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Toro Field Pro 6040 Service Manual
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Toro Field Pro 6040 Service Manual

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Form No. 22267SL Rev A
Field Pro
®
6040
Model 08839

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Summary of Contents for Toro Field Pro 6040

  • Page 1 Form No. 22267SL Rev A Field Pro ® 6040 Model 08839...
  • Page 2 Revision History Revision Date Description Initial Issue 11/2022 Revision History Page 2 Field Pro® 6040 22267SL Rev A...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual.
  • Page 4 Reader Comments Page 4 Field Pro® 6040 22267SL Rev A...
  • Page 5 Service Manual for reference. Additional copies of the Operator’s Manuals, Installation Instructions and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. Field Pro® 6040...
  • Page 6 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed •...

  • Page 7: Table Of Contents

    Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Jacking Instructions ..................1–6 Safety and Instructional Decals ..............1–6 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–5 Shop Supplies .................... 2–12 Special Tools ....................
  • Page 8 Preface Page 8 Field Pro® 6040 22267SL Rev A...
  • Page 9 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Think Safety First ..........................1–3 Jacking Instructions ..........................1–6 Safety and Instructional Decals ......................1–6 Field Pro® 6040 Page 1–1 Safety 22267SL Rev A...

  • Page 10: Safety Instructions

    Safety Instructions DANGER This safety symbol means danger. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions could kill or cause serious permanent injury or disability. WARNING This safety symbol means warning. When you see this symbol, carefully read the instructions that follow.

  • Page 11: Think Safety First

    Think Safety First Toro Products are tested and certified for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and accident prevention are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
  • Page 12 Think Safety First (continued) • Avoid injury to bystanders… Always clear the area of bystanders before starting or testing powered equipment. • Avoid injury due to projectiles… Always clear the area of sticks, rocks or any other debris that could be picked up and thrown by the powered equipment.
  • Page 13 Think Safety First (continued) – Use lifts or jacks and jack stands that are rated to support the total weight of the machine and any attachments. – Do not rely on jacks to support the machine. – If you are unfamiliar with any lifts, hoists or jacks, do not use them until you know how to operate them correctly.

  • Page 14: Jacking Instructions

    Safety and Instructional Decals Numerous safety and instruction decals are affixed to the Field Pro 6040. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog, Operator’s Manual, and accessory Installation Instructions.
  • Page 15 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine Specifications......................... 2–3 Hydraulic System Specifications ......................2–4 Chassis Specifications ........................2–4 Torque Specifications ........................... 2–5 Calculating the Torque Values When Using a Drive-Adapter Wrench ..........2–6 Identifying the Fastener........................

  • Page 16: Specifications

    Specifications Overall Dimensions g395755 Figure 1 Specifications and Maintenance: Specifications Page 2–2 Field Pro® 6040 22267SL Rev A...

  • Page 17: Engine Specifications

    Engine Specifications Item Description Make/Designation Kohler CH740–3136, 2-cylinder, air cooled, OHV gasoline engine Bore x Stroke 83 x 67 mm (3.27 x 2.64 inches) Total displacement 725 cm (44 in Governor Mechanical Low idle speed 1,575 to 1,725 rpm High idle speed 3,575 to 3,725 rpm Carburetor Float feed, fixed main jet, and solenoid fuel shut-off...

  • Page 18: Hydraulic System Specifications

    Hydraulic System Specifications Item Description Piston (traction) pumps Right side: Hydro-Gear PR, manually controlled variable displacement axial piston pump with charge pump and cooling fan Left side: Hydro-Gear PR, manually controlled variable displacement axial piston pump Maximum traction pump displacement (per 16.0 cm (0.97 in revolution)

  • Page 19: Torque Specifications

    Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.

  • Page 20: Calculating The Torque Values When Using A Drive-Adapter Wrench

    Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 2 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...

  • Page 21: Identifying The Fastener

    Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.

  • Page 22: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch)

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) Thread Size Grade 1, 5 and 8 with SAE Grade 1 Bolts, SAE Grade 5 Bolts, SAE Grade 8 Bolts, Thin Height Nuts Screws, Studs, and Screws, Studs, and Screws, Studs, and Sems with Regular Sems with Regular Sems with Regular...
  • Page 23 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch) (continued) Note: The torque values must be reduced when installing the fasteners into threaded aluminum or brass. The specified torque value should be determined based on the aluminum or base material strength, fastener size, length of thread engagement, etc.

  • Page 24: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)

    Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs Class 10.9 Bolts, Screws, and Studs Thread Size with Regular Height Nuts (Class 8 with Regular Height Nuts (Class 10 or Stronger Nuts) or Stronger Nuts) M5 X 0.8 6 to 7 N·m (51 to 63 in-lb)

  • Page 25: Other Torque Specifications

    Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 14 to 18 N·m (120 to 160 in-lb) 7 to 9 N·m (61 to 85 in-lb) 5/16 - 18 UNC 20 to 28 N·m (180 to 250 in-lb) 14 to 18 N·m (125 to 165 in-lb) 3/8 - 16 UNC...

  • Page 26: Shop Supplies

    Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
  • Page 27 Shop Supplies (continued) GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.

  • Page 28: Special Tools

    Special Tools Special tools are available from your Toro Distributor or from K-Line Tools at https://www.klineind.com. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit K–Line Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests.
  • Page 29 Hydraulic Test Fitting Kit K–Line Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12 8 ORFS (13–16–16) TOR4079–4...
  • Page 30 Hydraulic Hose Kit K–Line Part No. TOR6007 This kit includes the fittings and hoses that are used to connect high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components. Bidirectional High Flow Hydraulic Filter Kit K–Line Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (344 bar or 5,000 psi) capabilities.
  • Page 31 Speed Setting Tool Toro Part No. 132–7595 Use this to adjust the left side traction control rod when adjusting the traction speed. Refer to Adjusting the Traction Speed (page 5–41) for additional information. Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage.
  • Page 32 Dielectric Gel (continued) Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug the connector into the component,...
  • Page 33 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 Troubleshooting – Hydraulic ........................3–3 General Hydraulic System Problems ..................... 3–4 Troubleshooting – Electrical ........................3–5 Starting Problems ..........................3–6 General Operation Problems ......................... 3–9 The information In this chapter is intended to help troubleshoot machine operation issues.

  • Page 34: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems

    GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...

  • Page 35: Troubleshooting - Hydraulic

    Troubleshooting – Hydraulic The following tables contain suggestions that can be used to solve performance issues specific to the hydraulic system. The suggestions are not all-inclusive. There can be more than one cause for a machine malfunction. Review the hydraulic schematic found in Appendix A (page A–1) and information on the hydraulic system operation in the...

  • Page 36: General Hydraulic System Problems

    General Hydraulic System Problems Problem Possible Cause Corrective Action Hydraulic fluid is leaking from the The fitting(s), hose(s), or tube(s) are Secure or replace loose or damaged system. loose or damaged. hydraulic connections. The O-ring(s) or seal(s) are missing or Install a new O-ring(s) or seal(s).

  • Page 37: Troubleshooting - Electrical

    Troubleshooting – Electrical CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. Pay attention to the InfoCenter display screens. Use the main information screen icons and the operator’s advisories to help troubleshoot electrical issues.

  • Page 38: Starting Problems

    Starting Problems Problem Possible Cause Corrective Action The starter solenoid clicks, but the The battery charge is low. Charge the battery. starter does not crank. The battery is discharged or damaged. Charge and test the battery. Replace the battery if necessary. The battery cables are loose or Clean and secure the battery cables.
  • Page 39 Starting Problems (continued) Problem Possible Cause Corrective Action Nothing happens when you attempt to The traction control bars are not in the Inspect the traction control operation. start the engine using the key switch. position. EUTRAL Test the traction control switch(es) and replace if necessary;...
  • Page 40 Starting Problems (continued) Problem Possible Cause Corrective Action The engine cranks, but does not start. The fuel tank is empty. Fill the fuel tank. Use the choke to start the engine. The engine and/or fuel is too cold. Move the machine to a heated environment prior to starting.

