Toro Diesel Z Master Service Manual

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Z580-D / Z593-D / Z595-D

Diesel Z Master

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Page 1 LCE Products Z580-D / Z593-D / Z595-D Diesel 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.
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Page 4: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION General Information ........................1-1 Think Safety First ........................1-1 SPECIFICATIONS Speciﬁ cations Z593-D & Z595-D ....................2-1 Conﬁ gurations ........................2-1 Power System ........................2-1 Mowing Deck .........................2-2 Operator Zone ........................2-3 Dimensions ..........................2-3 Speciﬁ cations Z580-D ........................2-4 Conﬁ gurations ........................2-4 Power System ........................2-4 Mowing Deck .........................2-5 Operator Zone ........................2-5...
Page 5 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..................3-47 Motion Control Assembly Removal ..................3-47 Right Hand Motion Control ....................3-48 Left Hand Motion Control ....................3-50 Motion Control Assembly Installation ...................3-53 Left Hand Motion Control ....................3-53 Right Hand Motion Control ....................3-55 Motion Control Damper Replacment ..................3-61...
Page 6 TABLE OF CONTENTS ENGINE cont. Cooling Fan Replacement ......................5-49 Cooling Fan Removal ......................5-49 Cooling Fan Installation .......................5-50 Air Cleaner Replacement ......................5-51 Air Cleaner Removal ......................5-51 Air Cleaner Installation ......................5-54 Alternator Belt Replacement.......................5-56 Alternator Belt Removal .......................5-56 Alternator Belt Installation ....................5-58 Checking Alternator Belt Tension ....................5-61 Tensioning the Alternator Belt .....................5-62 Fuel Filter Service........................5-63...
Page 7 TABLE OF CONTENTS ELECTRICAL cont. Delay Module..........................6-9 Purpose ..........................6-9 Location ..........................6-9 How It Works ........................6-10 Testing ..........................6-10 High Temperature Audible Alarm (Solid Tone) ................6-11 Purpose ..........................6-11 Location ..........................6-11 How It Works ........................6-12 Testing ..........................6-12 Temperature Sender ........................6-12 Purpose ..........................6-12 Location ..........................6-12 How It Works ........................6-13...
Page 8 TABLE OF CONTENTS MOWER DECKS Mower Belt Replacement ......................7-1 Mower Deck Removal ......................7-3 Mower Deck Installation ......................7-6 Mower Spindle Replacement......................7-9 Mower Spindle Removal ......................7-9 Mower Deck Spindle Rebuild .....................7-12 Mower Spindle Installation ....................7-20 Mower Deck Idler Assembly Replacement .................7-24 Mower Deck Idler Assembly Removal .................7-24 Mower Deck Idler Assembly Installation ................7-26 Fixed Pulley Replacement ......................7-30 Fixed Pulley Removal ......................7-30...
Page 9 TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK. Z580/Z593/Z595 Diesel 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.
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Page 12: Specifications
SPECIFICATIONS Speciﬁ cations Z593-D & Z595-D Conﬁ gurations Z593-D Pro Performance Z595-D Pro Performance 23 hp Kubota® 3 Cyl Diesel 52”/60” Turbo Force 25 hp Kubota® 3 Cyl Diesel 52”/60”/72” Turbo Force Power System Z593-D Pro Performance Z595-D Pro Performance Heavy Duty Canister Air Cleaner Standard Standard...
Page 13: Mowing Deck
SPECIFICATIONS Speciﬁ cations Z593-D & Z595-D cont. Mowing Deck Z593-D Pro Performance Z595-D Pro Performance Type TURBO FORCE™ TURBO FORCE™ Deck Construction Fabricated, 7-ga Steel Fabricated, 7-ga Steel w/Bull-Nose bumper w/Bull-Nose bumper Deck Material High-Strength Steel High-Strength Steel Deck Depth 5-1/2”...
Page 14: Operator Zone
SPECIFICATIONS Speciﬁ cations Z593-D & Z595-D cont. Operator Zone Z593-D Pro Performance Z595-D Pro Performance Steering Controls 1-5/8” (1.625cm) Diameter 1-5/8” (1.625cm) Diameter Grips, Adjustable, Dampened Grips, Adjustable, Dampened Floor Pan Pierced, extruded tread Pierced, extruded tread No-tools deck access No-tools deck access Seat Non-suspension...
Page 15: Specifi Cations Z580-D
SPECIFICATIONS Speciﬁ cations Z580-D Conﬁ gurations Z580-D 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)
Page 16: Mowing Deck
SPECIFICATIONS Speciﬁ cations 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 Bafﬂ e Standard Spindle Housings 9-3/8” (23.8cm) Diameter Cast Iron Spindle Shaft / Bearings 1”...
Page 17: Dimensions
SPECIFICATIONS Speciﬁ cations Z580-D cont. Dimensions Z580-D 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”...
Page 18: Torque Specifi Cations
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 19: 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 20: 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 21: Other Torque Specifications
SPECIFICATIONS Other Torque Speciﬁ cations 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 22: 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 23: U.s. To Metric Conversions
SPECIFICATIONS U.S. to Metric Conversions U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 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 2.59 Square Miles Square Kilometers Square Feet Square Meters...
Page 24: Chassis
CHASSIS 4. Slide the castor fork assembly out of the frame (Fig. Castor Fork Assembly Replacement 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.
Page 25 CHASSIS 2. Remove the top tapered bearing (Fig. 005). 4. Remove the bottom tapered bearing (Fig. 007). Fig 005 IMG_7706 Fig 007 IMG_7711a 3. Remove the bottom grease seal (Fig. 006). 5. Drive the top and bottom tapered bearing cups out of the caster fork hub (Fig.
Page 26 CHASSIS 6. Install new tapered bearing cups by pressing each 7. Pack the upper and lower tapered bearings with bearing cup into the caster fork hub so that the thick- grease (No. 2 general purpose lithium base or er part of the taper is pressed in ﬁ rst. The bearing molybdenum grease) (Fig.
Page 27: Castor Fork Assembly Installation
CHASSIS 9. Install the grease seal into the caster fork hub (Fig. Castor Fork Assembly Installation 012). 1. Install 3 Bellville washers as shown (Fig. 014): Fig 012 IMG_7725a Fig 014 ﬁ g. 49 G001297 A. Belleville washers 10. Install the upper bearing into the caster fork hub (Fig.
Page 28: Front Wheel Removal & Bearing Replacement
CHASSIS 3. Install the locknut. Tighten the locknut until the 5. Remove the grease ﬁ tting and install the grease Belleville washers are ﬂ at, then back the nut off 1/4 plug. turn to properly set the preload on the bearings (Fig. 016).
Page 29 CHASSIS 3. Remove the wheel assembly from the fork (Fig. 5. Remove both bearing spacers (one on each side) 020). from the wheel assembly (Fig. 022). Fig 020 IMG_7878 Fig 022 IMG_7744a 4. Remove the castor spacer from the wheel assembly 6.
Page 30 CHASSIS Wheel Assembly (Fig. 024). 8. Pack both tapered bearings with grease (No. 2 gen- eral purpose lithium base or molybdenum grease) (Fig. 026). Fig 024 IMG_7880a A. Bearing spacer (2) E. Wheel and tire Fig 026 IMG_7718a B. Grease seal (2) assembly C.
Page 31 CHASSIS 10. Install the grease seals into each side of the wheel 12. Install the castor spacer into the wheel hub (Fig. hub (Fig. 028). 030). Fig 028 IMG_7883a Fig 030 IMG_7885a 11. Install a bearing spacer into each side of the wheel 13.
Page 32: Fuel Tank Replacement
CHASSIS 14. Install the axle bolt and nut securing the wheel as- Fuel Tank Replacement sembly to the fork (Fig. 032). Right Side Fuel Tank Removal 1. Raise the seat and remove the front engine shield (Fig. 034). Fig 032 IMG_7736 15.
Page 33 CHASSIS 3. Disconnect the negative battery cable. 6. Remove the clamp securing the return fuel line to the ﬁ tting on the operator’s side of the fuel tank. 4. Remove the right rear wheel assembly (Fig. 036). Slide the fuel hose off the ﬁ tting and drain the fuel from the fuel line (Fig.
Page 34: Right Side Fuel Tank Installation
CHASSIS 8. Remove the bolt and washers securing the left front Right Side Fuel Tank Installation corner of the fuel tank to the frame (Fig. 040). 1. Position the fuel tank onto the frame (Fig. 042). Fig 040 IMG_7764 Fig 042 IMG_7768 9.
Page 35 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). Fig 044 IMG_7783 Fig 046 IMG_7788 4. Slide a hose clamp onto the intake fuel line. Slide the intake fuel line onto the ﬁ...
Page 36 CHASSIS 7. Tighten the 3 nuts until three threads protrude past 9. Install the right rear wheel assembly (Fig. 050). the nut. Do not over-tighten (Fig. 048). Fig 050 IMG_7753a Fig 048 PICT-3290 10. Install the negative battery cable. 8. Tighten the bolt located in the front left corner of the 11.
Page 37: Left Side Fuel Tank Removal
CHASSIS 3. Disconnect the negative battery cable. Left Side Fuel Tank Removal 4. Remove the left rear wheel assembly (Fig. 054). 1. Raise the seat and remove the front engine shield (Fig. 052). Fig 054 IMG_7794 Fig 052 IMG_7751 5. Remove the 4 screws and washers securing the control panel to the fuel tank (Fig.
Page 38 CHASSIS 6. Remove the cable tie securing the throttle cable to 8. Remove the hose clamp from the fuel return line and the fuel ﬁ tting (Fig. 056). ﬁ tting located on the operator’s side of the fuel tank (Fig. 058). Fig 056 IMG_7799 Fig 058...
Page 39 CHASSIS 11. Remove the hose clamp from the fuel intake line and 10. Remove the nuts, springs and washers from the 3 ﬁ tting located on the underside of the fuel tank (Fig. fuel tank mounting studs located on the underside of 060).
Page 40: Left Side Fuel Tank Installation
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 ﬁ tting barb located on the operator’s side of the fuel tank. Slide the hose clamp into position and tighten (Fig.
