90743sl.pdf Groundsmaster 580-D (Rev G) Dec, 2007

NOTE:Model 30581: Use this book along with Part No. 95866SL Mitsubishi S4S--DT Engine Service Manual.Model 30582 and 30583: Use this book along with Part No. 04131SL Mitsubishi S4S--Y2DT61TG Engine Ser-vice Manual.

Part No. 90743SL, Rev. G

Service Manual

GroundsmasterR 580--D

Preface

The purpose of this publication is to provide the servicetechnician with information for troubleshooting, testing,and repair of major systems and components on theGroundsmaster 580--D, Model 30580, 30581, 30582,and 30583 (see NOTE above).

REFER TO THE TRACTION UNIT AND CUTTINGUNIT OPERATOR’S MANUALS FOR OPERATING,MAINTENANCE AND ADJUSTMENT INSTRUC-TIONS. Space is provided in Chapter 2 of this book toinsert the Operator’s Manuals and Parts Catalogs foryour machine. Replacement Operator’s Manuals areavailable on the internet at www.toro.com or by sendingcomplete Model and Serial Number to:

The Toro Company8111 Lyndale Avenue SouthMinneapolis, MN 55420

TheToroCompany reserves the right to change productspecifications or this publication without notice.

This safety symbol means DANGER, WARN-ING, or CAUTION, PERSONAL SAFETYINSTRUCTION. When you see this symbol,carefully read the instructions that follow.Failure to obey the instructions may result inpersonal injury.

NOTE: A NOTE will give general information about thecorrect operation, maintenance, service, testing or re-pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-portant instructions whichmust be followed to pre-vent damage to systems or components on themachine.

E The Toro Company -- 1989, 1997, 1999, 2003, 2004, 2005, 2007

Groundsmaster 580–D

This page is intentionally blank.

Rev. EGroundsmaster 580–D

Table Of Contents

Chapter 1 – Safety

Safety Instructions 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 – 4. . . . . . . . . . . . . . . .

Chapter 2 – Product Records and Maintenance

Product Records 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions 2 – 2. . . . . . . . . . . . . . . . Torque Specifications 2 – 3. . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 – Engine (Model 30580)

General Information 3 – 3. . . . . . . . . . . . . . . . . . . . . . . . Specifications 3 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 3 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 3 – 26. . . . . . . . . . . . . . . . . . . . . . . . . . . General Overhaul Instructions 3 – 30. . . . . . . . . . . . . . Adjustments 3 – 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal and Installation 3 – 39. . . . . . . . . . . . Engine Accessory Removal and Installation 3 – 43. . Cylinder Head and Valves 3 – 48. . . . . . . . . . . . . . . . . . Flywheel, Timing Gears and Camshaft 3 – 61. . . . . . . Pistons, Connecting Rods,Crankshaft and Block 3 – 73. . . . . . . . . . . . . . . . . . . . . . Inlet and Exhaust Systems 3 – 91. . . . . . . . . . . . . . . . . Lubrication System 3 – 106. . . . . . . . . . . . . . . . . . . . . . . Cooling System 3 – 112. . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 3 – 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Overhaul Information 3 – 125. . . . . . . . . . . . . .

Chapter 3A – Engine (Model 30581)

General Information 3A – 1. . . . . . . . . . . . . . . . . . . . . . . Specifications 3A – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3B – Engine (Model 30582)

General Information 3B – 1. . . . . . . . . . . . . . . . . . . . . . . Specifications 3B – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 – Hydraulic System

Specifications 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 4 – 3. . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Flow Diagrams 4 – 6. . . . . . . . . . . . . . . . . . . .

Special Tools 4 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 4 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . Testing 4 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 4 – 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Traction Drive System Repairs 4 – 32. . . . . . . . . . . . . . PTO System Repairs 4 – 36. . . . . . . . . . . . . . . . . . . . . . Auxiliary (Lift/Counterbalance) System Repairs 4 – 42Steering System Repairs 4 – 52. . . . . . . . . . . . . . . . . . . Hydraulic Reservoir and Filter 4 – 55. . . . . . . . . . . . . . . 4 Wheel Drive Kit (Optional) Repairs 4 – 57. . . . . . . . .

Chapter 5 – Electrical System(Model 30580, S/N Below 30101)

Electrical Diagrams 5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 5 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing 5 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs 5 – 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 – Wheels, Brakes & Steering

Specifications 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 6 – 3. . . . . . . . . . . . . . . . . . . . . . . . Adjustments 6 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs 6 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 – Cutting Units

Specifications 7 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 7 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs 7 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 – Electrical System(Models 30580 (S/N 30101 & Up), 30581 and 30582)

Electrical Diagrams 8 – 2. . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 8 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Identification and Testing 8 – 10. . . . . . . . Service and Repairs 8 – 12. . . . . . . . . . . . . . . . . . . . . . .

Chapter 9 – Foldout Diagrams

Hydraulic Schematics 9 – 3. . . . . . . . . . . . . . . . . . . . . . . Electrical Schematics 9 – 5. . . . . . . . . . . . . . . . . . . . . . . Wire Harness Drawings 9 – 7. . . . . . . . . . . . . . . . . . . . .

Groundsmaster 580–D


Rev. E

CAUTION

Groundsmaster 580--D Page 1 -- 1 Safety

Chapter 1

Safety

Table of Contents

SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . .Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Service 3. . . . . . . . . . . . . . . . . . . . .SAFETY AND INSTRUCTION DECALS 4. . . . . . . . . .

Safety Instructions

The GROUNDSMASTERR 580-D meets or exceedsthe American National Standards Institute’s safety stan-dards for riding mowers. Although hazard control andaccident prevention partially are dependent upon thedesign and configuration of the machine, these factorsare also dependent upon the awareness, concern, andproper training of the personnel involved in the opera-tion, transport, maintenance, and storage of the ma-chine.

Improper use or maintenance by the operator or ownerof the machine can result in injury. Reduce the potentialfor any injury by complying with the following safetyinstructions.

TO REDUCE THE POTENTIAL FOR INJURY,COMPLY WITH THE FOLLOWING SAFETYINSTRUCTIONS.

Before Operating

1. Read and understand the Operator’s Manual beforestarting and operating the machine. Become familiarwith all controls and know how to stop quickly. A replace-ment Operator’s Manual is available on the Internet atwww.Toro.com or by sending complete Model and Seri-al Number to:

The Toro CompanyAttn. Technical Publications8111 Lyndale Avenue SouthMinneapolis, Minnesota 55420--1196.

If you have questions about this Service Manual, pleasecontact:

The Toro CompanyCommercial Service Department8111 Lyndale Avenue SouthMinneapolis, Minnesota 55420--1196.

2. Never allow children to operate the machine oradults to operate it without proper instruction.

3. Become familiar with the controls and know how tostop the machine and engine quickly.

4. Keep all shields, safety devices and decals in place.If a shield, safety device or decal is malfunctioning, illeg-ible or damaged, repair or replace it before operating themachine.

5. Always wear substantial shoes. Do not operate ma-chine while wearing sandals, tennis shoes, sneakers orwhen barefoot. Do not wear loose fitting clothing thatcould get caught in moving parts and possibly causepersonal injury.

6. Wearing safety glasses, safety shoes, long pantsand a helmet is advisable and required by some local or-dinances and insurance regulations.

7. Make sure the work area is clear of objects whichmight be picked up and thrown by the cutter blades.

8. Do not carry passengers on the machine. Keep ev-eryone, especially children and pets, away from theareas of operation.

Rev. A Groundsmaster 580--DPage 1 -- 2Safety

9. Since diesel fuel is highly flammable, handle it care-fully:

A. Use an approved fuel container.B. Do not remove fuel tank cap while engine is hotor running.C. Do not smoke while handling fuel.

D. Fill fuel tank outdoors and only to within an inch(25 mm) from the top of the tank, not the filler neck.Do not overfill.E. Wipe up any spilled fuel.

10. Be sure interlock switches are adjusted correctly soengine cannot be started unless traction pedal is re-leased -- neutral position -- and PTO switch is in NEU-TRAL position.

While Operating

11. Check interlock switches daily for proper operation.If a switch malfunctions, replace or adjust it before oper-ating the machine. The interlock system is for yourprotection, so do not bypass it. Replace all interlockswitches every two years.

12. Do not run engine in a confined area without ade-quate ventilation. Exhaust is hazardous and could bedeadly.

13. Sit on the seat when starting and operating the ma-chine.

14. Before starting the engine each day, test warninglamps and signal lights to assure proper operation.

15. Pay attention when using the machine. To preventloss of control:

A. Mow only in daylight or when there is good artifi-cial light.B. Watch for holes or other hidden hazards.C. Be extremely careful when operating close tosand traps, ditches, creeks, steep hillsides or otherhazards.D. Reduce speed when making sharp turns. Avoidsudden stops and starts.E. Look to the rear to assure no one is behind themachine before backing up.F. Watch for traffic when near or crossing roads.Always yield the right--of--way.G. Reduce speed when driving downhill.

16. Keep hands, feet and clothing away from movingparts and the cutting units.

17. This product may exceed noise levels of 85 dB(A) atthe operator position. Ear protectors are recommended,for prolonged exposure, to reduce the potential of per-manent hearing damage.

18. Do not touch engine, turbo--charger, radiator, muf-fler or exhaust pipe while engine is running or soon afterit is stopped. These areas could be hot enough to causeburns.

19. Before getting off the seat:A. Move traction pedal to neutral.B. Set parking brake.C. Disengage cutting units and wait for blades tostop.D. Stop engine and remove key from switch.E. Do not park on slopes unless wheels arechocked or blocked.

20. If a cutting blade strikes a solid object or vibrates ab-normally, stop immediately, turn engine off, set parkingbrake and wait for all motion to stop. Inspect for damage.Repair or replace any damaged parts before operating.

Rev. AGroundsmaster 580--D Page 1 -- 3 Safety

Maintenance and Service

21. Before servicing or making adjustments, stop en-gine and remove key from the switch.

22. Assure entire machine is properly maintained and ingood operating condition. Frequently check all nuts,bolts and screws.

23. Frequently check all hydraulic line connectors andfittings. Assure all hydraulic hoses and lines are in goodcondition before applying pressure to the system.

24. If the Groundsmaster 580--D loses power andneeds to be moved, either by--pass the hydraulic pumpor unlock the front wheel hubs. Unlocking the frontwheels disables the machine braking system. Block thewheels before unlocking the hubs to keep the machinefrom moving. To tow the machine, connect to the towingvehicle with a rigid towing device. Do not use chains,cables or other non--rigid devices for towing. Lock thehubs when towing is completed.

25. Keep body and hands away from pin hole leaks ornozzles that eject high pressure hydraulic fluid. Usecardboard or paper to find hydraulic leaks. Hydraulicfluid escaping under pressure can penetrate skin andcause injury. Fluid accidentally injected into the skinmust be surgically removed within a few hours by a doc-tor or gangrene may occur.

26. Before any hydraulic system maintenance, stop en-gine and lower cutting units to the ground so all pressureis relieved.

27. For major repairs or other assistance, contact yourlocal Toro Distributor.

28. To reduce potential fire hazard, keep engine areafree of excessive grease, grass, leaves and dirt.

29. If engine must be running to perform maintenanceor an adjustment, keep hands, feet, clothing and otherparts of the body away from cutting units and other mov-ing parts. Keep everyone away.

30. Do not overspeed the engine by changing governorsetting. Maximum engine speed is 2750 rpm. To assuresafety and accuracy, have an Authorized Toro Distribu-tor check maximum engine speed.

31. Shut engine off before checking or adding oil to thecrankcase.

32. Disconnect battery before servicing the machine. Ifbattery voltage is required for troubleshooting or testprocedures, temporarily connect the battery.

33. For optimum performance and safety, use genuineToro replacement parts and accessories. Replacementparts and accessories made by other manufacturerscould be dangerous and may void the product warrantyof The Toro Company.

Rev. E Groundsmaster 580--DPage 1 -- 4Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed tothe Groundsmaster 580--D. If any decal becomes illeg-ible or damaged, install a new decal. Part numbers forreplacement decals are listed in your Parts Catalog. Or-der replacement decals from your Authorized Toro Dis-tributor.

Rev. EGroundsmaster 580--D Page 2 -- 1 Product Records and Maintenance

Chapter 2

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .

Decimal and Millimeter Equivalents 2. . . . . . . . . . . .U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . .Capscrew Markings and Torque Values -- U.S. 3. . .Capscrew Markings and Torque Values -- Metric 3.

Product Records

Insert Operator’s Manual and Parts Catalog for yourGroundsmaster 580--D at the end of this chapter. Addi-tionally, if any optional equipment or accessories havebeen installed to your Groundsmaster, insert the Instal-lation Instructions, Operator’s Manuals and Parts Cata-logs for those options at the end of this chapter.

Maintenance

Maintenance procedures and recommended service in-tervals for the Groundsmaster 580--D are covered in theOperator’s Manual. Refer to that publication when per-forming regular equipment maintenance.

Groundsmaster 580–DPage 2 – 2Product Records and Maintenance

Equivalents and Conversions

Groundsmaster 580–D Page 2 – 3 Product Records and Maintenance

Torque Specifications

Rev. E Groundsmaster 580--DPage 2 -- 4Product Records and Maintenance


Chapter 3

Engine (Model 30580)

Table of Contents

NOTE: This Chapter provides engine information for TORO Model 30580.See Chapter 3A for Model 30581 or Chapter 3B for Model 30582.

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 3Engine Serial Number Location. . . . . . . . . . . . . . 3Engine External Views. . . . . . . . . . . . . . . . . . . . . 4Engine Sectional Views . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6Definition of Terms. . . . . . . . . . . . . . . . . . . . . . . . 6General Specifications . . . . . . . . . . . . . . . . . . . . 7Service and Overhaul Standards . . . . . . . . . . . 11Tightening Torques . . . . . . . . . . . . . . . . . . . . . . 20Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 23TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 26GENERAL OVERHAUL INSTRUCTIONS . . . . . . . 30

Determining When To Overhaul The Engine . . . 30Disassembly Precautions . . . . . . . . . . . . . . . . . 30Reassembly Precautions. . . . . . . . . . . . . . . . . . 30Testing Compression Pressure . . . . . . . . . . . . . 31

ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 32Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . 32Priming / Bleeding Fuel System . . . . . . . . . . . . 33Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . 34No-Load Minimum and Maximum Speed . . . . . 35Throttle Lever and Control Cable Adjustment . . 37Fuel Stop Solenoid Adjustment . . . . . . . . . . . . . 38Fan Drive Belt Inspection and Adjustment . . . . 38

ENGINE REMOVAL AND INSTALLATION . . . . . . . 39ACCESSORY REMOVAL AND INSTALLATION. . . 43

Prepratory Steps . . . . . . . . . . . . . . . . . . . . . . . . 43Engine Accessory Removal . . . . . . . . . . . . . . . 43Engine Accessory Installation . . . . . . . . . . . . . . 47

CYLINDER HEAD AND VALVES . . . . . . . . . . . . . . 48Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Inspection and Repair . . . . . . . . . . . . . . . . . . . . 50Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

FLYWHEEL, TIMING GEARS AND CAMSHAFT . . 61Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Inspection and Repair . . . . . . . . . . . . . . . . . . . . 64Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

PISTONS, CONNECTING RODS,CRANKSHAFT & BLOCK . . . . . . . . . . . . . . . . . 73Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Inspection and Repair . . . . . . . . . . . . . . . . . . . . 76Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

INLET AND EXHAUST SYSTEMS. . . . . . . . . . . . . 91Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 92Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 106Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 112Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 112Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Radiator, Fan and Fan Belt . . . . . . . . . . . . . . . 115

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 116Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . 117Fuel Feed Pump . . . . . . . . . . . . . . . . . . . . . . . 120Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . 122Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

GENERAL OVERHAUL INFORMATION . . . . . . . 125Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Lock Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Split Pins and Spring Pins . . . . . . . . . . . . . . . . 127

Rev. EGroundsmaster® 580-D Page 3 - 1 Table of Contents


Stopping the Engine

Important: Before stopping the engine after mowing or full load operation, cool the turbocharger by allowing the engine to idle at low speed for 5 minutes. Failure to do so may lead to turbocharger failure.

Rev. E


ConeremovingTool

34791-01100For removing crankshaftpulley

Rev. D

NOTE: The crankshaft pulley uses a tapered cone to secure the pulley to the crankshaft. Use Mitsubishi Special Tool 34791-01100 for pulley removal.

Rev. E


Groundsmaster 580–D Page 3A – 1 Table of ContentsRev. E

Chapter 3A

Engine (Model 30581)

Table of Contents

General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

The engine used in the Groundsmaster 580–D moweris manufactured by Mitsubishi Heavy Industries Limited.Service and repair parts for Mitsubishi engines are sup-plied through TORO Distributors. Repair parts may beordered by TORO part number. If no parts list is avail-able be sure to provide your Distributor with the TOROmodel number and serial number.