  • Page 41: General Operation Problems

    General Operation Problems Problem Possible Cause Corrective Action The battery does not charge. The battery cables are loose or Clean and secure the battery cables. corroded. The ground connection is loose or Clean and secure the ground corroded. connections at the engine block. The battery is discharged or damaged.
  • Page 42 Troubleshooting: General Operation Problems Page 3–10 Field Pro® 6040 22267SL Rev A...
  • Page 43 Chapter 4 Engine Table of Contents General Information ..........................4–2 Operator’s Manual ..........................4–2 Engine Owner’s Manual........................4–2 Engine Service Manual ........................4–2 Fuel Shutoff Valve ..........................4–3 Kohler Gasoline Engine ........................4–4 Adjustments ............................4–5 Adjusting the Choke Control ......................4–5 Adjusting the Engine Idle Speed ......................

  • Page 44: General Information

    Service and repair parts for the engine in your Field Pro 6040 are supplied through your Authorized Toro Distributor. Be prepared to provide your distributor with the Toro Model and Serial Number of your machine to obtain parts.

  • Page 45: Fuel Shutoff Valve

    Fuel Shutoff Valve g396027 Figure 5 (shown with operator cushion lowered) Fuel tank Fuel shutoff valve The fuel shutoff valve located behind the fuel tank should be closed when removing the fuel tank or engine from the machine. Additionally, close the shutoff valve if the machine is being transported on a trailer or when placing the machine in long term storage.

  • Page 46: Kohler Gasoline Engine

    Kohler Gasoline Engine g396026 Figure 6 (shown with hydraulic fluid cooler removed) Throttle and Choke linkages Voltage regulator/rectifier Pulse style fuel pump Fuel shut-off solenoid Oil cooler The engine includes a pulse style fuel pump and a fuel shut-off solenoid. Oscillating crankcase pressure causes a diaphragm inside the pulse style fuel pump to pull fuel in on the piston down-stroke and to push it into carburetor on the piston up-stroke.

  • Page 47: Adjustments

    Adjustments Adjusting the Choke Control g402367 Figure 7 Air intake hose adapter Choke cable clamp Choke control cable 1. Park the machine on a level surface, engage the parking brake, set the key switch to the O position and remove key from the switch. 2.

  • Page 48: Adjusting The Engine Idle Speed

    Adjusting the Engine Idle Speed g402366 Figure 8 Throttle stop screw Throttle control cable Throttle cable clamp 1. Allow the engine to reach operating temperature before checking or adjusting the engine speed. 2. Park the machine on a level surface and engage the parking brake. 3.

  • Page 49: Service And Repairs

    IMPORTANT The engine that powers the Field Pro 6040 is air–cooled. The engine also includes an oil cooler. Operating the engine with a blocked grass screen, a plugged or dirty blower housing, or dirty or otherwise obstructed oil cooler may result in engine overheating and engine damage.
  • Page 50 Cleaning the Engine Cooling System (continued) IMPORTANT Never operate the engine without the blower housing installed. Overheating and engine damage will result. 6. Make sure the grass screen and the blower housing are installed before operating the engine. Engine: Service and Repairs Page 4–8 Field Pro®...

  • Page 51: Fuel System

    Fuel System DANGER Gasoline fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle gasoline fuel. • Do not smoke while filling the fuel tank. •...
  • Page 52 Removing the Fuel Tank g397757 Figure 10 Fuel hose – tank to shutoff valve Fuel hose – shutoff valve to filter Fuel hose – filter to fuel pump Supply fitting Fuel gauge Fuel filter Vent fitting Grommet Grommet (2 each) Fuel tank R-clamp Fuel tank cap...
  • Page 53 Installing the Fuel Tank Refer to Figure 10 for this procedure. 1. Install any previously removed fuel tank assembly components. 2. If the fuel filter or shutoff valve was removed, ensure that the arrow on the filter or valve body indicating fuel flow points toward the engine. 3.

  • Page 54: Fuel Evaporative Control System

    Fresh air filter Hose – tank to carbon canister Field Pro 6040 machines are equipped with a fuel evaporative control system designed to collect and store evaporative emissions from the fuel tank. The evaporate control system uses a carbon canister and a series of vent hoses to collect these evaporative emissions.
  • Page 55 Disassembling the Fuel Evaporative Control System (continued) 1. Remove the fuel tank; refer to Removing the Fuel Tank (page 4–10) 2. Record the evaporative control system hose and clamp routing/location for installation purposes. 3. Remove the evaporative control system components as necessary. 4.

  • Page 56: Air Cleaner

    Air Cleaner g398768 Figure 12 Clamp assembly Intake elbow Bracket Element, air cleaner Body, air cleaner Cap. air cleaner Pipe plug Vactuator valve Removing and Installing the Air Cleaner Refer to Figure 12 for this procedure. 1. Park the machine on a level surface, engage the parking brake, set the key switch to the O position and remove key from the switch.
  • Page 57 Removing and Installing the Air Cleaner (continued) 7. If the pipe plug was removed or replaced, apply sealant to the threads of the plug and install the plug in the air cleaner housing. Tighten the plug from 1.0 to 1.2 N·m (9 to 11 in-lb). 8.

  • Page 58: Exhaust System

    Exhaust System g399318 Figure 13 Header, RH Header, LH Muffler bracket Cap screw (2 each) Hex nut (4 each) Flange nut (2 each) Muffler clamp (2 each) Lock washer (4 each) Muffler Gasket (2 each) Removing the Exhaust System Refer to Figure 13 for this procedure.
  • Page 59 Removing the Exhaust System (continued) 5. Remove and discard the exhaust gaskets. Remove any remaining gasket material or debris from the header flanges and the engine sealing surfaces. Installing the Exhaust System Refer to Figure 13 for this procedure. 1. Loosen the top 2 fasteners securing the muffler bracket and tensioner assembly to the engine.

  • Page 60: Pump Drive Belt Tensioner

    Pump Drive Belt Tensioner g400767 Figure 14 Cap screw (4 each) Engine pulley Spacer Muffler bracket Torsion spring Tensioner pulley Set screw (2 each) Flange nut (3 each) Belt shield Square key Tensioner arm Tensioner mount plate The pump drive belt transfers power from the engine to the hydraulic pump assemblies.
  • Page 61 Removing the Pump Drive Belt Tensioner (continued) CAUTION Be careful when removing or installing tensioner torsion spring. The spring is under heavy load and may cause personal injury. A. Secure the tensioner mount plate in a vise. B. Use a 3/8” or 1/2” square drive tool to move the tensioner arm away from the stop bolt.
  • Page 62 Installing the Pump Drive Belt Tensioner (continued) 5. Install the belt shield. 6. Install the pump drive belt; refer to the traction unit Operator’s Manual. 7. Test drive belt operation before returning the machine to service. Engine: Service and Repairs Page 4–20 Field Pro®...

