Handle Neutral 4. Begin with either the left or right motion control lever. Position 5. Move the lever to the neutral position but not locked (Fig. 323). If the motion control levers do not align or do not move easily into the console notch, adjustment is required.

  • Page 115: Setting The Hydrostatic Pump Neutral

    HYDRAULIC SYSTEM Setting the Hydrostatic Pump Neutral 8. If adjustment is needed, loosen the nut and jam nut against the yoke (Fig. 324). 1. Raise the machine and support with jack stands so that the rear tires are off the ground (Fig. 325). Fig 324 fig.

  • Page 116: Setting The Right Hydraulic Pump Neutral Position

    HYDRAULIC SYSTEM Setting the Right Hydraulic Pump Neutral 3. Remove the bolt and nut securing the seat rod to the seat. Rotate the seat rod up and out of the way of Position the hydrostatic pump (Fig. 327). 5. Place the motion control levers in the neutral position.

  • Page 117: Setting The Left Hydraulic Pump Neutral Position

    HYDRAULIC SYSTEM Setting the Left Hydraulic Pump Neutral 12. Start the engine, open the throttle 1/2 way and release the parking brake. Position 13. Adjust the pump rod length by rotating double nuts 10. Place the motion control levers in the neutral on rod, in the appropriate direction, until wheel is position.
  • Page 118 HYDRAULIC SYSTEM 16. Tighten the jam nuts at the ball joints (Fig. 332). Fig 332 PICT-3486a 17. After both pump neutrals are set, shut off the machine. 18. Remove the jumper wire from the wire harness ter- minals and plug the terminals into the seat switch (Fig.

  • Page 119: Adjusting The Tracking

    HYDRAULIC SYSTEM Adjusting the Tracking 6. To make the machine go left, turn the knob towards the left side of the machine (Fig. 335). The machine has a knob located under the seat to adjust the tracking. Important: Adjust the handle neutral and hydrostatic pump neutral before adjusting the tracking.

  • Page 120: Hydraulic Flow Testing

    HYDRAULIC SYSTEM Hydraulic Flow Testing 2. Clean any dirt or debris away from the hydraulic line fittings. Mark each of the hoses and fittings so they will be properly re-installed after testing. Remove the The following procedure was performed on the right hydraulic lines.
  • Page 121 6. Lift the seat and unplug the harness terminals from the seat switch. Temporarily install a jumper wire Fig 338 PICT-3507a across the harness terminals (Fig. 340). 4. Check the hydraulic reservoir. Fill as needed with Toro Hypr-Oil™ 500 hydraulic oil or Mobil ® ® 15w-50 oil. Fig 340...
  • Page 122 HYDRAULIC SYSTEM 7. Verify the restrictor valve on the hydraulic flow tester 10. Stroke the left hand hydrostatic lever fully forward. is in the fully “Opened” position (Fig. 341). Very slowly, rotate the “T” handle of the adjustable flow tester restrictor valve until the pressure gauge reaches 500 PSI (3447 kPa).
  • Page 123 HYDRAULIC SYSTEM 12. Record the difference or “flow droop” of the pump. 17. Reinstall the rear tire and lower the unit to the For the Hydro-Gear PR Series pump, maximum ground. allowable “flow droop” is 2.5 gpm (9.46lpm). Any droop greater than 2.5 gpm (9.46lpm) is considered 18.

  • Page 124: Traction Pump Drive Belt Replacement

    HYDRAULIC SYSTEM Traction Pump Drive Belt 5. Unplug the harness connector from the electric PTO clutch (Fig. 348). 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.
  • Page 125 Fig 350 IMG-0461a Fig 352 PICT-3519a 8. With a spring tool (Toro p/n: 92-5771), remove the gear box idler assem bly spring (Fig. 351). 10. Using a spring tool (Toro p/n: 92-5771), remove the traction pump idler assembly spring (Fig. 353).

  • Page 126: Traction Pump Drive Belt Installation

    HYDRAULIC SYSTEM Traction Pump Drive Belt Installation 11. Remove the traction pump drive belt from the pump pulley. Lift up on the gearbox idler pulley and re- move the belt by sliding it out around the electric 1. Slide the traction pump drive belt over the electric PTO clutch (Fig.
  • Page 127 HYDRAULIC SYSTEM 3. Using a spring tool (Toro p/n: 92-5771), install the 5. Position the clutch stop bracket (Fig. 359). traction pump idler assembly spring (Fig. 357). Fig 359 IMG-0461a Fig 357 IMG-0421a 6. Using a spring tool (Toro p/n: 92-5771) install the gear box idler assembly spring (Fig.
  • Page 128 HYDRAULIC SYSTEM 7. Install 2 carriage bolts and nuts to secure the clutch 9. Install the front engine panel (Fig. 363). stop bracket to the frame (Fig. 361). Fig 363 IMG-0303a Fig 361 IMG-0460a 10. Install the negative battery cable from the battery. 8.

  • Page 129: Hydraulic Oil Cooler Replacement

    HYDRAULIC SYSTEM Hydraulic Oil Cooler Replacement 4. Lift the hydraulic cooler from the radiator top plate (Fig. 366). Hydraulic Oil Cooler Removal 1. Park the machine on a level surface, disengage the PTO, engage the parking, turn the ignition OFF and remove the key.

  • Page 130: Hydraulic Oil Cooler Installation

    HYDRAULIC SYSTEM Hydraulic Oil Cooler Installation 3. Install carriage bolt through the right side radiator top plate and R-clamp and then a washer and nut (Fig. 370). 1. Install R-clamps on the right and left side of the hydraulic oil cooler (Fig. 368). Fig 370 IMG-0471a Fig 368...

