Toro 74253, 74253CP, 74254, 74254CP, 74274 Service Manual
LCE Products
Z580/Z589 DFI Z Master
Service Manual
ABOUT THIS MANUAL
This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to
make the information in this manual complete and correct.
Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems
and the related topics covered in this manual.
The following service materials are available in addition to this service manual:
Hydrostatic Pumps: Hydro-Gear P Series Pumps - Service and Repair Manual
Form #BLN 52503
Wheel Motors: Hydro-Gear HGM-E Wheel Motor Service Manual
Form #492-9139
Engine: Kawasaki FD791D Engine Service Manual (available through Kawasaki)
Form #99924-2061-03
Hydraulic Troubleshooting: Interactive hydraulic troubleshooting and failure analysis on DVD
Form #492-4777
Electrical Troubleshooting: Interactive electrical troubleshooting and wiring diagrams on DVD
Form # 492-9193
The Z Master Z580/Z589 with liquid-cooled DFI Kawasaki engine, model years 2007 to 2009, are covered in this
manual.
The hydrostatic drive system is precision machinery. Maintain strict cleanliness control during all stages of service
and repair. Cover or cap all hose ends and ttings whenever they are exposed. Even a small amount of dirt or other
contamination can severely damage the system.
We are hopeful that you will nd this manual a valuable addition to your service shop. If you have any questions or
comments regarding this manual, please contact us at the following address:
The Toro Company
LCE Service Training Department
8111 Lyndale Avenue South
Bloomington, MN 55420
The Toro Company reserves the right to change product specications or this manual without notice.
Copyright© All Rights Reserved
©2011 The Toro Company
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TABLE OF CONTENTS
SAFETY INFORMATION
General Information ......................................................................................................................1-1
Think Safety First ...................................................................................................................1-1
SPECIFICATIONS
Specications ...............................................................................................................................2-1
Congurations ........................................................................................................................2-1
Power System ........................................................................................................................2-1
Electrical ................................................................................................................................2-2
Mowing Deck .........................................................................................................................2-2
Operator Zone ........................................................................................................................2-3
Dimensions ............................................................................................................................2-3
Torque Specications ...................................................................................................................2-4
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) ....................................2-5
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) ......................................2-6
Other Torque Specications .........................................................................................................2-7
Equivalents and Conversions .......................................................................................................2-8
U.S. to Metric Conversions ...........................................................................................................2-9
CHASSIS
Castor Fork Assembly Replacement ............................................................................................3-1
Castor Fork Assembly Removal .............................................................................................3-1
Castor Bearing Replacement .................................................................................................3-2
Castor Fork Assembly Installation ..........................................................................................3-4
Front Wheel Bearing Replacement ..............................................................................................3-6
Fuel Tank Replacement ................................................................................................................ 3-9
Right Side Fuel Tank Removal ...............................................................................................3-9
Right Side Fuel Tank Installation .......................................................................................... 3-11
Left Side Fuel Tank Removal ...............................................................................................3-14
Left Side Fuel Tank Installation ............................................................................................3-17
Fuel Tank Fitting Replacement ...................................................................................................3-20
Hood Assembly Replacement ....................................................................................................3-22
Hood Assembly Removal .....................................................................................................3-22
Hood Assembly Installation ..................................................................................................3-23
Throttle Control Assembly Replacement ....................................................................................3-25
Throttle Control Assembly Removal .....................................................................................3-25
Throttle Control Assembly Installation ..................................................................................3-27
Brake Lever Replacement ..........................................................................................................3-31
Brake Lever Removal ..........................................................................................................3-31
Brake Lever Installation .......................................................................................................3-33
Brake Band Replacement...........................................................................................................3-34
Brake Band Removal ...........................................................................................................3-34
Brake Band Installation ........................................................................................................3-35
Brake Cross Shaft Replacement ................................................................................................3-37
Brake Cross Shaft Removal .................................................................................................3-37
Brake Cross Shaft Installation ..............................................................................................3-39
Deck Lift Lever Replacement .....................................................................................................3-41
Deck Lift Lever Removal ......................................................................................................3-41
Deck Lift Lever Installation ...................................................................................................3-45
iZ580/Z589 DFI Z Master Service Manual
TABLE OF CONTENTS
CHASSIS cont.