  • Page 63: Engine

    Engine g402342 Figure 15 Operator cushion assembly Engine assembly Cap screw (4 used) Hydraulic fluid filter assembly Oil drain valve Flange nut (4 used) Removing the Engine Refer to Figure 15 for this procedure. 1. Disconnect the negative battery cable from the battery; refer to Removing and Installing the Battery (page 6–29).
  • Page 64 Removing the Engine (continued) 8. Remove the fuel tank and evaporative canister; refer to Removing the Fuel Tank (page 4–10) Disassembling the Fuel Evaporative Control System (page 4–12). 9. Disconnect the throttle and choke control cables from the engine. g402341 Figure 16 Choke control cable Throttle cable clamp...
  • Page 65 Removing the Engine (continued) g401593 Figure 17 Positive (+) battery cable Wire harness ground Machine wire harness Fusible link harness Negative (-) battery cable 11. Remove the fasteners that secure the engine to the chassis. CAUTION Use an appropriate lift and the lifting lugs provided to prevent the engine from falling and causing personal injury or product damage.
  • Page 66 Installing the Engine (continued) IMPORTANT Ensure that you do not damage fuel hoses, electrical harness, or other parts when lowering the engine into place. 2. Secure the engine to the chassis with the previously removed fasteners. 3. Connect the engine electrical connections: •...
  • Page 67 Chapter 5 Hydraulic System Table of Contents General Information ..........................5–3 Operator’s Manual ..........................5–3 Relieving Pressure from the Hydraulic System .................. 5–3 Towing or Moving the Machine By Hand .................... 5–4 Traction Circuit Component Failure....................5–6 Hydraulic Hoses..........................5–7 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting)............

  • Page 68: Additional Reference Materials

    Additional Reference Materials Hydro-Gear P Series Hydrostatic Pumps Service and Repair Manual Hydro-Gear HGM-H™ Series Motor Service and Repair Manual Hydraulic System: Service and Repairs Page 5–2 Field Pro® 6040 22267SL Rev A...

  • Page 69: General Information

    General Information Operator’s Manual The traction unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Field Pro 6040. Refer to the traction unit Operator’s Manual for additional information when servicing the machine. Relieving Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system.

  • Page 70: Towing Or Moving The Machine By Hand

    Towing or Moving the Machine By Hand IMPORTANT If towing limits are exceeded, severe damage to the hydraulic pumps and wheel motors may occur. If it becomes necessary to tow or move the machine by hand, the traction pumps must be set to bypass hydraulic fluid. Move the machine at a speed below 4.8 kph (3 mph), and for a very short distance.
  • Page 71 Towing or Moving the Machine By Hand (continued) IMPORTANT Do not start or run the engine when the valve is set to the bypass position. 8. After moving the machine and before starting the engine, close and tighten the bypass valves from 12.4 to 14.7 N⋅ ⋅ ⋅ m (110 to 130 in-lb). Field Pro®...

  • Page 72: Traction Circuit Component Failure

    Traction Circuit Component Failure The traction circuit for Field Pro 6040 machines consists of 2 closed loop circuits (one for each rear wheel) with a shared charge circuit. Each closed loop circuit includes its own hydraulic pump and hydraulic wheel motor. If a component in the traction circuit should fail, unwanted material and contamination from the damaged component will circulate throughout that traction circuit.

  • Page 73: Hydraulic Hoses

    Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).

  • Page 74: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal Fitting)

    Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) g221221 Figure 19 Tube or hose Swivel nut O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2.
  • Page 75 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) (continued) Hose/Tube Installation Torque Table (continued) Hose/Tube Side Thread Size Fitting Dash Size Installation Torque (inch)—threads per inch) 1—14 81 to 89 N∙m (60 to 66 ft-lb) 1–3/16—12 115 to 127 N∙m (85 to 94 ft-lb) 1–7/16—12 149 to 164 N∙m (110 to 121 ft-lb) 1–11/16—12...

  • Page 76: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)

    Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 21 Fitting O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2.
  • Page 77 Installing an Adjustable Fitting g212224 Figure 22 Locknut Back-up washer O-ring g212225 Figure 23 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material.
  • Page 78 Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 23): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values;...

  • Page 79: Hydraulic Schematics

    Hydraulic Schematics The hydraulic schematic for the Field Pro 6040 machine is located in Appendix A (page A–1). Field Pro® 6040 Page 5–13 Hydraulic System: Hydraulic Schematics 22267SL Rev A...

  • Page 80: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Traction Circuit g416800 Figure 24 Traction Circuit Diagram (Forward) The hydraulic traction circuit is a closed loop system consisting of two manually controlled variable displacement piston (traction) pumps and two hydraulic wheel motors. Each pump is responsible for supplying fluid flow to one wheel motor. With the exception of the charge circuit, each wheel circuit is a separate closed loop system.
  • Page 81 charge pump and a cooling fan. The left side piston pump drives an external fixed displacement gear pump for attachment hydraulic needs. The traction pumps are driven by the engine via a single V-belt. V-belt tension is controlled by a spring loaded idler. Forward Direction With the engine running and the traction control levers in the N position,...
  • Page 82 Traction Circuit Charge (continued) in the right side piston pump. Charge flow not consumed by the traction circuit is returned to supply the charge pump, or is returned to the hydraulic reservoir. The charge circuit functions the same when the pumps operate in either the forward or the reverse direction.

  • Page 83: Lift And Tilt Angle Circuits

    Lift and Tilt Angle Circuits g416815 Figure 25 Lift and Tilt Angle Circuits Diagram Field Pro® 6040 Page 5–17 Hydraulic System: Hydraulic Flow Diagrams 22267SL Rev A...
  • Page 84 The gear pump attached to the left side piston (traction) pump supplies hydraulic flow for the attachment lift and angle circuits. Lift and Tilt Angle Circuits Idle When the lift or tilt angle system is idle (control lever is in the N position) EUTRAL the control valve holds the cylinder stationary.

  • Page 85: Testing The Hydraulic System

    Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 2–14).
  • Page 86 IMPORTANT Use 2 people to perform all the tests, with 1 person in the Operator’s position and the other to read and record the test results. 1. Use the following resources to assist with hydraulic system troubleshooting. • The Hydraulic Schematic in Appendix A (page A–1) •...

  • Page 87: Hydraulic Test Selection

    Hydraulic Test Selection Before beginning any hydraulic test, identify if the problem is related to the traction circuit or the lift and tilt angle circuits. Once the faulty system has been identified, perform tests that relate to that circuit. If a traction circuit problem exists, consider performing one or more of the following tests: Testing the Traction Circuit –...

  • Page 88: Testing The Traction Circuit - Charge Pressure

    Testing the Traction Circuit – Charge Pressure g417130 Figure 26 Traction Circuit – Charge Pressure Test The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. The test involves measuring the charge pressure available and measuring the amount of drop in charge pressure when a moderate load is placed on the piston (traction) pumps.
  • Page 89 Special Equipment Required: • Pressure Gauge (accurate below 3,500 kPa (500 psi)) • Hydraulic Tester – Flow meter with pressure gauge that has at least a 57 liters/minute (15 gallons/minute) capacity • 2 Hydraulic test hoses • Non-contact tachometer (photo tach) Test Procedure 1.
  • Page 90 Test Procedure (continued) g417547 Figure 28 (shown from below machine) Hydraulic tube Test fitting with cap 7. Install a pressure gauge at the hydraulic tube test fitting shown. 8. Install the rear wheel and lower the machine to the ground. 9.
  • Page 91 Test Procedure (continued) 15. Apply a load to the right side traction pump by slowly moving the right side traction control lever in the F direction until 6200 to 8275 kPa (900 to ORWARD 1200 PSI) is reached on the flow meter pressure gauge. 16.