General maintenance procedures are described in yourToro Operator’s Manual.

Information on engine troubleshooting, testing, disas-sembly and reassembly is provided in the MitsubishiS4S–DT Engine Service Manual, Part No. 95866SL.

Note: Refer to Chapter 3 – Engine (Model 30580) forinformation regarding engine removal and installation.

Stopping the Engine

IMPORTANT: Before stopping the engine aftermowing or full load operation, cool the turbochar-ger by allowing the engine to idle at low speed for 5minutes. Failure to do so may lead to turbochargerfailure.

Groundsmaster 580–DPage 3A – 2Specifications Rev. B

Specifications

Item Description

Make / Designation Mitsubishi Model S4S–DT4 cycle, 4 cylinder Diesel Engine

Number of Cylinders 4

Total Displacement 3331 cc (203.3 cu. in.)

Fuel Diesel Fuel No. 2–D

Fuel Capacity 28 U.S. gallon (106 liter)

Idle Speed (no load) 1150 +/– 50 RPM

High Idle (no load) 2750 +/– 50 RPM

Engine Oil (do not use multi–viscosity oils) API Service Classification CD or better–20 to 20o F (–29 to –7o C) SAE 1020 to 105o F (–7 to 41o C) SAE 30105o F (41o C) and above SAE 40

Oil Capacity 10.6 U.S. quart (10 liter) with filter

Groundsmaster 580--D Page 3B -- 1 Table of ContentsRev. G

Chapter 3B

Engine (Models 30582 and 30583)

Table of Contents

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .MITSUBISHI S4S--Y2DT61TG SERVICE MANUAL

General Information

The engine used in the Groundsmaster 580--D Models30582 and 30583mower is manufactured byMitsubishiHeavy Industries Limited. Service and repair parts forthis Mitsubishi engine are supplied through TORO Dis-tributors. Repair parts may be ordered by TORO partnumber. If no parts list is available be sure to provideyourDistributorwith theTOROmodel number andserialnumber.

General maintenance procedures are described in yourOperator’sManual. Informationonengine troubleshoot-ing, testing, disassembly and reassembly is identified inthe Mitsubishi S4S--Y2DT61TG Service Manual that isincluded at the end of this section.

Note: Refer to Chapter 3 -- Engine (Model 30580) forinformation regarding engine removal and installation.

Stopping the Engine

IMPORTANT: Before stopping the engine aftermowing or full load operation, cool the turbochar-ger by allowing the engine to idle at low speed for 5minutes. Failure to do so may lead to turbochargerfailure.

Groundsmaster 580–DPage 3B – 2Specifications Rev. E

Specifications

Item Description

Make / Designation Mitsubishi Model S4S–DT4 cycle, OHV, Liquid Cooled, Turbocharged Diesel Engine

Number of Cylinders 4

Total Displacement 3331 cc (203.3 cu. in.)

Fuel Diesel Fuel No. 2–D

Fuel Capacity 28 U.S. gallon (106 liter)

Idle Speed (no load) 1100 + 50 RPM

High Idle (no load) 2700 + 50 RPM

Engine Oil See Operator’s Manual for Oil Recommendations

Oil Capacity 10.5 U.S. quart (10 liter) with filter

Groundsmaster 580--D Page 4 -- 1 Table of ContentsRev. G

Chapter 4

Hydraulic System

Table of Contents

NOTE: SeeChapter 9 -- Foldout Diagrams for HydraulicSchematics

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .Hydraulic Hoses 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Fitting Installation 3. . . . . . . . . . . . . . . . . . .Pushing or Towing 5. . . . . . . . . . . . . . . . . . . . . . . . . . .Draining and Refilling System 5. . . . . . . . . . . . . . . . .

HYDRAULIC FLOW DIAGRAMS 6. . . . . . . . . . . . . . . .Typical Circuits -- Engine Running 6. . . . . . . . . . . . . .Typical Circuits -- Mowing 10. . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . .TESTING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NO. 1: Traction Circuit Working Pressureand Relief Pressure 24. . . . . . . . . . . . . . . . . . . . . . . .TEST NO. 2: Traction Circuit Charge Pressure 25.TEST NO. 3: Steering Circuit Working Pressureand Relief Pressure 26. . . . . . . . . . . . . . . . . . . . . . . .TEST NO. 4: Lift Circuit Working Pressure andRelief Pressure 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NO. 5: Counterbalance Pressure 28. . . . . . . .Diagnosing Cutting Performance Problems 28.3. . .Deck Motor Internal Leakage Test 28.4. . . . . . . . . . .TEST NO. 6: Deck Drive Circuit WorkingPressure and Relief Pressure 29. . . . . . . . . . . . . . .

ADJUSTMENTS 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Traction Control Neutral Adjustment 30. . . . . . . . . . .Traction Control Rod Adjustment 31. . . . . . . . . . . . . .Cruise Control Adjustment 31. . . . . . . . . . . . . . . . . . .

TRACTION DRIVE SYSTEM REPAIRS 32. . . . . . . . .Mow/Transport Solenoid Service 32. . . . . . . . . . . . . .Variable Displacement Pump Removal andInstallation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel Motor Removal and Installation 35. . . . . . . . .

PTO SYSTEM REPAIRS 36. . . . . . . . . . . . . . . . . . . . . .PTO Valve Block Service 36. . . . . . . . . . . . . . . . . . . .PTO Valve Block Service (S/N 50001 and Up) 36.1PTO Pump Removal and Installation 38. . . . . . . . . .PTO Pump Repair (Models 30580 and 30581) 38.1PTO Pump Repair (Models 30582 and 30583) 38.2Deck Motor Removal and Installation 39. . . . . . . . . .Deck Motor Repair 40. . . . . . . . . . . . . . . . . . . . . . . . . .Deck Motor Repair (P/N 94--4907) 40.1. . . . . . . . . .Wing Deck Hose Replacement(S/N 50001 and Up) 40.3. . . . . . . . . . . . . . . . . . . . .Wing Deck Motor Hydraulic Hose Replacement 41.

AUXILARY (LIFT/COUNTERBALANCE) SYSTEMREPAIRS 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Float/Traction Assist Manifold Block Service 42. . . .Steering/Auxiliary Pump Removal andInstallation 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering/Auxiliary Pump Repair(Models 30582 and 30583) 44.1. . . . . . . . . . . . . . .Steering/Auxiliary Pump Repair(Models 30580 and 30581) 45. . . . . . . . . . . . . . . . .Front Lift Cylinder Removal and Installation 46. . . .Front Lift Cylinder Repair 46. . . . . . . . . . . . . . . . . . . .Wing Lift Cylinder Removal and Installation 48. . . .Wing Lift Cylinder Repair 48. . . . . . . . . . . . . . . . . . . .Lift Control Valve Removal and Installation 50. . . . .Lift Control Valve Repair 50. . . . . . . . . . . . . . . . . . . . .

STEERING SYSTEM REPAIRS 52. . . . . . . . . . . . . . . .Steering Cylinder Removal and Installation 52. . . . .Steering Cylinder Repair 52. . . . . . . . . . . . . . . . . . . . .Steering Control Unit Removal and Installation 54. .Steering Control Unit Repair (Models 30580and 30581) 54.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Control Unit Repair (Models 30582and 30583) 54.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC RESERVOIR AND FILTER 55. . . . . . . .Flushing the Hydraulic System 55. . . . . . . . . . . . . . .Inspecting Reservoir Parts 56. . . . . . . . . . . . . . . . . . .

SAUER/SUNDSTRAND (DANFOSS)M46--AXIALPIS-TON PUMPS AND MOTORS SERVICE MANUAL

SAUER/SUNDSTRAND (DANFOSS)M46--AXIALPIS-TON PUMPS AND MOTORS REPAIR MANUAL

VICKERS GEAR PUMP OVERHAUL MANUALHALDEX/BARNES G20 & G30 SERIES HYDRAULICGEAR PUMPS INSPECTION/SERVICING

EATON CHAR--LYNN STEERING CONTROL UNITSREPAIR INFORMATION

EATON CHAR--LYNN 4000 COMPACT SERIES DISCVALVEGEROLERMOTORREPAIR INFORMATION

Groundsmaster 580--DPage 4 -- 2Specifications Rev. F

Specifications

Item Description

Traction Drive Pump Variable displacement axial piston pumpwith servo assisted manual displacement control (MDC)

Main relief pressure 5000 + 250 psi (344.8 + 7.2 bar)Charge relief pressure (Pump S/N below A--96--01--XXXXX) 230 + 10 psi (15.9 + .7 bar)Charge relief pressure (Pump S/N above A--96--01--XXXXX) 285 + 10 psi (15.9 + .7 bar)

Front Wheel Motor (2 used) Variable displacement axial piston motorMow/Transport speed, elec./hyd. solenoid actuated

PTO (Deck Drive) Pump Two section, external gear type

PTO (Deck Drive) Valve Block Toro, cartridge logic, elec./hyd. solenoid actuatedRelief pressure (3 relief valves: front deck, right deck, left deck) 3000 to 3200 psi (206.9 to 220.7 bar)

Deck Drive Motor (3 used) External gear type

Lift Control Valve 3 spoolLift circuit relief pressure (S/N below 240000000) 1500 + 50 psi (103.4 + 3.4 bar)Lift circuit relief pressure (S/N above 240000000) 2000 + 50 psi (137.9 + 3.4 bar)NOTE: Lift pressure when measured at the LIFT test port isLift Circuit Relief Pressure + Counterbalance Pressure

Float/Traction Assist Manifold Block Toro, cartridge logicCounterbalance pressure 400 + 25 psi (27.6 + 1.7 bar)“Traction Plus” counterbalance pressure 600 + 25 psi (41.4 + 1.7 bar)“Traction Plus” shift pressure 2000 + 50 psi (137.9 + 3.4 bar)

Lift/Steering Pump External gear type w/priority flow dividerSteering relief pressure 1500 + 50 psi (103.4 + 3.4 bar)

Steering Control Hydraulic power steering control unit

Hydraulic Oil Refer to Operator’s Manual for hydraulic oil recommendations

Reservoir Capacity 32 U.S. gallon (121.1 liter)

System Capacity 40 U.S. gallon (151.4 liter)

Oil Filter Screw--on cartridge type, 5 micron, 50 psi (3.4 bar) bypass

1. Hydraulic Oil Level Sight Glass2. Reservoir Fill Cap

Figure 27

Note: When measuring lift circuit relief pressure,counterbalance pressure, and “Traction Plus” counter-balance pressure on machines with serial numbersabove 250000000, pressures will be approximately 125psi (8.6 bar) higher than the specifications listed above.Refer to the Testing section in this chapter for detailedinformation.


Rev. E

Older model shown Deck drive test ports on newer models at deck motor

3. Start the engine and adjust throttle so engine speed is 2,500 rpm.

TEST NO. 2: Traction Circuit Charge Pressure

1. Hydraulic oil must be at operating temperature.

2. Connect a 1,000 psi gauge onto charge pressure testport (Fig. 10).

3. Start the engine and put throttle at idle position(approx. 1,200 rpm) with no load on the system.

TESTER READING TO BE:230 ± 10 PSI (Pump S/N Below A-96-01-XXXXX)285 ± 10 PSI (Pump S/N A-96-01-XXXXX & Up)

4. If there is no pressure or pressure is too low, checkfor restriction in pump intake line. Inspect charge reliefvalve and valve seat. Charge pressure can be adjustedby changing shim thickness behind the spring. Checkfor sheared charge pump key. If necessary, checkfor internal damage or worn parts in charge pump.

Figure 10

Figure 10

5. Also with pressure gauge still connected to the charge pressure test port, take a gauge reading while operating the machine in forward and reverse. Start the engine and put the throttle at full engine speed. Apply the brakes and push the traction pedal forward , then reverse.

6. If pressure is good under no load, but drops below specification when under traction load, the piston pump and/or traction motor(s) should be suspected of wear and inefficiency. When the pump and/or traction motor(s) are worn or damaged, the charge pump is not able to keep up with internal leakage in the traction circuit components.

Groundsmaster® 580-D Page 4 - 25 Rev. E Testing

Deck drive test ports on newer models at deck motor.Older model shown.

Rev. E


3. Start the engine and adjust throttle so engine speed is 2,500 rpm.

27 Rev. FGroundsmaster 580--D Page 4 -- Testing

TEST NO. 4: Lift Circuit Working Pressure and Relief Pressure

WORKING Pressure Test

1. Connect a 5,000 psi gauge to the LIFT test port.

a. On machines with serial number below250000000, the LIFT test port is located on the out-side of the control console (Fig. 12).

b. On machines with serial number above250000000, the LIFT test port is located underneaththe center of the machine (Fig. 12A).

2. Operate the machine while monitoring gauge.

TESTER READING TO BE:375 to 2,000 PSI (S/N below 240000000).375 to 2,500 PSI (S/N between 240000001 and

240999999).500 to 2,625 PSI (S/N above 250000000).

3. If working pressure is too high or too low, perform re-lief pressure test.

RELIEF Pressure Test

1. Hydraulic oil must be at operating temperature.



b. On machines with serial number above250000000, the LIFT test port is located underneaththe center of the machine (Fig. 12A).

3. Start the engine and adjust throttle so engine speedis 2,500 RPM.

4. Engage the lift control lever into the LIFT position.Momentarily hold lever in engaged position after full cyl-inder extension and read gauge.

TESTER READING TO BE:1,500 to 2,000 PSI (S/N below 240000000).2,000 to 2,500 PSI (S/N between 240000001 and

240999999).2,125 to 2,625 PSI (S/N above 250000000).

NOTE: Always set counterbalance pressure to correctamount before attempting to adjust lift relief pressure(see TEST 5).

5. If pressure is too high, inspect relief valve in lift controlvalve. If necessary, adjust relief valve by removing therequired shim(s). If pressure is too low, check for restric-tion in pump intake line. Check lift cylinder(s) for internalleakage. If cylinder is not leaking, clean relief valve, andadjust if necessary by adding required shim(s). If pres-sure is still too low, repair or replace steering/lift pump.

1. Lift test port (S/N below 250000000)2. Traction forward test port

Figure 12

21

NOTE: Deck drive Test Ports

also on this panel.on older models are

1. Lift test port (S/N above 250000000)Figure 12A

1

Rev. F28 Groundsmaster 580--DPage 4 --Testing

TEST NO. 5: Counterbalance Pressure

IMPORTANT: To prevent damage to test gauge,raise all decks before connecting 1,000 psi gauge toLIFT test port.

NOTE: Hydraulic oil must be at operating temperaturefor these tests or pressure reading will be too high.

COUNTERBALANCE Pressure Test



b. On machines with serial number above250000000, the LIFT test port is located underneaththe center of the machine (Fig. 14).

2. Start the engine and adjust throttle so engine speedis 2,500 RPM.

TESTER READING TO BE:400 to 425 PSI (S/N below 250000000).525 to 550 PSI (S/N above 250000000).

3. If pressure is incorrect, locate counterbalance reliefcartridge on control manifold (Fig. 15). Remove cap oncounterbalance relief valve and adjust the relief valvescrew until correct counterbalance pressure is attained.

“TRACTION PLUS” COUNTERBALANCE PressureTest



b. On machines with serial number above250000000, the LIFT test port is located underneaththe center of the machine (Fig. 14).

2. Start the engine and adjust throttle so engine speedis 2,500 RPM. Move GROUND SPEED switch to HIGHRANGE.

3. Engage service brake, momentarily push tractionpedal in the FORWARD direction and read the gauge.

TESTER READING TO BE:600 to 650 PSI (S/N below 250000000).725 to 775 PSI (S/N above 250000000).

4. If pressure is incorrect, locate “Traction Plus” reliefcartridge on control manifold (Fig. 15). Remove cap on“Traction Plus” relief valve and adjust the relief valvescrew until correct “Traction Plus” pressure is attained.

1. Lift test port (S/N below 250000000)2. Traction forward test port

Figure 13

21

NOTE: Deck drive Test Ports

also on this panel.on older models are

1. Lift test port (S/N above 250000000)Figure 14

1

1. Traction forward test port (S/N above 250000000)Figure 14A

1

Rev. F28.1Groundsmaster 580--D Page 4 -- Testing

“TRACTION PLUS” SHIFT Pressure Test

1. Connect a 1,000 psi gauge to the LIFT test port. Con-nect a 5,000 psi gauge to TRACTION FORWARD testport.

a. On machines with serial number below250000000, the LIFT and TRACTION FORWARDtest ports are located on the outside of the controlconsole (Fig. 13).

b. On machines with serial number above250000000, the LIFT and TRACTION FORWARDtest ports are located underneath the center of themachine (Figs. 14 and 14A).