Motion Control Assembly Replacement......................................................................................3-48
Motion Control Assembly Removal ......................................................................................3-48
Right Hand Motion Control Assembly Removal ...................................................................3-50
Left Hand Motion Control Assembly Removal .....................................................................3-52
Left Hand Motion Control Assembly Installation ..................................................................3-55
Right Hand Motion Control Assembly Installation ................................................................3-57
Motion Control Assembly Installation ...................................................................................3-61
Motion Control Damper Replacment ..........................................................................................3-62
Motion Control Damper Removal .........................................................................................3-62
Motion Control Damper Installation ......................................................................................3-64
Adjusting the Parking Brake .......................................................................................................3-65
HYDRAULIC SYSTEM
Hydrostatic Tandem Pump Replacement .....................................................................................4-1
Hydrostatic Tandem Pump Removal ......................................................................................4-1
Hydrostatic Tandem Pump Installation ...................................................................................4-8
Wheel Motor Replacement .........................................................................................................4-17
Wheel Motor Removal .........................................................................................................4-17
Wheel Motor Installation ......................................................................................................4-21
Purging the Hydraulic System ....................................................................................................4-26
Adjusting the Control Handle Neutral Position ...........................................................................4-27
Setting the Hydrostatic Pump Neutral ........................................................................................4-28
Setting the Right Hydraulic Pump Neutral Position ..............................................................4-29
Setting the Left Hydraulic Pump Neutral Position ................................................................4-30
Adjusting the Tracking ................................................................................................................4-32
Hydraulic Flow Testing ................................................................................................................4-33
Hydraulic Flow Testing Procedure........................................................................................4-33
Traction Pump Drive Belt Replacement .....................................................................................4-37
Traction Pump Drive Belt Removal ......................................................................................4-37
Traction Pump Drive Belt Installation ...................................................................................4-39
Hydraulic Oil Cooler Replacement .............................................................................................4-42
Hydraulic Oil Cooler Removal ..............................................................................................4-42
Hydraulic Oil Cooler Installation ...........................................................................................4-43
Hydraulic Reservoir Tank Replacement .....................................................................................4-44
Hydraulic Reservoir Tank Removal ......................................................................................4-44
Hydraulic Reservoir Tank Installation ...................................................................................4-47
Pushing the Machine by Hand....................................................................................................4-50
Switching from Hand Pushing the Machine to Machine Operation ............................................4-50
ENGINE
Engine Replacement ....................................................................................................................5-1
Engine Removal .....................................................................................................................5-1
Engine Installation ..................................................................................................................5-9
Radiator Replacement ................................................................................................................5-19
Radiator Removal ................................................................................................................5-19
Radiator Installation .............................................................................................................5-22
Cooling Fan Replacement ..........................................................................................................5-26
Cooling Fan Removal ..........................................................................................................5-26
Cooling Fan Installation .......................................................................................................5-27
Fuel Pump Replacement ............................................................................................................5-29
Fuel Pump Removal ............................................................................................................5-29
Fuel Pump Installation .........................................................................................................5-31
Checking the Radiator Coolant...................................................................................................5-32
ii Z580/Z589 DFI Z Master Service Manual
TABLE OF CONTENTS
ELECTRICAL
General .........................................................................................................................................6-1
Relays...........................................................................................................................................6-1
Purpose ..................................................................................................................................6-1
Location .................................................................................................................................6-1
How It Works ..........................................................................................................................6-2
Testing ....................................................................................................................................6-2
PTO Switch ...................................................................................................................................6-3
Purpose ..................................................................................................................................6-3
Location .................................................................................................................................6-3
How It Works ..........................................................................................................................6-3
Testing ....................................................................................................................................6-4
Ignition Switch ..............................................................................................................................6-5
Purpose ..................................................................................................................................6-5
Location .................................................................................................................................6-5
How It Works ..........................................................................................................................6-5
Testing ....................................................................................................................................6-6
Neutral Safety Switch ...................................................................................................................6-6
Purpose ..................................................................................................................................6-6
Location .................................................................................................................................6-6
How It Works ..........................................................................................................................6-7
Testing ....................................................................................................................................6-7
Parking Brake Switch ...................................................................................................................6-7
Purpose ..................................................................................................................................6-7
Location .................................................................................................................................6-7
How It Works ..........................................................................................................................6-8
Testing ....................................................................................................................................6-8
Seat Switch...................................................................................................................................6-9
Purpose ..................................................................................................................................6-9
Location .................................................................................................................................6-9
How It Works ..........................................................................................................................6-9
Testing ....................................................................................................................................6-9
Delay Module..............................................................................................................................6-10
Purpose ................................................................................................................................6-10
Location ...............................................................................................................................6-10
How It Works ........................................................................................................................6-10
Testing .................................................................................................................................. 6-11
High Temperature Audible Alarm (Solid Tone) ............................................................................6-12
Purpose ................................................................................................................................6-12
Location ...............................................................................................................................6-12
How It Works ........................................................................................................................6-12
Testing ..................................................................................................................................6-12
Temperature Sender ................................................................................................................... 6-13
Purpose ................................................................................................................................6-13
Location ...............................................................................................................................6-13
How It Works ........................................................................................................................6-13
Testing ..................................................................................................................................6-13
Oil Pressure Switch ....................................................................................................................6-14
Purpose ................................................................................................................................6-14
Location ...............................................................................................................................6-14
How It Works ........................................................................................................................6-14
Testing ..................................................................................................................................6-14
iiiZ580/Z589 DFI Z Master Service Manual
TABLE OF CONTENTS
ELECTRICAL cont.