  • Page 131: Hydraulic Reservoir Tank Replacement

    4. Raise the floor pan assembly (Fig. 371). Fig 372 PICT-3389a 6. Unhook the idler spring from the mower deck idler arm and spring post with a spring tool (Toro p/n: 92- 5771) (Fig. 373). Fig 371 PICT-3388a Fig 373...
  • Page 132 HYDRAULIC SYSTEM 7. Remove the mower deck belt from the PTO drive 10. Slide the hose clamp down the oil cooler hose, off pulley (Fig. 374). the tank fitting barb (Fig. 376). Fig 374 IMG-0627a Fig 376 PICT-3396a 8. Place a drain pan under the hydraulic reservoir tank. 11.
  • Page 133 HYDRAULIC SYSTEM 12. Remove the 2 bolts, washers and nuts securing the reservoir to the hydraulic tank bracket (Fig. 378). Fig 378 PICT-3409a 13. Remove the hydraulic reservoir (Fig. 379). Fig 379 PICT-3411a 4-46 Z580/Z589 DFI Z Master Service Manual...

  • Page 134: Hydraulic Reservoir Tank Installation

    HYDRAULIC SYSTEM Hydraulic Reservoir Tank Installation 3. Install 2 bolts, washers and nuts to secure the reser- voir to the hydraulic tank bracket (Fig. 382). 1. Transfer the 2 hydraulic tank fittings to the new hydraulic reservoir tank (Fig. 380). Fig 382 PICT-3409a Fig 380...
  • Page 135 6. Install the hydraulic filter hose to the fitting on the 8. Hook the idler spring from the mower deck idler arm bottom of the hydraulic reservoir (Fig. 385). to the spring post using a spring tool (Toro p/n: 92- 5771) (Fig. 387). Fig 385...
  • Page 136 HYDRAULIC SYSTEM 9. Install the left hand mower deck belt cover (Fig. 11. Install the negative battery cable. 388). 12. Lower the seat. 13. Fill the reservoir to the cold oil level (Fig. 390). Fig 388 PICT-3389a Fig 390 fig 55 line art 10.

  • Page 137: Pushing The Machine By Hand

    HYDRAULIC SYSTEM Pushing the Machine by Hand Switching from Hand Pushing the Machine to Machine Operation 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked 1. Engage the parking brake. position and apply parking brake.

  • Page 138: Engine

    ENGINE Engine Replacement 7. Remove the 2 bolts and nuts retaining the air clean- er bracket to the bottom radiator plate (Fig. 394). Engine Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition OFF and remove the key. 2.
  • Page 139 ENGINE 9. Remove the 4 bolts, washers and nuts retaining the 11. Remove the rear 2 bolts, washers and nuts retain ing bottom radiator plate to the right hand and left hand the rear guard assembly to the bottom radiator plate radiator brace assemblies (Fig.
  • Page 140 ENGINE 13. Remove the bottom radiator plate from the radiator 15. Remove the air cleaner assembly from the engine brace assemblies (Fig. 400). (Fig. 402). Fig 402 IMG-0516a Fig 400 IMG-0514a 16. Loosen and remove the 2 bolts, washers, and nuts 14.
  • Page 141 ENGINE 17. Remove 1 bolt, washer and nut retaining the 19. Remove the 2 bolts and nuts retaining the rear guard R-clamp to the left side strap guard (Fig. 404). Re- assembly to the frame (Fig. 406). move the R-clamp. Fig 406 IMG-0522a Fig 404...
  • Page 142 24. Remove the cable tie securing the throttle cable to PTO Clutch Removal” on page 7-34. on the bracket behind the voltage regulator (Fig. 410). 22. Using a spring tool (Toro P/N 92-5771), remove the hydraulic pump idler arm spring (Fig. 408). Fig 410 IMG-0535a...
  • Page 143 ENGINE 26. Remove the Z-bend of the throttle cable from the 28. Pull the radiator overflow tube forward, away from engine throttle linkage (Fig. 412). the engine (Fig. 414). Fig 414 IMG-0542a Fig 412 IMG-0539a 29. Loosen the hose clamp located on the fuel line next 27.
  • Page 144 ENGINE 30. At the return fuel line “T” fitting, remove the hose 32. Remove the plug connector to the starter solenoid clamp and fuel line that runs to the fuel shutoff valve (Fig. 418). (Fig. 416). Fig 418 IMG-0551a Fig 416 IMG-0548a 33.
  • Page 145 ENGINE 34. Unplug the orange to white wire plug that goes to the 36. Cut the cable tie retaining the wires going to the voltage regulator (Fig. 420). starter solenoid (Fig. 422). Fig 420 IMG-0554a Fig 422 IMG-0560a 35. Unplug the connector from the wiring harness to the 37.

  • Page 146: Engine Installation

    ENGINE Engine Installation 38. From the bottom of the frame, remove the 4 engine bolts and Belleville washers securing the engine (Fig. 424). 1. Lower the engine onto the frame. Install 4 bolts and Belleville washers through the frame and into the base of the engine.
  • Page 147 ENGINE 4. Plug the orange and wire plug that goes to the 6. Install the plug connector to the starter solenoid (Fig. voltage regulator (Fig. 428). 430). Fig 428 IMG-0554a Fig 430 IMG-0575a 5. Install the 3 red wire terminals on the starter 7.
  • Page 148 ENGINE 8. Install the ground wires on the bolt and washer (Fig. 10. Install the fuel line from the fuel valve to the joint 432). connecting two fuel lines and tighten the hose clamp (Fig. 434). Fig 432 IMG-0580a Fig 434 IMG-0548a 9.
  • Page 149 ENGINE 12. Route the radiator overflow tube toward the rear of 14. Route the engine throttle cable behind the engine the engine between the fuel lines (Fig. 436). breather tube (Fig. 438). Fig 438 IMG-0541a Fig 436 IMG-0581a 15. The throttle cable routes back to the throttle linkage 13.
  • Page 150 ENGINE 16. Install the throttle cable into the throttle cable clamp. 18. Secure the throttle cable to the engine bracket Place the throttle lever in the Slow (idle) position located behind the voltage regulator with a cable tie (Fig. 440). (Fig.
  • Page 151 ENGINE 20. Connect the hydraulic pump idler spring to the pin on 23. Install the 2 bolts and nuts retaining the bottom of the idler arm, using a spring tool (Fig. 444). the rear guard assembly to the frame (Fig. 446). Fig 446 IMG-0522a Fig 444...
  • Page 152 ENGINE 25. Install a bolt through LH support bracket through the 27. Install the air cleaner inlet hose through the R-clamp strap guard and a nut (Fig. 448). located on the LH radiator brace assembly (Fig. 450). Fig 448 IMG-0603a Fig 450 IMG-0604a 26.
  • Page 153 ENGINE 29. With the cooling fan located on the bottom radiator plate, connect the cooling fan electrical plug to the wiring harness (Fig. 452). Fig 454 IMG-0608a 31. Install 2 bolts, washers and nuts retaining the rear Fig 452 IMG-0512a guard assembly to the bottom radiator plate (Fig.
  • Page 154 ENGINE 32. Install 2 bolts, washers, and nuts retaining the left 34. Install 2 bolts with washers through two holes on side of the bottom radiator plate to the LH radiator the bottom radiator plate, through the right and left brace assembly (Fig.
  • Page 155 ENGINE 36. Install 2 bolts through the air cleaner bracket and 39. Install the hood assembly. Refer to “Hood Assembly then through the bottom radiator plate and install 2 Installation” on page 3-23. nuts and tighten (Fig. 460). 40. Install the front engine panel (Fig. 462). Fig 460 IMG-0505a Fig 462...

