Table Of Contents - Toro Groundsmaster 580-D Service Manual

Table of Contents

Table Of Contents3
Safety Instructions5
Before Operating5
While Operating6
Maintenance And Service7
Safety And Instruction Decals8
Product Records And Maintenance9
Equivalents And Conversions10
Decimal And Millimeter Equivalents10
U.s To Metric Conversions10
Torque Specifications11
Capscrew Markings And Torque Values - U.s. Customary11
Capscrew Markings And Torque Values - Metric11
Engine13
General Information15
Engine Serial Number Location15
Stopping The Engine15
Engine External View16
Engine Sectional Views17
Specifications18
Definition Of Terms18
General Specifications - Mitsubishi S4Ft19
Service & Overhaul Standards23
Tightening Torque32
Important Bolts And Nuts32
General Bolts And Nuts33
Sealants34
Special Tools35
Troubleshooting38
Engine Fails To Start38
Lower Power39
Abnormal Engine Noises40
Excessive Oil Consumption41
Engine Runs Rough41
Excessive Smoke41
General Overhaul Instructions42
Determining When To Overhaul The Engine42
Disassembly Precautions42
Reassembly Precautions42
Testing Compression Pressure43
Adjustments44
Valve Clearance44
Priming / Bleeding Fuel System45
Fuel Injection Timing46
No-Load Minimum Idling Speed And Maximum Speed47
Fuel Stop Solenoid Adjustment50
Fan Drive Belt Inspection And Adjustment50
Engine Removal And Installation51
Removing Engine51
Installing Engine54
Engine Accessory Removal And Installation55
Preparatory Steps55
Engine Accessory Removal55
Engine Accessory Installation59
Cylinder Head And Valves60
Disassembly60
Inspection And Repair62
Valves, Valve Guides And Valve Seats63
Valve Springs67
Cylinder Head68
Valve Pushrods68
Reassembly69
Flywheel, Timing Gears And Camshaft73
Tappets78
Timing Gears79
Idler, Idler Bushing And Idler Shaft79
Flywheel And Ring Gear80
Crankshaft Pulley81
Reassembling Sequence82
Inspecting Timing Gear Backlash And End Play84
Inspecting Valve Timing84
Piston, Connecting Rods, Crankshaft & Block85
Removing Cylinder Sleeve89
Installing A New Cylinder Sleeve89
Pistons And Piston Rings90
Connecting Rods, Connecting Rod Bearings And Small-End Bushing92
Crankshaft94
Main Bearings97
Inlet And Exhaust Systems103
Description103
Exhaust Manifold104
Turbocharger105
Cleaning And Inspection109
Lubrication System118
Oil Pump119
Oil Filter123
Relief Valve123
Cooling System124
Water Pump124
Thermostat127
Radiator, Fan, And Fan Belt127
Fuel System128
Fuel Injection Nozzles129
Fuel Feed Pump132
Testing133
Repair133
Fuel Injection Pump134
Disassembly And Assembly Precautions135
Governor136
Injection Pump Testing136
General Overhaul Information137
Oil Seals137
O-Rings138
Bearings138
Lock Plates139
Split Pins And Spring Pins139
Engine (Model 30581)141
Engine (Models 30582 And 30583)143
Hydraulic System145
Traction Drive System Repairs145
Hydraulic Hoses147
Hydraulic Fitting Installation147
O-Ring Face Seal147
Sae Straight Thread O-Ring Port (Non-Adjustable)148
Sae Straight Thread O-Ring Port (Adjustable)148
Pushing Or Towing (Pump By-Pass Method)149
Draining And Refilling System149
Hydraulic Flow Diagrams150
Typical Circuits - Engine Running150
Typical Circuits - Mowing152
Hydraulic Pressure Test Kit155
Seal Installation Tools155
System Operates Hot156
Neutral Difficult Or Impossible To Find157
Machine Travels In One Direction Only157
Traction Response Is Sluggish157
Machine Will Not Travel In Either Direction157
Machine Will Not Go Into High Range158