Engine High Temperature & Malfunction Indicator Light Cluster ................................................6-15
Purpose ................................................................................................................................6-15
Location ...............................................................................................................................6-15
How It Works ........................................................................................................................6-15
Testing ..................................................................................................................................6-16
Hour Meter..................................................................................................................................6-16
Purpose ................................................................................................................................6-16
Location ...............................................................................................................................6-16
How It Works ........................................................................................................................6-17
Testing ..................................................................................................................................6-17
Electric PTO Clutch ....................................................................................................................6-17
Purpose ................................................................................................................................6-17
Location ...............................................................................................................................6-17
How It Works ........................................................................................................................6-18
Testing ..................................................................................................................................6-18
Clutch Coil Continuity Test ...................................................................................................6-19
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
Fixed Pulley Installation .......................................................................................................7-32
Electric PTO Clutch Replacement ..............................................................................................7-34
Electric PTO Clutch Removal...............................................................................................7-34
Electric PTO Clutch Installation............................................................................................7-36
Gearbox Assembly Replacement ...............................................................................................7-39
Gearbox Assembly Removal ................................................................................................7-39
Gearbox Assembly Installation .............................................................................................7-43
Checking the Gearbox Oil Level .................................................................................................7-48
Changing Gearbox Oil ................................................................................................................7-49
Strut Replacement ......................................................................................................................7-50
Strut Removal ......................................................................................................................7-50
Strut Installation ...................................................................................................................7-53
72” Mower Deck Belt Tension Adjustment Plate Replacement ...................................................7-56
72” Mower Deck Belt Tension Adjustment Plate Removal ...................................................7-56
72” Mower Deck Belt Tension Adjustment Plate Installation ................................................7-59
72” Mower Deck Belt Tension Adjustment .................................................................................. 7-62
iv Z580/Z589 DFI Z Master Service Manual
TABLE OF CONTENTS
MOWER DECKS cont.
Gearbox Rebuild.........................................................................................................................7-63
Pinion Shaft Teardown .........................................................................................................7-66
Cross Shaft Teardown ..........................................................................................................7-69
Open End Cap Teardown .....................................................................................................7-70
Closed End Cap Teardown ..................................................................................................7-70
Closed End Cap Rebuild ......................................................................................................7-71
Open End Cap Rebuild ........................................................................................................7-71
Cross Shaft Rebuild .............................................................................................................7-72
Pinion Shaft Rebuild ............................................................................................................7-73
Gearbox Assembly ...............................................................................................................7-75
Leveling the Mower ....................................................................................................................7-79
Setting up the Machine ........................................................................................................7-79
Leveling the Mower Side to Side ................................................................................................7-80
Adjusting the Front to Rear Mower Pitch ....................................................................................7-81
Adjusting the Compression Spring .............................................................................................7-82
vZ580/Z589 DFI Z Master Service Manual
TABLE OF CONTENTS
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vi Z580/Z589 DFI Z Master Service Manual
General Information
SAFETY INFORMATION
This symbol means WARNING or
PERSONAL SAFETY INSTRUCTION
- read the instruction because it has to
do with your safety. Failure to comply
with the instruction may result in
personal injury or even death.
