Toro 74264, 74264TE, 74265, 74265TE, 74266 Service Manual

LCE Products

Z580-D / Z593-D / Z595-D

Diesel 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
Diesel Engine:	Kubota D722/D902 3 Cylinder Liquid-Cooled Engine Repair Manual
	Form #492-4796
Hydraulic Troubleshooting:	Interactive hydraulic troubleshooting and failure analysis on DVD
	Form #492-4777
Electrical Troubleshooting:	Interactive electrical troubleshooting and wiring diagrams on DVD
	Form # 492-9171

The Z Master 593/595/580 model years 2006 to 2008 are covered in this manual. The manual may also be specified for use on later model products.

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

©2008 The Toro Company

THIS PAGE INTENTIONALLY LEFT BLANK.

TABLE OF CONTENTS
SAFETY INFORMATION
General Information......................................................................................................................	1-1
Think Safety First ...................................................................................................................	1-1
SPECIFICATIONS
Specifications Z593-D & Z595-D..................................................................................................	2-1
Configurations........................................................................................................................	2-1
Power System........................................................................................................................	2-1
Mowing Deck .........................................................................................................................	2-2
Operator Zone........................................................................................................................	2-3
Dimensions ............................................................................................................................	2-3
Specifications Z580-D ..................................................................................................................	2-4
Configurations........................................................................................................................	2-4
Power System........................................................................................................................	2-4
Mowing Deck .........................................................................................................................	2-5
Operator Zone........................................................................................................................	2-5
Dimensions ............................................................................................................................	2-6
Torque Specifications ...................................................................................................................	2-7
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)....................................	2-8
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) ......................................	2-9
Other Torque Specifications .......................................................................................................	2-10
Equivalents and Conversions.....................................................................................................	2-11
U.S. to Metric Conversions.........................................................................................................	2-12
CHASSIS
Castor Fork Assembly Replacement ............................................................................................	3-1
Castor Fork Assembly Removal.............................................................................................	3-1
Castor Bearing Replacement.................................................................................................	3-1
Castor Fork Assembly Installation..........................................................................................	3-4
Front Wheel Removal & Bearing Replacement............................................................................	3-5
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..................................................................................................	3-22
Throttle Control Assembly Replacement ....................................................................................	3-24
Throttle Control Assembly Removal.....................................................................................	3-24
Throttle Control Assembly Installation..................................................................................	3-26
Brake Lever Replacement..........................................................................................................	3-30
Brake Lever Removal ..........................................................................................................	3-30
Brake Lever Installation .......................................................................................................	3-31
Brake Band Replacement...........................................................................................................	3-32
Brake Band Removal ...........................................................................................................	3-32
Brake Band Installation ........................................................................................................	3-34
Brake Cross Shaft Replacement ................................................................................................	3-35
Brake Cross Shaft Removal.................................................................................................	3-35
Brake Cross Shaft Installation..............................................................................................	3-37

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TABLE OF CONTENTS

CHASSIS cont.
Deck Lift Lever Replacement .....................................................................................................	3-39
Deck Lift Lever Removal......................................................................................................	3-39
Deck Lift Lever Installation...................................................................................................	3-43
Motion Control Assembly Replacement......................................................................................	3-47
Motion Control Assembly Removal ......................................................................................	3-47
Right Hand Motion Control ............................................................................................	3-48
Left Hand Motion Control...............................................................................................	3-50
Motion Control Assembly Installation ...................................................................................	3-53
Left Hand Motion Control...............................................................................................	3-53
Right Hand Motion Control ............................................................................................	3-55
Motion Control Damper Replacment ..........................................................................................	3-61
Motion Control Damper Removal.........................................................................................	3-61
Motion Control Damper Installation......................................................................................	3-62
Adjusting the Parking Brake .......................................................................................................	3-63
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 ......................................................................................................	4-20
Purging the Hydraulic System ....................................................................................................	4-24
Adjusting the Control Handle Neutral Position ...........................................................................	4-25
Setting the Hydrostatic Pump Neutral ........................................................................................	4-27
Setting the Right Hydraulic Pump Neutral Position..............................................................	4-28
Setting the Left Hydraulic Pump Neutral Position ................................................................	4-28
Adjusting the Tracking ................................................................................................................	4-30
Hydraulic Flow Testing................................................................................................................	4-31
Hydraulic Flow Testing Procedure........................................................................................	4-31
Traction Pump Drive Belt Replacement .....................................................................................	4-35
Traction Pump Drive Belt Removal ......................................................................................	4-35
Traction Pump Drive Belt Installation ...................................................................................	4-37
Hydraulic Oil Cooler Replacement .............................................................................................	4-39
Hydraulic Oil Cooler Removal..............................................................................................	4-39
Hydraulic Oil Cooler Installation...........................................................................................	4-42
Hydraulic Reservoir Tank Replacement .....................................................................................	4-44
Hydraulic Reservoir Tank Removal......................................................................................	4-44
Hydraulic Reservoir Tank Installation...................................................................................	4-46
Pushing the Machine by Hand....................................................................................................	4-49
Switching from Pushing the Machine Back to Machine Operation.............................................	4-50
ENGINE
Engine Replacement ....................................................................................................................	5-1
Engine Removal.....................................................................................................................	5-1
Engine Installation................................................................................................................	5-19
Radiator Replacement................................................................................................................	5-42
Radiator Removal ................................................................................................................	5-42
Radiator Installation .............................................................................................................	5-46