Page 41 CHASSIS 4. Loosely install a bolt, lockwasher, and washer into 6. Tighten the 3 nuts until three threads protrude past the right front corner of the fuel tank securing it to the nut. Do not over-tighten the nuts (Fig. 070). the frame (Fig.
Page 42 CHASSIS 8. Install 4 screws and washers securing the control 10. Install the left rear tire assembly and lower the panel to the fuel tank (Fig. 072). machine to the ground. 11. Install the negative battery cable. 12. Install the front engine shield (Fig. 074). Fig 072 IMG_7797 9.
Page 43: Fuel Tank Fitting Replacement
CHASSIS 2. Using a magnet, remove the ﬁ tting from the inside of Fuel Tank Fitting Replacement the fuel tank (Fig. 077). There are 2 fuel ﬁ ttings located on each of the fuel tanks. The following procedure can be used to replace any of the ﬁ...
Page 44 CHASSIS 4. Loosely install a washer and nut to secure the fuel Right side fuel tank operator’s side ﬁ tting tank ﬁ tting to the fuel tank (Fig. 079). Fig 081 IMG_7779 Fig 079 IMG_7772 Left side fuel tank operator’s side ﬁ tting 5.
Page 45: Hood Assembly Replacement
CHASSIS 3. Lift the hood and remove it from the machine (Fig. Hood Assembly Replacement 085). Hood Assembly Removal 1. Unhook the rubber latch that is located on the rear of the hood (Fig. 083). Fig 085 IMG_7848 Hood Assembly Installation Fig 083 IMG_7836 1.
Page 46 CHASSIS Note: Check the clearance between the hood screen 2. Install a clevis pin, washer and hairpin into each of and the radiator cap. If there is any interfer- the pivot brackets (Fig. 089). ence, the hood can be adjusted using the slotted holes in the hood mounting brackets: Hood Hinge Plate adjustment slots (Fig.
Page 47: Throttle Control Assembly Replacement
CHASSIS 4. Remove the knob from the throttle control assembly Throttle Control Assembly (Fig. 092). Replacement The hood assembly has been removed for photo purposes. Throttle Control Assembly Removal 1. Raise the seat. 2. Disconnect the negative battery cable from the battery terminal.
Page 48 CHASSIS 6. Remove the 2 locknuts and carriage bolts securing 8. Loosen the swivel clamp at the end of the throttle the throttle control to the control panel (Fig. 094). cable located on the engine throttle linkage (Fig. 096). Fig 094 IMG_7894 Fig 096 IMG_7899...
Page 49: Throttle Control Assembly Installation
CHASSIS 10. Slide the throttle cable out of the throttle bracket and 12. Slide the cable out of the slot in the bottom of the swivel clamp (Fig. 098). control panel (Fig. 100). Note: The loose nut will slide off the cable upon sliding it out of the throttle linkage bracket.
Page 50 CHASSIS 2. Install the throttle control assembly into the slot in 4. Route the throttle cable back toward the engine so the control panel (Fig. 102). 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.
Page 51 CHASSIS 7. Slide the end of the throttle cable into the swivel 9. Push the speed control lever toward the back of the clamp (Fig. 106). engine (Fig. 108). Fig 106 IMG_7899 Fig 108 IMG_7914 8. Position the throttle control into the slow position 10.
Page 52 CHASSIS 11. Install the front engine shield assembly (Fig. 110). 13. Install the knob onto the throttle control assembly (Fig. 112). Fig 110 IMG_7895 Fig 112 IMG_7888 12. Install a cable tie securing the throttle cable to the fuel tank inlet ﬁ tting. Trim the excess (Fig. 111). 14.
Page 53: Brake Lever Replacement
CHASSIS 6. Lift the ﬂ oor pan assembly. Brake Lever Replacement 7. Remove the brake lever pivot shaft cotter pin (Fig. The left fuel tank and hood have been removed for photo 115). purposes. Brake Lever Removal 1. Raise the seat. 2.
Page 54: Brake Lever Installation
CHASSIS 9. With a hammer and punch tap out the two pivot Brake Lever Installation bushings (Fig. 117). 1. Raise the ﬂ oor pan assembly. 2. Install the two bushings into the brake lever pivot mounting hole (Fig. 119). Fig 117 PICT-2883 10.
Page 55: Brake Band Replacement
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). Fig 121 IMG_7922a 5.
Page 56 CHASSIS 2. Remove the 3 bolts, spacer and retainer from the 4. Remove the brake band from the wheel and hub brake band assembly (Fig. 124). assembly (Fig. 126). Fig 124 PICT-2920 Fig 126 PICT-2933 3. Remove the 2 spacers from the brake band (Fig. 5.
Page 57: Brake Band Installation
CHASSIS 3. Position the brake band retainer and loosely install 2 Brake Band Installation bolts through the retainer, brake band spacers and into the brake bracket (Fig. 130). 1. Slide the brake band onto the wheel hub assembly (Fig. 128). Fig 130 PICT-2941 Fig 128...
Page 58: Brake Cross Shaft Replacement
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.
Page 59 CHASSIS 4. Remove the clevis spring pins securing the brake 6. Remove the 2 bolts and nuts securing the right side rod linkage yokes to the left side of the brake cross ﬂ ange bearing to the frame. Remove the ﬂ ange shaft (Fig.
Page 60: Brake Cross Shaft Installation
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. Fig 139 PICT-2964 9.
Page 61 CHASSIS 3. Position the ﬂ ange bearing on the right end of the 5. Ensure the brake cross shaft rotates freely in the cross shaft and install 2 bolts and nuts securing the ﬂ ange bearings. ﬂ ange bearing to the frame (Fig. 143). 6.
Page 62: Deck Lift Lever Replacement
CHASSIS 8. Install the left and right rear tires and lower the 4. Place the mower deck in the transport position. machine to the ground (Fig. 147). Position wood blocks under each corner of the mower deck (Fig. 148). Fig 147 PICT-2919 Fig 148 PICT-2971...
Page 63 CHASSIS 6. Remove the lower stop bolt from the deck lift plate 8. Remove the hex nut from the back end of the right (Fig. 150). and left deck lift assemblies (Fig. 152). Fig 150 PICT-2978 Fig 152 PICT-2982 7. Loosen the jam nut and hex nut on the right hand 9.
Page 64 CHASSIS 10. Remove the bolt, nut and lift lever bushing that 12. Loosen the inner hex head ﬂ ange nut. Pivot the secures the inner deck lift plate to the frame (Fig. inner deck lift plate up (Fig. 156). 154). Fig 156 PICT-2991a Fig 154...
Page 65 CHASSIS 15. Remove the E-clip from the deck lift arm pivot (Fig. Note: There may be interference between the lift 158). lever assembly and the ﬂ oor pan hinge when trying to remove the lift lever assembly (Fig. 160). Fig 158 PICT-3002 Fig 160 PICT-3005...
Page 66: Deck Lift Lever Installation
CHASSIS Deck Lift Lever Assembly (Fig. 162) 2. Install an E-clip onto the deck lift lever pivot (Fig. 164). Fig 162 PICT-3015a Fig 164 PICT-3018 A. Bolt D. Nut B. Bushing E. Lift Lever Assembly C. Deck lift arm (2) 3.
Page 67 CHASSIS 4. Rotate the deck lift arms forward to align them with 6. Lower the ﬂ oor pan assembly. the bushing in the cross shaft assembly tab. Install a bolt and nut to secure (Fig. 166). 7. Tighten the nut on the bolt at the top of the inner deck lift plate (Fig.
Page 68 CHASSIS 9. Install a second nut onto the bolt securing the hitch 11. Lower the lift lever. The deck lift lever rods should pin lanyard in place (Fig. 170). run through the rear swivels (Fig. 172). Fig 170 PICT-3028 Fig 172 PICT-3029a 10.
Page 69 CHASSIS 13. Raise the mower deck to the transport position. 14. Check the deck level adjustment. Refer to “Leveling Remove the wood blocks. Tighten the adjusting the Mower” on page 7-82. nut on the deck lift assemblies so that the following length is achieved between the two large washers 15.
Page 70: Motion Control Assembly Replacement
CHASSIS 5. Remove the ﬂ oor 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.
Page 71: Right Hand Motion Control
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). Fig 179 PICT-3057 Fig 181 PICT-3066 Right Hand Motion Control 10.
Page 72 CHASSIS 11. Remove the bolt, washer and nut that secure the 13. Loosen the jam nut on the right hand neutral return right hand control rod assembly to the right hand spring assembly. Remove the yoke from the neutral motion control assembly (Fig. 183). return bolt (Fig.
Page 73: Left Hand Motion Control
CHASSIS 15. Remove the 2 bolts and nuts securing the side 17. Inspect the side ﬂ ange bearings. Replace if worn or ﬂ ange bearing to the left hand motion control damaged (Fig. 189). assembly (Fig. 187). Fig 189 PICT-3091a Fig 187 PICT-3086 A.
Page 74 CHASSIS 19. Raise the seat and remove the outside nut from the 22. Remove the cotter pin and clevis pin that secure the bolt that secures the motion control damper to the neutral return yoke to the left hand motion control left hand motion control assembly (Fig.
Page 75 CHASSIS 24. Remove the nut, bolt and washer securing the left 26. Remove the 2 bolts and nuts securing the side hand control rod ball joint to the hydrostatic pump ﬂ ange bearing to the inside of the traction frame control arm (Fig.
Page 76: Motion Control Assembly Installation
CHASSIS 28. Inspect the side ﬂ ange bearings. Replace if worn or 2. Position the left hand motion control assembly and damaged (Fig. 199). control shaft arm assembly into the traction frame (Fig. 201). Fig 199 PICT-3137a Fig 201 PICT-3134 A.
Page 77 CHASSIS 4. Position the left hand control rod assembly into the 6. Install the neutral return yoke onto the neutral return traction frame (Fig. 203). bolt (Fig. 205). Fig 203 PICT-3133 Fig 205 PICT-3126 5. Install a bolt, washer and nut securing the left hand 7.