  • Page 156: Radiator Replacement

    ENGINE Radiator Replacement 3. Raise the seat and remove the negative battery cable from the battery. Radiator Removal 4. Raise the hood assembly (Fig. 464). DANGER! Discharge of hot pressurized coolant or touching hot radiator and surrounding parts can cause severe burns. •...
  • Page 157 ENGINE 7. Allow the coolant to drain from the radiator. 11. Remove the 6 bolts and washers retaining the top radiator plate to the radiator (Fig. 468). 8. Turn the radiator petcock to the off position. 9. Remove the cable tie securing the overflow hose to the radiator cap barb (Fig.
  • Page 158 ENGINE 13. Remove the 6 bolts and washers retaining the radi- 15. Loosen and remove the hose clamp securing the left ator to the bottom radiator plate; 3 are located in hand radiator hose to the lower left hand corner of back of the radiator (Fig.

  • Page 159: Radiator Installation

    ENGINE Radiator Installation 18. Remove the radiator from the bottom radiator plate (Fig. 474). 1. Install the radiator on the bottom radiator plate (Fig. 475). Fig 474 IMG-0504a Fig 475 IMG-0504a 2. Install the left hand radiator hose on the lower left hand corner of the radiator and tighten the hose clamp (Fig.
  • Page 160 ENGINE 3. Install the right hand radiator hose to the right hand 5. Install the top radiator plate, along with the hydraulic corner of the radiator and tighten the hose clamp cooler, on top of the radiator (Fig. 479). (Fig. 477). Fig 479 IMG-0611a Fig 477...
  • Page 161 ENGINE 7. Slide the overflow hose through the slot located 9. With a pair of pliers, make sure the radiator petcock on the top radiator plate and onto the barb on the is closed (Fig. 483). radiator cap flange (Fig. 481). Fig 483 IMG-0472a Fig 481...
  • Page 162 ENGINE 12. Check the anti-freeze overflow bottle and make sure 13. Lower the hood assembly (Fig. 486). it is up to indicator line (Fig. 485). Fig 486 IMG-0616a 14. Install the negative battery cable to the battery and lower the seat. 15.

  • Page 163: Cooling Fan Replacement

    ENGINE Cooling Fan Replacement 3. Remove the rear guard assembly from the unit (Fig. 488). Cooling Fan Removal 1. Remove the radiator. Refer to “Radiator Removal” on page 5-19. 2. Remove the 6 bolts, washers, nuts on the top of the rear guard assembly and the 2 bolts and nuts at the bottom of the rear guard assembly (Fig.

  • Page 164: Cooling Fan Installation

    ENGINE Cooling Fan Installation 5. Lower the cooling fan and unplug the cooling fan connector from the harness connector (Fig. 490). 1. Slide the fan under the bottom radiator plate (Fig. 492). Fig 490 IMG-0499a Fig 492 IMG-0500a 6. Remove the cooling fan from under the bottom radiator plate (Fig.
  • Page 165 ENGINE 3. Install the 4 bolts, washers and nuts retaining the 5. Install 2 bolts, washers, and nuts on the top of fan assembly to the bottom radiator plate (Fig. 494). the rear guard and the bottom radiator plate and Tighten the bolts and nuts.

  • Page 166: Fuel Pump Replacement

    ENGINE Fuel Pump Replacement 5. Remove the cable tie around the fuel pump wires and the wiring harness (Fig. 498). Fuel Pump Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition switch OFF and remove the key.
  • Page 167 ENGINE 7. Remove 2 bolts and nuts retaining the fuel pump to 9. Loosen the hose clamp on the fuel line from the fuel the frame (Fig. 500). pump to the engine (Fig. 502). Remove the fuel line from the pump. Fig 500 IMG-0639a Fig 502...

  • Page 168: Fuel Pump Installation

    ENGINE Fuel Pump Installation 3. Install two bolts and nuts and mount the fuel pump to the frame (Fig. 506). 1. Install hose clamp around the fuel line from the engine to the fuel pump and tighten clamp (Fig. 504). Fig 506 IMG-0639a Fig 504...

  • Page 169: Checking The Radiator Coolant

    ENGINE Checking the Radiator Coolant Install a cable tie around fuel pump wires and the wiring harness (Fig. 508). Note: Do not open the radiator cap. Doing this may introduce air into the cooling system. 1. Position the machine on a level surface, stop the engine, and set the parking brake.

  • Page 170: Electrical

    ELECTRICAL General Location Note: Interactive Electrical Troubleshooting DVD, The 4 relays are located to the left of the engine attach- Form No. 492-9171 is also available. ed to the top support strap (Fig. 511). Relays There are four relays in the Z580 and Z589 liquid cooled Kawasaki DFI. Relays have 4 functions in the Z580 and Z590 Liquid Cooled models: •...

  • Page 171: How It Works

    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.

  • Page 172: Pto Switch

    ELECTRICAL PTO Switch 5. Disconnect voltage and multimeter leads from relay terminals (Fig. 514). Purpose The PTO (Power Take Off) switch is typically used to activate the Electric PTO Clutch and to function as part of the safety interlock system. Location The PTO switch is located on the control panel, on the left side of the operator (Fig.