ii	Z580/Z593/Z595 Diesel Service Manual

	TABLE OF CONTENTS
ENGINE cont.
Cooling Fan Replacement..........................................................................................................	5-49
Cooling Fan Removal ..........................................................................................................	5-49
Cooling Fan Installation .......................................................................................................	5-50
Air Cleaner Replacement ...........................................................................................................	5-51
Air Cleaner Removal............................................................................................................	5-51
Air Cleaner Installation.........................................................................................................	5-54
Alternator Belt Replacement.......................................................................................................	5-56
Alternator Belt Removal .......................................................................................................	5-56
Alternator Belt Installation ....................................................................................................	5-58
Checking Alternator Belt Tension................................................................................................	5-61
Tensioning the Alternator Belt.....................................................................................................	5-62
Fuel Filter Service.......................................................................................................................	5-63
Fuel Filter Replacement .............................................................................................................	5-64
Draining the Water Separator.....................................................................................................	5-66
Checking the Radiator Coolant...................................................................................................	5-66
ELECTRICAL
General.........................................................................................................................................	6-1
Engine Starting ......................................................................................................................	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..........................................................................................................................	6-6
Testing....................................................................................................................................	6-6
Parking Brake Switch ...................................................................................................................	6-7
Purpose..................................................................................................................................	6-7
Location .................................................................................................................................	6-7
How It Works..........................................................................................................................	6-7
Testing....................................................................................................................................	6-8
Seat Switch...................................................................................................................................	6-8
Purpose..................................................................................................................................	6-8
Location .................................................................................................................................	6-8
How It Works..........................................................................................................................	6-9
Testing....................................................................................................................................	6-9

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TABLE OF CONTENTS

ELECTRICAL cont.
Delay Module................................................................................................................................	6-9
Purpose..................................................................................................................................	6-9
Location .................................................................................................................................	6-9
How It Works........................................................................................................................	6-10
Testing..................................................................................................................................	6-10
High Temperature Audible Alarm (Solid Tone)............................................................................	6-11
Purpose................................................................................................................................	6-11
Location ...............................................................................................................................	6-11
How It Works........................................................................................................................	6-12
Testing..................................................................................................................................	6-12
Temperature Sender...................................................................................................................	6-12
Purpose................................................................................................................................	6-12
Location ...............................................................................................................................	6-12
How It Works........................................................................................................................	6-13
Testing..................................................................................................................................	6-13
Oil Pressure Switch ....................................................................................................................	6-13
Purpose................................................................................................................................	6-13
Location ...............................................................................................................................	6-13
How It Works........................................................................................................................	6-14
Testing..................................................................................................................................	6-14
High Temperature & Glow Plug Light Cluster .............................................................................	6-14
Purpose................................................................................................................................	6-14
Location ...............................................................................................................................	6-14
How It Works........................................................................................................................	6-15
Testing..................................................................................................................................	6-15
Glow Plug Switch........................................................................................................................	6-15
Purpose................................................................................................................................	6-15
Location ...............................................................................................................................	6-15
How It Works........................................................................................................................	6-16
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 ...................................................................................................	6-18
Engine Stop Solenoid.................................................................................................................	6-19
Purpose................................................................................................................................	6-19
Location ...............................................................................................................................	6-19
How It Works........................................................................................................................	6-19
Testing..................................................................................................................................	6-19
Pull Coil Terminal Test..........................................................................................................	6-20
Hold Coil Terminal Test ........................................................................................................	6-20