Page 78: Right Hand Motion Control
CHASSIS 8. Tighten the jam nut to secure the neutral adjustment 10. Position the right hand motion control assembly and yoke (Fig. 207). control shaft arm assembly into position under the traction frame (Fig. 209). Fig 207 PICT-3142 Fig 209 PICT-3088 Right Hand Motion Control 11.
Page 79 CHASSIS 12. Position the side ﬂ ange bearing to the inside of the 14. Position the neutral return yoke to the right hand traction control frame and loosely install 2 bolts and motion control tab and install a clevis pin. Install a nuts securing the side ﬂ...
Page 80 CHASSIS 16. Install the bolt, washer and nut securing the right 18. Raise the seat and insert the right and left damper hand control rod assembly to the right hand motion bolts into the right and left motion control assembly control assembly (Fig.
Page 81 CHASSIS Left hand neutral switch - access by raising seat. B. Flange bearings mounted to the left hand motion control assembly (Fig. 221). Fig 219 PICT-4221a Fig 221 PICT-3086 A. Left hand neutral switch located under the traction frame front console. C.
Page 82 CHASSIS 21. Position the left hand control lever to the left hand 23. Adjust the control handle neutral position. Refer to control shaft arm. Install 2 bolts, and washers “Adjusting the Control Handle Neutral Position” on securing the left lever to the control shaft arm (Fig. page 4-25.
Page 83 CHASSIS 26. Install 2 top pocket mounting bolts, washers and 28. Install both ﬂ oor pan assembly hinge bolts and nuts nuts and 2 bottom pocket mounting bolts and nuts (Fig. 228). (Fig. 226). Note: Raise the seat to install the top 2 bolts washer and nuts.
Page 84: Motion Control Damper Replacment
CHASSIS 5. Remove the outer nut from the bolt on the upper end Motion Control Damper Replacment 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.
Page 85: Motion Control Damper Installation
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). Fig 232 PICT-3181a Fig 234 PICT-3173 Motion Control Damper Installation 4.
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. 236). Fig 236 ﬁ g. 57 G001294 A. Brake lever in B. Spring 2-1/2” (64mm) engaged position C.
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Page 88: Hydraulic System
HYDRAULIC SYSTEM 5. Using a spring removal tool (Toro part no. 92-5771), Hydrostatic Tandem Pump remove the pump idler arm spring (Fig. 238). 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. 240). 9. Remove the key from the keyway (Fig. 242). Fig 240 PICT-3188a Fig 242 PICT-3192a 8. Remove the pump pulley (Fig. 241). 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. 246). (Fig. 244). Fig 246 PICT-3198 Fig 244 PICT-3196 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 ﬁ lter (Fig. 248). left rear tires. 18. Mark or tag the wheel motor hydraulic hoses and ﬁ...
Page 92 HYDRAULIC SYSTEM 21. Remove the two hydraulic hoses from the left wheel 23. Remove the hose clamp located on the hydraulic motor (Fig. 252). hose routed from the oil cooler to the left side of the hydrostatic pump (Fig. 254). Fig 252 PICT-3208 Fig 254...
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. 258). 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. 260). ﬁ ttings (Fig. 262). Fig 260 PICT-3271 Fig 262 PICT-3300 30. Mark the wheel motor hose and pump ﬁ tting 32.
Page 95: Hydrostatic Tandem Pump Installation
HYDRAULIC SYSTEM 33. Remove the set screw securing the control arm to Hydrostatic Tandem Pump Installation the pump control shaft. Remove the control arm from the pump control shaft (Fig. 264). 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. 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.
Page 97 HYDRAULIC SYSTEM 9. Tighten the 2 bolts securing the pump mounting 11. Install the left 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 ﬁ...
Page 98 HYDRAULIC SYSTEM 14. Tighten the right hand wheel motor hose ﬁ ttings at 17. Slide a hose clamp over the hydraulic suction hose the pump and at the wheel motor. (Fig. 278). 15. With the hose clamp on the oil cooler hose, slide the hose onto the pump ﬁ...
Page 99 HYDRAULIC SYSTEM 19. Position the hose clamp and tighten (Fig. 280). 21. Install a cable tie securing the PTO clutch wire to the frame (Fig. 282). Fig 280 PICT-3337 Fig 282 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. 286). securing the left hand control rod assembly to the pump control arm (Fig.
Page 101 (Fig. 288). 290). Fig 288 PICT-3307a Fig 290 PICT-3345a 28. Loosely install the 2 set screws into the pump pulley Belt Alignment Tool (Toro p/n: 110-0876) (Fig. 291): (Fig. 289). Fig 291 alignment tool Fig 289 PICT-3342a 4-14...
Page 102 HYDRAULIC SYSTEM 30. Hook the belt alignmentn 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 removal tool (Toro part no. 92-5771), 12.1 + 1.6 in-lbs. (1.37 + 0.18 Nm) (Fig. 294). install the pump idler arm spring (Fig. 296).
Page 104: Wheel Motor Replacement
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.
Page 105 HYDRAULIC SYSTEM 7. Using a Wheel Hub Puller (Toro p/n: TOR4097), 10. Mark or tag the wheel motor hoses and ﬁ ttings to remove the wheel hub from the wheel motor shaft ensure they are reconnected correctly (Fig. 302). (Fig. 300).
Page 106 HYDRAULIC SYSTEM 12. Remove the wheel motor ﬁ ttings from the wheel 14. Remove the front 2 wheel motor mounting bolts, motor (Fig. 304). spacers and nuts (Fig. 306). Fig 304 PICT-3367 Fig 306 PICT-3376 13. Loosen all 4 wheel motor mounting bolts (Fig. 305). 15.
Page 107: Wheel Motor Installation
HYDRAULIC SYSTEM 16. Remove the 2 rear wheel motor mounting bolts, Wheel Motor Installation 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 108 HYDRAULIC SYSTEM 1. Insert the wheel motor into the frame. Loosely install 3. Loosely install the 2 front wheel motor mounting the 2 rear wheel motor mounting bolts, long spacers bolts, short spacers and nuts (Fig. 313). and nuts (Fig. 311). Fig 313 PICT-3376 Fig 311...
Page 109 HYDRAULIC SYSTEM 5. Install the wheel motor ﬁ ttings. Note the location 7. Slide the brake band assembly over the wheel motor markings (Fig. 315). hub. Install the 3 spacers, the retainer and 3 brake band bolts into brake bracket (Fig. 317). Fig 315 PICT-3367 Fig 317...
Page 110 HYDRAULIC SYSTEM 10. Apply the parking brake. Note: If more than two threads are showing remove nut and install washer between hub and nut 11. Install a castle nut onto the wheel motor shaft. and then: Torque the castle nut to 125 ft-lbs (170 Nm) (Fig. 319).
Page 111: Purging The Hydraulic System
HYDRAULIC SYSTEM 13. Install a cotter pin into the wheel motor shaft (Fig. Purging the Hydraulic System 322). The hydraulic system is normally self-bleeding however; it may be necessary to bleed the system if ﬂ uid is changed, or after work is performed on the system. 1.
Page 112: Adjusting The Control Handle Neutral Position
HYDRAULIC SYSTEM 2. Start the engine and run it at low idle speed. Engage Adjusting the Control Handle Neutral the motion control lever on one side and spin the Position wheel by hand (Fig. 324). If the motion control levers do not align or do not move easily into the console notch, adjustment is required.
Page 113 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.
Page 114: Setting The Hydrostatic Pump Neutral
HYDRAULIC SYSTEM 3. Remove the bolt and nut securing the seat rod to the Setting the Hydrostatic Pump Neutral seat. Rotate the seat rod up and out of the way of the hydrostatic pump (Fig. 330). 1. Raise the machine and support with jack stands so that the rear tires are off the ground (Fig.
Page 115: Setting The Right Hydraulic Pump Neutral Position
HYDRAULIC SYSTEM Setting the Right Hydraulic Pump Neutral Setting the Left Hydraulic Pump Neutral Position Position 5. Place the motion control levers in the neutral 10. Place the motion control levers in the neutral position. position. 6. Start the engine, open the throttle 1/2 way and 11.
Page 116 HYDRAULIC SYSTEM 12. Start the engine, open the throttle 1/2 way and 16. Tighten the jam nuts at the ball joints (Fig. 335). release the parking brake. 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.
Page 117: Adjusting The Tracking
HYDRAULIC SYSTEM 6. To make the machine go left, turn the knob towards Adjusting the Tracking the left side of the machine (Fig. 338). 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.
Page 118: Hydraulic Flow Testing
HYDRAULIC SYSTEM 2. Clean any dirt or debris away from the hydraulic line Hydraulic Flow Testing ﬁ ttings. Mark each of the hoses and ﬁ ttings so they will be properly re-installed after testing. Remove the The following procedure was performed on the right hydraulic lines.
Page 119 HYDRAULIC SYSTEM 3. Connect the hydraulic hose ﬁ ttings to the hydraulic 5. Unplug the wire harness clutch wire from the electric ﬂ ow tester (Fig. 341). PTO clutch to prevent accidental engagement of the mower deck (Fig. 342). Note: The ﬂ ow tester shown is bidirectional so it does not matter which order the hoses are connected to the ﬂ...
Page 120 HYDRAULIC SYSTEM 7. Verify the restrictor valve on the hydraulic ﬂ ow tester 10. Stroke the left hand hydrostatic lever fully forward. is in the fully “Opened” position (Fig. 344). Very slowly, rotate the “T” handle of the adjustable ﬂ ow tester restrictor valve until the pressure gauge reaches 500 PSI (3447 kPa).
Page 121 HYDRAULIC SYSTEM 12. Record the difference or “ﬂ ow 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 “ﬂ ow droop” is 2.5 gpm (9.46lpm). Any droop greater than 2.5 gpm (9.46lpm) is considered 18.
Page 122: Traction Pump Drive Belt Replacement
HYDRAULIC SYSTEM 5. Unplug the harness connector from the electric PTO Traction Pump Drive Belt clutch (Fig. 351). 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 123 Fig 353 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). Fig 354 PICT-3517a Fig 356 PICT-3522...