!
troubleshooting, service, and repair of the Z Master
Z580/Z589 with liquid-cooled DFI Kawasaki engine.
This manual is intended as a service
and repair manual only. The safety
instructions provided herein are for
Think Safety First
Avoid unexpected starting of engine...
Always turn off the engine and disconnect the spark plug
wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations...
The riding mower and attachment operator’s manual
contain safety information and operating tips for safe
operating practices. Operator’s manuals are available
online at www.toro.com, through your Toro parts source
or:
The Toro Company
Publications Department
8111 Lyndale Avenue South
Bloomington, MN 55420
Avoid injury from batteries...
Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes, and clothing. Battery gases can
explode. Keep cigarettes, sparks, and ames away from
the battery.
1
Stay clear of all moving parts whenever the engine is
running. Treat all normally moving parts as if they were
moving whenever the engine is running or has the
potential to start.
Avoid burns...
Do not touch the engine, mufer, or other components
which may increase in temperature during operation,
while the unit is running or shortly after it has been
running.
Avoid res and explosions...
Avoid spilling fuel and never smoke while working with
any type of fuel or lubricant. Wipe up any spilled fuel
or oil immediately. Never remove the fuel cap or add
fuel when the engine is running. Always use approved
labeled containers for storing or transporting fuel and
lubricants.
Avoid asphyxiation...
Never operate an engine in a conned area without
proper ventilation.
Avoid injury due to inferior parts...
Use only original equipment parts to ensure that
important safety criteria are met.
Avoid injury to bystanders...
Always clear the area of bystanders before starting or
testing powered equipment.
Avoid injury due to projectiles...
Always clear the area of sticks, rocks, or any other
debris that could be picked up and thrown by the
powered equipment.
Avoid modications...
Never alter or modify any part unless it is a factory
approved procedure.
Avoid unsafe operation...
Always test the safety interlock system after making
adjustments or repairs on the machine. Refer to the
Electrical section in this manual for more information.
1-1Z580/Z589 DFI Z Master Service Manual
1
SAFETY INFORMATION
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1-2 Z580/Z589 DFI Z Master Service Manual
SPECIFICATIONS
Specications
Congurations
Model Engine Deck
74253 29 hp Kawasaki Liquid Cool DFI 60” (152.4cm) Turbo Force SD Mower
74254 29 hp Kawasaki Liquid Cool DFI 72” (182.8cm) Turbo Force SD Mower
74253CP 29 hp Kawasaki Liquid Cool DFI 60” (152.4cm) Turbo Force SD Mower
74254CP 29 hp Kawasaki Liquid Cool DFI 72” (182.8cm) Turbo Force SD Mower
Power System
Engine Kawasaki FD791D-AS07
High Idle 3800 ± 100 RPM
Low Idle 2250 ± 150 RPM
Engine Oil Capacity 2.1 qt. (1.98 L)
Heavy Duty Canister Air Cleaner Standard
Hydraulic Pumps Hydro-Gear variable displacement 16 cc/rev hydrostatic
with shock valves
Wheel Motors Twin Hydro-Gear HGM 18E positive displacement with
1.25” (3.175cm) heavy duty tapered shafts
Ground Speed Forward: 0 - 11 mph (0 - 17.7 k/hr)
Reverse: 0 - 6.3 mph (0 - 10.1 k/hr)
Hour Meter Standard
Rear Drive Tires 24” x 12.0 -12” 4 ply
Front Caster Tires 13” x 6.5 - 6” Semi-pneumatic with smooth tread
Tire Pressure 13 psi (89.6 kPa) (rear drive tires only)
Fuel / Capacity 12 gallons (6 gallons per tank) (45.4 L / 22.7 L per tank)
Cooling System Capacity 5.5 qt. (5.2 liter)
2
2-1Z580/Z589 DFI Z Master Service Manual
2
SPECIFICATIONS
Electrical
Engine Charging Coil 40 Amp
Voltage 12 volt, negative ground
Battery BCI group 26, 540 CCA
Gauges and Alarms • Top panel mounted hour meter
• Audio alarm for excess engine temperature
• Lighted indicators for engine malfunction and excess engine temperature
• Push/pull PTO switch
Fuses Blade type, 30 Amp ignition, 30 Amp cooling fan and 10 Amp engine
Mowing Deck
60” (152.4cm) 72” (182.8cm)
Type Turbo Force™ Turbo Force™
Deck Construction Fabricated, 7-gauge high-strength
steel
Deck Depth 5-1/2” (13.97cm) 5-1/2” (13.97cm)
Adjustable Discharge Bafe Standard Standard
Spindle Housings Reinforced cast iron Reinforced cast iron