  • Page 92: Testing The Traction Circuit - Wheel Motor Efficiency

    Testing the Traction Circuit – Wheel Motor Efficiency g417685 Figure 29 Traction Circuit – Wheel Motor Efficiency (right side test shown) Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit performance. Too much hydraulic fluid flow through a single stationary wheel motor under load indicates an internal leak in the wheel motor.
  • Page 93 Special Equipment Required: • Flow meter with pressure gauge that has at least a 57 L/minute (15 gallons/minute) capacity. • 2 Hydraulic test hoses • Non-contact tachometer (photo tach) IMPORTANT Refer to Traction Circuit Component Failure (page 5–6) information regarding the importance of removing contamination from the traction circuit.
  • Page 94 Test Procedure (continued) g417682 Figure 31 Left Side Left side traction pump Left side wheel motor Hydraulic tube 4. Disconnect both ends of the hydraulic tube and remove the tube from the machine. 5. Install one hydraulic test hose to the exposed fitting at the traction pump, and a second test hose to the exposed fitting at the wheel motor.
  • Page 95 Test Procedure (continued) 13. Slowly press the traction control lever of the side being tested in the forward direction until 6,900 kPa (1,000 psi) is displayed on the tester pressure gauge. Ensure that the wheel being tested is not rotating and record the flow meter reading.

  • Page 96: Testing The Traction Circuit - Piston (Traction) Pump Flow And Relief Pressure

    Testing the Traction Circuit – Piston (traction) Pump Flow and Relief Pressure g417685 Figure 32 Traction Circuit – Piston (traction) Pump Flow and Relief Pressure (right side test shown) The piston (traction) pump flow test is the third in a series of tests recommended to determine the traction circuit performance.
  • Page 97 Continued operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance. Note: The dual traction circuit design of the Field Pro 6040 machine requires each traction pump to be tested individually. Special Equipment Required: •...
  • Page 98 Test Procedure (continued) g417549 Figure 33 Right Side Right side wheel motor Right side traction pump Hydraulic tube g417682 Figure 34 Left Side Left side traction pump Left side wheel motor Hydraulic tube 5. Disconnect both ends of the hydraulic tube and remove the tube from the machine.
  • Page 99 Test Procedure (continued) 6. Install one hydraulic test hose to the exposed fitting at the traction pump, and a second test hose to the exposed fitting at the wheel motor. 7. Install a hydraulic tester to the exposed ends of the test hoses. Make sure the tester is installed in the correct flow direction (toward the wheel motor) and the tester flow control valve is fully open.
  • Page 100 Test Procedure (continued) pump is worn and should be replaced or repaired; refer to Piston (Traction) Pumps (page 5–61) Servicing the Piston (Traction) Pumps (page 5–64). 16. After testing: A. Remove the hydraulic hoses and tester. B. Install the hydraulic tube previously removed. C.

  • Page 101: Testing The Lift And Tilt Angle Circuits - Gear Pump Flow

    Testing the Lift and Tilt Angle Circuits – Gear Pump Flow g417934 Figure 35 Lift Circuit – Gear Pump Flow Field Pro® 6040 Page 5–35 Hydraulic System: Testing the Hydraulic System 22267SL Rev A...
  • Page 102 The gear pump is designed to satisfy the lift cylinder needs. The Gear Pump Flow Test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
  • Page 103 Test Procedure (continued) 8. Start the engine and run it at low-idle speed. Correct any hydraulic fluid leaks at the test connections before continuing the test. 9. Set the throttle to the full speed (3,575 to 3,725 RPM). Verify the engine RPM with a non-contact tachometer.

  • Page 104: Testing The Lift And Tilt Angle Circuits - Relief Valve (Rv1) Pressure

    Testing the Lift and Tilt Angle Circuits – Relief Valve (RV1) Pressure g417890 Figure 37 Lift Circuit – Relief Valve (RV1) Pressure The relief valve for the lift circuits (RV1) is located in the control valve. If lift operations perform poorly, perform the gear pump flow test; refer to Testing the Lift and Tilt Angle Circuits –...
  • Page 105 Test Procedure (continued) g417879 Figure 38 Control valve assembly P1 port test fitting 5. Start the engine and run it at low-idle speed. Correct any hydraulic fluid leaks at the test connections before continuing the test. 6. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 5 minutes.

  • Page 106: Adjustments

    Adjustments Hydraulic Pump Drive Belt Tension The hydraulic pumps are driven by the engine via a V-belt. V-belt tension is controlled by a spring loaded tensioner; refer to Pump Drive Belt Tensioner (page 4–18). Refer to the traction unit Operator’s Manual for pump drive belt replacement information.

  • Page 107: Adjusting The Traction Speed

    Special Equipment Required: • Non-contact tachometer (phototach) • Speed setting tool Toro part number 132–7595 1. Raise the rear wheels off the ground; refer to Jacking Instructions (page 1–6). 2. Remove the hood and lower the operator’s cushion.
  • Page 108 Adjusting the Traction Speed (continued) g404939 Figure 39 Upper Jam nut Right hand control rod Flats (on control rod) Lower Jam nut (left hand threads) B. Start the engine and set the throttle control to full speed. C. Move the right hand traction control lever to the full F position.
  • Page 109 Adjusting the Traction Speed (continued) g404938 Figure 40 Left hand control rod Flats (on control rod) Lower Jam nut (left hand threads) G. Use the flats on the control rod to turn the rod in either direction until the left hand traction control lever aligns with the right hand traction control lever.
  • Page 110 Adjusting the Traction Speed (continued) g403516 Figure 41 Left hand traction control lever Right hand traction control lever H. Tighten the control rod jam nut. Install the speed setting tool. The pin of the tool must fit in the hole of the adjustment bracket, and the body of the tool must fit over the tab of the control rod plate.
  • Page 111 Adjusting the Traction Speed (continued) g404971 Figure 42 Set screw Knob Speed setting tool Tab (on control rod plate) Adjustment bracket Control rod J. Loosen the fasteners securing the control rod to the adjustment bracket and control rod plate slightly. K.

  • Page 112: Service And Repairs

    Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, relieve any residual pressure from the hydraulic system; refer to Relieving Pressure from the Hydraulic System (page 5–3).
  • Page 113 After Repairing or Replacing the Components (continued) Fitting) (page 5–8) Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 5. Whenever hydraulic fluid has been drained from the pumps (system drain, flush, or pump removal/installation) it is important to properly prime the hydraulic pumps, refer to Priming the Hydraulic System (page 5–54).

  • Page 114: Checking The Hydraulic Lines And Hoses

    Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. •...

  • Page 115: Flushing The Hydraulic System

    Flushing the Hydraulic System IMPORTANT If a component failure occurs in the traction circuit; refer to Filtering the Closed-loop Traction Circuit (page 5–51) for additional information. IMPORTANT Flush the hydraulic system whenever there is a severe component failure or the system is contaminated (for example, the fluid appears milky, black, or contains metal particles).
  • Page 116 Flushing the Hydraulic System (continued) 8. Fill the hydraulic reservoir with the correct type and quantity of new hydraulic fluid; refer to the traction unit Operator’s Manual. 9. Prime the hydraulic pumps; refer to Priming the Hydraulic System (page 5–54). 10.

  • Page 117: Filtering The Closed-Loop Traction Circuit

    To effectively remove contamination from the closed−loop traction circuit, use of a Toro bidirectional high flow hydraulic filter and hydraulic hose kit is recommended; refer to...
  • Page 118 Left traction pump A port Left wheel motor B port Hydraulic tube 5. Connect the Toro high flow hydraulic filter in series between the disconnected fittings. Use the hydraulic hose kit to connect the filter to the machine if necessary; refer to Hydraulic Hose Kit (page 2–16).
  • Page 119 IMPORTANT If you are using a filter that is not the Toro high flow filter that is bi-directional, do not press the traction control in the opposite direction.