2. Start the engine and adjust throttle so engine speedis 2,500 RPM. Move GROUND SPEED switch to LOWRANGE.

3. While watching gauges, engage service brake andslowly push traction pedal in the FORWARD direction.Note pressure at TRACTION FORWARD PORT whenpressure at LIFT port shifts from Counterbalance pres-sure to “Traction Plus” pressure (see Counterbalanceand “Traction Plus” Pressure Tests above).

TESTER READING TO BE 2,000 to 2,050 PSI.

4. If SHIFT pressure is incorrect, locate “TRACTIONPLUS” shift cartridge on control manifold. Remove capon “TRACTION PLUS” shift cartridge and adjust the car-tridge screw until correct SHIFT pressure is obtained(Fig. 15).

1. Counterbalance relief cartridge2. “Traction Plus” relief cartridge (upper)3. “Traction Plus” shift cartridge (lower)

Figure 15

2

1

2

28.2 Rev. F Groundsmaster 580--DPage 4 --Testing


Rev. F28.3Groundsmaster 580--D Page 4 -- Testing

Diagnosing Cutting Performance Problems

Over a period of time, the seals in the deck motors candeteriorate and wear from heat and contamination. Aleaking motor seal will by--pass oil to the case drain lineand make the motor less efficient. Eventually enough oilloss will occur and cause the deck motor to stall in heavycutting conditions. Continued operation with a motor inan inefficient condition can generate so much heat thatthe cartridge seals in the hydraulic manifold block can beaffected, compounding the problem.

If the deck motors slow during operation, use the follow-ing procedure to analyze the problem:

1. Make sure deck drive area is clean, drive belt is atproper tension and belts are free of grease.

2. Check the hydraulic oil for water contamination andreplace as necessary (appears cloudy or milky).

3. Make sure deck drive hydraulic circuit working and re-lief pressures are within specification.

4. Check PTO manifold block logic cartridges and reliefvalves for burnt or hardened o--rings. Replace o--ringsas necessary.

5. Test deck motor for internal leakage (see Deck MotorInternal Leakage Test on the next page).

Figure 15A

Rev. F28.4

DANGER

Groundsmaster 580--DPage 4 --Testing

Deck Motor Internal Leakage Test

NOTE: Test only one deck at a time. Decks not beingtested should be in the raised position so the deck willnot operate when the PTO is engaged.

1. Determine which deck motor is turning slow. The leftand right decks are powered in series by the same cir-cuit, therefore one deck could affect the other.

2. To prevent deck blades from rotating, remove oneouter blade from the deck to be tested and install a long-er blade (P/N 29--5530) from a Groundsmaster 72 inchdeck. Put the front cutting edge of the longer bladeagainst the deck housing (Fig. 15B).

Make sure other two decks not being testedare in the raised position. Blades on the otherdecks will rotate if in the lowered positionwhen PTO switch is engaged. To prevent seri-ous personal injury or death, keep clear of ro-tating blades. Other blades on deck beingtested will rotate if belt on spindle with longerblade breaks or slips.

3. Remove the case drain line (smallest of the threelines) from the deck motor (Fig. 15C).

4. Connect a flow meter in line with the case drain (oilflow will be away from the motor).

5. With the other decks in the raised position, start theengine and engage the PTO. Move the throttle to fullspeed position and note the oil flow exiting the motorthrough the case drain line. If the flow exceeds 1.5 GPM,the deck motor should be repaired or replaced.

NOTE: If one motor shows excessive case drain flow,other motors may also be in a similar condition. Failureto test all three motors may lead to repeat failures.

Alternate Deck Motor Test(If a flow meter is not available)

1. Do steps 1 -- 3 as described above, except disconnectthe case drain line from the bulkhead instead of the mo-tor. Put a cap on the bulkhead fitting.

2. Put the case drain line from the motor into a 5 galloncontainer and secure the line in place.

3. Start the engine and engage the PTO for exactly 15seconds at full throttle, then disengage the PTO andstop the engine.

4. Measure the amount of oil in the container. Multiplythe amount collected by 4 to get the gallons per minuteflow discharged from the case drain line. If the flow ex-ceeds 1.5 GPM, the deck motor should be repaired orreplaced.

NOTE: If one motor shows excessive case drain flow,other motors may also be in a similar condition. Failureto test all three motors may lead to repeat failures.

LONGER BLADE(Front edge against

deck housing)

Figure 15B

1. Deck motor 2. Case drain lineFigure 15C

2

1

Rev. E


NOTE: The Traction Control Neutral Adjustment information listed is for models 30580 and 30581. For model 30582 and 30583 neutral adjustment, steps 5 to 7 are not relevent. Refer to Variable Pump Neutral Start Switch Spool Replacement Procedure in the Sauer/ Danfoss Traction Pump and Motor Service Manual included at the end of this chapter.

Rev. G

NOTE: Machines with serial numbers above 90001 do not use a jam nut and setscrew. On these machines, locate collar so there is from .060 to .120 inch (1.5 to 3.0 mm) clearance between cruise control coil and clutch plate.

Rev. E

NOTE: Refer to the Sauer/Sundstrand M46-Axial Piston Pumps and Motors Service Manual at the end of this chapter for traction pump service procedures.

Rev. E

NOTE: For Service and Repair Procedures of the front wheel motors used on the Groundsmaster 580-D, see the Sundstrand Sauer M46-Axial Piston Pumps and Motors Repair Manual that follows this Chapter.

Rev. E

Torque to 35 Ft-lbs

(47.1 N-m)

Torque to 35 Ft-lbs

(47.1 N-m)

(47.1 N-m)

Torque to 35 Ft-lbs

Torque to 65 Ft-lbs

Torque to 60 Ft-lbs(81.4 N-m)

(88.1 N-m)

Rev. E

Rev. EGroundsmaster 580-D Page 4 - 36.1 PTO System Repairs

PTO Valve Block Service (S/N 50001 & UP)

3

6

1

4

2

5

Loctite 242

Torque to 15 in-lbs

Torque to 35 ft-lbs

Torque to 60 ft–lbs

Torque to 65 ft–lbs

Torque to 35 ft-lbs

Torque to 35 ft-lbs(47.5 N–m)

(47.5 N–m)

(47.5 N–m)(88.1 N–m)

(81.4 N–m)

(1.7 N–m)

Figure 27A

1. Solenoid valve (SV2 shown) 4. Brake relief cartridge (R2BR shown)2. Bypass (main) relief cartridge (R3BY shown) 5. Brake logic cartridge (BR2 shown)3. Bypass (main) logic cartridge (BY2 shown) 6. Orifice

Rev. E Groundsmaster 580–DPage 4 - 36.2PTO System Repairs

PTO Solenoid Valve Service (S/N 50001 & UP)

Figure 28A

1. Clean valve block to prevent contamination whenvalve cartridge is removed.

2. Remove cartridge valve:

A. Remove nut from solenoid.

B. Remove solenoid coil and o-ring at each end ofsolenoid coil.

C. Use a deep socket to remove cartridge valve.NOTE: Use care when handling valve cartridges,because slight bending or distortion of stem tubecan cause binding and malfunction.

3. Visually inspect port in block for damage to sealingareas, damaged threads or contamination.

4. Visually inspect cartridge for damaged seals and con-tamination.

A. O-rings and backup rings must be arrangedproperly on the valve for proper operation and seal-ing. Replace any damaged seals.

B. Contamination may cause valves to stick or hangup. Contamination can become lodged in smallvalve orifices or seal areas on poppet type valvescausing malfunction.

C. If cartridge valve seals appear pitted or dam-aged, the hydraulic system may be overheating orthere may be water in the system.

5. Clean and check for proper valve operation:

A. Use clean mineral spirits to clean cartridge valve.Submerge the valve in clean mineral spirits and usea probe to push the internal spool in and out 20 to 30times to flush out contamination. Mineral spiritsdoes not affect the o-ring material. Particles as fineas talcum powder can affect the operation of highpressure hydraulic valves.

Cartridge Installation

1. Lubricate all o-rings with clean hydraulic oil.

2. Carefully thread cartridge into the port by hand. Valvecartridge should go in easily without binding.

3. Use a torque wrench and deep socket to tighten car-tridge valves to the torque specified in Figure 27A. Ex-cessive torque may cause the spool to bind andmalfunction.

NOTE: Use care when handling solenoid valve car-tridges because slight bending or distortion of stem tubecan cause binding and malfunction.

4. Install solenoid coil. Make sure there is an o-ring ateach end of the coil. Apply “Loctite 242” or equivalent tothreads of stem tube before installing nut. Tighten nut toa torque of 15 in-lb (1.7 N–m).

5. If problem still exists, remove valve and clean againor replace valve.

NOTE: When installing a cartridge valve into manifold, torque valve as specified in Figures 27 and 27A.

NOTE: When installing solenoid valve into manifold, torque solenoid valve 35 Ft-lbs (47.1 N-m).

Rev. E

Rev. GGroundsmaster 580-D Page 4 - 38.1 PTO System Repairs

PTO Pump Repair (Models 30580 and 30581)

3

8

14

4

2

5

3

7

13

4

9

5

3

6

11

4

12

5

3

6

1

4

105

7

8

10

12

12

15

16

17

18

192021

22

23

24

Figure 31A

1. Coupler 2. Adapter section 3. Gland4. Retainer 5. Flex plate 6. O--ring7. Center section 8. Idler gear 9. Gear10. O--ring 11. Rear cover 12. Lockwasher (16 used)13. Capscrew (4 used) 14. Capscrew (4 used) 15. O--ring16. Port section 17. Gear 18. Shaft end cover19. Plug 20. Shaft seal 21. Retaining ring22. Seal 23. Nut 24. Stud

Note: For service and repair procedures of the PTOpump used on models 30580 and 30581, see the Vick-ers Gear PumpOverhaul Manual that follows this chap-ter.

Rev. G Groundsmaster 580--DPage 4 - 38.2PTO System Repairs

PTO Pump Repair (Models 30582 and 30583)

3

6

1

4

2

5

20

21

19

10

7

9

11

8

13

16

14

12

15

2

2

2

5

5

5

3

3

3

4

4

4

1817

Figure 31B

1. Shaft coupling 2. O--ring 3. Seal gland4. Seal retainer 5. Wear plate 6. Center section7. Idler gear 8. Drive gear 9. Rear cover10. Capscrew (4 used) 11. Capscrew (4 used) 12. Center housing13. Center section 14. Idler gear 15. Drive gear16. Shaft end cover 17. Shaft seal 18. Seal19. Stud (8 used) 20. Lockwasher (16 used) 21. Nut (8 used)

Note: For service and repair procedures of the PTOpump used on models 30582 and 30583, see the Hal-dexBarnesG20andG30SeriesHydraulic Gear PumpsService Manual that follows this chapter.

Rev. AGroundsmaster 580-D Page 4 - 40.1 PTO System Repairs

Deck Motor Repair (P/N 94-4907)

12

3

4

6

7

8

7

4

Torque to 70 + 5 ft-lbs

Mounting flange

Body

Drive Shaft

Gears

Mark before disassembling

5

Figure 35A

1. Hex nut 4. Load plate 7. Load seal2. Flat washer 5. O-ring seal 8. Square key3. Shaft seal 6. Retaining ring * Seal Kit (Items 3, 5-8)

Disassembly

1. Use a marker or scribe to make a line across the bodyand mounting flange for proper reassembly (put markalong drive shaft side of body and flange as shown).

2. Remove key (8) from shaft.

3. Remove nuts (1) and washers (2).

4. Use a soft face hammer to lightly tap the mountingflange to disengage it from the body. Slide the flange offof the shaft.

5. Remove O-ring seal (5).

5. Remove retaining ring (6) and push the shaft seal (3)squarely out of the mounting flange, taking care not todamage any sealing surfaces.

NOTE: Before disassembling internal components,mark the load plates for proper reassembly. Mark on anarea away from the seal location. Mark “F” for flange endand “B” for body end.

6. With the motor lying on its side, hold the driveshaftand pull it squarely out of the body bringing the loadplates (4) with it.

7. Remove the load plates (4) from the gears. Removethe load seals (7) from the load plates.

Inspection and Repair

1. Wash each of the components with cleaning solventor mineral spirits and dry with a lint free cloth or com-pressed air.

2. Body: Inspect the body bore cut-in where gears wipeinto the body. The cut-in should be bright and polishedin appearance with a depth of less than .08 mm. Replacethe motor if the surface is scored, has a matt appear-ance or shows signs that the tip of the gears have dugin and torn away the surface material. Inspect for dam-age to port threads and body O-ring recesses.

Rev. A Groundsmaster 580-DPage 4 - 40.2PTO System Repairs

Check the shaft seal recess for scoring or damage thatcould result in oil leakage around the outside diameterof the shaft seal.

NOTE: Replacement shaft seals can be refitted withLoctite hydraulic sealant to overcome slight damage tothis area.

3. Load Plates: The side faces which are against thegears should be perfectly flat showing no signs of scor-ing. Typically there are bright polished areas on this sur-face caused by loading against the gear side faces. Thisis often more noticeable on the low pressure side. Theload plates should be replaced if there is any generalscoring, fine scoring with a dull appearance, or tearingof the surface material. Often there is an area where thetips of the opposing gears have wiped an overlap witha half moon shape. There must be no noticeable wearstep; it is critical that the load plate side face is complete-ly flat to the gear side face. The load plate bearing linersshould not show any scoring or other damage. The gen-eral outside area of the load plate should not show anysignificant wear.

4. Gears: The gear faces should be examined for bruis-ing or scoring. Operation with contaminated hydraulicfluid will often show scoring between the root of the gearand the journal that leaves a wear step. If a wear stepcan be felt, along the root diameter, by drawing a sharppointed tool across the surface from the journal out-wards toward the tip of the gear, then the gear is unser-viceable and the motor should be replaced.

The gear teeth should be carefully examined for bruisingor pitting.

The journal bearing surfaces should be completely freefrom scoring or bruising. The surface should appearhighly polished and smooth to the touch.

Examine the area where the shaft seal lips run on the dri-veshaft, this shows up as a polished ring or rings. If a no-ticeable groove can be felt or there is scoring, the shaftis unserviceable and the motor should be replaced.

Reassembly

NOTE: Install new seals when reassembling the motor.Use petroleum jelly to hold seals and O-rings in placeduring assembly.

1. Install new load seals (7) on the load plate (4) youmarked “B”. Install load plate (4) into body.

2. Put body on work bench so gear openings face up.

3. Install gears into their original positions in the body.NOTE: Install gear with driveshaft into the side of thebody you marked in step 1 under Disassembly.

4. Install new load seals (7) on the load plate (4) youmarked “F”. Install load plate into mounting flange.

5. Install new O-ring seal (6) in mounting flange.

6. Install mounting flange over drive shaft and onto thebody.

7. Install washers (2) and nuts (1). Tighten nuts evenlyin a crossing pattern to a torque of 70 + ft--lb.

8. Install shaft seal.

Shaft Seal Installation

1. Apply grease to seal bore in mounting flange. NOTE:If using Loctite hydraulic sealant to overcome slightdamage to the seal bore area, do not apply grease.

2. Pack lips of new shaft seal (3) with high melting pointgrease.

3. Install Mylar sleeve from seal kit onto drive shaft,checking to make sure that the sleeve covers all sharpedges of the shaft.

4. Slide new shaft seal onto shaft down to flange housingwith the exposed spring side of the seal facing the motor.

5. Press the shaft seal in until it bottoms squarely in thebore.

6. Put on protective eyewear, such as safety glasses ora face shield, then install the retaining ring (6).

Running--in

A motor which has been rebuilt with new load plates,must be run-in before it is subjected to full load condi-tions. Ideally this should be done on a test stand wherepressure can be gradually applied. If a test stand is notavailable, install the motor on the machine and operatethe cutting deck at low speed with no load for at least oneminute. Gradually increase speed, running for one min-ute at a time at each speed until you reach full engineRPM. Stop the machine and check to make sure the mo-tor is not running hotter than the others.

Groundsmaster 580–D Page 4 – 40.3 PTO System RepairsRev. A

Wing Deck Hose Replacement (S/N 50001 & Up)

Routing of wing deck hoses through the wing arms re-quires accurate hose positioning or the hoses can bedamaged as the wing decks are raised and lowered.

In order to reduce hose damage due to incorrect routing,a Hose Routing Kit (P/N 93–9956) is available for pre-viously manufactured products (S/N 80101 – 49999).The kit contains all the parts, hoses and instructionsnecessary to re–route the wing deck hoses external tothe arms. The external routing reduces the possibility ofdamage due to incorrect routing. Current production willincludes the external hose routing.