Page 124: Traction Pump Drive Belt Installation
Fig 359 ﬁ g. 108-5955 Fig 357 PICT-3523 3. Using a spring removal tool (Toro p/n: 92-5771), Traction Pump Drive Belt Installation install the pump idler assembly spring (Fig. 360). 1. Slide the traction pump drive belt over the electric PTO clutch (Fig.
Page 125 HYDRAULIC SYSTEM 4. With tension released from the gearbox idler, install 6. Install 2 carriage bolts and nuts to secure the clutch the PTO clutch belt around the electric PTO clutch stop bracket to the frame (Fig. 363). and gearbox pulleys as shown (Fig. 361): Fig 363 PICT-3514 Fig 361...
Page 126: Hydraulic Oil Cooler Replacement
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.
Page 127 HYDRAULIC SYSTEM 6. Remove the nut securing the right side guard strap 8. Remove the 2 bolts, washers and nuts securing the to the frame and radiator support. Remove the right left hand top brace and guard strap to the radiator hand fan guard (Fig.
Page 128 HYDRAULIC SYSTEM 10. Remove the 4 bolts and nuts securing the oil cooler 12. Remove the 2 hoses from the oil cooler (Fig. 373). to the frame (Fig. 371). Fig 373 PICT-3454 Fig 371 PICT-3447 13. Remove the 4 r-clamps and transfer them to the new 11.
Page 129: Hydraulic Oil Cooler Installation
HYDRAULIC SYSTEM 3. Position the oil cooler and install 4 bolts and nuts Hydraulic Oil Cooler Installation securing the oil cooler to the frame (Fig. 377). 1. Install the 2 hoses onto the oil cooler (Fig. 375). Fig 377 PICT-3447 Fig 375 PICT-3454 4.
Page 130 HYDRAULIC SYSTEM 5. Install 2 bolts, washers and nuts securing the left 7. Position the right side top brace. Install 3 bolts, hand top brace and guard strap to the radiator washers and nuts securing the top brace, frame and support and frame (Fig.
Page 131: Hydraulic Reservoir Tank Replacement
HYDRAULIC SYSTEM 5. Remove the left hand mower deck belt cover (Fig. Hydraulic Reservoir Tank 383). 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.
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. 385). the tank ﬁ tting barb (Fig. 387). Fig 385 PICT-3393 Fig 387 PICT-3396a 8. Place a drain pan under the hydraulic reservoir tank. 11.
Page 133: Hydraulic Reservoir Tank Installation
HYDRAULIC SYSTEM 12. Remove the 2 bolts, washers and nuts securing the Hydraulic Reservoir Tank Installation reservoir to the hydraulic tank bracket (Fig. 389). 1. Transfer the 2 hydraulic tank ﬁ ttings to the new hydraulic reservoir tank (Fig. 391). Fig 389 PICT-3409 Fig 391...
Page 134 HYDRAULIC SYSTEM 3. Install 2 bolts, washers and nuts to secure the reser- 5. Position the hose clamp to secure the oil cooler hose voir to the hydraulic tank bracket (Fig. 393). to the tank ﬁ tting barb (Fig. 395). Fig 393 PICT-3409 Fig 395...
Page 135 HYDRAULIC SYSTEM 7. Route the mower deck belt around the PTO drive 9. Install the left hand mower deck belt cover (Fig. pulley (Fig. 397). 399). Fig 397 PICT-3393 Fig 399 PICT-3389 8. Hook the idler spring from the mower deck idler arm 10.
Page 136: Pushing The Machine By Hand
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 13. Fill the reservoir to the cold oil level (Fig. 401). position and apply parking brake.
Page 137: Switching From Pushing The Machine Back To Machine Operation
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. Fig 403 PICT-3524a 4.
Page 138: Engine
ENGINE 5. Remove the Hood Assembly. Refer to “Hood Engine Replacement Assembly Removal” on page 3-22. Engine Removal 6. Remove the bolt, washer and nut securing the hose clamp to the left hand guard strap (Fig. 405). 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key.
Page 139 ENGINE 8. Remove the 3 bolts, washers and nuts securing right 11. Remove the 2 bolts, washers and nut securing right side top brace frame and radiator support. Remove side guard strap to the frame and radiator support. the right side top brace (Fig. 407). Remove the guard strap (Fig.
Page 140 ENGINE 13. Remove the bolt, washer and nut securing the left 15. Remove the radiator cap. Place a funnel below the hand guard strap to the frame. Remove the left hand radiator drain plug located on the lower right hand guard strap (Fig.
Page 141 ENGINE 18. Loosen the hose clamp securing the left hand 21. Remove the cable tie securing the overﬂ ow hose to radiator hose to the lower left hand corner of the the radiator cap barb (Fig. 415). radiator (Fig. 413). Fig 415 PICT-3542a Fig 413...
Page 142 ENGINE 23. Pull the over ﬂ ow hose out and away from the 25. Remove the 2 R-clamps located on the inside of the radiator (Fig. 417). front panel of the bottom radiator plate assembly (Fig. 419). Fig 417 PICT-3544 Fig 419 PICT-3549 24.
Page 143 ENGINE 27. Slide the right hand radiator hose off the water pump 29. Remove the radiator assembly from the frame (Fig. (Fig. 421). 423). Fig 421 PICT-3685 Fig 423 PICT-3554 28. Remove the 10 bolts, nuts and 2 washers securing 30.
Page 144 ENGINE 31. Move the oil cooler assembly away from the engine 34. Loosen the hose clamp on the lower end of the left area of the machine to prevent damage to oil cooler hand radiator hose (Fig. 427). and hoses. 32.
Page 145 ENGINE 36. Remove the nut and bolt securing the wire harness 38. Remove the 4 mufﬂ er manifold mounting bolts and R-clamp to the mufﬂ er bracket (Fig. 429). lock washers (Fig. 431). Fig 429 PICT-3567 Fig 431 PICT-3573a 37. Remove the 2 mufﬂ er mounting bolts and lock 39.
Page 146 ENGINE 40. Remove the cable tie securing the harness to the oil 42. Remove the screw and lock washer securing the switch located under the oil ﬁ lter (Fig. 433). harness terminal to the oil switch (Fig. 435). Fig 433 PICT-3578 Fig 435 PICT-3581...
Page 147 ENGINE 44. Slide the rubber boot off the alternator connection 46. Remove the bolts and washers securing 2 R-clamps and remove the nut securing the harness terminal to the engine block (Fig. 439). to the alternator. Remove the harness terminal (Fig. 437).
Page 148 ENGINE 48. Unplug the harness terminal from the engine therm- 50. Remove the cable tie securing the harness to the oswitch (Fig. 441). engine stop solenoid wire (Fig. 443). Fig 441 PICT-3595 Fig 443 PICT-3598 49. Remove the nut securing the harness terminal to the 51.
Page 149 ENGINE 52. Loosen the swivel clamp and rearmost nut holding 54. Remove the 2 hose clamps securing the fuel lines to the throttle cable into the throttle support bracket the fuel injection pump and fuel return (Fig. 447). (Fig. 445). Fig 447 PICT-3606 Fig 445...
Page 150 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.
Page 151 ENGINE c. Remove the gearbox drive belt from around the e. Remove the electric PTO clutch from the stub shaft electric PTO clutch pulley (Fig. 453). (Fig. 455). Fig 453 PICT-3934a Fig 455 PICT-3615 d. Remove the center clutch bolt, 2 cupped washers Machines with an Ogura Clutch: and clutch retainer securing the electric PTO clutch to the stub shaft (Fig.
Page 152 ENGINE b. Unplug the harness connector from the electric PTO d. Loosen the bolt holding the electric PTO clutch to clutch (Fig. 457). the stub shaft (Fig. 459). Fig 457 PICT-3979a Fig 459 PICT-3995a c. Remove the carriage bolts, washers and nuts hold- e.
Page 153 ENGINE Remove the electric PTO clutch from the stub shaft h. Remove the clutch adapter from the stub shaft (Fig. (Fig. 461). 463). Fig 461 PICT-3998 Fig 463 PICT-3954a g. Remove the key from the stub shaft (Fig. 462). 59. Remove the 3 engine mounting bolts, washers and nuts (Fig.
Page 154 ENGINE Front right and front left engine mounting bolts. 61. Remove the large washer off the top of the rear engine mount (Fig. 467). Fig 465 PICT-3621 Fig 467 PICT-3629a 60. Attach a properly rated hoist to the 2 engine hooks. 62.
Page 155 ENGINE 63. Inspect the 3 sets of engine isolation mounts and 65. Remove the stub shaft from the ﬂ ywheel (Fig. 471). spacers. Replace if damaged or worn (Fig. 469). Note: The engine isolation mounts come in pairs. If one half of the pair is damaged, the whole mount should be replaced.
Page 156: Engine Installation
ENGINE 67. Remove the right side engine mount by removing Engine Installation the 2 bolts and lock washers securing it to the engine (Fig. 473). 1. Apply thread locking compound to the 8 engine mounting bracket bolts (Fig. 475). Fig 473 PICT-3643a Fig 475 PICT-3648a...
Page 157 ENGINE 3. Install the right side engine mount bracket to the 5. Torque all 8 engine mount bracket mounting bolts to engine with 2 mounting bolts and lock washers (Fig. 29 ft-lbs. (39 Nm) (Fig. 479). 477). Fig 479 PICT-3650 Fig 477 PICT-3643a 6.
Page 158 ENGINE 7. Position the stub shaft to the ﬂ ywheel (Fig. 481). 9. Install the 3 sets of engine isolation mounts and the 3 isolation mount spacers (Fig. 483). Fig 481 PICT-3642 Fig 483 PICT-3652 8. Install the 5 mounting bolts securing the stub shaft to the ﬂ...
Page 159 ENGINE 10. Place a large washer on the top of the rear engine 12. Install 3 engine mounting bolts, washers and nuts isolation mount (Fig. 485). (Fig. 487 and Fig. 488): Rear engine mounting bolt. Fig 485 PICT-3629a Fig 487 PICT-3617 11.