  • Page 120: Priming The Hydraulic System

    Priming the Hydraulic System Whenever hydraulic fluid has been drained from the pumps or wheel motors (system drain, flush, pump removal/installation, or wheel motor removal/installation) it is important to properly prime the hydraulic system. Priming the hydraulic system ensures that the gear pump, the piston (traction) pumps, and the wheel motors have sufficient fluid while charging the hydraulic system.

  • Page 121: Charging The Hydraulic System

    Charging the Hydraulic System IMPORTANT Air must be purged from the hydraulic system to reduce the chance of component damage. When initially starting the hydraulic system with new or rebuilt components such as wheel motors, pumps, or cylinders, it is important that the hydraulic system is charged properly to remove air from the system.
  • Page 122 Charging the Hydraulic System (continued) 11. Lower the machine to the ground. 12. Operate the machine by gradually increasing its work load to full over a 10 minute period. 13. Stop the machine, check the hydraulic components for leaks and tighten any loose connections.

  • Page 123: Hydraulic Reservoir

    Hydraulic Reservoir g411198 Figure 45 Tee fitting Suction strainer Hydraulic Reservoir Battery tray Drain plug Dipstick Mounting bumper Elbow fitting Elbow fitting Clamp Removing and Installing the Hydraulic Reservoir Refer to Figure 45 for this procedure. 1. Park the machine on a level surface, engage the parking brake, set the key switch to the O position and remove the key from the key switch.
  • Page 124 Removing and Installing the Hydraulic Reservoir (continued) or plug the disconnected hydraulic tubes and fittings to prevent hydraulic system contamination. 7. Remove the hydraulic reservoir from the machine. 8. Remove, clean, and inspect the suction strainer. Discard the O-ring. 9. Clean hydraulic reservoir with solvent. 10.

  • Page 125: Hydraulic Fluid Cooler

    Hydraulic Fluid Cooler g410289 Figure 46 Shroud bracket Elbow fitting Rubber clamp (2 each) Fan shroud Cooler cover Hydraulic fluid cooler Foam seal Flange head screw (2 each) Foam seal Tee fitting Foam seal Removing the Hydraulic Fluid Cooler Refer to Figure 46 for this procedure.
  • Page 126 Removing the Hydraulic Fluid Cooler (continued) 9. Inspect the foam seals for wear or damage and replace them if necessary. Installing the Hydraulic Fluid Cooler Refer to Figure 46 for this procedure. 1. If previously removed, install the hydraulic fittings to the fluid cooler; refer Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10).

  • Page 127: Piston (Traction) Pumps

    Piston (Traction) Pumps g412339 Figure 47 Traction control rod Pump pulley Shaft coupler Piston (traction) pump RH Piston (traction) pump LH O-Ring Set screw (2 each) Belt shield Gear pump Pump arm The hydraulic pumps are driven by the engine via a V-belt. V-belt tension is controlled by a spring loaded tensioner;...
  • Page 128 Removing the Piston (Traction) Pump Refer to Figure 47 for this procedure. 1. Remove the pump drive belt; refer to the traction unit Operator’s Manual. 2. Remove the belt shield. 3. Loosen the set screws and remove the hydraulic pump pulley. Retrieve the key from the pump shaft.
  • Page 129 Installing the Piston (Traction) Pump (continued) A. Fit the key into the pump shaft. B. Apply a thin coating of anti-seize lubricant to the pump shaft. C. Install the pump pulley with the pulley hub forward and the face of the hub flush with the end of the pump shaft.

  • Page 130: Servicing The Piston (Traction) Pumps

    Right side pump RTN assembly The left and right piston (traction) pumps used on the Field Pro 6040 machine are Hydro-Gear PR Series pumps. The right side pump includes a internal charge pump, has a cooling fan attached, and the Return to Neutral (RTN) assembly is on the right side of the pump.

  • Page 131: Gear Pump

    Gear Pump g411757 Figure 49 Elbow fitting Shaft coupler Piston (traction) pump, LH Gear pump Barb fitting O-ring Hose clamp The gear pump can be removed separately or with the left side traction (piston) pump; refer to Removing the Piston (Traction) Pump (page 5–62).
  • Page 132 Installing the Gear Pump Refer to Figure 49 for this procedure. 1. Lubricate new O-rings and place them onto the fittings. If previously removed, install the fittings into the pump ports. Tighten the elbow fitting from 42 to 47 N·m (31 to 35 ft-lb), and the barb fitting from 28 to 31 N·m (21 to 23 ft-lb). 2.

  • Page 133: Servicing The Gear Pump

    Servicing the Gear Pump g411769 Figure 50 Pump body Driven shaft/gear Shaft seal Front cover Retaining ring Cap screw (4 each) Rear cover Antiextrusion Washer (4 each) Thrust plate Antiextrusion Body seal (2 each) Thrust plate Uni-ring Dowel pin (4 each) Drive shaft/gear Front seal Service the gear pump for cleaning, inspection and seal replacement only.
  • Page 134 Disassembling the Gear Pump (continued) g320241 Figure 51 Marker line IMPORTANT Avoid distorting any pump components when clamping gear pump in a vise. Use a vise with soft jaws. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4.
  • Page 135 Inspecting the Gear Pump If internal pump parts are found to be worn or damaged, gear pump replacement is necessary. 1. Remove any nicks and burrs from all parts with emery cloth. CAUTION Use eye protection such as goggles when using compressed air. 2.
  • Page 136 Assembling the Gear Pump (continued) 4. Install the pressure seals, flat side outward, into the grooves in the thrust plates. Follow by carefully placing the uni-rings, flat side outward, between the pressure seals and the grooves in the thrust plate. 5.

  • Page 137: Wheel Motors

    Wheel Motors g412077 Figure 53 (right side wheel motor shown) Elbow fitting (2 each) Elbow fitting Wheel motor Cap screw (4 each) Flange nut (4 each) Brake link Flange nut Cap screw If wheel motor hub removal is necessary (to replace the drive studs for example); refer to the Hydro-Gear HGM-H™...
  • Page 138 Installing the Wheel Motor Refer toFigure 53 for this procedure. 1. Lubricate new O-rings and place them onto the fittings. If previously removed, install the fittings into the motor ports; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10).

  • Page 139: Servicing The Wheel Motor

    Pin, Dowel Gear, Ring Shaft, Brake The left and right wheel motors used on the Field Pro 6040 machine are similar in construction but have different (mirrored) brake assemblies attached. Individual repair components will be made available separately from your Authorized Toro Distributor.
  • Page 140 Servicing the Wheel Motor (continued) IMPORTANT If a wheel motor failure occurred, refer to Traction Circuit Component Failure (page 5–6) for information regarding the importance of removing contamination from the traction circuit. Hydraulic System: Service and Repairs Page 5–74 Field Pro® 6040 22267SL Rev A...

  • Page 141: Control Valve

    Control Valve g415104 Figure 55 Support bracket Control valve bracket Cap screw Flange nut (4 each) Cap screw (3 each) Control valve Removing the Control Valve Refer to Figure 55 for this procedure. 1. Park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the key switch.
  • Page 142 Installing the Control Valve Refer to Figure 55 for this procedure. 1. Ensure that all control valve components are properly installed prior to installing the control valve into the machine; refer to Servicing the Control Valve (page 5–77). 2. Fit the control valve to the machine and secure it with the previously removed fasteners.

  • Page 143: Servicing The Control Valve

    Control valve Individual repair components will be made available separately from your Authorized Toro Distributor. The ports on the control valve are marked for easy identification of components and connections. Example: P is the pressure connection port from the gear pump;...
  • Page 144 Servicing the Control Valve (continued) IMPORTANT Some of the fittings used on the control valve include a control orifice. Some of the fittings used on the control valve include a control orifice and a check valve. Pay special attention to the markings on the fittings and ensure that each fitting is installed in the correct control valve port during assembly.