�

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Figure 36A

Groundsmaster 580–DPage 4 – 40.4PTO System Repairs Rev. A


Torque all cartridges to

35 Ft-lbs (47.5 N-m)

Rev. E

NOTE: When installing cartridge into float/traction assist manifold, torque cartridge to 35 ft-lbs (47.5 N-m). If cartridge is overtightened, cartridge damage may occur.

Rev. E

Rev. GGroundsmaster 580--D Auxiliary (Lift/Counterbalance) System RepairsPage 4 -- 44.1

Steering/Auxiliary Pump Repair (Models 30582 and 30583)

1. Cap screw (4 used)2. Shaft seal3. Pre--load seal4. Load seal5. Sealing ring

6. Front wear plate7. Drive shaft8. Dowel9. Rear wear plate10. Cap screw (3 used)

11. Rear cover (flow divider) assembly12. Gear plate13. Idler gear14. Front body

Figure 39A

56

9

10

11

1213

14

4

7

1

8

2

3

8

5

360 to 380 in--lbs(40.7 to 42.9 N--m)

360 to 380 in--lbs(40.7 to 42.9 N--m)

Disassembly

1. Plug pump ports and clean the outside of the pumpthoroughly. After cleaning, remove plugs and drain anyoil out of the pump.

2. Use a marker or scribe to make a diagonal markacross the front body, gear plate and rear cover for reas-sembly purposes (Fig. 39B).

IMPORTANT: Avoid using excessive clampingpressure on the pumphousing to prevent distortingthe housing.

3. Clampmounting flange of pump in a vise. Loosen allcap screws.

4. Remove pump from the vise and remove capscrews.

IMPORTANT: Toprevent componentdamage,neverpry components apart. Light tapping with a plastichammer on drive shaft should separate pump.

5. Carefully remove front body. Lift front body straightup to allow drive shaft and idler gear to remain in rearcover. Remove front wear plate. Identify intersectinggear teeth of drive shaft and idler gear with a marker toensure proper gear placement during assembly.

6. Carefully remove idler gear and drive gear.

7. Remove gear plate and rear wear plate from rearcover.

8. Remove and discard pre--load seal, load seal andsealing rings.

IMPORTANT: Make sure not to damage the counterbore when removing the shaft seal from the frontbody.

9. Remove shaft seal from the front body.

Note: Rear cover assembly includes priority flow di-vider valve and steering relief valve. These componentsare retained in the cover with tamper proof plugs. Disas-sembly of rear cover is not recommended.

Inspection

1. Remove nicks and burrs from all parts with emerycloth.

2. Inspect gear plate for excessive scoring, gouges orwear. Evidence of damage indicates need for compo-nent replacement.

3. Inspect front body and rear cover for damage orwear.

Rev. EGroundsmaster 580--DAuxiliary (Lift/Counterbalance) System Repairs Page 4 -- 44.2

4. Inspect drive shaft gear and idler gear (Fig. 39C):

A. Drive shaft spline should be free of twisted or bro-ken teeth.

B. Gear shafts should be free of rough surfaces andexcessive wear at bushing points and sealing areas.Scoring, rough surfaces or wear on gear shafts indi-cates need for replacement.

C. Gear teeth should be free of excessive scoringand wear. Any broken or nicked gear teeth must bereplaced.

D. Inspect gear face edge for sharpness. Sharpedges of gears will mill into wear plates and, thus,must be replaced.

Assembly

Note: When assembling the pump, check the markeror scribe marks on each part to make sure that parts areproperly aligned during assembly (Fig. 39B).

1. Lubricate new sealing rings, pre--load seal and loadseal with a thin coat of petroleum jelly. Lubricate all otherinternal parts freely with clean hydraulic oil.

2. Install new shaft seal in front body. Seal should bepressed into place until it reaches the bottom of the bore.Grease seal lip.

3. Place rear cover on a flat surface.

4. Install the sealing ring into the rear cover groove. Fol-low by placing the rear wear plate on the cover. Makesure to position the wear plate as shown in Figure 39Awith the bronze side toward the gear position. Lubricatethe exposed side of the rear wear plate with clean hy-draulic oil.

5. Lubricate the drive shaft and idler gear with clean hy-draulic oil and install the gears into the proper bearingsin the rear cover. Make sure to align the gears usingmark placed during disassembly.

6. Install locating dowels in rear cover.

7. Carefully install gear plate making sure to alignscribe marks on the gear plate and rear cover.

8. Lubricate bronze side of front wear plate with cleanhydraulic oil. Place the front wear plate on the drive shaftand idler gear. Make sure to position the wear plate asshown in Figure 39A with the bronze side toward thegears.

9. Install new pre--load seal, load seal and sealing ringto the front body.

Figure 39B

SCRIBE MARK

1. Gear shaft spline2. Gear shaft

3. Gear teeth4. Gear face edge

Figure 39C

4

1

2

3

IMPORTANT: To prevent shaft seal damage duringassembly, use seal protector or tape on drive shaftsplines.

10.Gently slide the front body onto the assembly. Makesure to align scribe marks on the front body and gearplate. Firm hand pressure should be sufficient to engagethe dowels.

11.Check to make sure that pump component surfacesare flush. If gaps exist between components, check as-sembly for a shifted seal or sealing ring. Correct beforeproceeding.

12.Install cap screws and hand tighten to secure as-sembly.

13.Place mounting flange of the pump into a vise and al-ternately torque the screws from 360 to 380 in--lbs (40.7to 42.9 N--m).

14.Remove pump from vise.

15.Place a small amount of clean hydraulic oil in the inletof the pump and rotate the drive shaft one revolution. Ifany binding is noted, disassemble the pump and checkfor assembly problems.

(Models 30580 and 30581)

Rev. E

Groundsmaster 580--D Page 4 -- 54.1 Steering System RepairsRev. G

Steering Control Unit Repair (Models 30580 and 30581)

For service of the steering control unit onModels 30580and 30581, see the Eaton Char--Lynn Steering ControlUnits Repair Information at the end of this chapter.

Steering Control Unit Repair (Model 30582 and 30583)

1. Steering valve housing2. Dust seal3. O--ring4. Spool5. Spring retaining ring6. Pin7. Sleeve8. Centering springs/spacers

9. Cap screw10. End cap11. O--ring12. Seal ring13. O--ring14. Geroter15. O--ring16. Spacer

17. Geroter drive18. Wear plate19. Bearing race20. Thrust bearing21. Plug22. O--ring23. Relief valve24. Quad seal

Figure 49A

3

5

6

910

16

1112

1314

15

47

1

2

1718

1919 20

2122

23

24

8

140 to 160 in--lb(16 to 18 N--m)

150 in--lb(17 N--m)

Disassembly (Fig. 49A)

NOTE: Cleanliness is extremely important whenrepairing steering control units. Work in a clean area.Before disconnecting the hydraulic lines, clean the portarea of the steering valve assembly. Before disassem-bly, drain the oil, then plug the ports and thoroughlyclean the exterior. During repairs, always protectmachined surfaces.

1. Remove the seven cap screws from the steeringvalve assembly.

2. Remove end cap, geroter, spacer, geroter drive,wear plate, seal ring, and o--rings from housing.

3. Remove the plug and relief valve.

4. Slide the spool and sleeve assembly from the hous-ing.

5. Remove the thrust bearing and bearing races (2).

6. Remove the quad seal.

7. Use a small blade screwdriver to carefully pry thedust seal from thehousing. Becareful to not damage thedust seal seat in the housing.

8. Remove the pin that holds the spool and sleeve to-gether.

Groundsmaster 580--DPage 4 -- 54.2Steering System Repairs Rev. E

9. Carefully slide the spool out of the sleeve. The cen-tering springs and spring retaining ring will stay with thespool as it is removed.

CAUTION

The centering springs are under tension. Re-move the retaining ring carefully.

10.Remove the spring retaining ring and centeringsprings from the spool.

Reassembly (Fig. 49A)

Check all mating surfaces. Replace any parts withscratches or burrs that could cause leakage. Wash allmetal parts in clean solvent. Blow them dry with pressur-ized air. Do not wipe parts dry with paper towels or cloth.Lint in a hydraulic system will cause damage.

NOTE: Always use new seals and o--rings whenreassembling the steering control unit.

IMPORTANT: During reassembly, lubricate the newseals with petroleum jelly. Also, lubricate machinedsurfaces and bearings with clean hydraulic fluid.

1. Install the quad seal:

A. Put one of the bearing races and sleeve into thehousing.

B. Together, the housing and bearing race create agroove into which the quad seal will be installed.

C. Hold the bearing race tightly against the input endof the housing by pushing on the gerotor end of thesleeve.

D. Fit the quad seal into its seat through the input endof the housing. Be sure the seal is not twisted.

E. Remove the sleeve and bearing race.

2. Lubricate and install the dust seal.

3. Install the centering springs in the spool. It is best toinstall the two flat pieces first. Next, install the curvedpieces, three at a time.

4. Fit the retaining ring over the centering springs.

5. Apply a light coating of clean hydraulic fluid to thespool and slide it into the sleeve. Be sure the centeringsprings fit into the notches in the sleeve.

6. Install the pin.

7. Apply a light coating of petroleum jelly to the inneredge of the dust and quad seals.

8. Put the thrust bearing and races into the housing.The thrust bearing goes between the two races(Fig. 49B).

IMPORTANT: Do not damage the dust or quad sealswhen installing the spool and sleeve assembly.

9. Apply a light coating of clean hydraulic fluid to thespool and sleeve assembly and slide carefully the as-sembly into the housing.

10.Clamp the housing in a vise. Use only enough clamp-ing force to hold the housing securely.

11.Lubricate and install a new o-ring seal in the groovein the housing.

12.Install the wear plate and align screw holes in thewear plate with threaded holes in the housing.

NOTE: The holes in the wear plate are symmetrical.

13.Install the geroter drive, making sure the slot in thedrive engages the pin.

14.Lubricate and install new o-ring in wear plate groove.

15.Install the gerotor and align the screw holes.

16.Lubricate and install new o-ring in gerotor ringgroove.

17.Lubricate and install new o-ring and seal ring in gero-tor star groove.

18.Install the spacer.

19.Install the end cap and seven cap screws. Tightenthe cap screws, in a crossing pattern, from 140 to 160in-lb (16 to 18 N--m).

20.Remove the steering control unit from the vise.

21.Install the relief valve and plug. Tighten the plug to150 in-lb (17 N--m).

Thrust Bearingand Race (2)

Quad Seal

Dust Seal

Figure 49B

Groundsmaster 580--D Page 5 -- 1 Table of ContentsRev. E

Chapter 5

Electrical System (Model 30580, S/N Below 30101)

Table of Contents

ELECTRICAL DIAGRAMS 2. . . . . . . . . . . . . . . . . . . . . .Controller Logic Chart 2. . . . . . . . . . . . . . . . . . . . . . . .Logic Grid (with Controller Update Kit) 3. . . . . . . . . .Electrical Schematic 4. . . . . . . . . . . . . . . . . . . . . . . . .Wiring Diagram -- Gauge Package 5. . . . . . . . . . . . .

SPECIAL TOOLS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .TROUBLESHOOTING 9. . . . . . . . . . . . . . . . . . . . . . . . .

Starting Problems 9. . . . . . . . . . . . . . . . . . . . . . . . . . .General Run and Transport Problems 12. . . . . . . . .Deck Operation Problems 16. . . . . . . . . . . . . . . . . . . .Verify Interlock Operation 19. . . . . . . . . . . . . . . . . . . .

TESTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ignition Key Switch 20. . . . . . . . . . . . . . . . . . . . . . . . . .Controller 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seat Switch 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Traction (Neutral) Switch 22. . . . . . . . . . . . . . . . . . . .Deck Down Switches 22. . . . . . . . . . . . . . . . . . . . . . . .Service Brake Switch 23. . . . . . . . . . . . . . . . . . . . . . .Parking Brake Switch 23. . . . . . . . . . . . . . . . . . . . . . .Start Relay 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Stop Solenoid 25. . . . . . . . . . . . . . . . . . . . . . . . . .Battery 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warning Indicator Lights 26. . . . . . . . . . . . . . . . . . . . .Hourmeter 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature and Fuel Level Gauges 26. . . . . . . . . .Engine Temperature Switches and

Gauge Sender 27. . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Temperature Warning Switch 28. . . . . . . .Engine Oil Pressure Switch 28. . . . . . . . . . . . . . . . . .2 -- Speed (Mow/Transport) Switch 29. . . . . . . . . . . .PTO (Deck) Solenoids 29. . . . . . . . . . . . . . . . . . . . . . .Cruise Control 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Oil Level Sensing Unit 30. . . . . . . . . . . . . .Fuel Gauge Sender 30. . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Oil Filter Warning Switch 31. . . . . . . . . . . .Air Cleaner Warning Switch 31. . . . . . . . . . . . . . . . . .

REPAIRS 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Service 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuses and Circuit Breaker 33. . . . . . . . . . . . . . . . . . .Traction (Neutral) Switch Replacement

and Adjustment 34. . . . . . . . . . . . . . . . . . . . . . . . . .Controller Replacement 35. . . . . . . . . . . . . . . . . . . . .Solenoid Valve Coil Replacement 36. . . . . . . . . . . . .Starter 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alternator 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note: Additional troubleshooting information for oldermachines equipped with the Controller Update Kit isavailable in Chapter 8 -- Electrical System (S/N 30101& Up).

Groundsmaster 580–D Page 5 – 3 Rev. A

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INPUTS

0 Hi Range Disengage12 Key Run

3 Traction Neutral

4 Seat Switch

5 High Coolant Temp

6 High Temp Override

7 Cruise Control Enable

8 PTO Engage

9 PTO Disengage

10 Front Deck Down

11 Right Deck Down

12 Left Deck Down

13 Hi Range Engage

14 Hyd. Oil Level (x=ok)

15 Cruise Control Engage

16 Service Brake (x=off)

17 Parking Brake (x=off)

AO Start Key

OUTPUTS

0

1 Front Deck Engage

2 Right Deck Engage

3 Left Deck Engage

4 Gauge Power ON

5

6 Cruise Control Clutch

7 ETR Hold / Alt

8

9

10

11

12 Start

13 Hi Range Engage

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Wiring Schematics and Diagrams

Page 5 - 4Wiring Schematics and Diagrams Groundsmaster 580 - D

Ele

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Rev. E

Wiring Schematics and DiagramsPage 5 - 5Groundsmaster 580 - D Rev. E


Wiring Schematics and Diagrams Page 5 - 6 Groundsmaster® 580-DRev. E

Page 5 - 7 Rev. E

Page 5 - 8 Rev. E

Page 5 - 9 Rev. E

Page 5 - 10 Rev. E

Page 5 - 11 Rev. E

Page 5 - 12 Rev. E

Page 5 - 13 Rev. E

Page 5 - 14 Rev. E

Page 5 - 15 Rev. E

Page 5 - 16 Rev. E

Page 5 - 17 Rev. E

Page 5 - 18 Rev. E

Page 5 - 19 Rev. E

Page 5 - 20 Rev. E

Page 5 - 21 Rev. E

Note: If machine is equipped with Controller Update Kit, refer to Chapter 8 - Electrical System (S/N 30101 & Up).

Page 5 - 22 Rev. E

Page 5 - 23 Rev. E

Page 5 - 24 Rev. E

Page 5 - 25 Rev. E

Page 5 - 26 Rev. E

Page 5 - 27 Rev. E

Page 5 - 28 Rev. E

Page 5 - 29 Rev. E

Page 5 - 30 Rev. E

Page 5 - 31 Rev. E

Page 5 - 32 Rev. E

Note: For machines with serial numbers 30101 & up, refer to updated information in Chapter 8 - Electrical System.

Page 5 - 33 Rev. E

Page 5 - 34 Rev. E

Page 5 - 35 Rev. E

Page 5 - 36 Rev. E

Rev. E

Older model shown. Older model shown.

Note: For models 30581 and 30582, starter repair information is included in the appropriate Mitsubishi Diesel Engine Service Manual found after chapter 3A (model 30581) or chapter 3B (model 30582).

Page 5 - 37

Page 5 - 38 Rev. E

Page 5 - 39 Rev. E

Page 5 - 40 Rev. E

Page 5 - 41 Rev. E

Page 5 - 42 Rev. E

Page 5 - 43 Rev. E

Rev. E

Note: For models 30581 and 30582, starter repair information is included in Chapter 8 - Electrical System (S/N 30101 & Up) and in the Mitsubishi Diesel Engine Service Manual found after chapter 3A (model 30581).

Page 5 - 44

Page 5 - 45 Rev. E

Page 5 - 46 Rev. E

Specifications

Planetary Wheel Drive Weight: Approx. 95 lb.

Planetary Wheel Drive Oil Capacity: Fill to bottom ofcheck/drain plug hole when check/drain plug is at either3 or 9 o’clock position (Fig. 1).

Planetary Wheel Drive Lubricant: API GL-5, SAE 80Wor 90W Gear Lubricant.