iv	Z580/Z593/Z595 Diesel Service Manual

TABLE OF CONTENTS
MOWER DECKS
Mower Belt Replacement .............................................................................................................	7-1
Mower Deck Removal............................................................................................................	7-3
Mower Deck Installation.........................................................................................................	7-6
Mower Spindle Replacement........................................................................................................	7-9
Mower Spindle Removal ........................................................................................................	7-9
Mower Deck Spindle Rebuild .....................................................................................................	7-12
Mower Spindle Installation ...................................................................................................	7-20
Mower Deck Idler Assembly Replacement.................................................................................	7-24
Mower Deck Idler Assembly Removal .................................................................................	7-24
Mower Deck Idler Assembly Installation ..............................................................................	7-26
Fixed Pulley Replacement..........................................................................................................	7-30
Fixed Pulley Removal ..........................................................................................................	7-30
Fixed Pulley Installation .......................................................................................................	7-32
Electric PTO Clutch Replacement ..............................................................................................	7-34
Electric PTO Clutch Removal
Warner Clutch................................................................................................................	7-34
Electric PTO Clutch Installation
Warner Clutch................................................................................................................	7-35
Electric PTO Clutch Removal
Ogura Clutch .................................................................................................................	7-38
Electric PTO Clutch Installation
Ogura Clutch .................................................................................................................	7-40
Gearbox Assembly Replacement ...............................................................................................	7-44
Gearbox Assembly Removal................................................................................................	7-44
Gearbox Assembly Installation.............................................................................................	7-49
Checking the Gearbox Oil Level.................................................................................................	7-54
Changing Gearbox Oil................................................................................................................	7-54
Strut Replacement......................................................................................................................	7-55
Strut Removal ......................................................................................................................	7-55
Strut Installation ...................................................................................................................	7-58
72” Mower Deck Belt Tension Adjustment Plate Replacement...................................................	7-61
72” Mower Deck Belt Tension Adjustment Plate Removal ...................................................	7-61
72” Mower Deck Belt Tension Adjustment Plate Removal ...................................................	7-63
72” Mower Deck Belt Tension Adjustment ..................................................................................	7-66
Gearbox Rebuild.........................................................................................................................	7-67
Pinion Shaft Teardown .........................................................................................................	7-70
Cross Shaft Teardown..........................................................................................................	7-72
Open End Cap Teardown.....................................................................................................	7-73
Closed End Cap Teardown ..................................................................................................	7-73
Closed End Cap Rebuild......................................................................................................	7-74
Open End Cap Rebuild ........................................................................................................	7-74
Cross Shaft Rebuild .............................................................................................................	7-74
Pinion Shaft Rebuild ............................................................................................................	7-75
Gearbox Assembly...............................................................................................................	7-78
Leveling the Mower ....................................................................................................................	7-82
Setting up the Machine ........................................................................................................	7-82
Leveling the Mower Side to Side................................................................................................	7-83
Adjusting the Front to Rear Mower Pitch....................................................................................	7-84
Adjusting the Compression Spring .............................................................................................	7-85

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TABLE OF CONTENTS

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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-!D, Z593-D and Z595-D.