  • Page 173: Testing

    ELECTRICAL Testing 6. Replace the switch if your test results do not cor- respond with those given in Fig. PTO switch test. 1. Disengage the PTO, set the parking brake, and turn 7. Mount the PTO switch back into the control panel the ignition to OFF and remove the key.

  • Page 174: Ignition Switch

    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 The ignition switch provides the proper switching for the released (Fig.

  • Page 175: Testing

    ELECTRICAL Neutral Safety Switch Testing Purpose 1. Disconnect the switch from the wiring harness. 2. Verify that continuity exists between the terminals Used to ensure the motion control handles are in neutral listed for the switch position. Verify that there is NO to start the unit.

  • Page 176: How It Works

    ELECTRICAL Parking Brake Switch How It Works Purpose 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 The purpose of the parking brake switch is to ensure the pushes on the plunger, closing the contact and connect- machine is in neutral and the parking brake is applied ing the terminals (Fig.

  • Page 177: How It Works

    ELECTRICAL How It Works Testing In the start position it is used to ensure the park brake 1. Disconnect the switch from the wiring harness. is in the ON position. At the same time it allows current to flow through for safety circuit. When the park brake The park brake switch is a double pole switch.

  • Page 178: Seat Switch

    ELECTRICAL Seat Switch How It Works Purpose When the seat is vacated, the switch is open and there should be NO continuity between the two terminals. When the seat is occupied, the switch closes and there The seat switch is in the safety circuit. If the engine is should be continuity between the two terminals (Fig.

  • Page 179: Delay Module

    ELECTRICAL Delay Module How It Works Purpose The seat delay module circuit board is made up of sev- eral different electrical components, such as a transient voltage suppressor, capacitor, transistors, carbon film When operating the unit on rough terrain and the oper- resistors, diodes and a relay. These all work together ator comes off the seat, the seat delay module will to supply seat switch temporary voltage to the circuit to temporarily delay the engine shutting down, preventing...

  • Page 180: Testing

    ELECTRICAL Testing Follow the procedure below to test the delay module function. 1. Raise the seat and disconnect the seat switch. 1. Disengage the parking brake. Install a jumper wire in place of the seat switch (Fig. 529). 2. Pull the right and left motion control levers out of the neutral position.

  • Page 181: High Temperature Audible Alarm (Solid Tone)

    ELECTRICAL High Temperature Audible Alarm How It Works (Solid Tone) A continuous tone will sound when the engine tempera- ture switch connects to ground as the engine reaches a Purpose certain temperature (Fig. 532). This machine has an audible alarm that alerts the user to turn off the engine or engine damage can occur from overheating.

  • Page 182: Temperature Sender

    ELECTRICAL Temperature Sender How It Works Purpose When the water temperature reaches an excessive operating temperature, the switch will close internally and ground the high temperature audible alarm and the The temperature sender is a temperature-dependent light on the control panel (Fig. 534). variable resistor.

  • Page 183: Oil Pressure Switch

    ELECTRICAL Oil Pressure Switch How It Works Purpose When the engine oil pressure builds, the switch closes to complete the circuit for both the hour meter and the cooling fan relay (Fig. 536). The oil pressure switch completes the circuit that activ- ates the hour meter and the radiator fan relay. Location The oil pressure switch is located on the lower left side of the engine block, next to the engine oil filter (Fig.

  • Page 184: Engine High Temperature & Malfunction Indicator Light Cluster

    ELECTRICAL Engine High Temperature & How It Works Malfunction Indicator Light Cluster The engine high temperature light is connected in par- allel with the high temperature audible alarm. The light Purpose gives a visual indicator that the engine has reached a high temperature. There are two purposes for this light cluster: The malfunction indicator light illuminates when it has 1.

  • Page 185: Testing

    ELECTRICAL Hour Meter Testing Purpose The indicator lights can be tested with an ohmmeter. There should be continuity between terminals, A - B and C - D (Fig. 539). The hour meter keeps track of the actual engine running hours. Location The hour meter is positioned on the control panel which is located on the left side of the operator position (Fig.

  • Page 186: How It Works

    ELECTRICAL Electric PTO Clutch How It Works Purpose 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 The electric clutch controls the engagement and disen- unwinds in about 2 seconds.

  • Page 187: How It Works

    ELECTRICAL How It Works Testing The PTO clutch is composed of three major compon- 1. Disengage the PTO, set the parking brake, turn the ents; the field, the clutch plate, and the friction plate. ignition to the “off” position and remove the ignition The clutch plate always turns with the engine.

  • Page 188: Clutch Coil Continuity Test

    ELECTRICAL Clutch Coil Continuity Test This test can be performed the same way on both the Warner and Orgura clutches. 1. Disengage PTO. 2. Raise the seat and disconnect the negative battery cable from the battery. 3. Unplug the harness connector from the clutch (Fig. 544).
  • Page 189 ELECTRICAL THIS PAGE INTENTIONALLY LEFT BLANK. 6-20 Z580/Z589 DFI Z Master Service Manual...

  • Page 190: Mower Decks

    3. Raise the floor pan (Fig. 545). Fig 546 PICT-4012a 5. Using a spring tool (Toro p/n: 92-5771), remove the mower deck belt idler spring (Fig. 547). Fig 545 PICT-4011a Fig 547...
  • Page 191 MOWER DECKS 6. Remove the belt guide from the idler arm pulley (Fig. 8. Install a new belt around the mower pulleys and the 548). gearbox pulley under the engine. Refer to the belt routing decal (Fig. 550). Fig 548 PICT-4060a Fig 550 fig.

  • Page 192: Mower Deck Removal

    MOWER DECKS Mower Deck Removal 10. Install mower deck belt idler spring (Fig. 552). 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.
  • Page 193 MOWER DECKS 6. Using a spring tool (Toro p/n: 92-5771), remove the 8. Place the mower deck in the transport position. mower deck idler spring (Fig. 556). 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.
  • Page 194 MOWER DECKS 10. Remove the outer nut from each of the 4 deck chain 12. Remove the bolt and nut securing the strut to the assemblies (Fig. 560). mower deck (Fig. 562). Fig 560 PICT-4023a Fig 562 PICT-4036a 11. Raise the deck lift lever to the transport position (Fig. 13.