Brake System: Enclosed, multiple hydraulic disc serv-ice brakes operated by right foot pedal. Mechanicalsteering brakes with two pedals which lock together forparking brake function. Dynamic braking throughclosed-loop hydrostatic drive system.

Brake Fluid: DOT 3 hydraulic brake fluid. Check andadd fluid at master cylinder reservoir (Fig. 2).

Rear Wheel Toe-in: 0.00 to 0.12 in. toe-in (wheels instraight ahead position).

Front Wheel Lug Nut Torque: 60 - 70 ft-lb.

Rear Wheel Lug Nut Torque: 30 - 35 ft-lb.

Tire Pressure:Normal mowing conditions – 15 psi front; 13 psi rear.Wet and/or soft conditions – 12 psi front; 9 psi rear.Dry and/or hard conditions – 18 psi front and rear.

IMPORTANT: Do not operate in HIGH RANGE forextended periods when tire pressure is less than 20psi because tires may be damaged.

Figure 1

1. Check/drain plug (3 or 9 o’clock position)

Figure 2

1. Master cylinder reservoir (cover removed)

Rev. A

1

Specifications Page 6 - 2 Groundsmaster® 580-D

Rev. E

NOTE: Refer to Operator's Manual for additional information regarding Cutting Unit service procedures.

Rev. E Groundsmaster 580--DPage 7 -- 6Adjustments

Belt Tension Adjustment

IMPORTANT: After first ten hours of operation, checknew belts for proper tension; thereafter, check tensionevery 50 hours.

Front Cutting Unit (S/N below 220000000)

Note: Belts for wing unit spindles are tensioned byspring loaded idlers and normally do not require tension-ing.

1. Position machine on level surface, lower cutting unitto shop floor, engage parking brake, shut engine off andremove key from ignition switch.

2. Remove deck covers.

3. Note position of shoulder bolts in slots in tensionplate. Optimum belt tension will be maintained when theflanges on the shoulder bolts are 1/8 in. (3 mm) from thepulley ends of the slots (Fig. 9A). If the shoulder boltflanges are more than 3/8 in. (9 mm) from the pulley endof the slots, an adjustment should be made.

4. To adjust, loosen jam nuts (Fig. 9B) and extend ten-sion arm until the shoulder bolt flanges are within 1/8 in.(3 mm) of the pulley end of the slots (Fig. 9A).

Note: When the shoulder bolt flanges are positioned 1/8in. (3 mm) from the pulley end of the slots, the length ofthe compression spring (Fig. 8) will be approximately 5in. (127 mm).

5. Tighten jam nuts to secure adjustment. Install deckcovers.

Front Cutting Unit (S/N 220000001 and above) (Fig.9C)

1. Position machine on level surface, lower cutting unitto shop floor, engage parking brake, stop engine and re-move key from ignition switch.

2. Remove deck covers.

3. Loosen jam nut and relieve tension on springs withtensioner bolt.

4. Loosen four (4) cap screws securing slide plate tomotor mount.

5. Tighten tensioner bolt until springs are compressedto dimension shown in Figure 9C.

6. Tighten jam nut to secure adjustment.

7. Tighten four (4) cap screws securing slide plate tomotor mount.

8. Install deck covers.

1. Compression Spring and Tension Plate2. Wing Unit Drive Belt3. Gearbox Plate4. Center Drive Belt5. Lift Arm

1

23

4

5

Figure 8

1. Tension Plate 2. Shoulder Bolts

1

2

1/8 in.(3 mm)

Figure 9A

1. Tension Arm 2. Jam Nuts

1

2

Figure 9B

2

Rev. EGroundsmaster 580--D Page 7 -- 7 Adjustments

Outboard Cutting Units

1. Remove deck covers. To check belt tension, apply 8lb. (35.5 N) force at mid--span of belt and check deflec-tion. There should be approximately 5/16 in. (7.9 mm)deflection. If deflection is incorrect, proceed to step 2. Ifdeflection is correct, proceed to step 3.

2. To tension belts, loosen flange locknut at top of idlerpulley (Fig. 10). Slide pulley against belt until proper ten-sion is reached. Hold pulley in position and tighten lock-nut.


1. Jam nut 2. Tensioner Bolt 3. Slide PlateFigure 9C

1

3

2

3.060 in. (77.7 mm)New belt:

Old belt:3.250 in. (82.6 mm)

1. Idler Pulley Flange Locknut2. Drive Belts

1

2

Figure 10

Front Cutting Unit Lift Arm Ball Joint Adjustment

Ball joint must be threaded into each lift arm so there is adistance of 2 in. (50.8 mm) from end of lift arm to centerline of ball joint (Fig. 11). Tighten jam nut on ball jointagainst end of lift arm.

2 in.(50.8 mm)

Figure 11

Note: If machine is equipped with a cab enclosure, take care when pivoting front cutting unit to prevent deck motor from contacting cab windshield.

Rev. E

Rev. E Groundsmaster 580--DPage 7 -- 12Repairs

Belt Replacement

Front Cutting Unit (S/N below 220000000)

1. Position machine on level surface, lower cutting unitto shop floor, engage parking brake, shut engine off andremove key from ignition switch.

Note: Wing spindle drive belts must be removed beforeremoving center section belt.

2. Remove belt covers. Lift each wing to release idlerpulley tension and slip belt off pulleys (Fig. 20).

3. Loosen jam nuts securing tension arm until com-pression spring on idler assembly is relaxed (Fig. 21).

4. Remove flange head screws securing gearboxplate and separate plate and drive motor assembly fromthe cutting unit (Fig. 20). Be careful not to bend, twist,kink or damage flexible hydraulic lines.

5. Remove old belt. Position new belt in pulleys andassemble gear box and plate assembly to cutting unit.

6. Adjust belt tension (See Belt Tension Adjustment inthe Adjustments section of this chapter).

7. Install wing drive belts. Lift wings to allow belts to slipover outer drive spindle pulleys and install belt covers.

Front Cutting Unit (S/N 220000001 and above) (Fig.21A)


Note: Wing spindle drive belts must be removed beforeremoving center section belt.

2. Remove belt covers. Lift each wing to release idlerpulley tension and slip belt off pulleys.

3. Loosen jam nut and relieve tension on springs withtensioner bolt.

4. Loosen four (4) capscrews securing slide plate tomotor mount.

Note: Do not loosen motor mount adjusting screws dur-ing belt replacement.

5. Remove four (4) capscrews securing motor mountto cutting deck. Position motor mount to allow belt re-moval taking care not to bend, twist, kink or damage flex-ible hydraulic lines.

6. Replace belt(s) as required. Install belts on pulleysas shown in Figure 21B.

7. Position motor mount onto deck while routing beltaround drive pulley. Be careful not to bend, twist, kink ordamage flexible hydraulic lines.

8. Secure motor mount to cutting deck with four (4)capscrews.

Figure 201. Tension Plate & Spring2. Wing Unit Drive Belt3. Gearbox Plate

4. Center Drive Belt5. Lift Arm

1

23

4

5

Figure 211. Tension Arm 2. Jam Nuts

1

2 2

Figure 21A1. Slide Plate2. Motor Mount3. Drive Motor4. Drive Pulley

5. Mount Adjusting Screw6. Tensioner Bolt7. Center Deck Spindle8. Height Gauge

1

2

4 5

67

8

5

5

Rev. EGroundsmaster 580--D Page 7 -- 13 Repairs

9. Check and adjust the drive pulley height as follows:

A. Slide the height gauge under the drive pulley(not under the hub).

B. Loosen jam nuts on three (3) motor mount ad-justing screws. Equally tighten or loosen adjustingscrews until bottom of pulley rests on height gauge(approximately 1 1/2 in. (38.1 mm)).

C. Tighten jam nuts to secure adjustment. Removeheight gauge.


11. Tighten four (4) cap screws securing slide plate tomotor mount.

12. Check distance between idler arm and idler stopscrew (Fig. 21C). Distance should be approximately.380 in. (9.7 mm). If necessary, adjust as follows:

A. Loosen jam nuts on idler stop screw.

B. Adjust stop screw until distance between idlerarm and idler stop screw is approximately .380 in.(9.7 mm).

C. Tighten jam nuts to secure adjustment.


Outboard Cutting Units


Note: To remove lower belt, the other two belts must beremoved first.

2. Remove deck covers.Loosen flange locknuts onidler pulleys and slide pulleys away from belts.

3. Remove flange head screws securing gearboxplate to deck. To separate plate and drive motor assem-bly from deck, rotate plate end toward traction unit. Tipplate, motor and pulley assembly on its side and removefrom deck. Be careful not to bend, twist, kink or damageflexible hydraulic lines.

4. Remove belt(s). Position new belts in pulleys andassemble gearbox and plate assembly to deck.


Figure 21B1. Top and Middle Grooves2. Bottom Grooves

3. Top Grooves4. Top and Middle Grooves

12

3

4

Figure 21C1. Idler arm 2. Idler stop screw

12

.380 in.(9.7 mm)

1. Idler Pulley Flange Locknut2. Drive Belts

1

2

Figure 22

Rev. E RepairsPage 7 -- 15Groundsmaster 580--D

Spindle Service

Removing Spindle Housing Assembly

1. Lower cutting unit to ground and engage parkingbrake. Turn engine off and remove key from ignitionswitch.

2. Remove belt cover from top of spindle housing to beserviced. Loosen belt tension and remove belt fromspindle.

3. Raise cutting unit to transport position, turn engineoff and remove key from ignition switch. Make sure thatparking brake is engaged.

4. Using a rag or thickly padded glove, grasp end ofblade. Remove blade bolt, lock washer, anti--scalp cupand blade from spindle assembly.

5. Remove six (6) carriage bolts and flange nuts hold-ing spindle housing assembly to cutting unit housing. Liftspindle housing assembly from cutting unit.

Disassembly (Fig. 25)

1. Remove lock nut and thrust washer retaining pulleyon spindle shaft. Slide pulley from shaft.

2. If equipped, remove o--ring from top of spindle shaft.

3. Press the spindle shaft out of the spindle housingusing an arbor press. The spindle shaft spacer remainson the spindle shaft as the shaft is being removed.

4. Remove oil seals from spindle housing. Note posi-tion of seal lips for assembly purposes.

5. Remove the bearing cones, inner bearing spacerand spacer ring from the spindle housing.

6. Using a punch and hammer, drive both of thebearing cups out of the spindle housing. Also, drive thelarge spacer out of the housing.

7. The large snap ring can remain inside the spindlehousing. Removal of the large snap ring is very difficult.

Assembly (Fig. 25)

Important: If new bearings will be installed into aused spindle housing that has the original largesnap ring installed, discard the large snap ring thatcomes with the new bearing set because it is notnecessary to replace the original large snap ring inthe spindle housing. However, new bearings withtheir matched spacer set, spacer ring and largesnap ring must always be installed when the spindlehousing is being replaced.

NOTE: A replacement bearing set contains bearings, amatched spacer set, spacer ring and large snap ring(Fig. 26). These parts cannot be purchased separately.

1. If large snap ring was removed or if replacing thespindle housing, install large snap ring into groove inbore of spindle housing. Make sure snap ring is seatedin housing groove.

Figure 251. Grease Fitting2. Lock Nut3. Thrust Washer4. Pulley5. Oil Seal6. Bearing Set7. Spindle Housing

8. Spindle Shaft Spacer9. Spindle Shaft10. Blade11. Anti--Scalp Cup12. Lock Washer13. Blade Bolt

10

1 2

3

4

9

11

12

56

7

8

13

5

140 to 160 ft--lb(190 to 217 N--m)

140 to 165 ft--lb(190 to 217 N--m)

1. Bearing2. Inner Bearing Spacer3. Spacer Ring

4. Outer Bearing Spacer5. Large Snap Ring

Figure 26

2

3

4

5

1

1

Rev. ERepairs Page 7 -- 16 Groundsmaster 580--D

2. Using an arbor press, push outer bearing spacerinto top of spindle housing; tightly against snap ring. Thespacer must contact the snap ring to be sure of thecorrect assembly of components.

3. Thoroughly oil the bearing cups. Use an arbor pressto push the bearing cups into the top and bottom of thespindle housing. The top bearing cup must contact thespacer that was installed in step 2, and the bottombearing cup must contact the snap ring. Make sure thatthe assembly is correct by supporting the first cup andpressing the second cup against it (Fig. 27).

4. Apply a film of grease on lips of both seals. Pack thebearing cones with grease.

5. Install bearing cone and seal into bottom of spindlehousing. BOTTOM SEAL MUST HAVE THE LIPFACING OUT so old grease can be purged duringspindle lubrication.

7. Slide spacer ring and inner bearing spacer intospindle housing. Install bearing cone and seal into top ofspindle housing. UPPER SEAL MUST HAVE THE LIPFACING IN.

6. Check the spindle shaft to make sure it is free ofburrs and nicks that could possibly cut the seals. Thor-oughly lubricate the shaft and seal lips.

8. Slide spindle shaft spacer onto spindle shaft.Carefully slide spindle shaft through spindle housing.The bottom seal and spindle shaft spacer should fittogether when the spindle is fully installed.

9. If equipped, position o--ring to top of spindle shaft.

10. Push pulley onto splines of spindle shaft and securespindle assembly with thrust washer and lock nut.Tighten the lock nut from 140 to 160 ft--lb (190 to 217N--m). Rotate the spindle shaft to be sure that the shaftrotates freely.

11. Attach a hand grease gun to grease fitting and fillcavity with grease until grease starts to come out of low-er seal. NOTE: Pneumatic grease guns can cause airpockets when filling large cavities with grease andtherefore, are not recommended to be used for propergreasing of spindle housings.

Installing Spindle Housing Assembly

1. Position spindle assembly to cutting unit. Securethe spindle assembly in place with six (6) carriage boltsand flange nuts.

2. Install the belt (see Belt Replacement in this sec-tion). Check and adjust belt tension (see Inspecting andAdjusting Cutting Unit Belt Tension in the Adjustmentssection).

3. Reinstall the belt covers.

4. Position blade (blade sail facing up) and anti--scalpcup to spindle shaft. Secure with lock washer and bladebolt. Torque bolt from 140 to 165 ft--lb (190 to 217 N--m).

1. Bearing Cup2. Large Snap Ring3. Large Spacer

4. Arbor Press5. Support6. Arbor Press Base

Figure 27

1

2

3

4

56

PRESS

Models 30580 (S/N 30101 & Up), 30581, 30582 and 30583

Rev. GGroundsmaster 580--D Page 8 -- 1 Electrical System (S/N 30101 & Up) (Rev. E)

Chapter 8

Electrical System

Table of Contents

ELECTRICAL DIAGRAMS 2. . . . . . . . . . . . . . . . . . . . . .(See Chapter 9 -- Foldout Diagrams for additionalelectrical diagrams)

Controller Logic Grid 2. . . . . . . . . . . . . . . . . . . . . . . . .Wire Harness Diagram: Console Gauge Panel 3. . .Wiring Diagram: Console Gauge Panel 4. . . . . . . . .

SPECIAL TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ELECTRICAL SYSTEM QUICK CHECKS 7. . . . . . . .TROUBLESHOOTING 8. . . . . . . . . . . . . . . . . . . . . . . . .Quick Reference Troubleshooting Guide 8. . . . . . . .

COMPONENT IDENTIFICATION AND TESTING 11.Electronic Control Unit (ECU) 11. . . . . . . . . . . . . . . .

Neutral Switch (Model 30582 and 30583) 11. . . . . .Seat Switch (S/N Between 30101 and 80000) 12. .Seat Switch (S/N 80001 and up) 12. . . . . . . . . . . . . .Engine Temperature Switches(S/N 80001 and Up) 13. . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS 14. . . . . . . . . . . . . . . . . . . . .Circuit Protection 14. . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Service 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alternator 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note: Only new and changed information is providedin this Chapter. The Troubleshooting section of thischapter is also useful for older machines equipped withthe Controller Update Kit. See Chapter 5 -- ElectricalSystem (Model 30580, S/N Below 30101) for addition-al electrical system information.

Note: Somewiring harness differences exist betweenModels 30580 (S/N 30101 and Up), 30581, 30582 and30583. The wiring diagrams for all models are providedin Chapter 9 -- Foldout Diagrams.