Page 160 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 PICT-3957a Fig 489 PICT-3656 d. Install the center clutch bolt, two spring washers, and the clutch retainer (Fig.
Page 161 ENGINE e. Torque the center clutch bolt to 50 ft-lbs. (67.8 Nm) g. Hook the spring up from the gearbox idler assembly (Fig. 493). to the frame (Fig. 495). Fig 493 PICT-4006 Fig 495 PICT-3872 Install the gearbox belt around the electric PTO h.
Page 162 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 PICT-3955 Fig 497 PICT-3656 d. Align the key with the clutch and slide the clutch onto the stub shaft (Fig.
Page 163 ENGINE e. Apply thread locking compound to the bolt (Fig. g. Torque the bolt to 50 ft-lbs. (67.8 Nm) (Fig. 503). 501). Fig 503 PICT-3967 Fig 501 PICT-3957a h. Install the PTO drive belt onto the clutch. Install the spring for the idler arm (Fig. 504). Secure the clutch to the stub shaft with retainer, ﬂ...
Page 164 ENGINE Install the clutch stop on the machine with 2 carriage k. Install a tie strap around the wire on the electric PTO bolts, 2 ﬂ at washers, and 2 locknuts (Fig. 505). clutch (Fig. 507). Note: Make sure there is a twist in the clutch stop. Fig 507 PICT-3988a Fig 505...
Page 165 ENGINE 15. Slide the fuel line onto the fuel return barb (Fig. 509). 17. Slide the 2 hose clamps up the fuel line, onto the ﬁ tting barbs and tighten (Fig. 511). Fig 509 PICT-3611 Fig 511 PICT-3606 16. Slide the fuel line onto the fuel injection pump (Fig. 510).
Page 166 ENGINE 19. Plug the harness into the stop solenoid connector 21. Slide the harness terminal onto the front glow plug (Fig. 513). cord terminal and install a nut to secure (Fig. 515). Fig 513 PICT-3599 Fig 515 PICT-3596 20. Install the cable tie securing the harness to the 22.
Page 167 ENGINE 23. Apply thread locking compound to the engine block 25. Position the 2 harness R-clamps to the front of the grounding bolt (Fig. 517). engine and install the bolts and washers to secure (Fig. 519). Fig 517 PICT-3669a Fig 519 PICT-3590 A.
Page 168 ENGINE 27. Slide the harness terminal onto the alternator termi- 29. Position the harness terminal to the oil switch and nal and install a nut. Slide the rubber boot up over install a screw and lock washer to secure (Fig. 523). the connection (Fig.
Page 169 ENGINE 31. Install a cable tie securing the harness to the oil 33. Apply thread locking compound to the 4 mufﬂ er switch located under the oil ﬁ lter (Fig. 525). manifold mounting bolts (Fig. 527). Fig 525 PICT-3578 Fig 527 PICT-3645a 32.
Page 170 ENGINE 35. Apply thread locking compound to the 2 lower muf- 37. Tighten the top 4 mufﬂ er mounting bolts (Fig. 531). ﬂ er mounting bolts (Fig. 529). Fig 531 PICT-3573a Fig 529 PICT-3645a 38. Torque the 2 lower mufﬂ er mounting bolts to 29 ft- 36.
Page 171 ENGINE 39. Position the wire harness R-clamp to the underside 41. Slide the hose clamp into position and tighten (Fig. of the mufﬂ er mounting bracket. Install a bolt and nut 535). to secure (Fig. 533). Fig 535 PICT-3565 Fig 533 PICT-3567 42.
Page 172 ENGINE 43. Install 2 bolts securing the fan and retainer plate to 45. Loosely install 2 bolts and ﬂ ange nuts securing the the engine (Fig. 537). rear radiator support to the frame (Fig. 539). Fig 537 PICT-3563a Fig 539 PICT-3562 44.
Page 173 ENGINE 47. Loosely install 10 bolts, nuts and 2 washers securing 49. Slide the right hand radiator hose onto the water the radiator assembly to the frame (Fig. 541). 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.
Page 174 ENGINE 51. Position the 2 harness R-clamps to the inside of the 53. Route the overﬂ ow hose up, through the front right front panel on the bottom radiator plate assembly. hand corner of the radiator frame assembly, to the Install a bolt and nut securing each R-clamp (Fig.
Page 175 ENGINE 55. Install a cable tie securing the overﬂ ow hose to the 57. Position the hose clamp and tighten (Fig. 550). barb (Fig. 548). Fig 550 PICT-3539a Fig 548 PICT-3692 58. Slide the left hand guard strap between the frame 56.
Page 176 ENGINE 59. Position the cooler shield to the rear radiator support 61. Position the left hand radiator hose R-clamp to the (Fig. 552). 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.
Page 177 ENGINE 63. Align the left hand top frame brace, cooler shield and 65. Slide the front end of the right hand guard strap left fan guard with the rear radiator brace and loosely between the right hand radiator brace and the frame. install a bolt, washer and nut to secure (Fig.
Page 178 ENGINE 67. Position the front end of the right hand top frame 69. Tighten all the fasteners securing the right and left brace to the inside of the right hand radiator brace. guard straps and frame braces to the frame and rear Loosely install 2 bolts, washers and nuts to secure support.
Page 179: Radiator Replacement
ENGINE 76. Check the coolant level in the overﬂ ow bottle and Radiator Replacement add as necessary. 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. •...
Page 180 ENGINE 5. Place a drain pan under the lower right hand corner 9. Loosen the hose clamp securing the left hand of the radiator. 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.
Page 181 ENGINE 12. Remove the cable tie securing the overﬂ ow hose to 14. Pull the overﬂ ow hose out and away from the the radiator cap barb (Fig. 568). radiator (Fig. 570). Fig 568 PICT-3542a Fig 570 PICT-3544a 13. Slide the overﬂ ow hose from the barb on the radiator 15.
Page 182 ENGINE 16. Remove the top radiator plate (Fig. 572). 18. Raise the front end of the radiator and loosen the hose clamp securing the right hand radiator hose to the ﬂ ange on the upper right hand corner of the radiator (Fig.
Page 183: Radiator Installation
ENGINE 20. Remove the radiator (Fig. 576). 2. Lift up the front end of the radiator and slide the right hand radiator hose onto the radiator ﬂ ange (Fig. 578). Fig 576 PICT-3753 Fig 578 PICT-3765a Radiator Installation 3. Slide the hose clamp into position and tighten (Fig. 1.
Page 184 ENGINE 4. Install 6 bolts and washers (3 on the left and 3 on 6. Install 6 bolts and washers to secure the top radiator the right) securing the radiator to the bottom radiator plate to the radiator (Fig. 582). plate and cooling shroud (Fig.
Page 185 ENGINE 8. Slide the overﬂ ow hose onto the barb onto the 10. Slide the left hand radiator hose onto the lower left radiator ﬁ ller neck barb ﬁ tting (Fig. 584). hand corner of the radiator (Fig. 586). Fig 584 PICT-3690 Fig 586 PICT-3734...
Page 186: Cooling Fan Replacement
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 Cooling Fan Removal antifreeze/Dex-Cool and water. 1. Remove the Radiator. Refer to “Radiator Removal” 14. Install the radiator cap (Fig. 588). on page 5-42.
Page 187: Cooling Fan Installation
ENGINE 4. Remove the 4 bolts, washers and nuts securing the Cooling Fan Installation cooling fan to the shroud (Fig. 591). 1. Position the cooling fan to the back side of the shroud. Position the fan onto the shroud as shown (Fig.
Page 188: Air Cleaner Replacement
ENGINE 3. Position the cooling fan and shroud assembly into Air Cleaner Replacement the bottom radiator plate (Fig. 595). Air Cleaner Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key. 2.
Page 189 ENGINE 5. Raise the hood assembly (Fig. 598). 7. Remove the 2 bolts, washers and nuts securing the air cleaner mounting bracket to the frame (Fig. 600). Fig 598 PICT-3729 Fig 600 PICT-3824 6. Remove the bottom cover and air cleaner element from the air cleaner assembly (Fig.
Page 190 ENGINE 9. Push the air cleaner intake hose out of the R-clamp 11. Loosen the hose clamp securing the intake hose to (Fig. 602). the air cleaner (Fig. 604). Fig 602 PICT-3845 Fig 604 PICT-3867 10. Remove the air cleaner/hose assembly (Fig. 603). 12.
Page 191: Air Cleaner Installation
ENGINE 3. Position the upper half of the air cleaner and hose Air Cleaner Installation assembly up to the left side of the engine (Fig. 608). 1. Slide the air cleaner intake hose onto the air cleaner (Fig. 606). Fig 608 PICT-3848 Fig 606 PICT-3868...
Page 192 ENGINE 5. Slide the engine intake hose onto the air cleaner. 7. Install the air cleaner element and bottom cover onto Position the hose clamp and tighten (Fig. 610). the air cleaner assembly (Fig. 612). Fig 610 PICT-3825 Fig 612 PICT-3866 6.
Page 193: Alternator Belt Replacement
ENGINE 5. Remove the nut from the bolt securing the right Alternator Belt Replacement guard strap to the frame and radiator support. Re- move the right fan guard (Fig. 615). Alternator Belt Removal 1. Park the machine on a level surface, disengage the PTO, turn the ignition off and remove the key.
Page 194 ENGINE 7. Remove the 2 bolts, washers and nuts securing 9. Remove the 4 bolts, washers and nuts securing the the left side of the cooler shield to the rear radiator oil cooler to the rear radiator support. Lower the oil support (Fig.
Page 195: Alternator Belt Installation
ENGINE 11. Remove the retainer and fan (Fig. 621). 13. Rotate the belt cover to the side and remove the belt from the pulleys and alternator (Fig. 623). Fig 621 PICT-3795a Fig 623 PICT-3799 12. Loosen the bottom bolt and remove the upper bolt securing the alternator and belt cover (Fig.