  • Page 195: Mower Deck Installation

    MOWER DECKS Mower Deck Installation 15. Tie the struts up, out of the way of the mower deck. 16. Remove the 4 wood blocks from each corner of the 1. Turn the right front wheel so the castor fork is angled mower deck.
  • Page 196 MOWER DECKS 3. Slide a wood block under each corner of the mower 6. Place the mower deck in the transport position. deck. Remove the wood blocks from 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 7.
  • Page 197 MOWER DECKS 9. Route the mower deck belt around the mower deck 11. Install the left and right mower deck belt covers (Fig. pulleys and gearbox deck drive pulley. Refer to the 574). belt routing decal (Fig. 572). Fig 574 PICT-4012a Fig 572 fig.

  • Page 198: Mower Spindle Replacement

    3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 576). Fig 577 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 578). Fig 576 PICT-4011a Fig 578...
  • Page 199 MOWER DECKS 7. Remove the mower deck belt from the spindle pulley 9. 72” mower decks: Remove 3 bolts retaining the (Fig. 579). pulley to the pulley hub (Fig. 581). Fig 579 PICT-4044a Fig 581 DSC-2662a 8. Remove the nuts from the 6 spindle mounting bolts 10.
  • Page 200 MOWER DECKS 13. 60” mower decks: Remove the 6 spindle mounting 15. 60” mower decks: Remove the spindle blade bolt bolts securing the spindle housing to the mower and washer (Fig. 585). deck (Fig. 583). Fig 585 PICT-4050a Fig 583 PICT-4046a 16.

  • Page 201: Mower Deck Spindle Rebuild

    MOWER DECKS Mower Deck Spindle Rebuild 17. 60” mower decks: Remove the 3 bolts securing the pulley to the spindle hub (Fig. 587). 1. Remove the nut and washer (Fig. 589). Fig 587 PICT-4055a Fig 589 DSC-2669a 18. 60” mower decks: Remove the pulley from the spindle assembly (Fig.
  • Page 202 MOWER DECKS 3. Remove the bearing shield (Fig. 591). 5. Remove the seal spacer from the top of the spindle housing (Fig. 593). Fig 591 DSC-2671a Fig 593 DSC-2673a 4. Remove the spindle housing from the spindle shaft assembly (Fig. 592). 6.
  • Page 203 MOWER DECKS 7. Remove the top oil seal from the spindle housing 9. Remove the spacer (Fig. 597). (Fig. 595). Fig 597 DSC-2677a Fig 595 DSC-2675a 10. Turn the spindle housing over and remove the oil 8. Remove the tapered roller bearing from the top of seal from the bottom of the spindle housing (Fig.
  • Page 204 MOWER DECKS 11. Remove the tapered roller bearing from the bottom 13. Remove the large spacer in the spindle housing (Fig. of the spindle (Fig. 599). 601). Fig 599 DSC-2680a Fig 601 DSC-2682a 12. Using a hammer and a driver with a square edge, 14.
  • Page 205 MOWER DECKS 15. Install the spacer through the top of the spindle 17. Turn the spindle housing over and install the lower housing (Fig. 603). bearing race into the spindle housing (Fig. 605). Note: The wider inside diameter of the bearing race should be facing up to accept the tapered bearing.
  • Page 206 MOWER DECKS 19. Install the lower seal (Fig. 607). 21. Install the inner spacer to the spindle assembly (Fig. 609). Note: The open lip of the seal should be facing outward. Fig 609 DSC-2700a Fig 607 DSC-2692a 22. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig.
  • Page 207 MOWER DECKS 23. Install the seal. Press it flush with the top of the 25. Lower the spindle housing over the spindle shaft housing (Fig. 611). (Fig. 613). Note: The open lip of the seal faces inward. Fig 613 DSC-2703a Fig 611 DSC-2696a 26.
  • Page 208 MOWER DECKS 27. Install bearing shield (Fig. 615). 29. Install the pulley hub on the spindle shaft (Fig. 617). Fig 615 DSC-2705a Fig 617 DSC-2707a 28. Install the square key onto the spindle shaft (Fig. 30. Install the heavy washer and nut on the top of the 616).

  • Page 209: Mower Spindle Installation

    MOWER DECKS Mower Spindle Installation 31. Torque the top nut to 100 to 120 ft-lbs. (135.58 to 162.7 Nm) (Fig. 619). 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.
  • Page 210 MOWER DECKS 4. 60” mower decks: Position the pulley onto the 6. 60” mower decks: Position the blade to the spindle spindle assembly (Fig. 622). shaft retainer (Fig. 624). Fig 624 PICT-4053a Fig 622 PICT-4056a 5. 60” mower decks: Install 3 bolts securing the 7.
  • Page 211 MOWER DECKS 8. 60” mower decks: Carefully position the spindle 10. Install a nut onto each of the 6 spindle mounting assembly into the mower deck (Fig. 626). bolts (Fig. 628). Fig 626 PICT-4049a Fig 628 PICT-4045a 11. Route the mower deck belt around the spindle 9.
  • Page 212 MOWER DECKS 12. Install the mower deck idler spring (Fig. 630). 14. Lower the floor pan assembly (Fig. 632). Fig 630 PICT-4013a Fig 632 PICT-4011a 13. Install the left and right mower deck belt covers (Fig. 15. Install the negative battery cable to the battery. 631).

  • Page 213: Mower Deck Idler Assembly Replacement

    3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 633). Fig 634 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 635). Fig 633 PICT-4011a Fig 635...
  • Page 214 MOWER DECKS 7. Remove the bolt, belt guide and 2 flat washers 9. Remove the bolt, nut and 2 washers securing the securing the idler pulley to the idler arm (Fig. 636). idler arm assembly to the mower deck (Fig. 638). Note: One of the washers is between the idler arm and mower deck.