Groundsmaster 580--DPage 8 -- 2Electrical System (S/N 30101 & Up) (Rev. E)

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1ParkingBrake(X=OFF)

2KeyRun

3TractionNeutral

4SeatSwitch

5HighCoolantTemp

6HighTempOverride

7CruiseControlEnable

8PTOEngage

9PTODisengage

10FrontDeckDown

11RightDeckDown

12LeftDeckDown

13HiRangeEngage

14Hyd.OilLevel(x=ok)

15CruiseControlEngage

16ServiceBrake(x=off)

17NotUsed

KeyInStart

OUTPUTS

0NotUsed

1NotUsed

2RightDeckEngage

3LeftDeckEngage

4GaugePowerON

5FrontDeckEngage

6CruiseControlClutch

7ETRHold/Alt

8NotUsed

9OutputFail

10Harness

11NotUsed

12Start

13HiRangeEngage

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Groundsmaster 580--D Page 8 -- 3 Electrical System (S/N 30101 & Up) (Rev. E)

ALARM

FUEL SENDER

WATER IN FUEL

ENGINE TEMP.

AUDIO ALARM

OIL FILTER PLUGGED

GROUND

YELLOW/RED

AIR CLEANER

NO.

BLUE

ORANGE

GREEN/WHITE

TAN

PINKHYD. OIL LOW

OIL TEMP. SWITCH

INPUT POWERFROM CONTROLLER

AUDIO ALARM

OIL PRESSURE SWITCH

VOLTMETER

1

2

3

4

5

6

7

8

9

10

16

17

18

19

20

21

22

23

24

11

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6

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18

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21

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9

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PIN

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BLACK

BROWN

BROWN/RED

RED/WHITE

GREEN/RED

YELLOW

PURPLE

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Special Tools

Order special tools from your Toro Distributor. Some tools may be listed in the Parts Catalog for theGroundsmaster 580--D. Some tools may also be avail-able from a local supplier.

Digital Multimeter

The Digital Multimeter can test electrical componentsand circuits for current, resistance, or voltage drop. Ob-tain Digital Multimeter from a local supplier.

Note: Toro recommends the use of a DIGITAL multi-meter when testing electrical circuits. The high imped-ance (internal resistance) of a digital meter will ensurethat excess current is not allowed through themeter. Ex-cess current cancausedamage toacircuit that is notde-signed to carry it.

Figure 1

Inductive Ammeter (AC/DC Current Transducer -- Hall Effect)

Use this tool, connected to a Digital multimeter for doingcurrent draw tests. This tool can be useful when check-ing glow plug and starter circuits. Obtain Inductive Am-meter from a local supplier.

Skin--Over Grease

Special non--conductive grease which forms a light pro-tective skin to help waterproof electrical switches andcontacts.

Toro P/N 505--165

Figure 2


Diagnostic ACE Display

The diagnostic display is connected to the wiringharness connector located under the control panel tohelp the user verify correct electrical functions of the ma-chine.

Diagnostic ACE Display, Toro P/N 85--4750Decal, V1.0, Toro P/N 88--1860

(S/N Below 30101 with Controller Update Kit)

Decal, V2.0, Toro P/N 92--4087(S/N 30101 & Up)

Figure 3

Decal

DiagnosticACE Display

Figure 4


Electrical System Quick Checks

Battery Test (Open Circuit Test)

Use a multimeter to measure the voltage between thebattery terminals.

Set the multimeter to the DC volts setting. The batteryshould be at a temperature of 60o to 100o F (16o to 38o

C). The ignition key should be in the OFF position andall accessories turned off. Connect the positive (+) me-ter lead to the positive battery post and the negative (--)meter lead to the negative battery post. Use the table tothe right to determine charge level of the battery.

NOTE: This test provides a relative condition of the bat-tery. Load testing of the battery will provide additionaland more accurate information.

Voltage Measured Battery Charge Level

12.68 v (or higher) Fully charged (100%)

12.45 v 75% charged

12.24 v 50% charged

12.06 v 25% charged

11.89 v 0% charged

Charging System Test

This is a simple test used to determine if the chargingsystem is functioning. It will tell you if the charging sys-tem has an output, but not its capacity.

Use a multimeter set to the DC volts position. Connectthe positive (+) meter lead to the positive battery postand the negative (--) meter lead to the negative batterypost. Leave the multimeter test leads connected to thebattery and record the battery voltage.

NOTE: Upon starting the engine, the battery voltagewill drop and then should increase once the engine isrunning.

NOTE: Depending upon the condition of the batterycharge and battery temperature, the charging systemvoltage will increase at different rates as the batterycharges.

Start the engine and run at 2700 RPM (high idle). Allowthe battery to charge for at least 3 minutes. Record thebattery voltage.

After allowing the engine to run for at least three (3) min-utes, battery voltage should be at least 0.5 volts higherthan initial battery voltage (see example in table to theright).

NOTE: While engine is running, if battery voltage ex-ceeds 16 volts, the regulator in the charging systemshould be inspected.

After allowing the engine to run for at least three (3) min-utes, if battery voltage does not increase at least 0.5volts, additional testing of the battery and/or chargingsystem should be performed.

Acceptable voltage increase:

Initial Battery Voltage = 12.25 v

Battery Voltage after 3 Minute Charge = 12.80 v

Difference = +0.55 v


Troubleshooting

For all electrical problems, use of the Quick Refer-ence Troubleshooting Guide is recommended. Us-ing the Diagnostic ACE Display allows you toquickly find the source of the electrical problem.

If the machine has any interlock switches by--passed,they must be reconnected for proper troubleshootingand safety.

See Chapter 5 -- Electrical System (S/N Below 30101)for additional Troubleshooting information. Only compo-nents that are different or new information is provided inthis Chapter.

Quick Reference Troubleshooting Guide

Diagnostic Lamp

The Groundsmaster 580--D is equipped with a diagnos-tic lamp that indicates if the Electronic Controller Unit(ECU) is functioning correctly. The diagnostic light willbe on when the ECU is functioning correctly and theignition switch is to the ON position. The light will flashif the ECU detects any of the following malfunctions inthe electrical system:

1. An electrically ”open” condition.

2. An electrically ”shorted” condition.

3. There is an over temperature condition in theECU circuitry.

2

1

3

Figure 5

1. Diagnostic lamp 2. ECU 3. Loopback connector

Diagnostic ACE Display

The Groundsmaster 580--D is equipped with an ECUthat controls most of the machine functions. The control-ler determines which function is required for various in-put switch conditions (i.e. seat switch, ignition switch,etc.) by producing various outputs to actuate solenoidsor relays.

Each of the input switches, output solenoids, and relaysmust be connected and functioning properly for the ECUto properly control the machine.

The Diagnostic ACE display will help the user verify cor-rect electrical functions of the machine.

1

Figure 6

1. Diagnostic ACE display

Verify Input Functions

1. Park machine on a level surface, lower the cuttingunits, stop the engine and engage the parking brake.

2. Locate wire harness and loopback connector. Care-fully unplug loopback connector from harness connec-tor.

3. Connect Diagnostic ACE display connector to theharness connector. Make sure correct overlay decal ispositioned on Diagnostic ACE display.

4. Turn Ignition switch to ON; do not start machine.


Note: The red text on the overlay decal refers to inputswitches and the green text refers to output switches.

5. The Inputs Displayed LED on lower right column ofthe Diagnostic ACE should be lighted. If the Outputs Dis-played LED is lighted, press and release Toggle Input/Output button on Diagnostic ACE to change to theInputs Displayed LED. Do not hold button down.

Note: The Diagnostic ACE will illuminate a LEDassociated with each input when its associated inputswitch is closed.

6. Change each switch individually from open toclosed (i.e., sit on seat, engage traction pedal, etc.).

A. Observe that the appropriate LED on DiagnosticACE blinks on and off when its correspondingswitch is opened and closed. Check each switchthat can be actuated by hand.

B. Now start engine and raise and lower each cut-ting unit. Note the appropriate LED on the Diagnos-tic ACE (i.e. LED is illuminated when cutting unit islowered and LED is not illuminated when cutting unitis raised.

7. If switch is closed and appropriate LED does notturn on, check all wiring and connections to switch and/or check switch with an ohm meter. Replace any defec-tive switches and repair any defective wiring.

Verify Output Function

The Diagnostic ACE also has the ability to detect whichoutput solenoids or relays are turned on. This is a quickway to determine if a machine malfunction is electricalor hydraulic.

1. Park machine on a level surface, lower the cuttingunits, stop the engine and engage the parking brake.

2. Locate wire harness and connectors near control-ler. Carefully unplug loopback connector from harnessconnector.

3. Connect the Diagnostic ACE connector to the har-ness connector. Make sure correct overlay decal is posi-tioned on Diagnostic ACE.

4. Turn Ignition switch to ON; do not start machine.

Note: The red text on the overlay decal refers to inputswitches and the green text refers to output switches.

5. The Outputs Displayed LED on the lower right col-umn of the Diagnostic ACE should be lighted. If the In-puts Displayed LED is lighted, press ToggleInput/Output button on the Diagnostic ACE to changethe LED to Outputs Displayed.

Note: It may be necessary to toggle between InputsDisplayed and Outputs Displayed several times to dothe following step. To toggle back and forth, pressToggle Input/Output button once. This may be done asoften as required. Do not hold button.

6. Operate desired function switch on the machine.The appropriate output LED’s should illuminate to indi-cate that the ECU is turning on that function.

Note: If any output LED is blinking, this indicates anelectrical problem with that OUTPUT. Repair or replacedefective electrical parts immediately. To reset ablinkingLED, turn Ignition switch to OFF and then back to ON.

If output LED’s are not blinking and not lighted, verifythat the required input switches are in their necessarypositions to allow that function to occur. Verify correctswitch position or output.

If the output LED’s are on as specified with the machinenot functioning properly, a non--electrical problem exits.Repair as necessary.

If each input switch is in the correct position and func-tioning correctly with the output LED’s not correctlylighted, an ECU problem exits. If this condition occurs,contact your Toro Distributor for assistance.

Note: Due to electrical system constraints, the outputLED’s for “START”, “MONITOR” and “ETR/ALT” maynot blink even though an electrical problem may exist forthose functions. If the machine problem appears to bewith one of these functions, be certain to check the elec-trical circuit with a volt / ohm meter to verify that no elec-trical problem exists to these functions.

If electronic controller experiences an output failure foreither the cruise control or one of the cutting units, thecontroller will disable the machine function.

Indications that this is the cause of the problem include:A. Flashing green diagnostic light.B. Diagnostic ACE will illuminate the “output fail”LED.C. Diagnostic ACE will flash which output failed.D. Machine will not respond to ignition key inputs.

The above indicates an ECU problem, contact your localAuthorized TORO Distributor for assistance.

If each output switch is in the correct position and func-tioning correctly, but the output LED’s are not correctlyilluminated, this indicates an ECU problem. If this oc-curs, contact your Toro Distributor for assistance.


Retrieving Stored Faults

Note: The machine may require installation of up-dated software for this function to operate. This requiredsoftware was installed on machines starting with S/N70001. Older machines can have new softwareinstalled. Contact your Toro Distributor for assistance.

1. Turn ignition switch to OFF. Unplug loopback con-nector and connect Diagnostic ACE to the ECU harnessconnector.

2. Move PTO switch to the ENGAGED position andhold.

3. Turn Ignition switch to ON while continuing to holdthe PTO switch in the ENGAGED position until the topleft light on the Diagnostic ACE comes on (approximate-ly 2 seconds).

4. Make sure Diagnostic ACE is set to OUTPUTS.

5. Release the PTO switch.

There will be 8 records displayed. The fault is dis-played on the 8th record. Each record will be dis-played for 10 seconds. Records will repeat until theIgnition switch is turned to OFF. The machine willnot start in this mode.

6. Observe Diagnostic ACE for the playback of the re-tained fault in the ECU memory. The problem circuit willbe flashing.

Clearing Fault Memory

Once a fault is repaired, it must be must be cleared fromthe ECU memory so any future fault can then be stored.

1. Turn Ignition switch to OFF.

2. Move the PTO switch to the ENGAGED position andhold.

3. Depress and hold Temp Override button OR theCruise Set button.

4. Turn Ignition switch ON while holding the PTOswitch in the ENGAGED position, and keeping the HighTemp Override button or Cruise Set button depressed.Maintain this condition until the green lamp on the ECUstarts to flash (approximately 2 seconds).

5. Release the PTO Switch and button. Turn Ignitionswitch to OFF. Fault memory is now cleared.

IMPORTANT: The Diagnostic ACE display must notbe left connected to the machine. After using theDiagnostic ACE, disconnect it from the machineand reconnect loopback connector to the harnessconnector. The machine will not operate without theloopback connector installed to the harness. StoreDiagnostic ACE in a dry, secure location.


Component Identification and Testing

SeeChapter5 -- ElectricalSystem(S/NBelow30101)for additional Component Identification and Testing in-formation. Only components that are different or new in-formation is provided in this Chapter.

Electronic Control Unit (ECU)

TheToro electronic control unit (ECU) senses the condi-tion of various switches, such as the seat switch, cuttingunit down switches, traction neutral switch, etc., and di-rects power output to allow certain machine functions,such as engine run, cutting units engage, etc.

Because of the solid state circuitry built into the control-ler, there is no method to test it directly. The controllermay be damaged if an attempt is made to test it with anelectrical test device, such as a volt--ohm meter.

IMPORTANT: Before welding on the machine, dis-connect both battery cables from the battery, dis-connect both wire harness connectors from theelectronic control unit and disconnect the terminalconnector from the alternator to prevent damage tothe electrical system.

1

Figure 7

1. Electronic control unit (ECU)

Neutral Switch (Model 30582 and 30583)

The neutral switch onmodel 30582 and 30583 is closedwhen the traction pedal is in the neutral position. Theswitch threads into the mounting cover on the bottom ofthe hydrostat (Fig. 8).

Note: For model 30580 and model 30581 neutralswitch information, refer to Traction (Neutral) SwitchTesting and Traction (Neutral) Switch Replacement andAdjustment in Chapter 5.

1. Make sure the engine is off.

2. Disconnect electrical connector from the switch.

3. Check the continuity of the switch by connecting amultimeter (ohms setting) across the connector termi-nals.

4. With the traction pedal in the neutral position, thereshould be continuity between the switch terminals.

5. With the traction pedal in the the forward or backwardposition, there should be no continuity between theswitch terminals.

Figure 8

BOTTOM OF

NEUTRALSWITCH

HYDROSTAT


Seat Switch (S/N Between 30101 and 80000)

The seat switch is a proximity type, normally open (NO)reed switch that closes when the operator is on the seat.With the operator on the seat, the magnet on the bottomof the seat activates the reed switch causing it to closeand complete the circuit.

1. Raise the seat to get access to the seat switch wiringconnector.

2. Disconnect the seat switch wiring connector andinstall a continuity tester or ohm meter between the twoleads of the seat switch.

3. Lower the seat. The continuity tester should show nocontinuity.

Note: Make sure the compression spring holds theseat up off the seat switch when there is no operator onthe seat.

4. Have the operator sit on the seat, slowly depressingthe seat switch magnet. The continuity tester shouldshow continuity as the seat approaches the bottom of itstravel.

1

Figure 9

1. Seat switch

Seat Switch (S/N 80001 and Up)

The seat switch is normally open and closes when theoperator is on the seat. The switch and its electrical con-nector are located directly under the seat.

1. Make sure the engine and ignition switch is Off.

2. Disconnect switch harness connector from the ma-chine wire harness.

3. Check the continuity of the switch by connecting amultimeter (ohms setting) across the switch harnessconnector terminals.

4. With no operator in the seat, there should be no conti-nuity between the terminals.

5. Press directly onto the seat switch through the seatcushion. There should be continuity as the seat cushionapproaches the bottom of its travel.

6. Connect switch harness connector to the machinewire harness.

If switch removal is necessary, remove seat plate withseat from seat adjusters. Remove switch from bottom ofseat.

1. Seat2. Seat plate3. Screw (2 used)

4. Seat switch5. Switch harness

Figure 10

2

3

1

4

5


Engine Temperature Switches (S/N 80001 and Up)

The high temperature warning and shutdown switchesare located near the engine thermostat housing (Fig.11).

The high temperature warning switch has a green/redwire attached it.

The high temperature shutdown switch has an orange/black wire attached it.

Note: Information on the GM 580--D temperaturegauge sender is included in Chapter 5.

Circuit Test

If a problem with either switch system is encountered,the following procedure can be used to determine if theproblem is related to the switch or the switch circuit:

1. Locate switch to be tested. Start engine.

2. Use a jumper wire to ground the switch terminal.

A. If the warning switch terminal is grounded, thecontrol panel warning indicator should illuminateand the audible alarm should sound.

B. If the shutdown switch terminal is grounded, theengine should stop running.

3. If the results with the grounded switch terminal are notcorrect, the switch circuit needs repair (see electricalschematics and diagrams in Chapter 9 -- Foldout Dia-grams). If the results with the grounded switch terminalare correct, the switch should be tested.

Switch Test

CAUTION

Make sure engine is cool before removing thetemperature warning switch.

1. Lower coolant level in the engine and remove theswitch that is to be tested.

2. Put switch in a container of oil with a thermometer andslowly heat the oil (Fig. 12).

CAUTION

Handle the hot oil with extreme care to preventpersonal injury or fire.