Machine Goes Into High Range But Top Speed Is Too Slow158
Machine Does Not Go Into Low Range158
Engine Shuts Off When On Side Hill Or Down Hill159
No Decks Operate159
All Decks Operate Slowly159
One Deck Does Not Operate160
One Deck Operates Slowly And/Or Loses Power In Heavy Cutting161
Right Wing Deck Blades "Creep" When System Is Cold, Or Right Deck Runs Briefly When Raised Or Off If Left Wing Is On161
Steering Problems161
One Deck Will Not Stop Operating162
One Deck Stops Too Slowly162
Deck(S) Do Not Lift Or Lift Too Slowly163
Decks "Chatter" While Lowering163
Wing Decks Raise By Themselves When Climbing A Hill164
Deck Weight Is Not Transferred To Traction Unit When Climbing A Hill164
Wing Decks Cut At Uneven Height On Level Ground164
Wing Deck Drops With Lift Valve In Centered Position164
Before Performing Hydraulic Tests165
Traction Circuit Pressure And Relief Pressure166
Traction Circuit Charge Pressure167
Steering Circuit Working Pressure And Relief Pressure168
Lift Circuit Working Pressure And Relief Pressure169
Counterbalance Pressure170
Diagnosing Cutting Performance Problems173
Deck Motor Internal Leakage Test174
Alternate Deck Motor Test174
Deck Drive Circuit Working Pressure And Relief Pressure175
Traction Control Neutral Adjustment176
Traction Control Rod Adjustment177
Cruise Control Adjustment177
Mow/Transport Solenoid Service178
Variable Displacement Pump Removal And Installation179
After Repair Or Replacement180
Pto System Repairs182
Pto Valve Block Service182
Cartridge Installation184
Cartridge Replacement185
Pto Pump Removal And Installation186
After Pump Repair Or Replacement186
Pto Pump Repair187
Pto Pump Repair (Models 30582 And 30583)188
Deck Motor Removal And Installation189
Removing Deck Motor189
Installing Deck Motor189
Deck Motor Repair190
Deck Motor Repair (P/N 94-4907)191
Shaft Seal Installation192
Running-In192
Wing Deck Hose Replacement (S/N 50001 & Up)193
Wing Deck Motor Hydraulic Hose Replacement195
To Get Correct Hose Position195
Auxiliary (Lift/Counterbalance) System Repairs196
Float/Traction Assist Manifold Block Service196
Steering/Auxiliary Pump Removal And Installation198
Steering/Auxiliary Pump Repair (Models 30582 And 30583)199
Steering/Auxiliary Pump Repair (Models 30580 And 30581)201
Flow Divider Cover202
Front Lift Cylinder Removal And Installation202
Front Lift Cylinder Repair202
Wing Lift Cylinder Removal And Installation204
Wing Lift Cylinder Repair204
Lift Control Valve Removal And Installation206
Lift Control Valve Repair206
Steering System Repairs208
Steering Cylinder Removal And Installation208
Steering Cylinder Repair208
Ball Joint Adjustment208
Steering Control Unit Removal And Installation210
Steering Control Unit Repair (Models 30580 And 30581)211
Steering Control Unit Repair (Model 30582 And 30583)211
Hydraulic Reservoir And Filter213
Flushing The Hydraulic System213
Inspecting Reservoir Parts214
Electrical Diagrams215
Repairs215
Wiring Schematic And Diagrams216
Controller Logic Chart216
Electrical Schematic218
Gauge Package219
Starting Problems223
General Run And Transport Problems226
Deck Operation Problems230
Verify Interlock System Operation233
Ignition Key Switch234
Controller235
Seat Switch235
Traction (Neutral) Switch236
Deck Down Switches236
Service Brake Switch237
Parking Brake Switch237
Start Relay238
Fuel Stop Solenoid239
To Test While Connected To Wire Harness239
Battery240
Warning Indicator Lights240
Hormeter240
Temperature And Fuel Level Gauges240