  • Page 215: Mower Deck Idler Assembly Installation

    MOWER DECKS Mower Deck Idler Assembly Installation 11. Remove the 2 bushings and 1 spacer from the idler arm (Fig. 640). 1. Install a grease fitting into the idler arm pivot (Fig. 642). Fig 640 PICT-4073a Fig 642 PICT-4070a 12. Remove the grease fitting from the idler arm pivot (Fig.
  • Page 216 MOWER DECKS 3. Slide a spacer into the idler arm pivot (Fig. 644). 5. Position the idler arm assembly onto the mower deck with the pivot placed over the washer (Fig. 646). Fig 644 PICT-4082a Fig 646 PICT-4084a 4. Position a washer onto the mower deck in the idler arm pivot location (Fig.
  • Page 217 MOWER DECKS 7. Position the pulley onto the idler arm assembly (Fig. 9. Position the belt guide onto the 2 washers so that it 648). is 45 degrees from the idler arm (Fig. 650). Fig 648 PICT-4063a Fig 650 belt guide position_a A.
  • Page 218 MOWER DECKS 11. Apply grease to the idler arm pivot grease fitting 13. Install the mower deck idler spring (Fig. 654). (Fig. 652). Fig 654 PICT-4013a Fig 652 PICT-4127a 14. Install the left and right mower deck belt covers (Fig. 12.

  • Page 219: Fixed Pulley Replacement

    MOWER DECKS Fixed Pulley Replacement 15. Lower the floor pan assembly (Fig. 656). Fixed Pulley Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2. Raise the seat. 3. Remove the negative battery cable from the battery. 4.
  • Page 220 (Fig. 660). Fig 658 PICT-4012a Fig 660 PICT-4090a 6. Using a spring tool (Toro p/n: 92-5771), remove the 8. Remove the pulley from the pulley mount (Fig. 661). mower deck idler spring (Fig. 659). Fig 661 PICT-4093a...

  • Page 221: Fixed Pulley Installation

    MOWER DECKS Fixed Pulley Installation 9. Remove the pulley mount (Fig. 662). 1. Position the pulley mount onto the mower deck (Fig. 663). Fig 662 PICT-4095a Fig 663 PICT-4095a 2. Position the pulley onto the pulley mount (Fig. 664). Fig 664 PICT-4093a 7-32 Z580/Z589 DFI Z Master Service Manual...
  • Page 222 MOWER DECKS 3. Install a bolt, washer and nut securing the fixed 5. Install the mower deck idler spring (Fig. 667). pulley to the mower deck (Fig. 665). Fig 667 PICT-4013a Fig 665 PICT-4100a 6. Install the left and right mower deck belt covers (Fig. 4.

  • Page 223: Electric Pto Clutch Replacement

    MOWER DECKS Electric PTO Clutch Replacement 7. Lower the floor pan assembly (Fig. 669). Electric PTO Clutch Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition OFF and remove the key. 2. Raise the seat. 3.
  • Page 224 PTO clutch pulley (Fig. 673). Fig 671 IMG-0528a Fig 673 PICT-3934a 6. Using a spring tool (Toro p/n: 92-5771) unhook the 8. Remove the center clutch bolt, spring washers, and spring from the gearbox idler arm assembly (Fig. clutch retainer (Fig. 674). 672).

  • Page 225: Electric Pto Clutch Installation

    MOWER DECKS Electric PTO Clutch Installation 9. Remove 2 bolts and nuts retaining the clutch stop strap to the frame (Fig. 675). 1. Apply anti-seize compound to the stub shaft (Fig. 677). Fig 675 IMG-0532a Fig 677 IMG-0596a 10. Remove the electric PTO clutch from the stub shaft (Fig.
  • Page 226 MOWER DECKS 3. Apply thread locking compound to the center clutch 5. Torque the center clutch bolt to 50 ft-lbs. (67.8 Nm) bolt (Fig. 679). (Fig. 681). Fig 679 IMG-0599a Fig 681 IMG-0600a 4. Install center clutch bolt, spring washers, and clutch 6.
  • Page 227 MOWER DECKS 7. With a spring tool (Toro p/n: 92-7551), hook the 9. Plug the harness connector to the electric PTO spring to the idler arm assembly (Fig. 683). clutch (Fig. 685). Fig 685 IMG-0528a Fig 683 IMG-0463a 10. Install the front engine panel (Fig. 686).

  • Page 228: Gearbox Assembly Replacement

    3. Remove the negative battery cable from the battery. 4. Remove the front engine panel (Fig. 687). Fig 688 IMG-0620a 6. Using a spring tool (Toro p/n: 92-5771) unhook the spring from the gearbox idler assembly (Fig. 689). Fig 687 IMG-0303a...
  • Page 229 (Fig. 690). 692). Fig 690 IMG-0626a Fig 692 PICT-3879a 8. Raise the floor pan assembly (Fig. 691). 10. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 693). Fig 691 PICT-3877a Fig 693 PICT-3880a 7-40...
  • Page 230 MOWER DECKS 11. Remove the deck drive belt from the gearbox pulley 13. Remove the gearbox assembly (Fig. 696). (Fig. 694). Fig 696 IMG-0632a Fig 694 IMG-0627a 14. Remove the 2 set screws from the gearbox driven 12. Remove the 4 mounting bolts and lock washers pulley (Fig.
  • Page 231 MOWER DECKS 15. Remove the pulley (Fig. 698). 17. Remove the 2 set screws from the gearbox drive pulley (Fig. 700). Fig 698 PICT-3909a Fig 700 PICT-3908a 16. Remove the key from the keyway (Fig. 699). 18. Remove the pulley (Fig. 701). Fig 699 PICT-3910a Fig 701...