3. Check continuity of the switch with a multimeter(ohms setting). The high temperature warning and shut-down switches are both normally open and should closewhen oil temperature reaches:

A. High temperature warning switch should closewhen oil temperature reaches 212oF (100oC).

B. High temperature shutdown switch should closewhen oil temperature reaches 232oF (111oC).

4. Replace switch if necessary.

6. Install switch to the water flange.

A. Clean threads of cylinder head and switch thor-oughly. Apply thread sealant to the threads of theswitch.

B. Screw switch into the cylinder head and tighten.

C. Connect wire harness wire to switch.

7. Fill engine cooling system (see Operator’s Manual).

1. High temperature warning switch2. Temperature gauge sender3. High temperature shutdown switch

Figure 11

1

2

3

Figure 12

VOA

Rev. GGroundsmaster 580--DPage 8 -- 14Electrical System (S/N 30101 & Up) (Rev. E)

Service and Repairs

SeeChapter5 -- ElectricalSystem(S/NBelow30101)for additional Service and Repairs information. Onlychanged and new information is provided in this Chap-ter.

Circuit Protection

On model 30580 (S/N 30101 and up), one 5 Amp fuseand two 15 Amp fuses are used for circuit protection. Inaddition, a 40 Amp circuit breaker with reset button isused for protection of the entire wiring circuit. The fusesand circuit breaker are located under the control panelto the right of the seat (Fig. 13). If total loss of electricalfunction occurs, find and correct the malfunction beforepressing the reset button.

On models 30581, 30582 and 30583, one 5 Amp fuseand two 15 Amp fuses are used for circuit protection.The fusesare locatedunder the control panel to the rightof the seat. In addition, four (4) fusible links are used inthe wire harness rather than the circuit breaker that wasused on model 30580. The fusible links attach to thestarter motor terminal (Fig. 14). Replacement fusiblelinks are identified in the Parts Catalog. See wire har-nessdrawings inChapter 9 -- FoldoutDiagrams for addi-tional information.

IMPORTANT: Do not install fuses in fuse block onleft side of instrument panel. Fuses should beinstalled in this fuse block only if machine isequipped with a road light kit.

Fuses can be removed to check continuity. The testme-ter should read less than 1 ohm.

2 1

Figure 13

1. Circuit breaker reset button2. Fuse block

2

1

Figure 14

1. Engine starter motor2. Fusible links

Figure 15


Battery Service

The batteries are the heart of the electrical system. Withregular and proper service, battery life can be extended.Additionally, battery and electrical component failurecan be prevented.

Note: Battery information for Model 30580 (S/N below30101) is included in Chapter 5.

Figure 16

Electrolyte Specific Gravity

Fully charged: 1.265 corrected to 80o F (26.7o C)Discharged: less than 1.240

Battery Specifications (S/N Between 30101 and220000200)

BCI Group LTV24 Battery (2 batteries required)650 Amp Cranking Performance at 0o F (--17.8o C)125 Minute Reserve Capacity at 80o F (26.7o C)

Battery Specifications (S/N 220000201 and Up)

BCI Group 34 Battery (2 batteries required)690 Amp Cranking Performance at 0_ F (--17.8o C)100 Minute Reserve Capacity at 80_F (26.7o C)

Wear safety goggles and rubber gloveswhen working with electrolyte. Chargethe battery in a well ventilated so gasesproduced while charging can dissipate.Since the gases are explosive, keep openflame and electrical spark away from thebattery; do not smoke. Nausea mayresult if the gases are inhaled. Unplugcharger from electrical outlet before con-necting to, or disconnecting chargerleads from battery posts.

CAUTION

Inspection, Maintenance, and Testing

1. Perform the following inspection and maintenancetasks:

A. Check for cracks caused by overly tight or loosehold--down clamp. Replace battery if cracked andleaking.

B. Check battery terminal posts for corrosion. Usea terminal brush to clean corrosion from the batteryterminal posts.

IMPORTANT: Before cleaning the battery, tape orblock the vent holes to the filler caps and make surethe caps are on tightly.

Figure 17

COVER SEAL

FILLER CAPS

CORRECTWATERLEVEL

CAP TUBES

C. Check for signs of wetness or leakage on the topof the battery which might indicate a loose or mis-sing filler cap, overcharging, loose terminal post, oroverfilling. Also, check the battery case for dirt andoil. Clean the battery with a solution of baking sodaand water, then rinse it with clean water.

D. Check that the cover seal is not broken away.Replace the battery if the seal is broken or leaking.

E. Check the electrolyte level in each cell. If the lev-el is below the tops of the plates in any cell, fill allcells with distilled water to the bottom of the captubes. Charge at 15 to 25 amps for 15 minutes to al-low sufficient mixing of the electrolyte.


2. Conduct a hydrometer test of the battery electrolyte.

IMPORTANT: Make sure the area around the cells isclean before opening the battery caps.

A. Measure the specific gravity of each cell with ahydrometer. Draw electrolyte in and out of thehydrometer barrel prior to taking a reading to warm--up the hydrometer. At the same time take the tem-perature of the cell.

B. Temperature correct each cell reading. For each10o F (5.5o C) above 80_F (26.7o C) add 0.004 tothe specific gravity reading. For each 10o F (5.5o C)below 80o F (26.7o C) subtract 0.004 from the spe-cific gravity reading.

Example: Cell Temperature 100o FCell Gravity 1.245ADD (20o above 80o F) 0.008Correction to 80o F 1.253

C. If the difference between the highest and lowestcell specific gravity is 0.050 or greater or the lowestcell specific gravity is less than 1.225, charge thebattery. Charge at the recommended rate and timegiven in Charging or until all cells specific gravity is1.225 or greater with the difference in specific grav-ity between the highest and lowest cell less than0.050. If these charging conditions can not be met,replace the battery.

3. Perform a high--discharge test with an adjustableload tester.

This is one of the most reliable means of testing a batteryas it simulates the cold--cranking test. A commercial bat-tery load tester is required to perform this test.

CAUTIONFollow the manufacturer’s instructions whenusing a battery tester.

A. Check the voltage across the battery terminalsprior to testing the battery. If the voltage is less than12.0 VDC, recharge the battery.

B. If the battery has been charged, apply a 150 ampload for 15 seconds to remove the surface charge.Use a battery load tester following the manufactur-er’s instructions.

C. Make sure the battery terminals are free of corro-sion.

D. Measure the temperature of the center cell.

E. Connect a battery load tester to the battery ter-minals following the manufacturer’s instruc-tions. Connect a digital multimeter to the batteryterminals.

F. Apply a test load of one half the Cranking Perfor-mance rating (see Fig. 17) of the battery for 15 se-conds.

G. Take a voltage reading at 15 seconds, then re-move the load.

H. Using the table below, determine the minimumvoltage for the cell temperature reading.

MinimumVoltage

Battery ElectrolyteTemperature

9.6 70o F (and up) 21.1o C (and up)

9.5 60o F 15.6o C

9.4 50o F 10.0o C

9.3 40o F 4.4o C

9.1 30o F --1.1o C

8.9 20o F --6.7o C

8.7 10o F --12.2o C

8.5 0o F --17.8o C

I. If the test voltage is below the minimum, replacethe battery. If the test voltage is at or above the mini-mum, return the battery to service.


Charging

To minimize possible damage to the battery and allowthe battery to be fully charged, the slow charging meth-od is presented here. This charging method can be ac-complished with a constant current battery chargerwhich is available in most shops.

CAUTIONFollow the manufacturer’s instructions whenusing a battery charger.

1. Determine the battery charge level from either itsopen circuit voltage or specific gravity.

Battery ChargeLevel

Open CircuitVoltage

SpecificGravity

100% 12.68 1.265

75% 12.45 1.225

50% 12.24 1.190

25% 12.06 1.155

0% 11.89 1.120

2. Determine the charging time and rate using themanufacturer’s battery charger instructions or thefollowing table.

ReserveCapacity(Minutes)

Battery Charge Level(Percent of Fully Charged)

(Minutes) 75% 50% 25% 0%

80 or less 3.8 hrsat

3 amps

7.5 hrsat

3 amps

11.3 hrsat

3 amps

15 hrsat

3 amps

81 to 125 5.3 hrsat

4 amps

10.5 hrsat

4 amps

15.8 hrsat

4 amps

21 hrsat

4 amps

126 to170

5.5 hrsat

5 amps

11 hrsat

5 amps

16.5 hrsat

5 amps

22 hrsat

5 amps

171 to250

5.8 hrsat

6 amps

11.5 hrsat

6 amps

17.3 hrsat

6 amps

23 hrsat

6 amps

above250

6 hrsat

10 amps

12 hrsat

10 amps

18 hrsat

10 amps

24 hrsat

10 amps

CAUTION

Do not charge a frozen battery because itcan explode and cause injury. Let the bat-tery warm to 60o F (15.5o C) before con-necting to a charger.

Charge the battery in a well--ventilatedplace to dissipate gases produced fromcharging. These gases are explosive;keep open flame and electrical sparkaway from the battery. Do not smoke.Nausea may result if the gases are in-haled. Unplug the charger from the elec-trical outlet before connecting or discon-necting the charger leads from the batteryposts.

3. Following the manufacturer’s instructions, con-nect the charger cables to the battery. Make sure a goodconnection is made.

4. Charge the battery following the manufacturer’sinstructions.

5. Occasionally check the temperature of the batteryelectrolyte. If the temperature exceeds 125o F (51.6o C)or the electrolyte is violently gassing or spewing, thecharging rate must be lowered or temporarily stopped.

6. Three hours prior to the end of the charging, mea-sure the specific gravity of a battery cell once per hour.The battery is fully charged when the cells are gassingfreely at a low charging rate and there is less than a0.003 change in specific gravity for three consecutivereadings.

Rev. GGroundsmaster 580--DPage 8 -- 18Electrical System (S/N 30101 & Up) (Rev. E)

Alternator

The alternator used on the Groundsmaster 580--D isbelt driven and attaches to the engine. If testing deter-mines that alternator is not functioning properly, benchinspection should be performed.

Note: For information on disassembly and assemblyof the alternator used on models 30581, 30582 and30583, see theMitsubishi S4S--DT ServiceManual thatfollows Chapter 3A -- Engine (Model 30581).

Brushes

Replace the alternator brushes if they are worn to theservice limit (Fig. 18).

MODELBrush Length

(New)Brush Length(Service Limit)

30581(50 Amp Alternator)

.728”(18.5mm)

.280”(7 mm)

30581 (w/AC Kit)(75 Amp Alternator)

.716”(18.2 mm)

.280”(7 mm)

30582 & 30583 (100Amp Alternator)

.728”(18.5mm)

.197”(5 mm)

Field Coil

Measure the resistance between the slip rings (Fig. 19).If the resistance is outside of the assembly standard, re-place the rotor.

MODEL Field Coil Resistance

30581 2.4 Ohms

30581(with AC Kit)

3.0 Ohms

30582 & 30583 2.8 Ohms

Stator Coil

Check for continuity between the lead wires (Fig. 20). Ifno continuity exists (infinite resistance), the coil has anopen circuit and needs to be replaced.

Check for continuity between the leadwires and the sta-tor core laminations. If continuity exists (no resistance),the stator coil is grounded and needs to be replaced.

Rectifier

Test the resistance between each diode lead wire andheat sink (Fig. 21). To test, connect thepositive (+)multi-meter test lead to the diode and the negative (--) multi-meter test lead to the heat sink, record resistance andthen switch test lead location.

Resistance should be infinite in one direction and nearlyzero in the other. If resistance is infinite in both direc-tions, the diode is open. If resistance is nearly zero inboth directions, the diode is closed. If the diode is openor closed, replace the recitifer.

SERVICE LIMIT(WORN)

BRUSHLENGTH(NEW)

Figure 18

Figure 19

Figure 20

DIODEHEAT SINK (--)

HEAT SINK (+) DIODE LEAD WIRE

Figure 21

Models 30580 (S/N 30101 & Up), 30581, 30582, and 30583

Rev. GGroundsmaster 580--D Page 9 -- 1 Foldout Diagrams

Chapter 9

Foldout Diagrams

Table of Contents

HYDRAULIC SCHEMATICSHydraulic Schematic (2WD Machines) 3. . . . . . . . . .Hydraulic Schematic (4WD Machines) 4. . . . . . . . . .

ELECTRICAL SCHEMATICSModel 30580 (S/N 30101 and Up) 5. . . . . . . . . . . . .Models 30581 and 30582 6. . . . . . . . . . . . . . . . . . . . .Model 30583 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRE HARNESS DRAWINGSModel 30580 (S/N 30101 and Up) WireHarness Drawing 8. . . . . . . . . . . . . . . . . . . . . . . . . . .Model 30580 (S/N 30101 and Up) WireHarness Diagram 9. . . . . . . . . . . . . . . . . . . . . . . . . . .Model 30581 Wire Harness Drawing 10. . . . . . . . . .Model 30581 Wire Harness Diagram 11. . . . . . . . . .Model 30582 (S/N Below 240999999) WireHarness Drawing 12. . . . . . . . . . . . . . . . . . . . . . . . . .Model 30582 (S/N Below 240999999) WireHarness Diagram 13. . . . . . . . . . . . . . . . . . . . . . . . . .Models 30582 (S/N Above 250000000) and 30583Wire Harness Drawing 14. . . . . . . . . . . . . . . . . . . . .Models 30582 (S/N Above 250000000) and 30583Wire Harness Diagram 15. . . . . . . . . . . . . . . . . . . . .4WD Wire Harness (S/N Below 240999999) 16. . . .4WD Wire Harness (S/N Above 250000000) 17. . .

Groundsmaster 580--DPage 9 -- 2Foldout Diagrams (Rev. E)


Page 9 -- 3(Rev. G)

RxBR pressure = 600 psi for models with

Charge pressure = 230 psi for piston pumps

NOTE: Hydraulic Schematic differences exist

serial numbers below 70000

with serial numbers below A--96--01--xxxx

as follows:

Hydraulic Schematic

Groundsmaster 580--D(2WD Machines)

Page 9 -- 4(Rev. G)

Hydraulic Schematic

Groundsmaster 580--D(4WD Machines)

Page 9 -- 5(Rev. G)

Model 30580 (S/N 30101 and Up)Electrical Schematic

Groundsmaster 580--D

Page 9 -- 6(Rev. G)

Model 30581 and 30582Electrical Schematic


(Model 30581 Only)

GRAY

YELLOW

BLUE

TAN

ORANGE

YELLOW/BLUE

ORANGE/BLACK

WHITE/BLACK

BROWN/WHITE

BROWN/RED

WHITE/GREEN

GREEN/BLACK

WHITE

GREEN

GREEN/YELLOW

BLUE/WHITE

YELLOW/RED

BROWN/RED

YELLOW

WHITE

GREEN

BLACK

BLACK

REDWHITE

GRAY/WHITE

BLACK

WHITE

VIOLET/WHITE

GREEN/RED

WHITE

ORANGE/WHITE

GREEN

BLUE

RED/BLUE

ORANGE

YELLOW/BLUE

BLUE/WHITE

BLACK

RED/WHITE

BLUE/WHITE

BLUE/WHITE

RED

RED

RED

YELLOW

RED

BLACK

RED

RED/BLA

CK

RED

BROWN/WHITE

BLUE

GREEN/WHITE

VIOLET

Page 9 -- 7(Rev. G)

Model 30583Electrical Schematic


GRAY

YELLOW

BLA

CK

GREEN

BLUE

TAN

WHITE

RED

ORANGE

GREEN

GREEN

ORANGE

YELLOW/BLUE

ORANGE/BLACK

WHITE/BLACK

BROWN/WHITE

BROWN/RED

WHITE/GREEN

GREEN/BLACK

WHITE

GREEN

GREEN/YELLOW

BLUE/WHITE

YELLOW/RED

BROWN/RED

YELLOW

WHITE

WHITE

GREEN

BLACK

WHITE

VIOLET/WHITE

GREEN/RED

WHITE

ORANGE/WHITE

GREEN

BLUE

RED/BLUE

ORANGE

YELLOW/BLUE

BLUE/WHITE

BLACKBLACK

RED/WHITE

GRAY/WHITE

YELLOWGRAY

YELLOW

RED/WHITE

RED ORANGE

BLUE/WHITE

BLUE/WHITE

RED

RED

BLU

E

RED

BLACK BLACK

RED/BLA

CK

GREEN/WHITE

BLUE

BROWN/WHITE

VIOLET

FORWARD 4WD (SV1)

REVERSE 4WD (SV2)

NOTE: The High Range/Low RangeGround Speed Switch on the machineconsole includes the terminals for both

and the High/Low Speed switches.the High Range Engage/Disengage

NOTE: The High Range/Low RangeGround Speed Switch on the machineconsole includes the terminals for both

and the High/Low Speed switches.the High Range Engage/Disengage

Page 9 -- 8(Rev. G)