  • Page 145: Center Lift Cylinder

    Center Lift Cylinder g413438 Figure 57 Front cylinder pin Lift cylinder Elbow fitting Rear cylinder pin Straight fitting Removing the Center Lift Cylinder Refer to Figure 57 for this procedure. 1. Remove the mid-mount attachment stop assembly from the machine; refer to Removing the Mid-Mount Attachment Stop (page 7–15).
  • Page 146 Installing the Center Lift Cylinder (continued) 1. Lubricate new O-rings and place them onto the fitting. If previously removed, install the fittings to the cylinder; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 2. Install the cylinder in the machine with the previously removed components. 3.

  • Page 147: Servicing The Center Lift Cylinder

    Servicing the Center Lift Cylinder g412540 Figure 58 Barrel assembly O-ring Dust seal Shaft assembly Backup ring O-ring Piston Piston seal Retaining ring Lock nut Wear ring Grease fitting (2 each) Head Shaft seal Disassembling the Cylinder Refer to Figure 58 for this procedure.
  • Page 148 Disassembling the Cylinder (continued) B. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. C. Rotate the head counter-clockwise to remove retaining ring from barrel and head. 4. Remove the plugs from the ports. Extract the shaft, head and piston assembly from the barrel by carefully twisting and pulling on the shaft.
  • Page 149 Assembling the Cylinder (continued) A. Align the retaining ring hole in the head with the access slot in the barrel. B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are covered.

  • Page 150: Rear Lift Cylinder

    Rear Lift Cylinder g413352 Figure 59 Cotter pin Extension spring RH lift arm Straight fitting Clevis pin Rear lift cylinder Cylinder pin Elbow fitting Removing the Rear Lift Cylinder Refer to Figure 59 for this procedure. 1. Park the machine on a level surface, engage the parking brake, set the key switch to the O position and remove the key from the switch.
  • Page 151 Installing the Rear Lift Cylinder Refer to Figure 59 for this procedure. 1. Lubricate new O-rings and place them onto the fitting. If previously removed, install the fittings to the cylinder; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10).

  • Page 152: Servicing The Rear Lift Cylinder

    Servicing the Rear Lift Cylinder g412561 Figure 60 Barrel assembly O-ring O-ring Backup ring Retaining ring Shaft assembly Piston Piston seal Grease fitting Lock nut BS seal Head Dust seal Disassembling the Cylinder Refer to Figure 60 for this procedure. 1.
  • Page 153 Disassembling the Cylinder (continued) B. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. C. Rotate the head counter-clockwise to remove retaining ring from barrel and head. 4. Remove the plugs from the ports. Extract the shaft, head and piston assembly from the barrel by carefully twisting and pulling on the shaft.
  • Page 154 Assembling the Cylinder (continued) B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are covered. C. Apply silicone sealer to the barrel access slot. Hydraulic System: Service and Repairs Page 5–88 Field Pro®...

  • Page 155: Angle Cylinder (Optional)

    Angle Cylinder (Optional) g413856 Figure 61 Elbow fitting (2 each) Rear cylinder pin Front cylinder pin Angle cylinder Removing the Optional Angle Cylinder Refer to Figure 61 for this procedure. 1. Park the machine on a level surface, lower the mid-mount attachment to the ground, set the key switch to the O position and remove the key from the switch.
  • Page 156 Installing the Optional Angle Cylinder (continued) 1. Lubricate new O-rings and place them onto the fitting. If previously removed, install the fittings to the cylinder; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–10). 2. Install the cylinder in the machine with the previously removed components. 3.

  • Page 157: Servicing The Optional Angle Cylinder

    Servicing the Optional Angle Cylinder g413129 Figure 62 Barrel assembly O-ring Dust seal Lock nut Head Internal collar Wear ring (2 each) O-ring Shaft assembly Piston Backup ring Grease fitting Piston seal Shaft seal Grease fitting Disassembling the Cylinder Refer to Figure 62 for this procedure.
  • Page 158 Disassembling the Cylinder (continued) IMPORTANT Prevent damage when clamping the cylinder in a vise; clamp on the clevis only. 2. Mount the cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3.
  • Page 159 Assembling the Cylinder (continued) IMPORTANT Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. 5. Mount the cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 6.

  • Page 160: Laser Level Control Manifold (Optional)

    Laser Level Control Manifold (Optional) g415781 Figure 63 Elbow fitting Manifold bracket Elbow fitting Manifold assembly Straight fitting (2 each) Removing the Laser Level Control Manifold Refer to Figure 63 for this procedure. 1. Park the machine on a level surface, lower any attachments, engage the parking brake, set the key switch to the O position and remove the key from the key switch.
  • Page 161 Removing the Laser Level Control Manifold (continued) 7. Remove the fasteners securing the manifold to the manifold bracket and remove the manifold assembly from the machine. 8. If necessary, record the locations and orientations of the fittings for assembly purposes then remove the hydraulic fittings from the manifold. 9.

  • Page 162: Servicing The Laser Level Control Manifold (Optional)

    Servicing the Laser Level Control Manifold (Optional) g415966 Figure 64 Coil nut (2 each) #4 zero-leak plug with O-ring Solenoid coil w/diode Orifice – 0.028 inch – OR Solenoid valve – SV Solenoid coil (2 each) Manifold block Coil spacer Piloted valve –...

  • Page 163: Servicing The Cartridge Valves

    Servicing the Cartridge Valves Note: For solenoid style cartridge valve coil testing information; refer to Hydraulic Solenoid Valve Coils (page 6–24). Read and adhere to the information provided in General Precautions for Removing and Installing the Hydraulic System Components (page 5–46) prior to removing hydraulic system components.
  • Page 164 Servicing the Cartridge Valves (continued) While energized, flush out any contamination with a nonflammable aerosol brake cleaner. De-energize the solenoid. Repeat the flush while energized procedure 5 or 6 times. Remove the solenoid from the cartridge. 8. Install the cartridge valve: A.
  • Page 165 Chapter 6 Electrical System Table of Contents General Information ..........................6–2 Operator’s Manual ..........................6–2 Kohler Engine Electrical Components....................6–2 Hour Meter/Controller ........................6–2 Electrical Schematics and Wire Harness Drawings/Diagrams............6–2 Electrical System Quick Checks ......................6–3 Testing the Charging System ......................6–3 Checking the Operation of the Interlock Switches ................

  • Page 166: General Information

    Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Field Pro 6040. Refer to the Operator’s Manual for additional information when servicing the machine. Kohler Engine Electrical Components When servicing or troubleshooting the engine electrical components, use the correct engine service manual.

  • Page 167: Electrical System Quick Checks

    Electrical System Quick Checks Testing the Charging System This is a simple test that determines if a charging system is functioning. It tells you if the charging system has an output, but not its capacity. 1. Use a digital multimeter to set DC volts and connect the positive (+) multimeter lead to the positive battery post and negative (-) multimeter lead to the negative battery post.

  • Page 168: Checking The Operation Of The Interlock Switches

    Checking the Operation of the Interlock Switches CAUTION The interlock system is for the operator’s protection; do not bypass any of the interlock system components. Check the operation of the interlock system daily to assure the system is operating correctly. If an interlock system component is out of adjustment or defective, replace it before operating the machine.

  • Page 169: Testing The Electrical Components

    Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., disconnect the key switch connector before doing a continuity check of the switch). IMPORTANT When testing the electrical components for continuity with a multimeter (ohms setting), ensure that you disconnect the power to the circuit.

  • Page 170: Fusible Link Harness

    Figure 65 Fusible link harness The Field Pro 6040 machine uses a fusible link for circuit protection. The fusible link is located in a harness that connects the battery positive cable (at the starter B+ terminal) to the machine wire harness. If the link fails, current to the hour meter/controller, key switch, and start relay is interrupted.