Engine Temperature Switches And Gauge Sender241
High Temperature Warning Switch241
High Temperature Shut-Down Switch241
Temperature Gauge Sender241
Hydraulic Oil Temperature Warning Switch242
Engine Oil Pressure Switch242
2-Speed (Mow/Transport) Solenoid243
Pto (Deck) Solenoids243
Cruise Control243
Hydraulic Oil Level Sensing Unit244
Fuel Gauge Sender244
Hydraulic Oil Filter Warning Switch245
Air Cleaner Warning Switch245
Battery Service246
Fuses And Circuit Breakers247
Traction (Neutral) Switch Replacement And Adjustment248
Controller Replacement249
Solenoid Valve Coil Replacement250
Starter251
Alternator258
Wheels, Brakes And Steering261
Disengage Planetary Wheel Drive For Towing263
Bleeding Service Brakes264
Service Brake Adjustment265
Steering/Parking Brake Adjustment266
Rear Wheel Toe-In Adjustment267
Steering Cylinder Adjustment268
Rear Wheel Bearing Adjustment269
Rear Axle Pivot Adjustment269
Rear Wheel Bearing Service270
Planetary Wheel Drive Removal And Installation271
Planetary Wheel Drive Disassembly272
Planetary Wheel Drive Assembly273
Wheel Brake Service274
Brake Housing Removal276
Wheel Motor Shaft Cup Ring Service276
Brake Actuator Seal Replacement277
Master Cylinder Service278
Cutting Units279
Height-Of-Cut Adjustment280
Skid Adjustment281
Mismatch Adjustments282
Cutting Blade Mismatch283
Front Cutting Unit Wing And Wing Blade Mismatch283
Cutting Unit Mismatch283
Belt Tension Adjustment284
Outboard Cutting Units285
Front Cutting Unit Lift Arm Ball Joint Adjustment285
Outboard Cutting Unit Tie Rod Adjustment286
Outboard Cutting Unit Spring (Break-Away) Adjustment286
Blade Service287
Inspecting And Sharpening Blade289
Belt Replacement290
Separating Cutting Units From Traction Unit292
Spindle Service293
Removing Spindle Housing Assembly293
Electrical System295
Component Identification And Testing295
Controller Logic Grid296
Wire Harness Diagram: Console Gauge Panel297
Wiring Diagram: Console Gauge Panel298
Digital Multimeter299
Inductive Ammeter (Ac/Dc Current Transducer - - Hall Effect)299
Skin- -Over Grease299
Diagnostic Ace Display300
Electrical System Quick Checks301
Battery Test (Open Circuit Test)301
Charging System Test301
Quick Reference Troubleshooting Guide302
Diagnostic Lamp302
Verify Input Functions302
Verify Output Function303
Retrieving Stored Faults304
Clearing Fault Memory304
Electronic Control Unit (Ecu)305
Neutral Switch (Model 30582 And 30583)305
Seat Switch (S/N Between 30101 And 80000)306
Seat Switch (S/N 80001 And Up)306
Engine Temperature Switches (S/N 80001 And Up)307
Service And Repairs308
Circuit Protection308
Charging311
Brushes312
Field Coil312
Stator Coil312
Foldout Diagrams313
Hydraulic Schematic (2Wd Machines)315
Hydraulic Schematic (4Wd Machines)316
Model 30580 (S/N 30101 And Up)317
Models 30581 And 30582318
Model 30583319
Groundsmaster 580-D Wire Harness Drawing Model 30580 (S/N 30101 And Up)320
Wire Harness Diagram321
Groundsmaster 580-D Wire Harness Drawing Model 30581322
Groundsmaster 580-D Wire Harness Diagram Model 30581323
Groundsmaster 580-D Wire Harness Drawing Model 30582 (S/N Below 240999999)324
Groundsmaster 580-D Wire Harness Diagram Model 30582 (S/N Below 240999999)325
Groundsmaster 580-D Wire Harness Drawing Models 30582 (S/N Above 250000000) And 30583326
Groundsmaster 580-D Wire Harness Diagram Models 30582 (S/N Above 250000000) And 30583327
4Wd Wire Harness (S/N Below 240999999)328
4Wd Wire Harness (S/N Above 250000000)329