  • Page 232: Gearbox Assembly Installation

    MOWER DECKS Gearbox Assembly Installation 19. Remove the key from the keyway (Fig. 702). 1. Apply anti-seize compound to both gearbox as- sembly shafts (Fig. 703). Fig 702 PICT-3912a 20. Inspect the keys, gearbox shafts and pulleys. Re- Fig 703 PICT-3913a place if worn or damaged.
  • Page 233 MOWER DECKS 3. Apply thread locking compound to all 4 pulley set 4. Tighten the set screws (Fig. 707). screws. Start the set screws into the pulley hubs (Fig. 705). Fig 707 PICT-3919a Fig 705 PICT-3917a 5. Torque each set screw to 145 + 20 in-lbs. (16 + 2.25 Nm) (Fig.
  • Page 234 MOWER DECKS 6. Install a key into the gearbox driven shaft keyway Note: Install the pulley so that the hub is .06” (Fig. 709). (1.5mm) from the end of the gearbox driven shaft. Tighten the set screws (Fig. 711). Fig 709 PICT-3924a Fig 711 PICT-3925a...
  • Page 235 Fig 715 IMG-0627a Fig 713 IMG-0632a 12. Using a spring tool (Toro p/n: 92-5771), install the 10. Install 4 mounting bolts and lock washers securing mower deck idler spring (Fig. 716). the gearbox assembly to the frame. Torque the 4 mounting bolts to 145 + 20 in-lbs.
  • Page 236 (Fig. 719). Fig 717 PICT-3879a Fig 719 IMG-0626a 14. Lower the floor pan assembly (Fig. 718). 16. Using a spring tool (Toro p/n: 92-5771), install the spring to the gearbox idler assembly (Fig. 720). Fig 718 PICT-3877a Fig 720 IMG-0463a...

  • Page 237: Checking The Gearbox Oil Level

    MOWER DECKS Checking the Gearbox Oil Level 17. Install the right rear wheel and tire assembly (Fig. 721). 1. Park the machine on a level surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

  • Page 238: Changing Gearbox Oil

    MOWER DECKS Changing Gearbox Oil 3. Drain the oil from the gearbox into a drain pan. 4. Fill the gearbox assembly with 75W-90 Synthetic Service Interval: Initial at 100 hours, then yearly. Gear Lube until the oil level reaches the plug open- ings (Fig.

  • Page 239: Strut Replacement

    4. Raise the floor pan assembly (Fig. 727). Fig 728 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring. Remove the mower deck belt from the gearbox deck drive pulley (Fig. 729). Fig 727...
  • Page 240 MOWER DECKS 7. Remove the bolt and nut securing the strut pin to the 9. Remove the nut, lockwasher and bolt securing the mower deck strut bracket (Fig. 730). strut balljoint to the frame (Fig. 732). Fig 730 PICT-4108a Fig 732 PICT-4105a 8.
  • Page 241 MOWER DECKS 11. Remove the grease fittings from the strut (Fig. 734). 13. Remove the balljoint and jam nut from the strut (Fig. 736). Fig 734 PICT-4116a Fig 736 PICT-4121a 12. Loosen the balljoint jam nut (Fig. 735). Fig 735 PICT-4119a 7-52 Z580/Z589 DFI Z Master Service Manual...

  • Page 242: Strut Installation

    MOWER DECKS Strut Installation 2. Tighten the jam nut to secure the balljoint position (Fig. 738). 1. Install the balljoint and jam nut into the strut. The Note: Position balljoint perpendicular to strut. 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.
  • Page 243 MOWER DECKS 4. Position the strut assembly balljoint to the frame. 6. Install a bolt and nut securing the strut pin to the Secure it to the frame with a bolt, lockwasher and mower deck strut bracket (Fig. 742). nut (Fig. 740). Fig 742 PICT-4108a Fig 740...
  • Page 244 MOWER DECKS 8. Route the mower deck belt. Refer to the belt routing 10. Install the left and right mower deck belt covers (Fig. decal (Fig. 744). 746). Fig 744 fig. 108-5981 Fig 746 PICT-4012a 9. Install the mower deck idler spring (Fig. 745). 11.

  • Page 245: 72" Mower Deck Belt Tension Adjustment Plate Replacement

    3. Remove the negative battery cable from the battery. 4. Raise the floor pan assembly (Fig. 748). Fig 749 PICT-4012a 6. Using a spring tool (Toro p/n: 92-5771), remove the mower deck idler spring (Fig. 750). Fig 748 PICT-4011a Fig 750...
  • Page 246 MOWER DECKS 7. Remove the belt from around the adjustment plate 10. Remove the tension adjustment plate assembly (Fig. pulley. 753). 8. Remove the nut from the pivot bolt (Fig. 751). Note: The pivot bolt will fall through to the under- side of the deck when the nut is removed.
  • Page 247 MOWER DECKS 12. Remove the nut, washer and bolt securing the pulley 14. Remove the idler bushing (Fig. 757). to the adjustment plate (Fig. 755). Fig 757 6672a Fig 755 6670a 13. Remove the pulley from the idler bushing (Fig. 756). Fig 756 6671a 7-58...

  • Page 248: 72" Mower Deck Belt Tension Adjustment Plate Installation

    MOWER DECKS 72” Mower Deck Belt Tension Adjustment 3. Install a washer and nut onto the pulley bolt securing the pulley to the adjustment plate (Fig. 760). Plate Installation 1. Position the idler bushing onto the tension adjust- ment plate (Fig. 758). Fig 760 6670a Fig 758...
  • Page 249 MOWER DECKS 5. Position the tension adjustment plate assembly onto 7. Route the belt around the adjustment plate pulley. the mower deck making sure the spacers are in Refer to the belt routing decal (Fig. 764). place (Fig. 762). Fig 764 fig.
  • Page 250 MOWER DECKS 9. Adjust the mower belt tension. Refer to “72” Mower 12. Install the negative battery cable to the battery. Deck Belt Tension Adjustment” on page 7-62. 13. Lower the seat. 10. Install the left and right mower deck belt covers (Fig. 766).

  • Page 251: 72" Mower Deck Belt Tension Adjustment

    MOWER DECKS 72” Mower Deck Belt Tension 5. Loosen the bolts holding the idler plate (Fig. 768). Adjustment Important: To ensure proper mower belt tension, which will result in longer belt life, check the mower belt tension after the first 8 hours of use and 8 hours after each belt change.