Page 196 ENGINE 2. Position the belt cover and install the upper bolt to 5. Install 2 bolts securing the fan and retainer plate to secure. Tighten the bottom bolt (Fig. 625). the engine (Fig. 627). Fig 625 PICT-3797 Fig 627 PICT-3794 3.
Page 197 ENGINE 7. Position the cooler shield so the left ﬂ ange is 9. Position the right hand guard strap. Install 2 bolts, between the left hand straps and the rear radiator washers and nuts securing right side guard strap to support (Fig.
Page 198: Checking Alternator Belt Tension
ENGINE 11. Position the right hand top brace. Install 3 bolts, Checking Alternator Belt Tension washers and nuts securing the right hand top brace to the frame and rear radiator support (Fig. 633). 1. Check the tension of the alternator belt. There should be 1/4”...
Page 199: Tensioning The Alternator Belt
ENGINE 2. Using a wooden handle or pry bar to pivot the alter- Tensioning the Alternator Belt nator away, from the engine block, tension the drive belt until there is 1/4” to 11/32” (7 to 9mm) deﬂ ection 1. Slightly loosen the bottom alternator bolt. Loosen the in the belt between the engine and the alternator top alternator bolt (Fig.
Page 200: Fuel Filter Service
ENGINE 3. Tighten the top and bottom alternator bolt (Fig. 637). Fuel Filter Service Models through 2007: the fuel system includes 2 re- placeable, in-line fuel ﬁ lters (15 micron). Both fuel ﬁ lters should be replaced at the same time. 2008 and later Models: the fuel system includes 1 re- placeable, in-line fuel ﬁ...
Page 201: Fuel Filter Replacement
ENGINE Note: Arrow on ﬁ lter shows direction of fuel ﬂ ow Fuel Filter Replacement (Fig. 639). 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.
Page 202 ENGINE 5. Loosen the two hose clamps and disconnect the fuel 7. Connect the fuel lines to the fuel ﬁ lter so that the lines from the fuel ﬁ lter (Fig. 642). fuel ﬂ ows through the ﬁ lter in the direction of the arrow on the side of the ﬁ...
Page 203: Draining The Water Separator
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 1.
Page 204: General
ELECTRICAL General Relays Note: Interactive Electrical Troubleshooting DVD, There are 3 relays: Form No. 492-9171 is also available. 1. Glow Relay (furthest forward) 2. Start Relay 3. Fan Relay Engine Starting Purpose Turn the ignition switch to the RUN position, push the glow plug switch for 10 seconds.
Page 205: 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 206: Pto Switch
ELECTRICAL 5. Disconnect voltage and multimeter leads from relay Location terminals (Fig. 650). 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 How It Works Purpose Contacts inside the switch electrically connect various...
Page 207: Testing
ELECTRICAL 6. Replace the switch if your test results do not cor- Testing 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 208: 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 209: Testing
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 2. Verify that continuity exists between the terminals in the neutral position (handles in the out position), it listed for the switch position.
Page 210: Parking Brake Switch
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 ﬂ ow through for safety circuit. When the park brake The purpose of the parking brake switch is to ensure the is released in the OFF position it bypasses both neutral machine is in neutral and the parking brake is applied...
Page 211: Testing
ELECTRICAL Testing Seat Switch 1. Disconnect the switch from the wiring harness. Purpose The park brake switch is a double pole switch. When The seat switch is in the safety circuit. If the engine is the park brake is in the ON position, a pair of closed running and the operator vacates the seat with either terminals is part of the starting safety interlock circuit.
Page 212: How It Works
ELECTRICAL How It Works Delay Module When the seat is vacated, the switch is open and there Purpose should be NO continuity between the two terminals. When the seat is occupied, the swtich closes and there When operating the unit on rough terrain and the oper- should be continuity between the two terminals (Fig.
Page 213: How It Works
ELECTRICAL How It Works Testing The seat delay module circuit board is made up of sev- 1. Raise the seat and disconnect the seat switch. eral different electrical components, such as a transient Install a jumper wire in place of the seat switch (Fig. voltage suppressor, capacitor, transistors, carbon ﬁ...
Page 214: High Temperature Audible Alarm (Solid Tone)
ELECTRICAL Follow the procedure below to test the delay module High Temperature Audible Alarm function. (Solid Tone) 1. Disengage the parking brake. Purpose 2. Pull the right and left motion control levers out of the neutral position. This machine has an audible alarm that alerts the user to turn off the engine or engine damage can occur from 3.
Page 215: How It Works
ELECTRICAL How It Works Temperature Sender A continuous tone will sound when the engine tempera- Purpose ture switch connects to ground as the engine reaches a certain temperature (Fig. 668). The temperature sender is a temperature-dependent variable resistor. As the coolant temperature increases, the internal resistance decreases.
Page 216: How It Works
ELECTRICAL How It Works Oil Pressure Switch When the water temperature reaches an excessive Purpose operating temperature the switch will close internally and ground the high temperature audible alarm. This The oil pressure switch completes the circuit that completes the alarm circuit and the alarm sounds (Fig. activates the hour meter and the radiator fan relay.
Page 217: How It Works
ELECTRICAL How It Works High Temperature & Glow Plug Light Cluster When the engine oil pressure builds the switch closes to complete the circuit for both the hour meter and the Purpose cooling fan relay (Fig. 672). There are two purposes for this light cluster: 1.
Page 218: How It Works
ELECTRICAL How It Works Glow Plug Switch The high temperature light is connected in parallel with Purpose the high temperature audible alarm. The light gives a visual indicator that the engine has reached a high temp- The glow plug switch activates the glow plug relay in erature.
Page 219: How It Works
ELECTRICAL How It Works Hour Meter The glow pug switch is manually depressed and held in Purpose place for 10 seconds. This activates the relay that closes the circuit which sends current to the glow plugs. The hour meter keeps track of the actual engine running hours.
Page 220: How It Works
ELECTRICAL How It Works Electric PTO Clutch The hour meter is made up of an electric “winder” and a There are two different electric PTO clutches: mechanical clock movement. When power is applied, a coil is energized to wind the movement. The movement •...
Page 221: How It Works
ELECTRICAL 5. The meter should read: How It Works Warner clutch: 1.0 – 2.7 ohms, Ogura clutch: 2.4 ohms The PTO clutch is composed of three major compon- ents; the ﬁ eld, the clutch plate, and the friction plate. If the reading is above or below these readings, the The clutch plate always turns with the engine.
Page 222: Engine Stop Solenoid
ELECTRICAL 4. Using a continuity tester, touch one tester lead to How It Works one of the clutch terminals and the other lead to the clutch housing. The ignition switch removes power to the stop solenoid when the key is turned to the Off position, the plunger of 5.
Page 223: Pull Coil Terminal Test
ELECTRICAL Pull Coil Terminal Test Hold Coil Terminal Test This test checks both the pulling coil and pulling coil This test checks the holding coil. timer module (Fig. 684). 1. Connect a jumper lead from the ground (A) terminal to the negative battery terminal. 2.
Page 224: Mower Decks
3. Raise the ﬂ oor pan (Fig. 685). Fig 686 PICT-4012 5. Using a spring removal tool (Toro p/n: 92-5771), re- move the mower deck belt idler spring (Fig. 687). Fig 685 PICT-4011 Fig 687...
Page 225 MOWER DECKS 6. Remove the belt guide from the idler arm pulley (Fig. 8. Install a new belt around the mower pulleys and the 688). gearbox pulley under the engine. Refer to the belt routing decal (Fig. 690). Fig 688 PICT-4060 Fig 690 ﬁ...
Page 226: Mower Deck Removal
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.
Page 227 MOWER DECKS 6. Using a spring removal tool (Toro p/n: 92-5771), re- 8. Place the mower deck in the transport position. move the mower deck idler spring (Fig. 696). 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 228 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. 700). mower deck (Fig. 702). Fig 700 PICT-4023 Fig 702 PICT-4036 11. Raise the deck lift lever to the transport position (Fig. 13.
Page 229: Mower Deck Installation
MOWER DECKS 15. Tie the struts up, out of the way of the mower deck Mower Deck Installation being removed. 1. Turn the right front wheel so the castor fork is angled 16. Remove the 4 wood blocks from each corner of the forward to allow more clearance for sliding the mower deck.
Page 230 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 231 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 714). belt routing decal (Fig. 712). Fig 714 PICT-4012 Fig 712 ﬁ...
Page 232: Mower Spindle Replacement
3. Remove the negative battery cable from the battery. 4. Raise the ﬂ oor pan assembly (Fig. 716). Fig 717 PICT-4012 6. Using a spring removal tool (Toro p/n: 92-5771), re- move the mower deck idler spring (Fig. 718). Fig 716 PICT-4011...
Page 233 MOWER DECKS 7. Remove the mower deck belt from the spindle pulley 9. 72” mower decks: Remove 3 bolts retaining the (Fig. 719). pulley to the pulley hub (Fig. 721). Fig 719 PICT-4044 Fig 721 CLR DSC-2662 8. Remove the nuts from the 6 spindle mounting bolts 10.
Page 234 MOWER DECKS 13. 52” mower decks: Remove the 6 spindle mounting 15. 52” mower decks: Remove the spindle blade bolt bolts securing the spindle housing to the mower and washer (Fig. 725). deck (Fig. 723). Fig 725 PICT-4050 Fig 723 PICT-4046 16.
Page 235: Mower Deck Spindle Rebuild
MOWER DECKS 17. 52” mower decks: Remove the 3 bolts securing Mower Deck Spindle Rebuild the pulley to the spindle hub (Fig. 727). 1. Remove the nut and washer (Fig. 729). Fig 727 PICT-4055 Fig 729 CLR DSC-2669 18. 52” mower decks: Remove the pulley from the spindle assembly (Fig.
Page 236 MOWER DECKS 3. Remove the bearing shield (Fig. 731). 5. Remove the seal spacer from the top of the spindle housing (Fig. 733). Fig 731 CLR DSC-2671 Fig 733 CLR DSC-2673 4. Remove the spindle housing from the spindle shaft assembly (Fig.
