Toro Groundsmaster 580-D User manual

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
GroundsmasterR580--D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Groundsmaster 580--D, Model 30580, 30581, 30582,
and 30583 (see NOTE above).
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals are
available on the internet at www.toro.com or by sending
complete Model and Serial Number to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
EThe Toro Company -- 1989, 1997, 1999, 2003, 2004, 2005, 2007

Groundsmaster 580–D
This page is intentionally blank.

Rev. E
Groundsmaster 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 – 42
Steering 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
This page is intentionally blank.

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 GROUNDSMASTERR580-D meets or exceeds
the American National Standards Institute’s safety stan-
dards for riding mowers. Although hazard control and
accident prevention partially are dependent upon the
design and configuration of the machine, these factors
are also dependent upon the awareness, concern, and
proper 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 owner
of the machine can result in injury. Reduce the potential
for any injury by complying with the following safety
instructions.
TO REDUCE THE POTENTIAL FOR INJURY,
COMPLY WITH THE FOLLOWING SAFETY
INSTRUCTIONS.
Before Operating
1. Read and understand the Operator’s Manual before
starting and operating the machine. Become familiar
with all controls and know how to stop quickly. A replace-
ment Operator’s Manual is available on the Internet at
www.Toro.com or by sending complete Model and Seri-
al Number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420--1196.
If you have questions about this Service Manual, please
contact:
The Toro Company
Commercial Service Department
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420--1196.
2. Never allow children to operate the machine or
adults to operate it without proper instruction.
3. Become familiar with the controls and know how to
stop 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 the
machine.
5. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes, sneakers or
when barefoot. Do not wear loose fitting clothing that
could get caught in moving parts and possibly cause
personal injury.
6. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local or-
dinances and insurance regulations.
7. Make sure the work area is clear of objects which
might 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 the
areas of operation.