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Toro
Lawn Mower
Diesel Z Master
Toro Diesel Z Master User Manual
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LCE Products
Z580-D / Z593-D / Z595-D
Diesel Z Master
Service Manual
2
Table of Contents
Table of Contents
4
Safety Information
10
General Information
10
Think Safety First
10
Specifications
12
Specifi Cations Z593-D & Z595-D
12
Confi Gurations
12
Power System
12
Mowing Deck
13
Operator Zone
14
Dimensions
14
Specifi Cations Z580-D
15
Confi Gurations
15
Power System
15
Mowing Deck
16
Operator Zone
16
Dimensions
17
Torque Specifi Cations
18
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
19
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
20
Other Torque Specifications
21
Equivalents and Conversions
22
U.S. to Metric Conversions
23
Chassis
24
Castor Fork Assembly Replacement
24
Castor Fork Assembly Removal
24
Castor Bearing Replacement
24
Castor Fork Assembly Installation
27
Front Wheel Removal & Bearing Replacement
28
Fuel Tank Replacement
32
Right Side Fuel Tank Removal
32
Right Side Fuel Tank Installation
34
Left Side Fuel Tank Removal
37
Left Side Fuel Tank Installation
40
Fuel Tank Fitting Replacement
43
Hood Assembly Replacement
45
Hood Assembly Removal
45
Hood Assembly Installation
45
Throttle Control Assembly Replacement
47
Throttle Control Assembly Removal
47
Throttle Control Assembly Installation
49
Brake Lever Replacement
53
Brake Lever Removal
53
Brake Lever Installation
54
Brake Band Replacement
55
Brake Band Removal
55
Brake Band Installation
57
Brake Cross Shaft Replacement
58
Brake Cross Shaft Removal
58
Brake Cross Shaft Installation
60
Deck Lift Lever Replacement
62
Deck Lift Lever Removal
62
Deck Lift Lever Installation
66
Motion Control Assembly Replacement
70
Motion Control Assembly Removal
70
Right Hand Motion Control
71
Left Hand Motion Control
73
Motion Control Assembly Installation
76
Left Hand Motion Control
76
Right Hand Motion Control
78
Motion Control Damper Replacment
84
Motion Control Damper Removal
84
Motion Control Damper Installation
85
Adjusting the Parking Brake
86
Hydraulic System
88
Hydrostatic Tandem Pump Replacement
88
Hydrostatic Tandem Pump Removal
88
Hydrostatic Tandem Pump Installation
95
Wheel Motor Replacement
104
Wheel Motor Removal
104
Wheel Motor Installation
107
Purging the Hydraulic System
111
Adjusting the Control Handle Neutral Position
112
Setting the Hydrostatic Pump Neutral
114
Setting the Right Hydraulic Pump Neutral Position
115
Setting the Left Hydraulic Pump Neutral Position
115
Adjusting the Tracking
117
Hydraulic Flow Testing
118
Hydraulic Flow Testing Procedure
118
Traction Pump Drive Belt Replacement
122
Traction Pump Drive Belt Removal
122
Traction Pump Drive Belt Installation
124
Hydraulic Oil Cooler Replacement
126
Hydraulic Oil Cooler Removal
126
Hydraulic Oil Cooler Installation
129
Hydraulic Reservoir Tank Replacement
131
Hydraulic Reservoir Tank Removal
131
Hydraulic Reservoir Tank Installation
133
Pushing the Machine by Hand
136
Switching from Pushing the Machine Back to Machine Operation
137
Engine
138
Engine Replacement
138
Engine Removal
138
Engine Installation
156
Radiator Replacement
179
Radiator Removal
179
Radiator Installation
183
Cooling Fan Replacement
186
Cooling Fan Removal
186
Cooling Fan Installation
187
Air Cleaner Replacement
188
Air Cleaner Removal
188
Air Cleaner Installation
191
Alternator Belt Replacement
193
Alternator Belt Removal
193
Alternator Belt Installation
195
Checking Alternator Belt Tension
198
Tensioning the Alternator Belt
199
Fuel Filter Service
200
Fuel Filter Replacement
201
Draining the Water Separator
203
Checking the Radiator Coolant
203
General
204
Engine Starting
204
Relays
204
Purpose
204
Location
204
How It Works
205
Testing
205
PTO Switch
206
Purpose
206
Location
206
How It Works
206
Testing
207
Ignition Switch
208
Purpose
208
Location
208
How It Works
208
Testing
209
Neutral Safety Switch
209
Purpose
209
Location
209
How It Works
209
Parking Brake Switch
210
Purpose
210
Location
210
How It Works
210
Testing
211
Seat Switch
211
Purpose
211
Location
211
How It Works
212
Testing
212
Delay Module
212
Purpose
212
Location
212
How It Works
213
Testing
213
High Temperature Audible Alarm (Solid Tone)
214
Purpose
214
Location
214
How It Works
215
Testing
215
Temperature Sender
215
Purpose
215
Location
215
How It Works
216
Testing
216
Oil Pressure Switch
216
Purpose
216
Location
216
How It Works
217
Testing
217
High Temperature & Glow Plug Light Cluster
217
Purpose
217
Location
217
How It Works
218
Testing
218
Glow Plug Switch
218
Purpose
218
Location
218
How It Works
219
Testing
219
Hour Meter
219
Purpose
219
Location
219
How It Works
220
Testing
220
Electric PTO Clutch
220
Purpose
220
Location
220
How It Works
221
Testing
221
Clutch Coil Continuity Test
221
Engine Stop Solenoid
222
Purpose
222
Location
222
How It Works
222
Testing
222
Pull Coil Terminal Test
223
Hold Coil Terminal Test
223
Mower Decks
224
Mower Belt Replacement
224
Mower Deck Removal
226
Mower Deck Installation
229
Mower Spindle Replacement
232
Mower Spindle Removal
232
Mower Deck Spindle Rebuild
235
Mower Spindle Installation
243
Mower Deck Idler Assembly Replacement
247
Mower Deck Idler Assembly Removal
247
Mower Deck Idler Assembly Installation
249
Fixed Pulley Replacement
253
Fixed Pulley Removal
253
Fixed Pulley Installation
255
Electric PTO Clutch Replacement
257
Electric PTO Clutch Removal Warner Clutch
257
Electric PTO Clutch Installation Warner Clutch
258
Electric PTO Clutch Removal Ogura Clutch
261
Electric PTO Clutch Installation Ogura Clutch
263
Gearbox Assembly Replacement
267
Gearbox Assembly Removal
267
Gearbox Assembly Installation
272
Checking the Gearbox Oil Level
277
Changing Gearbox Oil
277
Strut Replacement
278
Strut Removal
278
Strut Installation
281
72" Mower Deck Belt Tension Adjustment Plate Replacement
284
72" Mower Deck Belt Tension Adjustment Plate Removal
284
72" Mower Deck Belt Tension Adjustment
284
Gearbox Rebuild
290
Pinion Shaft Teardown
293
Cross Shaft Teardown
295
Open End Cap Teardown
296
Closed End Cap Teardown
296
Closed End Cap Rebuild
297
Open End Cap Rebuild
297
Cross Shaft Rebuild
297
Pinion Shaft Rebuild
298
Gearbox Assembly
301
Leveling the Mower
305
Setting up the Machine
305
Leveling the Mower Side to Side
306
Adjusting the Front to Rear Mower Pitch
307
Adjusting the Compression Spring
308
5
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Toro Diesel Z Master Specifications
General
Fuel Type
Diesel
Transmission
Hydrostatic
Engine Type
Diesel
Cutting Width
60 inches
Fuel Tank Capacity
12 gallons
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