Page 237 MOWER DECKS 7. Remove the top oil seal from the spindle housing 9. Remove the spacer (Fig. 737). (Fig. 735). Fig 737 CLR DSC-2677 Fig 735 CLR DSC-2675 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 238 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. 739). 741). Fig 739 CLR DSC-2680 Fig 741 CLR DSC-2682 12. Using a hammer and a driver with a square edge, 14.
Page 239 MOWER DECKS 15. Install the spacer through the top of the spindle 17. Turn the spindle housing over and install the lower housing (Fig. 743). 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.
Page 240 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 CLR DSC-2700 Fig 747 CLR DSC-2692 22. Pack the tapered bearing with #2 grease and install the tapered bearing (Fig.
Page 241 MOWER DECKS 23. Install the seal. Press it ﬂ ush with the top of the 25. Lower the spindle housing over the spindle shaft housing (Fig. 751). (Fig. 753). Note: The open lip of the seal faces inward. Fig 753 CLR DSC-2703 Fig 751 CLR DSC-2696...
Page 242 MOWER DECKS 27. Install bearing shield (Fig. 755). 29. Install the pulley hub on the spindle shaft (Fig. 757). Fig 755 CLR DSC-2705 Fig 757 CLR DSC-2707 28. Install the square key onto the spindle shaft (Fig. 30. Install the heavy washer and nut on the top of the 756).
Page 243: Mower Spindle Installation
MOWER DECKS 31. Torque the top nut to 100 to 120 ft-lbs. (135.58 to Mower Spindle Installation 162.7 Nm) (Fig. 759). 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 244 MOWER DECKS 4. 52” mower decks: Position the pulley onto the 6. 52” mower decks: Position the blade to the spindle spindle assembly (Fig. 762). shaft retainer (Fig. 764). Fig 764 PICT-4053a Fig 762 PICT-4056 5. 52” mower decks: Install 3 bolts securing the 7.
Page 245 MOWER DECKS 8. 52” mower decks: Carefully position the spindle 10. Install a nut onto each of the 6 spindle mounting assembly into the mower deck (Fig. 766). bolts (Fig. 768). Fig 766 PICT-4049 Fig 768 PICT-4045 11. Route the mower deck belt around the spindle 9.
Page 246 MOWER DECKS 12. Install the mower deck idler spring (Fig. 770). 14. Lower the ﬂ oor pan assembly (Fig. 772). Fig 770 PICT-4013 Fig 772 PICT-4011 13. Install the left and right mower deck belt covers (Fig. 15. Install the negative battery cable to the battery. 771).
Page 247: Mower Deck Idler Assembly Replacement
3. Remove the negative battery cable from the battery. 4. Raise the ﬂ oor pan assembly (Fig. 773). Fig 774 PICT-4012 6. Using a spring removal tool (Toro p/n: 92-5771), re- move the mower deck idler spring (Fig. 775). Fig 773 PICT-4011...
Page 248 MOWER DECKS 7. Remove the bolt, belt guide and 2 ﬂ at washers 9. Remove the bolt, nut and 2 washers securing the securing the idler pulley to the idler arm (Fig. 776). idler arm assembly to the mower deck (Fig. 778). Note: One of the washers is between the idler arm and mower deck.
Page 249: Mower Deck Idler Assembly Installation
MOWER DECKS 11. Remove the 2 bushings and 1 spacer from the idler Mower Deck Idler Assembly Installation arm (Fig. 780). 1. Install a grease ﬁ tting into the idler arm pivot (Fig. 782). Fig 780 PICT-4073a Fig 782 PICT-4070a 12.
Page 250 MOWER DECKS 3. Slide a spacer into the idler arm pivot (Fig. 784). 5. Position the idler arm assembly onto the mower deck with the pivot placed over the washer (Fig. 786). Fig 784 PICT-4082a Fig 786 PICT-4084 4. Position a washer onto the mower deck in the idler arm pivot location (Fig.
Page 251 MOWER DECKS 7. Position the pulley onto the idler arm assembly (Fig. 9. Position the belt guide onto the 2 washers so that it 788). is 45 degrees from the idler arm (Fig. 790). Fig 788 PICT-4063 Fig 790 belt guide position A.
Page 252 MOWER DECKS 11. Apply grease to the idler arm pivot grease ﬁ tting 13. Install the mower deck idler spring (Fig. 794). (Fig. 792). Fig 794 PICT-4013 Fig 792 PICT-4127 14. Install the left and right mower deck belt covers (Fig. 12.
Page 253: Fixed Pulley Replacement
MOWER DECKS 15. Lower the ﬂ oor 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.
Page 254 (Fig. 800). Fig 798 PICT-4012 Fig 800 PICT-4090a 6. Using a spring removal tool (Toro p/n: 92-5771), re- 8. Remove the pulley from the pulley mount (Fig. 801). move the mower deck idler spring (Fig. 799). Fig 801 PICT-4093...
Page 255: Fixed Pulley Installation
MOWER DECKS 9. Remove the pulley mount (Fig. 802). 2. Position the pulley onto the pulley mount (Fig. 804). Fig 802 PICT-4095 Fig 804 PICT-4093 Fixed Pulley Installation 3. Install a bolt, washer and nut securing the ﬁ xed pulley to the mower deck (Fig. 805). 1.
Page 256 MOWER DECKS 4. Route the mower deck belt. Refer to the belt routing 6. Install the left and right mower deck belt covers (Fig. decal (Fig. 806). 808). Fig 806 ﬁ g. 108-5981 Fig 808 PICT-4012 5. Install the mower deck idler spring (Fig. 807). 7.
Page 257: Electric Pto Clutch Replacement
3. Remove the negative battery cable from the battery. 4. Remove the front engine panel (Fig. 810). Fig 811 PICT-3933 6. Using a spring removal tool (Toro p/n: 92-5771), unhook the spring from the gearbox idler arm assembly (Fig. 812). Fig 810...
Page 258: Electric Pto Clutch Installation Warner Clutch
MOWER DECKS 7. Remove the gearbox drive belt from around the 9. Remove the electric PTO clutch from the stub shaft electric PTO clutch pulley (Fig. 813). (Fig. 815). Fig 813 PICT-3934a Fig 815 PICT-3615 8. Remove the center clutch bolt, 2 spring washers and Electric PTO Clutch Installation clutch retainer securing the electric PTO clutch to Warner Clutch...
Page 259 MOWER DECKS 2. Slide the electric PTO clutch onto the stub shaft (Fig. 4. Install the center clutch bolt, two spring washers, 817). and the clutch retainer (Fig. 819). Note: Make sure the clutch stop bracket is in the Note: The direction of the spring washers. slot on the clutch.
Page 260 MOWER DECKS 6. Route the gearbox belt around the electric PTO 8. Plug the clutch harness into the electric PTO clutch clutch pulley (Fig. 821). plug (Fig. 823). Fig 821 PICT-4009 Fig 823 PICT-3933 7. Hook the gearbox idler spring to the frame (Fig. 9.
Page 261: Electric Pto Clutch Removal Ogura Clutch
MOWER DECKS 6. Unplug the harness connector from the electric PTO Electric PTO Clutch Removal clutch (Fig. 827). 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.
Page 262 MOWER DECKS 8. Using a spring removal tool (Toro p/n: 92-5771), 10. Remove the bolt, 2 curved washers, ﬂ at washer, and unhook the idler pulley spring from the frame and retainer (Fig. 831). remove the belt from around the electric PTO clutch (Fig.
Page 263: Electric Pto Clutch Installation Ogura Clutch
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.
Page 264 MOWER DECKS 5. Install the clutch stop to the clutch (Fig. 836): 7. Apply anti-seize compound to the stub shaft (Fig. 838). Fig 836 PICT-3944a Fig 838 PICT-3655 A. Nut D. Clutch stop B. Washer (2) E. Spacer C. Electric PTO clutch F.
Page 265 MOWER DECKS 9. Slide the clutch onto the stub shaft (Fig. 840). 11. Slide the 2 curved washers, a ﬂ at 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...
Page 266 MOWER DECKS 13. Route the PTO drive belt onto the clutch pulley. 15. Plug the clutch harness into the electric PTO clutch Install the idler arm spring (Fig. 844). plug (Fig. 846). Fig 844 PICT-3969 Fig 846 PICT-3979 14. Twist the clutch stop and install the end to the frame 16.
Page 267: Gearbox Assembly Replacement
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.
Page 268 850). (Fig. 852). Fig 850 IMG_7753a Fig 852 PICT-3876 6. Using a spring removal tool (Toro p/n: 92-5771) 8. Raise the ﬂ oor pan assembly (Fig. 853). unhook the spring from the gearbox idler assembly (Fig. 851). Fig 853 PICT-3877...
Page 269 Fig 854 PICT-3879 Fig 856 PICT-3881 10. Using a spring removal tool (Toro p/n: 92-5771), 12. Remove the 4 mounting bolts and lock washers remove the mower deck idler spring (Fig. 855). securing the gearbox assembly to the frame (Fig.
Page 270 MOWER DECKS 13. Remove the gearbox assembly (Fig. 858). 15. Remove the pulley (Fig. 860). Fig 858 PICT-3898 Fig 860 PICT-3909a 14. Remove the 2 set screws from the gearbox driven 16. Remove the key from the keyway (Fig. 861). pulley (Fig.
Page 271 MOWER DECKS 17. Remove the 2 set screws from the gearbox drive 19. Remove the key from the keyway (Fig. 864). pulley (Fig. 862). Fig 864 PICT-3912a Fig 862 PICT-3908 20. Inspect the keys, gearbox shafts and pulleys. Re- 18. Remove the pulley (Fig. 863). place if worn or damaged.
Page 272: Gearbox Assembly Installation
MOWER DECKS 3. Apply thread locking compound to all 4 pulley set Gearbox Assembly Installation screws. Start the set screws into the pulley hubs (Fig. 867). 1. Apply anti-seize compound to both gearbox as- sembly shafts (Fig. 865). Fig 867 PICT-3917a Fig 865 PICT-3913a...