  • Page 171: Fuses

    Fuses The individual control circuits are protected by a variety of fuses (F1 – F4) found in the fuse block located behind the operator cushion. g415137 Figure 66 Fuse block Identification and Function • Fuse F1 (15 A) protects the unswitched power supply to the key switch •...

  • Page 172: Hour Meter/Controller

    Hour Meter/Controller g415139 Figure 67 Hour meter/controller The hour meter/controller is attached to the machine control panel. Power for the controller is available at all times (unswitched). The controller circuit is protected by a 10 Amp fuse (F2). The hour meter/controller preforms the following functions: •...

  • Page 173: Key Switch

    Key Switch POSITION CLOSED CIRCUITS NONE B + I + A and X + Y START B + I + S The key switch is located on the control panel and has 3 positions: O and S TART Testing the Key Switch 1.

  • Page 174: Parking Brake Switch

    Parking Brake Switch g415977 Figure 68 Parking brake switch Parking brake lever Switch bracket The parking brake switch is a non-adjustable normally open plunger switch. The switch is actuated by the parking brake lever. The switch contacts should be open when the parking brake is engaged (switch plunger extended), and closed when the parking brake is disengaged (switch plunger depressed).
  • Page 175 Testing the Parking Brake Switch (continued) • Engage the parking brake – no continuity across switch terminals (open contacts) • Disengage the parking brake — continuity across switch terminals (closed contacts) 6. Replace the switch if necessary. 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses;...

  • Page 176: Operator Presence Switch (If Equipped)

    Operator Presence Switch (if equipped) g416029 Figure 69 Operator platform Operator presence switch (behind Sensing zone actuator) Switch bracket Switch actuator The operator presence is currently part of the optional laser level installation kit. The operator presence switch is a normally open proximity switch that is located near the right side pivot of the operator platform.
  • Page 177 Testing the Operator Presence Switch (continued) 2. Ensure that the operator platform and operator presence switch actuator moves freely. 3. The gap between the switch actuator and the sensing zone of the switch should be no greater than 10 mm (0.40 inch) when there is no weight on the operator platform.

  • Page 178: Neutral Switches

    Neutral Switches g416384 Figure 70 (left side assembly shown) Traction control lever, LH Switch bracket Neutral switch The neutral switches are normally open proximity switches. The switches are attached to a brackets located below the control panel, one on each side of the machine.
  • Page 179 Adjusting the Neutral Switches g416383 Figure 71 (left side assembly shown) Neutral switch Jam nut (2 each) 1. Park the machine on a level surface and set the key switch to the O position. 2. Lower the operator’s cushion. IMPORTANT Be careful not to scratch the face of the sensor when measuring or adjusting the sensor clearance.
  • Page 180 Testing the Neutral Switches The neutral switches and their circuit wiring can be tested using the hour meter/controller display when the key switch is in the O position. If testing determines that either switch or the circuit wiring are not functioning correctly, proceed with the following test procedure: 1.
  • Page 181 Testing the Neutral Switches (continued) 8. Test the operation of the neutral switches before returning the machine to service. Field Pro® 6040 Page 6–17 Electrical System: Testing the Electrical Components 22267SL Rev A...

  • Page 182: Light Switch (Optional)

    Light Switch (Optional) POSITION CLOSED CIRCUITS 2 + 1, 5 + 4 2 + 3, 5 + 6 The optional light switch is located on the control panel and has 2 positions: , and O Testing the Light Switch 1. Park the machine on a level surface and set the key switch to the O position.

  • Page 183: Relays

    (shown with hood removed) Diode assembly Battery Wireless hour meter relay The Field Pro 6040 machine uses a number of electrical relays. The standard relays are located on the right side plate of the control panel assembly. The Field Pro® 6040 Page 6–19...
  • Page 184 optional wireless hour meter kit includes an additional relay. The relay plugs into the wireless hour meter wire harness. The relay and wireless hour meter diode are tied to the main wire harness behind the battery. A tag near the wire harness relay connector or the color of the wires leading to the connector can be used to identify each relay.
  • Page 185 Testing Relays with 5 Terminals (continued) g256780 Figure 74 Relay with 5 terminals 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85.

  • Page 186: Diode Assemblies

    Diode Assemblies g416712 Figure 75 Diode assembly Battery Wireless hour meter relay A diode plugs into the optional wireless hour meter wire harness. The diode and wireless hour meter relay are tied to the main wire harness behind the battery. The diode works in conjunction with the wireless hour meter relay to separate the 2 different power supplies used to power the wireless hour meter.
  • Page 187 Testing the Diode Assembly (continued) Multimeter Multimeter Resistance Red (+) Lead Black (-) Lead DIODE DIODE VERY LOW TERMINAL A TERMINAL B DIODE DIODE VERY HIGH TERMINAL B TERMINAL A 5. If testing determines the diode is faulty, replace the diode. 6.

  • Page 188: Hydraulic Solenoid Valve Coils

    Hydraulic Solenoid Valve Coils g416410 Figure 76 Coil nut (2 each) Solenoid coil (2 each) Solenoid coil w/diode Coil spacer Manifold block Electric coil actuated hydraulic valves are used on the laser control manifold. When the coil is energized the hydraulic valve shifts to control hydraulic flow. Testing the Hydraulic Solenoid Valve Coils Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance).
  • Page 189 Testing the Hydraulic Solenoid Valve Coils (continued) be approximately 8.8 ohms when tested at 20° C (68° F). Measure the resistance across the coil terminals in both directions. The specified resistance should only be obtainable in one direction, confirming that both the coil and the diode are functioning properly.

  • Page 190: Service And Repairs

    A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with Toro Part No. 107-0392 battery terminal protector or petroleum jelly to prevent corrosion.

  • Page 191: Storing The Battery

    Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the battery cables. Always connect the positive (+) cable first. Apply a coating of Toro Part No. 107-0392 battery terminal protector or a light coat of petroleum jelly to the terminals to reduce corrosion after you make the connections.

  • Page 192: Servicing The Battery

    Servicing the Battery g414257 Figure 77 Battery positive (+) cable Fusible link harness Engine harness connector Battery negative (-) cable Engine and chassis ground Battery Main wire harness ground Battery Specifications Battery-electrolyte specific gravity Fully Charged: 1.25 to 1.28 at 27°C (80°F) (maintainable battery) Discharged: less than 1.24 Battery specifications...
  • Page 193 CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing. While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries. Removing and Installing the Battery g414259 Figure 78...
  • Page 194 Removing and Installing the Battery (continued) 6. Rotate the hold-down post forward and carefully remove the battery from the machine. 7. Clean the battery tray. 8. Install the battery in reverse order. 9. Connect and tighten the positive (+) cable to the battery before connecting negative (-) cable.
  • Page 195 Inspecting, Maintaining, and Testing the Battery (continued) post, or overfilling. Also, check the battery case for dirt and oil. Clean the battery with a solution of baking soda (sodium bicarbonate) and 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.
  • Page 196 Inspecting, Maintaining, and Testing the Battery (continued) B. If you charge the battery, apply a 150 A load for 15 seconds to remove the surface charge. Use a battery load tester following the manufacturer's instructions. C. Ensure that the battery terminals are free of corrosion. D.
  • Page 197 Charging the Battery (continued) Battery Charge Rate Battery Battery Charge Level (Percent of Fully Charged) Reserve Capacity (Minutes) 80 or less 3.8 hrs @ 3 A 7.5 hrs @ 3 A 11.3 hrs @ 3 A 15 hrs @ 3 A 81 to 125 5.3 hrs @ 4 A 10.5 hrs @ 4 A...
  • Page 198 Charging the Battery (continued) 6. When using a maintainable battery, measure the specific gravity of a battery cell once per hour beginning three hours before the end of the scheduled charge. Note: The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for 3 consecutive readings.
  • Page 199 Chapter 7 Chassis Table of Contents General Information ..........................7–2 Adjustments ............................7–3 Adjusting the Parking Brake Linkage ....................7–3 Service and Repairs ..........................7–5 Wheels ............................... 7–5 Front Axle............................7–9 Parking Brake Linkage ........................7–10 Parking Brake Assembly ........................7–12 Traction Control Linkage ........................