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

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SPECIFICATIONS

Specifications Z593-D & Z595-D

Configurations

	Z593-D Pro Performance		Z595-D Pro Performance
23 hp Kubota® 3 Cyl Diesel	52”/60” Turbo Force						2
25 hp Kubota® 3 Cyl Diesel			52”/60”/72” Turbo Force
Power System
		Z593-D Pro Performance		Z595-D Pro Performance
Heavy Duty Canister Air Cleaner		Standard		Standard
Clutch		200 ft-lbs. (271 Nm) Electromagnetic		200 ft-lbs. (271 Nm) Electromagnetic
Hydraulic Pumps		Tandem Hydro-Gear® 16cc, w/shock		Hydro-Gear® 16cc, w/system relief
		valves
Wheel Motors(2)		Hydro-Gear® 18E, 1-1/4” (3.175cm)		Hydro-Gear® 18E, 1-1/4” (3.175cm)
		Tapered Shaft		Tapered Shaft
Maximum Ground Speed (f/r)		11 mph (17.7 km/hr) /		11.2 mph (18 km/hr) /
		6.3 mph (10 km/hr)		6.3 mph (10 km/hr)
Hour Meter		Standard		Standard
Rear Drive Tires		23 x 9.5 - 12 (52”)		23 x 9.5 -12 (52”)
		24 x 12 - 12 (60”)		24 x 12 - 12 (60” & 72”)
Front Caster Tires		13 x 6.50 - 6		13 x 6.50 - 6
				Flat-free Semi-pneumatic
Fuel / Capacity		Diesel #2 / 12 gallons (45.4L)		Diesel #2 / 12 gallons (45.4L)

Z580/Z593/Z595 Diesel Service Manual

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SPECIFICATIONS

Specifications Z593-D & Z595-D cont.

Mowing Deck

			Z593-D Pro Performance	Z595-D Pro Performance
2		Type	TURBO FORCE™	TURBO FORCE™
		Deck Construction	Fabricated, 7-ga Steel	Fabricated, 7-ga Steel
			w/Bull-Nose bumper	w/Bull-Nose bumper
		Deck Material	High-Strength Steel	High-Strength Steel
		Deck Depth	5-1/2” (13.97cm)	5-1/2” (13.97cm)
		Adjustable Discharge Baffle	Standard	Standard
		Spindle Housings	9-3/8” (23.8cm) Diameter Cast Iron	9-3/8” (23.8cm) Diameter Cast Iron
		Spindle Shaft / Bearings	1” (2.54cm) Steel Shaft/Tapered Roller	1” (2.54cm) Steel Shaft/Tapered Roller
		Blades (3)	1/4” (.635cm) Heat Treated Steel	1/4” (.635cm) Heat Treated Steel
		Blade Tip Speed	18,500 ft/min (5,638.8 meters/min)	18,500 ft/min (5,638.8 meters/min)
		Belt Construction	Aramid Fiber V-Belt	Aramid Fiber V-Belt
		Enhanced Belt Wrap	Minimizes Belt Slip	Minimizes Belt Slip
		Discharge Chute	5/16” (.79cm) Rubber	5/16” (.79cm) Rubber
		Cutting Height	1-1/2” - 5” in .25” increments	1-1/2” - 5” in .25” increments
			(3.81 - 12.7cm in .635cm increments)	(3.81 - 12.7cm in .635cm increments)
		Anti-Scalp Rollers - 52”	6 Standard	5 Standard
		Anti-Scalp Rollers - 60” / 72”	6 Standard	6 Standard
		Carrier Frame Construction	2” x 2” x 3/16” (5.08 x 5.08 x .48cm)	2” x 2” x 3/16” (5.08 x 5.08 x .48cm)

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SPECIFICATIONS

Specifications Z593-D & Z595-D cont.

Operator Zone

		Z593-D Pro Performance	Z595-D Pro Performance
	Steering Controls	1-5/8” (1.625cm) Diameter	1-5/8” (1.625cm) Diameter		2
		Grips, Adjustable, Dampened	Grips, Adjustable, Dampened
	Floor Pan	Pierced, extruded tread	Pierced, extruded tread
		No-tools deck access	No-tools deck access
	Seat	Non-suspension	Elastomeric
	Seat Belt	Retractable	Retractable
	Arm Rests	Standard	Standard
	Seat Suspension System	Optional	Optional
	Beverage Holder	Standard	Standard
	Folding ROPS	Standard	Standard
	Z Stand	Optional	Optional
	Deck Lift Assist Pedal	Standard	Standard