Spindle Shaft / Bearings 1” (2.54cm) Steel shaft/tapered roller
bearings
Blade Tip Speed 18,500 ft/min (5,638.8 meters/min) at
high idle
Height of Cut 1.5” - 5” in .25” increments
(3.81 - 12.7cm in .635cm increments)
Anti-Scalp Rollers 6 Adjustable 6 Adjustable
Fabricated, 7-gauge high-strength
steel
1” (2.54cm) Steel shaft/tapered roller
bearings
18,500 ft/min (5,638.8 meters/min) at
high idle
1.5” - 5” in .25” increments
(3.81 - 12.7cm in .635cm increments)
2-2 Z580/Z589 DFI Z Master Service Manual
SPECIFICATIONS
Operator Zone
60” (152.4cm) 72” (182.8cm)
Steering Levers Dual, wrap-around hydraulically
dampened, with cushioned grips
Parking Brake Left hand operated lever with
cushioned grip
Folding ROPS Standard Standard
Deck Lift Assist Pedal Standard Standard
Arm Rests Standard Standard
Seat Belt Retractable Retractable
Z Stand Optional Optional
Dimensions
60” (152.4cm) 72” (182.8cm)
Weight 1423 lbs. (645kg) 1482 lbs. (672kg)
Wheel Base 53.6” (136cm) 56.8” (144.3kg)
Overall Length 81.6” (207cm) 84.6” (215cm)
Width Outside Tires 53.2” (135cm) 57.2” (145cm)
Overall Width (outside deck) 76” (193cm) 88” (224cm)
Gate Width 62” (157.5cm) 74” (188cm)
Overall Height 72” (183cm) 72” (183cm)
Dual, wrap-around hydraulically
dampened, with cushioned grips
Left hand operated lever with
cushioned grip
2
2-3Z580/Z589 DFI Z Master Service Manual
SPECIFICATIONS
2
Torque Specications
Torque Specifications
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.
These torque specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in the
service manual. The following factors shall be
considered when applying torque: cleanliness of the
fastener, use of a thread sealant (Loctite), degree of
lubrication on the fastener, presence of a prevailing
torque feature, hardness of the surface underneath of
the fastener’s head, or similar condition which affects
the installation.
As noted in the following tables, torque values should
be reduced by 25% for lubricated fasteners to
achieve the similar stress as a dry fastener. Torque
values may also have to be reduced when the fastener
is threaded into aluminum or brass. The specific
torque value should be determined based on the
aluminum or brass material strength, fastener size,
length of thread engagement, etc.
Fastener Identification
Inch Series Bolts and Screws
(A) Grade 1
(B) Grade 5
Figure A
(C) Grade 8
The standard method of verifying torque shall be
performed by marking a line on the fastener (head or
nut) and mating part, then back off fastener 1/4 of a
turn. Measure the torque required to tighten the
fastener until the lines match up.
Figure B
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
2-4 Z580/Z589 DFI Z Master Service Manual
SPECIFICATIONS
2
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, &
Thread Size
# 6 - 32 UNC
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8 - 32 UNC
# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10 - 24 UNC
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 17 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
8 with Thin
Height Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
10 ± 2 13 ± 2 147 ± 23
13 ± 2 25 ± 5 282 ± 30
18 ± 2 30 ± 5 339 ± 56
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
15 ± 2 170 ± 20 23 ± 2 260 ± 20
29 ± 3 330 ± 30 41 ± 4 460 ± 45
42 ± 4 475 ± 45 60 ± 6 674 ± 70
SAE Grade 8 Bolts, Screws,
Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
2
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the
minimum proof load specified in SAE J429. The
tolerance is approximately
value. Thin height nuts include jam nuts.
± 10% of the nominal torque
2-5Z580/Z589 DFI Z Master Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
2
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm
M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 53 ± 5 ft-lb 72 ± 7 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 92 ± 9 ft-lb 125 ± 12 N-m
M16 X 2.0 166 ± 15 ft-lb 225 ± 20 N-m 229 ± 22 ft-lb 310 ± 30 N-m
M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 37 ft-lb 610 ± 50 N-m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Strong Nuts)
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately
the nominal torque value. Thin height nuts include jam nuts.