  • Page 200: General Information

    General Information The Operator’s Manual and Installation Instructions provide information regarding the operation, general maintenance, and maintenance intervals for your Field Pro 6040 machine and its accessories. Refer to the Operator’s Manual and Installation Instructions for additional information when servicing the machine. Chassis: General Information Page 7–2 Field Pro®...

  • Page 201: Adjustments

    Adjustments Adjusting the Parking Brake Linkage g406185 Figure 79 Brake link (2 each) Lower jam nut (left hand threads) Compression spring Turnbuckle assembly (2 each) Flats (on turnbuckle rod) Flange nut 1. Park the machine on a level surface, set the key switch to the O position and remove the key from the switch.
  • Page 202 Adjusting the Parking Brake Linkage (continued) D. Tighten the upper and lower jam nuts on the turnbuckle assembly. 5. The compression spring length (distance between the trunion pin and the flange nut on the brake link) should be 90 mm (3.35 inch). If necessary, use the flange nut to adjust the compression spring length.

  • Page 203: Service And Repairs

    Service and Repairs Wheels Removing and Installing the Rear Wheels g414445 Figure 80 Wheel assembly Lug nut (5 each) 1. Raise the rear of the machine; refer to Jacking Instructions (page 1–6). 2. Loosen the lug nuts and remove the wheel assembly. 3.
  • Page 204 Removing the Front Wheel and Caster Fork g414444 Figure 81 Grease cap Bearing cup (2 each) Cap screw Lock nut Grease seal Caster fork Belleville washer (3 each) Lock nut Bearing cone (2 each) Wheel assembly 1. Raise the front of the machine; refer to Jacking Instructions (page 1–6).
  • Page 205 Installing the Front Wheel and Caster Fork (continued) 3. Install the lower bearing cone and a new grease seal, then install the upper bearing cone. 4. Fit the caster fork into the front axle and install the three (3) belleville washers as shown.
  • Page 206 Servicing the Front Wheels (continued) 7. Carefully fit the outer bearing spacers into the seals, then install the inner spacer. 8. Install the front wheel; refer to Installing the Front Wheel and Caster Fork (page 7–6). Chassis: Service and Repairs Page 7–8 Field Pro®...

  • Page 207: Front Axle

    Front Axle g414446 Figure 83 Thrust washer Front axle Thrust washer (as required) Lock nut Bushing Pivot pin Removing and Installing the Front Axle 1. Raise the front of the machine; refer to Jacking Instructions (page 1–6). 2. Remove the front wheels and caster forks; refer to Removing the Front Wheel and Caster Fork (page 7–6).

  • Page 208: Parking Brake Linkage

    Parking Brake Linkage g414696 Figure 84 Brake shaft Compression spring (2 each) Trunion pin (2 each) Switch bracket (switch attached) Flange nut (2 each) Bellcrank (2 each) Flange bearing (2 each) Turnbuckle (2 each) Brake link (2 each) Threaded hub (2 each) Removing and Installing the Parking Brake Linkage Refer to Figure 84...
  • Page 209 Installing the Parking Brake Linkage (continued) g414697 Figure 85 Turnbuckle Assembly 1. Verify the length of each turnbuckle prior to assembly. Each turnbuckle should measure 284 to 289 mm (11.2 to 11.4 inch). 2. If previously removed, install the bell cranks and turnbuckles to the wheel motors.

  • Page 210: Parking Brake Assembly

    Parking Brake Assembly g414261 Figure 86 Gear Torsion spring Magnet Brake rotor Retaining ring Screw Washer Brake handle Puck cam Motor shaft Spring pin Splined cam Puck Dowel pin Brake shaft Seal Retaining ring Brake spacer Washer Spring spacer Dowel pin The parking brake assemblies are included with the wheel motors.

  • Page 211: Traction Control Linkage

    Traction Control Linkage g415051 Figure 87 Neutral switch and bracket, RH Traction control lever, LH Pivot tab, LH Traction control lever, RH Traction control rod, LH Pivot tab, RH Traction control rod, RH Speed adjustment bracket Neutral switch and bracket, LH Control rod plate Removing and Installing the Traction Control Linkage Refer to...
  • Page 212 Removing and Installing the Traction Control Linkage (continued) 3. Remove the fasteners securing the traction control rod to the control lever. 4. Remove the fasteners securing the traction control rod to the piston (traction) pump and remove the rod from the machine. 5.

  • Page 213: Mid-Mount Attachment Stop

    Mid-Mount Attachment Stop g413825 Figure 89 Stop pin (2 each) Center lift cylinder Plastic bushing Top plate Lower plate Indicator Spacer (4 each) Stop plate Removing the Mid-Mount Attachment Stop Refer to Figure 89 for this procedure. 1. Park the machine on a level surface, Engage the parking brake, lower the mid-mount attachment to the ground, set the key switch to the O position and remove the key from the switch.
  • Page 214 Installing the Mid-Mount Attachment Stop (continued) 2. Secure the lower plate to the lift cylinder with the previously removed fasteners. 3. Fit the stop plate to the top plate and secure the top plate to the lower plate with the previously removed spacers and fasteners. Insert the stop pins in the storage holes to align the assembly before tightening the fasteners.
  • Page 215 Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Hydraulic Schematic ..........................A–3 Electrical Schematic...........................A–4 Wire Harness Drawing – Main......................A–5 Wire Harness Diagram – Main ......................A–6 Wire Harness – Light Kit (Optional) ....................A–7 Wire Harness – Wireless Hour Meter Kit (Optional)................A–8 Field Pro®...

  • Page 216: Electrical Drawing Designations

    Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).

  • Page 217: Hydraulic Schematic

    Hydraulic Schematic g397758 Field Pro 6040 Model 08839, Drawing 147-3330 Rev B, Sheet 1 of 1 22267SL Rev A Page A–3...

  • Page 218: Electrical Schematic

    Electrical Schematic g397755 Page A–4 22267SL Rev A Field Pro 6040 Model 08839, Drawing 122-2656 Rev B, Sheet 1 of 1...

  • Page 219: Wire Harness Drawing - Main

    Wire Harness Drawing – Main g397760 Field Pro 6040 Model 08839, Drawing 122-2657 Rev B, Sheet 1 of 2 22267SL Rev A Page A–5...

  • Page 220: Wire Harness Diagram - Main

    Wire Harness Diagram – Main g397759 Page A–6 22267SL Rev A Field Pro 6040 Model 08839, Drawing 122-2657 Rev B, Sheet 2 of 2...

  • Page 221: Wire Harness - Light Kit (Optional

    Wire Harness – Light Kit (Optional) g416786 Field Pro 6040 Light Kit, Drawing 122-2754 Rev A, Sheet 1 of 1 22267SL Rev A Page A–7...

  • Page 222: Wire Harness - Wireless Hour Meter Kit (Optional

    Wire Harness – Wireless Hour Meter Kit (Optional) g416785 Page A–8 22267SL Rev A Field Pro 6040 Wireless Hourmeter Kit , Drawing 122-2755 Rev A, Sheet...

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