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 fittings whenever they are exposed. Even a small amount of dirt or other contamination can severely damage the system.

We are hopeful that you will find 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 specifications 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
Specifications................................................................................................................................	2-1
Configurations........................................................................................................................	2-1
Power System........................................................................................................................	2-1
Electrical.................................................................................................................................	2-2
Mowing Deck..........................................................................................................................	2-2
Operator Zone........................................................................................................................	2-3
Dimensions.............................................................................................................................	2-3
Torque Specifications....................................................................................................................	2-4
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)....................................	2-5
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners).......................................	2-6
Other Torque Specifications..........................................................................................................	2-7
Equivalents and Conversions........................................................................................................	2-8
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

Z580/Z589 DFI Z Master Service Manual

i

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

Z580/Z589 DFI Z Master Service Manual

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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

Z580/Z589 DFI Z Master Service Manual

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TABLE OF CONTENTS

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vi	Z580/Z589 DFI Z Master Service Manual

SAFETY INFORMATION

General Information
			1
	This symbol means WARNING or	The riding mower and attachment operator’s manual
!	PERSONAL SAFETY INSTRUCTION	contain safety information and operating tips for safe
	- 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	or:
	personal injury or even death.	The Toro Company
	This manual is intended as a service	Publications Department
	and repair manual only. The safety	8111 Lyndale Avenue South
	instructions provided herein are for	Bloomington, MN 55420
troubleshooting, service, and repair of the Z Master
Z580/Z589 with liquid-cooled DFI Kawasaki engine.

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...

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, muffler, or other components which may increase in temperature during operation, while the unit is running or shortly after it has been running.

Avoid fires 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 confined area without proper ventilation.

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 flames away from the battery.

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 modifications...

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.

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SAFETY INFORMATION

1

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SPECIFICATIONS

Specifications

Configurations

Model	Engine	Deck
74253	29 hp Kawasaki Liquid Cool DFI	60” (152.4cm) Turbo Force SD Mower		2
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)

Z580/Z589 DFI Z Master Service Manual

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SPECIFICATIONS

Electrical

		Engine Charging Coil		40 Amp
		Voltage		12 volt, negative ground
		Battery		BCI group 26, 540 CCA
2
		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	Fabricated, 7-gauge high-strength
						steel	steel
		Deck Depth				5-1/2” (13.97cm)	5-1/2” (13.97cm)
		Adjustable Discharge Baffle				Standard	Standard
		Spindle Housings				Reinforced cast iron	Reinforced cast iron
		Spindle Shaft / Bearings				1” (2.54cm) Steel shaft/tapered roller	1” (2.54cm) Steel shaft/tapered roller
						bearings	bearings
		Blade Tip Speed				18,500 ft/min (5,638.8 meters/min) at	18,500 ft/min (5,638.8 meters/min) at
						high idle	high idle
		Height of Cut				1.5” - 5” in .25” increments	1.5” - 5” in .25” increments
						(3.81 - 12.7cm in .635cm increments)	(3.81 - 12.7cm in .635cm increments)
		Anti-Scalp Rollers				6 Adjustable	6 Adjustable

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						SPECIFICATIONS
Operator Zone
			60” (152.4cm)			72” (182.8cm)
Steering Levers	Dual, wrap-around hydraulically					Dual, wrap-around hydraulically
	dampened, with cushioned grips					dampened, with cushioned grips
Parking Brake	Left hand operated lever with					Left hand operated lever with				2
	cushioned grip					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)

Z580/Z589 DFI Z Master Service Manual

2-3

SPECIFICATIONS

Torque Specifications

Torque Specifications

Fastener Identification

Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or

2a 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.

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 A
Inch Series Bolts and Screws
(A) Grade 1		(C) Grade 8
(B) Grade 5