Page 273 MOWER DECKS 4. Tighten the set screws (Fig. 869). 6. Install a key into the gearbox driven shaft keyway (Fig. 871). Fig 869 PICT-3919a Fig 871 PICT-3924a 5. Torque each set screw to 145 + 20 in-lbs. (16 + 2.25 Nm) (Fig.
Page 274 MOWER DECKS Note: Install the pulley so that the hub is .06” 9. Position the gearbox assembly to the frame (Fig. (1.5mm) from the end of the gearbox driven 875). shaft. Tighten the set screws (Fig. 873). Fig 875 PICT-3898 Fig 873 PICT-3925 10.
Page 275 (Fig. 877). 879). Fig 877 PICT-3881 Fig 879 PICT-3879 12. Using a spring removal tool (Toro p/n: 92-5771), 14. Lower the ﬂ oor pan assembly (Fig. 880). install the mower deck idler spring (Fig. 878). Fig 880 PICT-3877 Fig 878...
Page 276 (Fig. 881). 883). Fig 881 PICT-3876 Fig 883 IMG_7753a 16. Using a spring removal tool (Toro p/n: 92-5771), 18. Install the front engine panel (Fig. 884). install the spring to the gearbox idler assembly (Fig. 882). Fig 884 IMG_7862...
Page 277: Checking The Gearbox Oil Level
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 1. Remove the gearbox assembly from the machine. to the neutral locked position and set the parking Refer to “Gearbox Assembly Removal”...
Page 278: Strut Replacement
MOWER DECKS 3. Drain the oil from the gearbox into a drain pan. Strut Replacement 4. Fill the gearbox assembly with 75W-90 Synthetic Note: The right rear wheel assembly has been Gear Lube until the oil level reaches the plug open- removed for photo purposes.
Page 279 Fig 890 PICT-4012 Fig 892 PICT-4108 6. Using a spring removal tool (Toro p/n: 92-5771), 8. Remove the strut pin (Fig. 893). remove the mower deck idler spring. Remove the mower deck belt from the gearbox deck drive pulley (Fig. 891).
Page 280 MOWER DECKS 9. Remove the nut, lockwasher and bolt securing the 11. Remove the grease ﬁ ttings from the strut (Fig. 896). strut balljoint to the frame (Fig. 894). Fig 896 PICT-4116a Fig 894 PICT-4105 12. Loosen the balljoint jam nut (Fig. 897). 10.
Page 281: Strut Installation
MOWER DECKS 13. Remove the balljoint and jam nut from the strut (Fig. 2. Tighten the jam nut to secure the balljoint position 898). (Fig. 900). Note: Balljoint to be positioned perpendicular to strut. Fig 898 PICT-4121a Fig 900 PICT-4119a Strut Installation 1.
Page 282 MOWER DECKS 4. Position the strut assembly balljoint up 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. 904). nut (Fig.
Page 283 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. 906). 908). Fig 906 ﬁ g. 55 G001067 Fig 908 PICT-4012 A. Mower belt D.
Page 284: 72" Mower Deck Belt Tension Adjustment Plate Replacement
3. Remove the negative battery cable from the battery. 4. Raise the ﬂ oor pan assembly (Fig. 910). Fig 911 PICT-4012 6. Using a spring removal tool (Toro p/n: 92-5771), re- move the mower deck idler spring (Fig. 912). Fig 910 PICT-4011...
Page 285 MOWER DECKS 7. Remove the belt from around the adjustment plate 10. Remove the tension adjustment plate assembly (Fig. pulley. 915). 8. Remove the nut from the pivot bolt (Fig. 913). Note: The pivot bolt will fall through to the under- side of the deck when the nut is removed.
Page 286 MOWER DECKS 12. Remove the nut, washer and bolt securing the pulley 14. Remove the idler bushing (Fig. 919). to the adjustment plate (Fig. 917). Fig 919 6672a Fig 917 6670a 72” Mower Deck Belt Tension Adjustment 13. Remove the pulley from the idler bushing (Fig. 918). Plate Removal 1.
Page 287 MOWER DECKS 2. Insert the mounting bolt up through the idler bushing 4. Position 2 spacers onto the mower deck (Fig. 923). and place the pulley onto the bushing (Fig. 921). 6669.jpg add arrows pointing to the spacers Fig 923 6669a Fig 921 6671a...
Page 288 MOWER DECKS 6. Insert 2 bolts up through the mower deck, spacers 8. Install the mower deck idler spring (Fig. 927). and tension adjustment plate. Install a washer and nut onto each bolt (Fig. 925). Fig 927 PICT-4013 Fig 925 6667a 9.
Page 289 MOWER DECKS 11. Lower the ﬂ oor 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”...
Page 290: Gearbox Rebuild
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 PICT-5646 Fig 931 PICT-5631 4. Remove the o-ring from the pinion pilot (Fig. 934). 2.
Page 291 MOWER DECKS 5. Remove the shim(s) (Fig. 935). Fig 937 IMG-8490 Fig 935 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 gear- box housing are patch lock bolts and must be replaced with new patch lock bolts.
Page 292 MOWER DECKS 8. Remove the o-ring from the closed end cap (Fig. 10. Remove the o-ring from the cross shaft pilot (Fig. 939). 941). Fig 939 IMG-8491 Fig 941 PICT-5664 9. Remove the open end cap and cross shaft assembly 11.
Page 293: Pinion Shaft Teardown
MOWER DECKS 12. Remove the cross shaft from the open end cap (Fig. 15. Remove the washer from the pinion shaft (Fig. 945). 943). Fig 945 IMG-8495 Fig 943 PICT-5667 16. Using a gear puller, remove the cross shaft gear Pinion Shaft Teardown from the pinion shaft (Fig.
Page 294 MOWER DECKS 17. Remove the key from the shaft keyway (Fig. 947). 19. Remove the bearing and shaft assembly from the pinion housing (Fig. 949). Fig 947 IMG-8501 Fig 949 IMG-8504 18. Place the pinion shaft assembly in a press, shaft side down.
Page 295: Cross Shaft Teardown
MOWER DECKS 21. Place the shaft assembly in a press and press the Cross Shaft Teardown bearing off the shaft (Fig. 951). 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.
Page 296: Open End Cap Teardown
MOWER DECKS 26. Position the cross shaft in the press so the opposite 28. Remove the bearing race form the open end cap bearing is facing up. Press the bearing off the shaft (Fig. 957). (Fig. 955). Note: The inner race and housing must be heated to remove the race.
Page 297: Closed End Cap Rebuild
MOWER DECKS 32. Press the bearing race into the open end cap (Fig. Closed End Cap Rebuild 961). 30. Press the bearing race into the open end cap (Fig. 959). Fig 961 IMG-8537 Fig 959 IMG-8537 Cross Shaft Rebuild Open End Cap Rebuild 33.
Page 298: Pinion Shaft Rebuild
MOWER DECKS 34. Install the key into the shaft keyway (Fig. 963). 37. Press the bearing onto the shaft (Fig. 965). Fig 963 IMG-8519 Fig 965 IMG-8530 35. Place the cross shaft in a press with the installed Pinion Shaft Rebuild bearing down.
Page 299 MOWER DECKS 39. Press a new bearing race into the inner end of the 41. Slide the bearing and shaft assembly into the pinion pinion housing (Fig. 967). housing (Fig. 969). Fig 967 IMG-8534 Fig 969 IMG-8541 40. Place the pinion shaft assembly in a press and press 42.
Page 300 MOWER DECKS 43. Install the key into the pinion shaft keyway (Fig. 45. Install a washer onto the pinion shaft (Fig. 973). 971). Fig 973 IMG-8547 Fig 971 IMG-8543 46. Install the lock nut onto the pinion shaft (Fig. 974). 44.
Page 301: Gearbox Assembly
MOWER DECKS 47. Place a protective wrap around the shaft keyway to 50. Install 4 new bolts securing the closed end cap to protect the grease seal on installation. the gearbox housing. Torque the bolts to 280 – 325 in-lbs. (31.6 – 36.7 Nm) (Fig. 977). 48.
Page 302 MOWER DECKS 52. Install .013” (.33mm) thickness of shims onto the 54. Apply a protective ﬁ lm onto the shaft keyway. open end cap (Fig. 979). 55. Install the open end cap assembly over the cross Note: The shim color corresponds to its thickness: shaft and onto the gearbox (Fig.
Page 303 MOWER DECKS 57. Check the cross shaft end play measurement, 59. Install a new o-ring on onto the pinion housing (Fig. it should be between .004” and .012” (.101 and 985). .305mm). Adjust the open end cap shims to adjust backlash (Fig.
Page 304 MOWER DECKS 61. Install 4 new bolts securing the pinion assembly to 62. Check the pinion shaft end play measurement, the to the gearbox housing. Torque the bolts to 280 – it should be between .004” and .012” (.101 and 325 in-lbs.
Page 305: Leveling The Mower
MOWER DECKS 63. Fill the gearbox with 6 oz. (.15 liters) of 75W-90 Leveling the Mower synthetic gear oil with anti-foaming agent until it starts to ﬂ ow out of the oil plug hole (Fig. 989). Setting up the Machine 1.
Page 306: Leveling The Mower Side To Side
MOWER DECKS 3. Record this measurement. This measurement needs Leveling the Mower Side to Side to be 3-1/8” to 3-1/4” (7.9 to 8.3cm). 1. Position the right blade side-to-side (Fig. 991). 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.
Page 307: Adjusting The Front To Rear Mower Pitch
MOWER DECKS 3. Record the measurement. Adjusting the Front to Rear Mower Pitch 4. Measure the right blade at the B location (Fig. 991) from a level surface to the cutting edge of the blade 1. Position the right blade front-to-rear (Fig. 994). tip (Fig.
Page 308: Adjusting The Compression Spring
MOWER DECKS 8. Adjust the lift nuts on both the left and the right side Adjusting the Compression Spring 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 1.
Page 309 MOWER DECKS THIS PAGE INTENTIONALLY LEFT BLANK. 7-86 Z580/Z593/Z595 Diesel Service Manual...
Page 310 Z580-D / Z593-D / Z595-D Diesel Z Master Service Manual Form No. 492-9188...

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