Z580-D - Z593-D - Z595-D

TABLE OF CONTENTS

SAFETY INFORMATION

General Information

Think Safety First

SPECIFICATIONS

Specifi cations Z593-D & Z595-D

Configurations

Power System Deck

Operator Zone

Dimensions

Specifi cations Z580-D

Confi gurations System

Mowing Deck

Operator Zone

Dimensions

Torque Specifications

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)

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

Other Torque Specifi cations

Equivalents and Conversions

U.S. to Metric Conversions

CHASSIS

Castor Fork Assembly Replacement

Castor Fork Assembly Removal

Castor Bearing Replacement

Castor Fork Assembly Installation

Front Wheel Removal & Bearing Replacement

Fuel Tank Replacement

Right Side Fuel Tank Removal

Right Side Fuel Tank Installation

Left Side Fuel Tank Removal

Left Side Fuel Tank Installation

Fuel Tank Fitting Replacement

Hood Assembly Replacement

Hood Assembly Removal

Hood Assembly Installation

Throttle Control Assembly Replacement

Throttle Control Assembly Removal

Throttle Control Assembly Installation

Brake Lever Replacement

Brake Lever Removal

Brake Lever Installation

Brake Band Replacement

Brake Band Removal

Brake Band Installation

Brake Cross Shaft Replacement Removal

Brake Cross Shaft Installation

Deck Lift Lever Replacement

Deck Lift Lever Removal

Deck Lift Lever Installation

Motion Control Assembly Replacement

Motion Control Assembly Removal

Right Hand Motion -48

Left Hand Motion Control

Motion Control Assembly Installation

Left Hand Motion Control

Right Hand Motion Control

Motion Control Damper Replacment

Motion Control Damper Removal

Motion Control Damper Installation

Adjusting the Parking Brake

HYDRAULIC SYSTEM

Hydrostatic Tandem Pump Replacement

Hydrostatic Tandem Pump Removal

Hydrostatic Tandem Pump Installation

Wheel Motor Replacement

Wheel Motor Removal

Wheel Motor Installation

Purging the Hydraulic System

Adjusting the Control Handle Neutral Position

Setting the Hydrostatic Pump Neutral

Setting the Right Hydraulic Pump Neutral Position

Setting the Left Hydraulic Pump Neutral Position

Adjusting the Tracking

Hydraulic Flow Testing

Hydraulic Flow Testing Procedure

Traction Pump Drive Belt Replacement

Traction Pump Drive Belt Removal

Traction Pump Drive Belt Installation

Hydraulic Oil Cooler Replacement

Hydraulic Oil Cooler Removal

Hydraulic Oil Cooler Installation

Hydraulic Reservoir Tank Replacement

Hydraulic Reservoir Tank Removal

Hydraulic Reservoir Tank Installation

Pushing the Machine by

Switching from Pushing the Machine Back to Machine Operation

ENGINE

Engine Replacement

Engine Removal

Engine Installation

Radiator Replacement

Radiator Removal

Radiator Installation

Cooling Fan Replacement Removal

Cooling Fan Installation

Air Cleaner Replacement

Air Cleaner Removal

Air Cleaner Installation

Alternator Belt Replacement

Alternator Belt Removal

Alternator Belt Installation

Checking Alternator Belt Tension

Tensioning the Alternator Belt

Fuel Filter Service

Fuel Filter Replacement

Draining the Water Separator

Checking the Radiator

ELECTRICAL

General

Engine Starting

Relays

Purpose

Location

How It Works

Testing

PTO Switch

Purpose

Location

How It Works

Testing

Ignition Switch

Purpose

Location

How It Works

Testing

Neutral Safety Switch

Purpose

Location

How It Works

Testing

Parking Brake Switch

Purpose

Location

How It Works

Testing

Seat Switch

Purpose

Location

How It Works

Testing

Delay Module

Purpose

Location

How It Works

Testing

High Temperature Audible Alarm (Solid Tone)

Purpose

Location

How It Works

Testing

Temperature Sender

Purpose

Location

How It Works

Testing

Oil Pressure Switch

Purpose

Location

How It Works

Testing .................................................................................................................................6-14

High Temperature & Glow Plug Light Cluster

Purpose

Location

How It Works

Testing

Glow Plug Switch

Purpose

Location

How It Works

Testing

Hour Meter

Purpose

Location

How It Works

Testing

Electric PTO Clutch

Purpose

Location

How It Works

Testing

Clutch Coil Continuity Test

Engine Stop Solenoid

Purpose

Location

How It Works

Testing

Pull Coil Terminal Test

MOWER DECKS

Mower Belt Replacement

Mower Deck Removal

Mower Deck Installation

Mower Spindle Replacement

Mower Spindle Removal

Mower Deck Spindle Rebuild

Mower Spindle Installation

Mower Deck Idler Assembly Replacement

Mower Deck Idler Assembly

Mower Deck Idler Assembly Installation

Fixed Pulley Replacement

Fixed Pulley Removal

Fixed Pulley Installation

Electric PTO Clutch Replacement

Electric PTO Clutch Removal

Warner Clutch

Electric PTO Clutch Installation

Warner Clutch

Electric PTO Clutch Removal

Ogura Clutch

Electric PTO Clutch Installation

Ogura Clutch

Gearbox Assembly Replacement

Gearbox Assembly Removal

Gearbox Assembly Installation

Checking the Gearbox Oil Level

Changing Gearbox Oil

Strut Replacement

Strut Removal

Strut Installation

72" Mower Deck Belt Tension Adjustment Plate Replacement

72" Mower Deck Belt Tension Adjustment Plate Removal

72" Mower Deck Belt Tension Adjustment Plate Removal

72" Mower Deck Belt Tension Adjustment

Gearbox Rebuild

Pinion Shaft Teardown

Cross Shaft Teardown

Open End Cap Teardown

Closed End Cap Teardown

Closed End Cap Rebuild

Open End Cap Rebuild

Cross Shaft Rebuild

Pinion Shaft Rebuild

Gearbox Assembly

Leveling the Mower

Setting up the Machine

Leveling the Mower Side to Side

Adjusting the Front to Rear Mower Pitch

Adjusting the Compression Spring