Toro Groundsmaster 5900 Series Manuals

Manuals and User Guides for Toro Groundsmaster 5900 Series. We have 4 Toro Groundsmaster 5900 Series manuals available for free PDF download: Service Manual, Installation Instructions Manual

Toro Groundsmaster 5900 Series Service Manual (559 pages)

Brand: Toro | Category: Lawn Mower | Size: 49.46 MB

Table of Contents
7
Chapter 1: Safety
11
Safety Instructions
12
Before Operating the Machine
12
While Operating the Machine
13
Maintenance and Service
14
Battery-Disconnect Switch
15
Jacking Instructions
16
Safety and Instructional Decals
18
Chapter 2: Specifications and Maintenance
19
Specifications
20
Overall Dimensions
20
Engine
21
Hydraulic System
22
Chassis
23
Cutting Decks
24
Torque Specifications
25
Calculating the Torque Values When Using a Drive-Adapter Wrench
26
Identifying the Fastener
27
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
28
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
29
Other Torque Specifications
30
Conversion Factors
30
Shop Supplies
31
Special Tools
33
Chapter 3: Troubleshooting
39
GEARS - the Systematic Approach to Defining, Diagnosing and Solving Problems
40
Gather Information
40
Evaluate Potential Causes
40
Assess Performance
40
Repair
40
Solution Confirmation
40
General Hydraulic System Problems
41
Traction Circuit Problems
42
PTO Problems
44
Lift/Lower Circuit Problems
45
Steering Circuit Problems
46
Starting Problems
47
General Run and Transport Problems
49
Cutting Deck (PTO) Operating Problems
50
Cutting Deck Lift/Lower Problems
52
Operator Advisories
54
To Start
55
To Engage Pto
55
To Set Cruise Control
55
To Lower Deck
56
To Float Deck
56
To Set High Range
56
To Set Low Range
57
For Traction
57
Engine
57
Fuel Level
58
Traction Pedal
58
To Raise Deck
58
Using the Infocenter Display for Troubleshooting
59
Machine Faults
61
Engine Faults
65
Factors that Can Affect Quality of Cut and Clipping Dispersion
67
Chapter 4: Yanmar Diesel Engine
67
General Information
70
Operator's Manuals
70
Yanmar Service and Troubleshooting Manuals
70
Stopping the Engine
70
Engine Electronic Control Unit (ECU)
71
Yanmar Engine
73
Diesel Particulate Filter
74
General Information
77
Service and Repairs
79
Air Filter
79
Exhaust System
81
Fuel System
85
Radiator
90
Engine
93
Pump Adapter Plate (Coupler)
99
Chapter 5: Hydraulic System
101
General Information
103
Operator's Manual
103
Relieving Hydraulic System Pressure
103
Towing Traction Unit
103
Traction Circuit Component Failure
105
Hydraulic Hoses
106
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal)
107
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)
109
Hydraulic Schematic
112
Hydraulic Flow Diagrams
113
Traction Circuit Operation
114
Traction Circuit: Low Range Traction Speed (Mow)
116
Traction Circuit: High Range Traction Speed (Transport)
119
Raise Cutting Deck
122
Lower Cutting Deck
125
PTO Mow Circuit
128
PTO Mow Circuit Cutting Deck Blade Braking
131
Steering Circuit
133
Testing
136
Before Performing Hydraulic Tests
136
Precautions for Hydraulic Testing
136
Which Hydraulic Tests Are Necessary
137
Traction Circuit Charge Pressure Test (Using Pressure Gauge)
139
Traction Circuit Relief Pressure Test (Using Pressure Gauge)
142
Counterbalance Pressure Test (Using Pressure Gauge)
145
Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter)
147
Cutting Deck Circuit Pressure Test (Using Pressure Gauge)
150
Cutting Deck Circuit Relief Pressure Test (Using Tester with Pressure Gauge and 40 GPM Flow Meter)
153
Cutting Deck Motor Case Drain Leakage Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter)
156
Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge)
160
Steering Circuit Relief Pressure Test (Using Pressure Gauge)
163
Steering Cylinder Internal Leakage Test
165
Gear Pump (PTO, Steering, Deck Lift/Lower and Traction Charge Circuits) Flow Test (Using Tester with Pressure Gauges and Flow Meter)
167
Adjustments
172
Adjust Manifold Relief Valves
172
Service and Repairs
173
General Precautions for Removing and Installing Hydraulic System Components
173
Check Hydraulic Lines and Hoses
175
Priming Hydraulic Pumps
176
Flush Hydraulic System
177
Charge Hydraulic System
179
Filtering Closed−Loop Traction Circuit
181
Hydraulic Reservoir
183
Gear Pump
186
Gear Pump Service
188
Traction Circuit
193
Piston (Traction) Pump
193
Piston (Traction) Pump Service
198
Front Wheel Motors
200
Rear Wheel Motors
205
Wheel Motor Service
207