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts (
Class 10 or Strong Nuts)
± 10% of
2-6 Z580/Z589 DFI Z Master Service Manual
Other Torque Specications
Other Torque Specifications
SPECIFICATIONS
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb
5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb
3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb
1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
No. 8 - 32 UNC 30 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non-lubricated fasteners.
Thread Cutting Screws
Thread
Size
No. 6 18 20 20 ± 5 in-lb
No. 8 15 18 30 ± 5 in-lb
Threads per Inch
Type A Type B
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
(Zinc Plated Steel)
Baseline Torque*
2
No.10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors
in-lb X 11.2985 - N-cm
ft-lb X 1.3558 = N-m
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and
finish must be considered when determining specific
torque values. All torque values are based on nonlubricated fasteners.
N-cm X - 0.08851 = in-lb
N-cm X 0.73776 - ft-lb
2-7Z580/Z589 DFI Z Master Service Manual
2
SPECIFICATIONS
Equivalents and Conversions
Equivalents and Conversions
Decimal and Millimeter Equivalents
Decimal and Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
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
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.9375 2.381 19/32 0.59375 15.081
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.541 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm
2-8 Z580/Z589 DFI Z Master Service Manual
Linear
Measurement
Area
Volume
Weight
Pressure
Work
Liquid Volume
Liquid Flows
Temperature
SPECIFICATIONS
U.S. to Metric Conversions
U.S. to Metric Conversions
To Convert Into Multiply By
Miles
Yards
Feet
Feet
Inches
Inches
Inches
Square Miles
Square Feet
Square Inches
Acre
Cubic Yards
Cubic Feet
Cubic Inches
Tons (Short)
Pounds
Ounces
Pounds/Sq. In. Kilopascal
Foot-pounds
Foot-pounds
Inch-pounds
Quarts
Gallons
Gallons/Minute Liters/Minute
Fahrenheit Celsius
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
Square Kilometers
Square Meters
Square Centimeters
Hectare
Cubic Meters
Cubic Meters
Cubic Centimeters
Metric Tons
Kilograms
Grams
Newton-Meters
Kilogram-Meters
Kilogram-Centimeters
Liters
Liters
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
6.895
1.356
0.1383
1.152144
0.9463
3.785
3.785
1. Subtract 32°
2. Multiply by 5/9
2
2-9Z580/Z589 DFI Z Master Service Manual
2
SPECIFICATIONS
THIS PAGE INTENTIONALLY LEFT BLANK.
2-10 Z580/Z589 DFI Z Master Service Manual
CHASSIS
Castor Fork Assembly Replacement
Castor Fork Assembly Removal
1. Raise the front of the machine off the ground leaving
enough clearance to remove the castor fork from the
carrier frame.
2. Remove the grease cap from the frame (Fig. 001).
3. Remove the locknut (Fig. 002).
3
Fig 002 IMG-7874a
4. Slide the castor fork assembly out of the frame (Fig.
003).
Fig 001 IMG-7694a
Fig 003 IMG-7700a
3-1Z580/Z589 DFI Z Master Service Manual
CHASSIS
3
Castor Bearing Replacement
1. Remove the 3 Belleville washers (Fig. 004).
Fig 004 IMG-7703a
3. Remove the bottom grease seal (Fig. 006).
Fig 006 IMG-7709a
4. Remove the bottom tapered bearing (Fig. 007).
2. Remove the top tapered bearing (Fig. 005).
Fig 005 IMG-7706a
Fig 007 IMG-7711a
3-2 Z580/Z589 DFI Z Master Service Manual
CHASSIS
5. Drive the top and bottom tapered bearing cups out of
the caster fork hub (Fig. 008).
Fig 008 IMG-7714a
6. Install new tapered bearing cups by pressing each
bearing cup into the caster fork hub so that the thick-
er part of the taper is pressed in rst. The bearing
cups should seat against the shoulder inside the
frame.
Section view of caster fork hub (Fig. 009):
7. Pack the upper and lower tapered bearings with
grease (No. 2 general purpose lithium base or
molybdenum grease).
8. Install the lower bearing into the caster fork hub (Fig.
010).
3
Fig 010 IMG-7722a
9. Install the grease seal into the caster fork hub (Fig.
011).