Figure B

Metric Bolts and Screws

(A) Class 8.8	(B) Class 10.9

2-4	Z580/Z589 DFI Z Master Service Manual

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,
	Thread Size	8 with Thin		Studs, & Sems with Regular				Studs, & Sems with Regular						Studs, & Sems with Regular
		Height Nuts		Height Nuts (SAE J995				Height Nuts (SAE J995						Height Nuts (SAE J995
				Grade 2 or Stronger Nuts)				Grade 2 or Stronger Nuts)						Grade 2 or Stronger Nuts)
		In-lb		In-lb		N-cm		In-lb			N-cm			In-lb		N-cm				2
	# 6 - 32 UNC	10	± 2	13	± 2	147	± 23	15	±	2	170	±	20	23	± 2	260	±	20
	# 6 - 40 UNF							17	±	2	190	±	20	25	± 2	280	±	20
	# 8 - 32 UNC	13	± 2	25	± 5	282	± 30	29	±	3	330	±	30	41	± 4	460	±	45	2
	# 8 - 36 UNF							31 ± 3			350 ± 30			43	± 4	31 ± 3
	# 10 - 24 UNC	18	± 2	30	± 5	339	± 56	42	± 4		475	±	45	60	± 6	674	± 70
	#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
		ft-lb		ft-lb		N-m		ft-lb			N-m			ft-lb		N-m
	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

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 ± 10% of the nominal torque value. Thin height nuts include jam nuts.

Z580/Z589 DFI Z Master Service Manual

2-5

SPECIFICATIONS

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)

Thread Size

Class 8.8 Bolts, Screws, and Studs with

Class 10.9 Bolts, Screws, and Studs with

Regular Height Nuts

Regular Height Nuts (

(Class 8 or Strong Nuts)

Class 10 or Strong Nuts)

M5 X 0.8

57 ± 5 in-lb

640

± 60 N-cm

78 ± 7 in-lb

885 ± 80 N-cm

2

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.

Note: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately ± 10% of the nominal torque value. Thin height nuts include jam nuts.

2-6	Z580/Z589 DFI Z Master Service Manual

SPECIFICATIONS

Other Torque Specifications

Other Torque Specifications

SAE Grade 8 Steel Set Screws

	Thread Size	Recommended Torque
		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

Wheel Bolts and Lug Nuts

Thread Size	Recommended Torque**
				2
7/16 - 20 UNF	65 ± 10 ft-lb	88 ± 14 N-m
Grade 5
1/2 - 20 UNF	80 ± 10 ft-lb	108 ± 14 N-m
Grade 5
M12 X 1.25	80 ± 10 ft-lb	108 ± 14 N-m
Class 8.8
M12 X 1.5	80 ± 10 ft-lb	108 ± 14 N-m
Class 8.8

** For steel wheels and non-lubricated fasteners.

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
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

Thread Cutting Screws

(Zinc Plated Steel)

	Thread	Threads per Inch		Baseline Torque*
	Size	Type A	Type B
	No. 6	18	20	20 ± 5 in-lb
	No. 8	15	18	30 ± 5 in-lb
	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.

Conversion Factors
in-lb X 11.2985 - N-cm	N-cm X - 0.08851 = in-lb
ft-lb X 1.3558 = N-m	N-cm X 0.73776 - ft-lb

Z580/Z589 DFI Z Master Service Manual

2-7

SPECIFICATIONS

Equivalents and Conversions

Equivalents and Conversions

Decimal and Millimeter Equivalents

Decimal and Millimeter Equivalents

		Fractions	Decimals	mm	Fractions		Decimals	mm
2		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

			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							2
		Feet	Centimeters		30.48
	Measurement	Inches	Meters		0.0254
		Inches	Centimeters
		Inches	Millimeters		2.54
					25.4
		Square Miles	Square Kilometers		2.59
	Area	Square Feet	Square Meters		0.0929
		Square Inches	Square Centimeters		6.452
		Acre	Hectare		0.4047
		Cubic Yards	Cubic Meters		0.7646
	Volume	Cubic Feet	Cubic Meters		0.02832
		Cubic Inches	Cubic Centimeters		16.39
		Tons (Short)	Metric Tons		0.9078
	Weight	Pounds	Kilograms		0.4536
		Ounces	Grams		28.3495
	Pressure	Pounds/Sq. In.	Kilopascal		6.895
		Foot-pounds	Newton-Meters		1.356
	Work	Foot-pounds	Kilogram-Meters		0.1383
		Inch-pounds	Kilogram-Centimeters		1.152144
	Liquid Volume	Quarts	Liters		0.9463
		Gallons	Liters		3.785
	Liquid Flows	Gallons/Minute	Liters/Minute		3.785
	Temperature	Fahrenheit	Celsius	1.	Subtract 32°
				2.	Multiply by 5/9

Z580/Z589 DFI Z Master Service Manual

2-9

SPECIFICATIONS

2

THIS PAGE INTENTIONALLY LEFT BLANK.