Model 30580 (S/N 30101 and up)Wire Harness DrawingGroundsmaster 580--D

Page 9 -- 9(Rev. G)

Model 30580 (S/N 30101 and up)Wire Harness DiagramGroundsmaster 580--D

PINK

BLACK

YELLOW

RED

BROWN/

GREEN/

PURPLE

TAN

GRAY

ORANGE

GREEN

GRAY/WH

PURPLE

OR/WH GREEN

GRAYRED/WHITE

REDRED RED

YELLOW

WHITE

BLUE

BROWN/WHITE

BLACKBLACKBLACK

BLACK

BLACK

BLACK

BLACK

BLACK

PINK

PURPLEORANGE ORANGEBROWN

BROWNYELLOW

BROWN/REDBLACK

PURPLERED

RED/BLUE

YELLOW

WHITEWHITE

ORANGE/WHITE

GREEN

GREEN

GREEN

ORANGE/WHITE

ORANGE/WHITE

ORANGE/WHITE

BLUEBROWN

RED

PURPLE

BROWN

BROWN

PURPLE

BLACKBLU/WH

BLUEGREEN

BLU/WH

BLUE

ORANGETANORANGE

GRAY/ ORANGE

PURPLEPURPLE

BROWN

RED/BLUE

RED/BLUE

RED/BLUE

GREEN/WHITE

BLUE

ORANGE

YELLOW/RED

YELLOW/RED

BLUE

BROWN

BROWN

PURPLE

BLACK/WHITE

GREENWHITE/

BROWN

BROWN

BROWN

WHITE

BLACKBROWN

BROWN/RED

YELLOWGREEN/RED

RED/WHITE

BLACKBLACK

BLACK

BLACKBLACK

BLACKBLACK

BLACK BLACK

BROWN YELLOW

BLACK

BLACK

YELLOW/RED

BLACK/WHITE

YELLOW/RED

BLACK/WHITE

RED/WHITE

BLACK/WHITE

BLACK/WHITE

BLACK/WHITE

BLACK/WHITE

BLACK

GREEN/WHITE

BLUE/WHITE

BLACK

REDBROWN/ GREEN/

RED

ORANGE/BLACK

ORANGE

ORANGE

WHITE

RED BLACK/WHITE

BLACK

BROWN

BLUE/WHITE

WHITE

BLUE

BLACK/WHITE

BLACK/WHITE

BLUEBLACK

BLACK

BLACK

BLACKBLACK

BLACK

BLACK

BLACK

BLACK

BLACKBLACK

ORANGE/

BLACK

BLACK

ORANGE

BLACK

WHITE

BLUE

WHITE

RED/WHITE

RED

GREEN

BLACK

BLACK

BLACK

TAN

YELLOW/

ORANGE/WHITE

PURPLE

BLUEBLUE

BLUE

BLACKBLUE

BLUE

REDBLACK

BLUE

BLACK

BLACK

PURPLE/

BROWN

TAN

WHITE

BLACKORANGE/WHITE

GREEN/YELLOW

GREEN/YELLOW

YELLOW/RED

BLACK

BLACK

WHITE BLACK

BLACK BLACK

BLACK

BLUERED/

BLUERED/

BLACK

YELLOW

WHITE/GREEN

YELLOW/BLACK

GREENRED

BLACK/WHITE

BLACKGRAY

WHITEGRAY/

YELLOW

BLACK

BLACK

WHITE/GREEN

YELLOW/BLACK

YELLOW/RED

WHITE

WHITEBLACKBLACK BLUERED/

WHITEBLUE/

WHITEBLUE/

ORANGE/WHITE

REDGREEN

ORANGE/WHITE

WHITE RED

WHITE/GREEN

BLACK GREEN/BLACK

BLACK

WHITEBLUE/

YELLOWGREEN/

BLACKBLACKBLACKWHITE/BLACK

BROWN/REDYELLOW

BLACK

GREEN

BLACK

GRAY

WHITE

BLACK

YELLOW/BLUE

WHITEGREEN/REDBLACK

BROWN/WHITEPURPLE/WHITE

BROWN/WHITE

GRN/WHITE

YELLOW

GREEN

GREEN/YEL

YELLOW/BLUE

ORANGEWHITE

BLUERED/BLUE

ORANGE/WHITEYELLOW/RED

BLUE/WHITEGREEN

ORANGERED

ORANGE/WHITEORANGE/BLACK

YELLOW/BLUEWHITE

BROWN/RED

WHITE/BLACK

BLUEGREEN/BLACK

WHITE/GREEN

Page 9 -- 10(Rev. G)

Model 30581Wire Harness DrawingGroundsmaster 580--D


Model 30581Wire Harness DiagramGroundsmaster 580--D

PINK

PINK

PURPLE

FUSIBLE LINK

YELLOW

REDRED

RED

BLUE

BROWN/WHITE

GREEN/WHITE

RED RED

RED

BLACKBLACK

BLACK BLACKBLACK

BLACK

BROWN

BROWNBROWN

PURPLE

BROWN BROWN

BLUEPURPLE

WHITEBLACK/PURPLE

BROWN

BROWN

BLUEWHITEORANGE/

BLUE/WHITE

BLUE/WHITE

BLUE/WHITE

WHITEORANGE/

WHITEORANGE/

ORANGE/WHITEWHITE WHITE

YELLOW

GREEN

GREEN

GREEN

REDBROWN/

RED

YELLOW

PURPLEORANGE ORANGE

YELLOW BROWNBROWN

BLACKBLACK

TAN

RED/BLUE

RED/BLUE

RED/BLUE

BROWN

BROWN

REDYELLOW/

BLACKGRAY/

WHITEBLACK

BROWN

ORANGE

BLUE

REDYELLOW/

WHITEGREEN/

TAN

BLACKBLACK

BLACK

BLACK

BLACKBLACK

BLACK/WHITE

BLACK/WHITE

BLACK/WHITE

BLACK/WHITE

BLACK/WHITE

PURPLE

YELLOW

GREEN/RED

BROWN/RED

RED/WHITE BROWN

ORANGE YELLOWBLACK

BLACK

BLACK/WHITE

BROWN

YELLOW/RED

RED/WHITE

ORANGE

BLACKWHITEGREEN/ BLUE/

WHITE

BLACK

REDBROWN/

GREEN/RED

ORANGE/BLACK

ORANGE

OR

WHITE

RED

BLACKBLACK

BLACK BLACK

BLACK

BLACKBLACK

BLACK

BLACK

BLACK

BLACKBLACK

BLACK/WHITE

BLACK/WHITE

BLACK/WHITE

BLUE/WHITE

WHITE

BLUE

BROWN

BLACK

GRAY

BLUEBLACK

ORANGE/WHITE

BLACK

GREENBLACK

BLUE

ORANGE

BLACK

FUSIBLE LINK

FUSIBLE LINK

FUSIBLE LINK

PURPLE

RED

RED

RED

WHITE

PURPLE

BLUE

GREENBLACK

BLACK/WHITE

BLACK

RED/BLACK

BLACKBLACK

BLUE/WHITE

BLACK

BLACKREDBLACK BLUE

RED

YELLOW/

BLACKTANBLACK

BLUE

ORANGEWHITE

BLACK

ORANGE/WHITE

GREEN/YELLOW

GREEN/YELLOW

BLUE

BLUE

BLUE

REDYELLOW/

BLACK

BLACK

WHITE WHITEBROWN/

BLACK

BLUERED/

BLACK

BLACK

BLUERED/

BLACKGRAY/

YELLOW

WHITE/GREEN

BLACKYELLOW/

GREEN

RED

WHITEBLACK/

BLACK

GRAY

WHITE

REDYELLOW/WHITE

BLACKBLUERED/

BLACK

BLUE/WHITE

BLUE/WHITE

WHITEORANGE/

BROWN

WHITEORANGE/

REDGREEN

WHITE/GREENBLACK

YELLOW/BLACK

WHITEGRAY/

YELLOW

BLACK

RED

WHITEORANGE/

WHITE

GREEN/BLACK

BLACK

BLACK

WHITE/GREEN

BLUE/WHITE

GREEN/YELLOW

BLACKBLACKBLACKBLACK

WHITE/BLACKRED

BROWN/BLACKYELLOW

GREEN

BLACKWHITE

GRAYBLUE/WHITE

BLACK

BLACK

BLUEYELLOW/RED

GREEN/

WHITEPURPLE/

BLACKBROWN/WHITE

BROWN/WHITEGRN/WHTAN

YELLOWYEL/BLUE

GREENGRN/YELORANGEWHITEBLUE

RED/BLUEWH/GRNGRN/BLACK

BLUEWH/BLACKBROWN/REDWHITE

YEL/BLUEORANGE/BLACK

REDORANGEGREEN

BLUE/WHITEYELLOW/RED

ORANGE/WHITE

ORANGE/WHITE

GREEN

GRAYRED/BLUE

BLACKBROWN/REDBLUE/WHITE

BLUEORANGE/WHITEBLUE/WHITEGRAY/WHITE

GREENBLUE

BLUE/WHITEBLACKPURPLE


Model 30582 (S/N Below 240999999)Wire Harness DrawingGroundsmaster 580--D


Wire Harness DiagramGroundsmaster 580--D

Model 30582 (S/N Below 240999999)

BLUEWHITE

PINK

REDGREEN/

WHITEPURPLE/

BLACK

BROWN/WHITE

BROWN/WHITE

GRN/WHTAN

YELLOWYEL/BLUE

GREENGRN/YELORANGE

WHITEBLUE

RED/BLUEWH/GRN

GRN/BLACK

BLUEWH/BLACK

BROWN/REDWHITE

YEL/BLUEORANGE/BLACK

REDORANGE

GREENBLUE/WHITEYELLOW/RED

ORANGE/WHITE

ORANGE/WHITE

PINK

BLACKBLACK

TAN

GREEN

GRAYRED/BLUE

BLACKBROWN/REDBLUE/WHITE

BLUEORANGE/WHITEBLUE/WHITEGRAY/WHITE

GREENBLUE

BLUE/WHITEBLACKPURPLE

WHITE

PURPLE

YELLOW

RED

REDRED

BLUE

BROWN/WHITE

GREEN/WHITE

BLACK

BLUEYELLOW/

BLUE/WHITE

BLACK GREENBLACK

GRAY

WHITE YELLOW

BLACK

BLACK BLACKREDBROWN/

WHITE/BLACK BLUE/

WHITE

GREEN/YELLOW

BLACK

BLACKWHITE/GREEN

RED

GREENBLACK

YELLOW/BLACK

WHITEORANGE/

BROWN

WHITEORANGE/

YELLOW

WHITEGRAY/

GREEN/BLACK

BLACK

WHITE/GREEN

WHITEORANGE/

WHITE BLACK

BLACK

BLACKRED

BLUE

BLUE

BLUE

BLACKBLACK

BLUERED/

WHITEBLUE/WHITE

BLUE/WHITE

GRAY

BLACK

WHITEBLACK/

RED

GREEN

BLACKYELLOW/

WHITE/GREEN

YELLOW

BLACKGRAY/

PURPLERED

YELLOW/

BLACK

WHITEBROWN/

BLACK

WHITEORANGE/

GREEN/YELLOW

GREEN/YELLOW

BLACKBLUERED/

BLUERED/

PURPLE

GREENBLACK

BLACK/WHITE

BLACK

BLACK

RED/BLACK

REDBLUE/WHITE

BLACKREDBLUE

BLUEYELLOW/

REDWHITE

BLACK

ORANGE

BLUE

BLACK

TAN

BLACK

WHITEBLACK/

WHITEBLACK/

WHITEBLACK/

BLACK/WHITE

BLACK

BLACKBLACK

BLACK

BLACK

BLACK

BLUERED/

BLUERED/

RED/BLUE

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK BLACK

RED

RED

RED

FUSIBLE LINK

BLUE

FUSIBLE LINK

FUSIBLE LINK

WHITEBLACK/

WHITEBLACK/

WHITEBLACK/

BLUE

BLACK

BLUE

BLUE/WHITE

WHITE

ORANGE/WHITEBLACK

GREENBLACK

ORANGE

BROWN

BLACK

GRAY

ORANGE

ORANGE

RED

WHITE

ORANGE/BLACK

REDGREEN/

BROWN/RED

BLUE/WHITE

BLACK

GREEN/WHITE

ORANGE

BLACK

WHITERED/

REDYELLOW/

WHITEBLACK/

WHITEBLACK/

RED

YELLOW

YELLOWBLACK

BLACK

YELLOW/RED

ORANGE

BROWNPURPLE

YELLOWRED/WHITE

BLACKBROWN/

REDGREEN/

BROWNWHITEGREEN/

TAN

BLUE

ORANGE

WHITE

REDYELLOW/

BLACKGRAY/

BROWN BROWN

BROWN

BROWN

BROWN

BLUE/WHITE

BLUE/WHITE

BLUE/WHITE

GREEN

GREEN

GREEN

WHITEORANGE/

WHITEORANGE/

WHITEORANGE/

WHITEBLACK/

PURPLEBLUE

WHITE WHITE

YELLOW

BLACK

BLACK

BLACKBLACK

BLACKBLACK

BLACK

REDBROWN/ PURPLE

ORANGE

ORANGE

YELLOW

PURPLE

BROWN

BROWN

PURPLE

BROWN

RED

RED

RED

RED

BROWNORANGE/BROWNBROWN


Wire Harness DrawingGroundsmaster 580--D

Models 30582 (S/N Above 250000000) and 30583


Wire Harness DiagramGroundsmaster 580--D

Models 30582 (S/N Above 250000000) and 30583

BLACK

GREEN

GREEN/YELLOW

YELLOW

GRAY

BLUE/WHITE

RED/BLUE

BLACK

BLACK

BLACK

BLACK

RED

BLACK

RED

BLACK

BLACK

ORANGE

BLU

E

BLACK

ORANGE/BLACK

RED/BLACK

BLACK

BLACK

FUSIBLE LINKFUSIBLE LINK

FUSIBLE LINK

ORANGE

BLACK

VIOLET

BLACKBLACK BLACK

BLACK

BLACK

BLUE/WHITERED

BLUE

BLACKBLACK

GREEN

ORANGE/WHITEBLUE

BLUE/WHITE

BLACK

GREEN/WHITETAN

GREEN/RED

WHITE

BLACKYELLOW

ORANGE

RED/WHITE

BROWN/REDBROWN

BLACK

YELLOW

YELLOW

YELLOW

BLACK

BLACK

VIOLET

RED

VIOLET

RED/BLUE

BLUE/WHITEGRAY/WHITE

YELLOW

YELLOW

YELLOWYELLOW

BLACK

PINK

BLACK

REDVIOLET

GREEN

ORANGEGRAY

ORANGE/WHITE

RED

BLACK

YELLOW

RED

VIOLET

BLACK

YELLOW

BLU

EBROWN

REDRED

BLUE

GREEN/WHITE

BLACKBLACK

BLACK

GREENVIOLET

ORANGE/WHITEBLUE

RED/BLUE

BROWN/REDBLACK

BLUE/WHITE

BLACK

GREEN

ORANGE/WHITE

YELLOW/BLUE

BROWN/RED

BLUE

RED/BLUE

TAN

BROWN/WHITE

GREEN/RED

BLACK

RED/WHITERED

WHITE

BLACK

RED

RED

GRAY

BLACK

VIOLET

BLACK

VIOLET

VIOLET/W

HITE

ORANGE

BLU

EBROWN

WHITE

GREEN

WHITE

BLU

E/W

HITE

BLACK

BLACK

BLACK

BROWN/WHITE

BLACK

GREEN/YELLOW

WHITE

GREEN/BLACK

WHITE/BLACK

WHITE

WHITE/GREEN

BLUE

YELLOW/BLUE

BLACK

BLACK

YELLOW/RED

RED

WHITE

ORANGE/WHITE

BLUE/WHITE

ORANGE

BLACK

BLACK

BLACK


4WD Wire Harness (S/N Below 240999999)Groundsmaster 580--D

BLACK

YELLOW

BLACK

BLACK

GREEN

BLACK

ORANGE

WHITE

GREEN

GREEN

GREEN

WHITE

YELLOW

GREEN

ORANGE

YELLOW

YELLOW


YELLOW

BLACK

GRAY

WHITE

GREEN

ORANGE

GRAY

YELLOW

YELLOW

WHITE

GREENGREEN

GREEN

GREENGREEN

ORANGE

BLACK BLACK

YELLOW

BLACK

SWITCH

4WD Wire Harness (S/N Above 250000000)Groundsmaster 580--D

Documents

90743sl.pdf Groundsmaster 580-D (Rev G) Dec, 2007