Dimensions

	Z593-D Pro Performance	Z595-D Pro Performance
Weight	(52”/60”) 1426 / 1470 lbs.	(60”/72”) 1443 / 1484 lbs.
	(646.8 / 666.8kg)	(654.5 / 673.1kg)
ROPS Height	72” (182.9cm)	72” (182.9cm)
ROPS Height Folded	53” (134.6cm)	53” (134.6cm)
Width w/ Deflector	54.0” / 62.0” (137.1 / 157.5cm)	(52”) 68” (173cm)
		(60”) 76” (193cm)
		(72”) 88” (224cm)
Length	79.5” / 81.6” (201.9 / 207.3cm)	(52”) 82.4” (209.3cm)
		(60”) 84.2” (213.9cm)
		(72”) 87.4” (221.9cm)

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SPECIFICATIONS

Specifications Z580-D

Configurations

			Z580-D
2		25 hp Kubota Liquid-Cooled Diesel	52”/60”/72” Turbo Force
		Power System
			Z580-D
		Heavy Duty Canister Air Cleaner	Standard
		Clutch	Adjustable .015” - .021” (0.35mm - 0.65mm)
			Ogura 150 ft-lbs. (203.37 Nm)
		Hydraulic Pump	Tandem Hydro-Gear® variable displacement
			16cc, w/shock valves
		Hydraulic Oil System Capacity	4.2 quarts (4.0 liters)
		Wheel Motors(2)	Twin Hydro-Gear® 18E, positive displacement
			1.25” (3.2cm) Tapered Shaft
		Maximum Ground Speed (f/r)	11 mph / 6.3 mph (17.7km/hr / 10km/hr)
		Hour Meter	Standard
		Rear Drive Tires	24 x 12.0 - 12 (52”)
			23 x 9.5 - 12 (60” & 72”)
		Front Caster Tires	Semi-Pneumatic 13 x 6.50 - 6
		Fuel / Capacity	Diesel # 2 or 20% Bio-Diesel / 12 gallons
			(45 liters)

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SPECIFICATIONS

Specifications Z580-D cont.

Mowing Deck

	Z580-D
Type	TURBO FORCE™		2
Deck Construction	Fabricated, 7-ga Steel w/Bull-Nose bumper
Deck Material	High-Strength Steel
Deck Depth	5-1/2” (13.97cm)
Adjustable Discharge Baffle	Standard
Spindle Housings	9-3/8” (23.8cm) Diameter Cast Iron
Spindle Shaft / Bearings	1” (2.54cm) Steel Shaft/Tapered Roller
Blades (3)	1/4” (.635cm) Heat Treated Steel
Blade Tip Speed	18,500 ft/min (5,638.8 meters/min)
Belt Construction	Single Kevlar cord V-Belt
Cutting Height	1-1/2” - 5” in .25” increments
	(3.81 - 12.7cm in .635cm increments)
Anti-Scalp Rollers - 52”	5 Standard
Anti-Scalp Rollers - 60” / 72”	6 Standard
Carrier Frame Construction	2” x 2” x 3/16” (5.08 x 5.08 x .48cm)

Operator Zone

	Z580-D
Steering Controls	1.5” (3.81cm) Diameter Grips, Adjustable, Dampened
Seat	Non-suspension - vinyl
Seat Belt	Retractable
Arm Rests	Standard
Seat Suspension System	Optional
Beverage Holder	Standard
Folding ROPS	Standard
Z Stand	Optional
Deck Lift Assist Pedal	Standard

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SPECIFICATIONS

Specifications Z580-D cont.

Dimensions

				Z580-D
2		Model	74266	74267	74274
		Wheel Base	54.3” / 137.9cm	56.1” / 142.5cm	59.3” / 150.6cm
		Overall Length	82.4” / 209.3cm	84.2” / 213.9cm	87.4” / 221.9cm
		Width Outside Tires	49.5” / 126cm	53.2” / 135cm	57.2” / 145cm
		Overall Width (outside deck)	68” / 173cm	76” / 193cm	88” / 224cm
		Gate Width	54” / 137cm	62” / 157.5cm	74” / 188cm
		Overall Height ROPS up	72” / 183cm	72” / 183cm	72” / 183cm
		Overall Height ROPS folded	53” / 135cm	53” / 135cm	53” / 135cm
		Weight	1429 lbs. / 648kg	1470 lbs. / 667kg	1543 lbs. / 700kg

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SPECIFICATIONS

Torque Specifications

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.