2-10	Z580/Z589 DFI Z Master Service Manual

CHASSIS

Castor Fork Assembly Replacement

3. Remove the locknut (Fig. 002).

Castor Fork Assembly Removal

1.Raise the front of the machine off the ground leaving enough clearance to remove the castor fork from the carrier frame.

2.Remove the grease cap from the frame (Fig. 001).

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

Z580/Z589 DFI Z Master Service Manual

3-1

CHASSIS

Castor Bearing Replacement

3. Remove the bottom grease seal (Fig. 006).

1. Remove the 3 Belleville washers (Fig. 004).

3

Fig 006

IMG-7709a

Fig 004

IMG-7703a

4. Remove the bottom tapered bearing (Fig. 007).

2. Remove the top tapered bearing (Fig. 005).

Fig 007

IMG-7711a

Fig 005

IMG-7706a

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).

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 008

IMG-7714a

6.Install new tapered bearing cups by pressing each bearing cup into the caster fork hub so that the thicker part of the taper is pressed in first. The bearing cups should seat against the shoulder inside the frame.

Section view of caster fork hub (Fig. 009):

Fig 010

IMG-7722a

9.Install the grease seal into the caster fork hub (Fig. 011).

A

B

C

A

Fig 011

IMG-7725a

Fig 009 tapered bearing cup install

A.Tapered Bearing Cup (2)

B.Caster fork hub (sectioned)

C.Machined shoulder inside caster fork hub (2)

Z580/Z589 DFI Z Master Service Manual

3-3

CHASSIS

10. Install the upper bearing into the caster fork hub	Castor Fork Assembly Installation
(Fig. 012).
	1. Install 3 Bellville washers as shown (Fig. 013):

				A
	3

Fig 012

IMG-7731a

Fig 013

fig. 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 Belle­ville washers are flat, then back the nut off 1/4 turn to properly set the preload on the bearings (Fig. 015).

5.Remove the grease fitting and install the grease plug.

6.Install the dust cap onto the frame (Fig. 017).

3

Fig 015

IMG-7874a

Fig 017

IMG-7734a

4.Remove the plug located on the side of the castor hub. Install a grease fitting. Apply grease (No.

2 general purpose lithium base or molybdenum grease) into the hub until it passes through the upper bearing­. Fill the top cavity with grease (Fig. 016).

Fig 016

PICT-2897a

Z580/Z589 DFI Z Master Service Manual

3-5

CHASSIS

Front Wheel Bearing Replacement		4. Remove the castor spacer from the wheel assembly
		(Fig. 020).
1.	Raise the front of the machine off the ground.
2.	Remove the wheel axle bolt and nut (Fig. 018).

3

Fig 020

IMG-7742a

Fig 018

IMG-7736a

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 021

IMG-7744a

Fig 019

IMG-7878a

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)

			E
	ABCD		DCBA
	H		FG
		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

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 first. The bearing cups should seat against the shoulder divots inside the wheel hub (Fig. 024).

3

Fig 024

IMG-7881a

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

Z580/Z589 DFI Z Master Service Manual

3-7

CHASSIS

10.Install the grease seals into each side of the wheel hub (Fig. 026).

12.Install the castor spacer into the wheel hub (Fig. 028).

3

Fig 026

IMG-7883a

Fig 028

IMG-7885a

11.Install a bearing spacer into each side of the wheel hub (Fig. 027).

13.Position the wheel assembly into the caster fork (Fig. 029).

Fig 027

IMG-7884a

Fig 029

IMG-7878a

3-8	Z580/Z589 DFI Z Master Service Manual

CHASSIS

14.Install the axle bolt and nut securing the wheel assembly to the fork (Fig. 030).

Fuel Tank Replacement

Right Side Fuel Tank Removal

1.Raise the seat and remove the front engine shield (Fig. 032).

3

Fig 030

IMG-7736a

15.Apply grease (No. 2 general purpose lithium base or molybdenum grease) to the wheel assembly grease fitting (Fig. 031).

Fig 032

IMG-0303a

2.Turn the fuel shut-off valve to OFF position (Fig. 033).

Fig 031

IMG-7886a

Fig 033

IMG-0304a

Z580/Z589 DFI Z Master Service Manual

3-9