A
B
C
A
Fig 009 tapered bearing cup install
A. Tapered Bearing Cup (2)
B. Caster fork hub (sectioned)
C. Machined shoulder inside caster fork hub (2)
Fig 011 IMG-7725a
3-3Z580/Z589 DFI Z Master Service Manual
CHASSIS
3
10. Install the upper bearing into the caster fork hub
(Fig. 012).
Fig 012 IMG-7731a
Castor Fork Assembly Installation
1. Install 3 Bellville washers as shown (Fig. 013):
A
Fig 013 g. 49 G001297
A. Belleville washers
2. Slide the castor fork assembly into the hub (Fig.
014).
Fig 014 IMG-7700a
3-4 Z580/Z589 DFI Z Master Service Manual
CHASSIS
3. Install the locknut. Tighten the locknut until the
Belle ville washers are at, then back the nut off 1/4
turn to properly set the preload on the bearings (Fig.
015).
Fig 015 IMG-7874a Fig 017 IMG-7734a
5. Remove the grease tting and install the grease
plug.
6. Install the dust cap onto the frame (Fig. 017).
3
4. Remove the plug located on the side of the castor
hub. Install a grease tting. Apply grease (No.
2 general purpose lithium base or molybdenum
grease) into the hub until it passes through the upper
bear ing. Fill the top cavity with grease (Fig. 016).
Fig 016 PICT-2897a
3-5Z580/Z589 DFI Z Master Service Manual
CHASSIS
3
Front Wheel Bearing Replacement
1. Raise the front of the machine off the ground.
2. Remove the wheel axle bolt and nut (Fig. 018).
Fig 018 IMG-7736a
4. Remove the castor spacer from the wheel assembly
(Fig. 020).
Fig 020 IMG-7742a
5. Remove both bearing spacers (one on each side)
from the wheel assembly (Fig. 021).
3. Remove the wheel assembly from the fork (Fig.
019).
Fig 019 IMG-7878a
Fig 021 IMG-7744a
3-6 Z580/Z589 DFI Z Master Service Manual
CHASSIS
6. Drive the bearing cup, bearing and bearing seal out
of the wheel assembly. Repeat on the opposite side
(Fig. 022).
Fig 022 IMG-7748a
Wheel Assembly (Fig. 023)
7. Install a new tapered bearing cup into the wheel
assembly by pressing each bearing cup into the
wheel hub so that the thicker part of the taper is
pressed into the wheel hub rst. The bearing cups
should seat against the shoulder divots inside the
wheel hub (Fig. 024).
3
Fig 024 IMG-7881a
E
A AB BC CD D
F
H
Fig 023 IMG-7880a
A. Bearing spacer (2) E. Wheel and tire
B. Grease seal (2) assembly
C. Tapered bearing (2) F. Caster spacer
D. Tapered bearing G. Wheel assembly axle
cup (2) bolt
H. Nut
G
8. Pack both tapered bearings with grease (No. 2 general purpose lithium base or molybdenum grease).
9. Install the tapered bearings into each side of the
wheel hub (Fig. 025).
Fig 025 IMG-7882a
3-7Z580/Z589 DFI Z Master Service Manual
CHASSIS
3
10. Install the grease seals into each side of the wheel
hub (Fig. 026).
Fig 026 IMG-7883a
11. Install a bearing spacer into each side of the wheel
hub (Fig. 027).
12. Install the castor spacer into the wheel hub (Fig.
028).
Fig 028 IMG-7885a
13. Position the wheel assembly into the caster fork (Fig.
029).
Fig 027 IMG-7884a
3-8 Z580/Z589 DFI Z Master Service Manual
Fig 029 IMG-7878a
CHASSIS
14. Install the axle bolt and nut securing the wheel as-
sembly to the fork (Fig. 030).
Fig 030 IMG-7736a
15. Apply grease (No. 2 general purpose lithium base or
molybdenum grease) to the wheel assembly grease
tting (Fig. 031).
Fuel Tank Replacement
Right Side Fuel Tank Removal
1. Raise the seat and remove the front engine shield
(Fig. 032).
3
Fig 032 IMG-0303a
Fig 031 IMG-7886a
2. Turn the fuel shut-off valve to OFF position (Fig.
033).
Fig 033 IMG-0304a
3-9Z580/Z589 DFI Z Master Service Manual
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