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.

Fastener Identification

2

	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

Z580/Z593/Z595 Diesel Service Manual

2-7

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)
2			In-lb		In-lb		N-cm		In-lb		N-cm			In-lb		N-cm
		# 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.

2-8	Z580/Z593/Z595 Diesel Service Manual

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.

Z580/Z593/Z595 Diesel Service Manual

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SPECIFICATIONS

		Other Torque Specifications
			Other Torque Specifications
			SAE Grade 8 Steel Set Screws
			Thread Size	Recommended Torque
	2
				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**
	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

Conversion Factors

in-lb X 11.2985 - N-cm

ft-lb X 1.3558 = N-m

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.

N-cm X - 0.08851 = in-lb

N-cm X 0.73776 - ft-lb

2-10	Z580/Z593/Z595 Diesel Service Manual

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		2
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

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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
2		Linear
			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

2-12	Z580/Z593/Z595 Diesel Service Manual

CHASSIS

Castor Fork Assembly Replacement

4.Slide the castor fork assembly out of the frame (Fig. 003).

Castor Fork Assembly Removal

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

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

3

Fig 003

IMG_7700

Castor Bearing Replacement

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

Fig 001

IMG_7694a

3. Remove the locknut (Fig. 002).

Fig 004

IMG_7703

Fig 002

IMG_7874a

Z580/Z593/Z595 Diesel Service Manual

3-1

CHASSIS

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

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

3

Fig 005

IMG_7706

Fig 007

IMG_7711a

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

5.Drive the top and bottom tapered bearing cups out of the caster fork hub (Fig. 008).

Fig 006

IMG_7709a

Fig 008

IMG_7714

3-2	Z580/Z593/Z595 Diesel Service Manual

CHASSIS

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):

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)

7.Pack the upper and lower tapered bearings with grease (No. 2 general purpose lithium base or molybdenum grease) (Fig. 010).

3

Fig 010

IMG_7719a

8.Install the lower bearing into the caster fork hub (Fig. 011).

Fig 011

IMG_7722

Z580/Z593/Z595 Diesel Service Manual

3-3

CHASSIS

9. Install the grease seal into the caster fork hub (Fig.	Castor Fork Assembly Installation
012).
	1. Install 3 Bellville washers as shown (Fig. 014):

3

Fig 012

IMG_7725a

10.Install the upper bearing into the caster fork hub (Fig. 013).

A

Fig 014

fig. 49 G001297

A. Belleville washers

2.Slide the castor fork assembly into the hub (Fig. 015).

Fig 013

IMG_7731

Fig 015

IMG_7700

3-4	Z580/Z593/Z595 Diesel 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. 016).

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

6.Install the dust cap onto the frame (Fig. 018).

3

Fig 016

IMG_7874a

Fig 018

IMG_7734

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. 017).

Front Wheel Removal & Bearing

Replacement

1.Raise the front of the machine off the ground.

2.Remove the wheel axle bolt and nut (Fig. 019).

Fig 017

PICT-2897

Fig 019

IMG_7736

Z580/Z593/Z595 Diesel Service Manual

3-5

CHASSIS

3.Remove the wheel assembly from the fork (Fig. 020).

5.Remove both bearing spacers (one on each side) from the wheel assembly (Fig. 022).

3

Fig 020

IMG_7878

Fig 022

IMG_7744a

4.Remove the castor spacer from the wheel assembly (Fig. 021).

6.Drive the bearing cup, bearing and bearing seal out of the wheel assembly. Repeat on the opposite side (Fig. 023).

Fig 021

IMG_7742a

Fig 023

IMG_7748a

3-6	Z580/Z593/Z595 Diesel Service Manual

CHASSIS

Wheel Assembly (Fig. 024).

			E
	ABCD		DCBA
	H		FG
		Fig 024	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

8.Pack both tapered bearings with grease (No. 2 general purpose lithium base or molybdenum grease) (Fig. 026).

3

Fig 026

IMG_7718a

9.Install the tapered bearings into each side of the wheel hub (Fig. 027).

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. 025).

Fig 027

IMG_7882a

Fig 025

IMG_7881a

Z580/Z593/Z595 Diesel Service Manual

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