  • Page 252: Gearbox Rebuild

    MOWER DECKS Gearbox Rebuild 3. Carefully remove the pinion assembly (Fig. 771). 1. Remove the two gearbox drain plugs and drain the oil from the gearbox (Fig. 769). Fig 771 PICT-5646a Fig 769 PICT-5631a 4. Remove the o-ring from the pinion pilot (Fig. 772). 2.
  • Page 253 MOWER DECKS 5. Remove the shim(s) (Fig. 773). Fig 775 IMG-8490a Fig 773 PICT-5650a 7. Remove the closed end cap (Fig. 776). 6. Remove the 8 end cap screws (4 securing each end cap) (Fig. 774 and Fig. 775). Note: The bolts securing the end caps to the gear- box housing are patch lock bolts and must be replaced with new patch lock bolts.
  • Page 254 MOWER DECKS 8. Remove the o-ring from the closed end cap (Fig. 10. Remove the o-ring from the cross shaft pilot (Fig. 777). 779). Fig 779 PICT-5664a Fig 777 IMG-8491a 11. Remove the shim(s) (Fig. 780). 9. Remove the open end cap and cross shaft assembly (Fig.

  • Page 255: Pinion Shaft Teardown

    MOWER DECKS Pinion Shaft Teardown 12. Remove the cross shaft from the open end cap (Fig. 781). 13. Secure the pinion shaft in a vise. 14. Remove the lock nut from the pinion shaft (Fig. 782). Fig 781 PICT-5667a Fig 782 IMG-8494a 15.
  • Page 256 MOWER DECKS 16. Using a gear puller, remove the cross shaft gear 18. Place the pinion shaft assembly in a press, shaft from the pinion shaft (Fig. 784). side down. Press the pinion shaft assembly out of the pinion housing (Fig. 786). Fig 784 IMG-8499 Fig 786...
  • Page 257 MOWER DECKS 20. Remove the grease seal from the shaft (Fig. 788). 22. Place the pinion housing in a vise and remove the inner and outer bearing races from the housing (Fig. 790). Note: The inner race and housing must be heated to remove the races.

  • Page 258: Cross Shaft Teardown

    MOWER DECKS Cross Shaft Teardown 26. Position the cross shaft in the press so the opposite bearing is facing up. Press the bearing off the shaft (Fig. 793). 23. Place the cross shaft in a press with the pinion gear bearing facing up.

  • Page 259: Open End Cap Teardown

    MOWER DECKS Closed End Cap Teardown Open End Cap Teardown 27. Remove the oil seal from the open end cap (Fig. 29. Remove the bearing race from the closed end cap 794). (Fig. 796). Note: The inner race and housing must be heated to remove the race.

  • Page 260: Closed End Cap Rebuild

    MOWER DECKS Closed End Cap Rebuild Open End Cap Rebuild 30. Press the bearing race into the open end cap (Fig. 31. Press the oil seal into the open end cap (Fig. 798). 797). Fig 798 IMG-8538a Fig 797 IMG-8537a 32.

  • Page 261: Cross Shaft Rebuild

    MOWER DECKS Cross Shaft Rebuild 35. Place the cross shaft in a press with the installed bearing down. 33. Place the cross shaft in the press and press a new 36. Align the keyway in the pinion gear with the key bearing onto the shaft (Fig.

  • Page 262: Pinion Shaft Rebuild

    MOWER DECKS Pinion Shaft Rebuild 40. Place the pinion shaft assembly in a press and press the bearing onto the shaft (Fig. 806). 38. Press a new bearing race into the outer end of the pinion housing (Fig. 804). Fig 806 IMG-8540a Fig 804 IMG-8532a...
  • Page 263 MOWER DECKS 42. Place the assembly into a press and press a new 44. Align the keyway in the pinion gear with the key bearing into the pinion housing (Fig. 808). installed in the shaft. Press the pinion gear onto the shaft (Fig.

  • Page 264: Gearbox Assembly

    MOWER DECKS Gearbox Assembly 46. Install the lock nut onto the pinion shaft (Fig. 812). Note: Secure the assembly in a vise and tighten the 49. Assemble the closed end cap onto the gearbox (Fig. lock nut enough to draw the gear and washer 814).
  • Page 265 MOWER DECKS 51. Insert the cross shaft into the gearbox. Seat the 53. Install a new end cap o-ring (Fig. 818). cross shaft bearing into the closed end cap (Fig. 816). Fig 818 IMG-8562a Fig 816 IMG-8558a 54. Apply a protective film onto the shaft keyway. 52.
  • Page 266 MOWER DECKS 56. Install 4 new bolts securing the open end cap to the 58. Install .013” (.33mm) thickness of shims onto the gearbox housing. Torque the bolts to 280 – 325 in- pinion housing (Fig. 822). lbs. (31.6 – 36.7 Nm) (Fig. 820). Note: The shim color corresponds to its thickness: Note: Tighten the bolts in a crisscross pattern.
  • Page 267 MOWER DECKS 60. Insert the pinion shaft assembly into the gearbox 62. Check the pinion shaft end play measurement, assembly seating the pinion gear into the cross shaft it should be between .004” and .012” (.101 and gear (Fig. 824). .305mm).

  • Page 268: Leveling The Mower

    MOWER DECKS Leveling the Mower 63. Fill the gearbox with 6 oz. (.15 liters) of 75W-90 synthetic gear oil with anti-foaming agent until it starts to flow out of the oil plug hole (Fig. 827). Setting up the Machine 1. Position mower on a flat surface. 2.

  • Page 269: Leveling The Mower Side To Side

    MOWER DECKS Leveling the Mower Side to Side 3. Record this measurement. The measurement should be 3-1/8” to 3-1/4” (7.9 to 8.3cm). 1. Position the right blade side-to-side (Fig. 829). 4. Position the left blade side-to-side (Fig. 829). 5. Measure the left blade at the C location (Fig. 65 m-1078) from level surface to cutting edge of the blade tips (Fig.

  • Page 270: Adjusting The Front To Rear Mower Pitch

    MOWER DECKS Adjusting the Front to Rear Mower 3. Record the measurement. Pitch 4. Measure the right blade at the B location (Fig. 829) from a level surface to the cutting edge of the blade 1. Position the right blade front-to-rear (Fig. 832). tip (Fig.

  • Page 271: Adjusting The Compression Spring

    MOWER DECKS Adjusting the Compression Spring 8. Adjust the lift nuts on both the left and the right side of the machine (Fig. 834 and Fig. 835) to achieve 1/4” to 3/8” (6 to 10mm) lower in front A than in the 1.
  • Page 272 Z580/Z589 DFI Z Master Service Manual Form No. 492-9215...

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