Traction Control Manifold
209
Traction Control Manifold Service
212
Brake Release Manifold
214
Brake Release Manifold Service
216
Cutting Deck Circuit
217
Cutting Deck Motor
218
Cutting Deck Motor Service
220
Cutting Deck Control Manifolds
225
Cutting Deck Control Manifold Service
228
Steering and Cutting Deck Lift Circuits
230
Steering Control Valve (for Machines Serial Number below 403450000)
231
Steering Control Valve (for Machines Serial Number above 403450001)
234
Steering Control Valve Service (for Machines Serial Number below 40345000)
237
Steering Control Valve Service (for Machines Serial Number above 403450001)
238
Steering Cylinders
239
Steering Cylinder Service
241
Front Cutting Deck Lift Cylinders
243
Front Cutting Deck Lift Cylinder Service
245
Wing Cutting Deck Lift Cylinders
248
Wing Cutting Deck Lift Cylinder Service
250
Steering/Deck Lift Control Manifold
252
Steering/Deck Lift Control Manifold Service
255
Cartridge Valve Service
258
Chapter 6: Electrical System
263
General Information
265
Operator's Manual
265
Operator Cab Components
265
Toro Electronic Controllers (TEC)
265
Engine Electronic Control Unit (ECU)
267
Yanmar Engine Electrical Components
267
Battery−Disconnect Switch
268
Electrical System Operation
269
12 Volt System
269
Can−Bus Communications
270
Electrical Drawings
270
Infocenter Display
271
Operator Information Screen
272
Main Menu
275
Service
276
Hours
277
Traction Pedal
278
Fan Override
280
Fan Demo
281
Regeneration
282
Diagnostics Screens
284
Electrical System Quick Checks
304
Adjustments
308
Cutting Deck Position Switch Adjustment
308
Component Testing
315
Fusible Link Harness
316
Mega Fuses
318
Fuses
319
Battery−Disconnect Switch
323
Toro Electronic Controllers (Tecs)
325
Key Switch
330
PTO Switch
332
Cutting Deck Raise/Lower Switches
334
Throttle Switch
336
High/Low Range Traction Speed Switch
338
Cruise Control Switch
340
Headlight Switch
342
Turn Signal Switch
344
Hazard Switch
346
Parking Brake Switch
348
Horn Button
350
Contactors
351
Seat Switch
353
Windshield Wiper/Washer Switch (Groundsmaster 5910)
354
Air Conditioning Switch (Groundsmaster 5910)
356
Fan Speed Switch (Groundsmaster 5910)
357
Work Light and Beacon Switches (Groundsmaster 5910 − Optional)
359
Relays with Four (4) Terminals
361
Relays with Five (5) Terminals
364
Air Filter Service Indicator
370
Fuel Sender
371
Fuel Pump
373
Hydraulic Oil Temperature Sender
375
Can−Bus Terminator Resistor
377
Resistor Assemblies
378
Diode Assemblies
380
Audible Alarm
384
Traction Pedal Position Sensor
385
Piston (Traction) Pump Control Solenoid Coils
386
Cutting Deck Position Switches
388
24 Volt Alternator
392
24 Volt Voltage Divider
394
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit)
396
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit)
398
Service and Repairs
400
Batteries
400
Hydraulic Solenoid Valve Coils
408
24 Volt Alternator/Air Conditioning Compressor Drive Belt
409
24 Volt Alternator
411
General Information
416
Operator's Manual
416
Service and Repairs
417
Wheels
417
Steering Column (for Machines Serial Number below 403450000)
419
Steering Column (for Machines Serial Number above 403450001)
422
Rear Axle
429
Front Deck Lift Arms
431
Wing Deck Lift Arms
435
Wing Deck Lift Arm Joint Yoke
441
Wing Deck Impact Arm Assembly
445
Console Arm
449
Traction Pedal
451
Operator Seat
454
Operator Seat Service
456
Operator Seat Suspension
458
Chapter 8: Cutting Decks
463
General Information
464
Operator's Manual
464
Blade Stopping Time
464
Service and Repairs
465
Front Cutting Deck
465
Front Cutting Deck Winglets
468
Drive Belt Idler Assemblies
473
Blade Spindle Service
479
General Information
488
Operator's Manual
488
Electrical Components, Schematics and Wire Harness Drawings
488
Air Conditioning System
488
Cab Heater System
489
Air Conditioning System Performance
489
Service and Repairs
490
General Precautions for Removing and Installing Air Conditioning System Components
490
Air Conditioning Compressor
492
Roof Assembly
495
Heating and Air Conditioning Components
497
A/C Condenser Fan Assembly
499
A/C Condenser Assembly
502
Mixing Box Assembly
505
Blower Fan
512
Windshield Wiper Assembly
515
Appendix A
519
Electrical Drawing Designations
520
Hydraulic Schematic
521
Electrical Schematic (Machine Serial Numbers below 316000200)
522
Electrical Schematic (Machine Serial Numbers below 316000200
523
Electrical Schematic (Machine Serial Numbers 316000201 to 399999999)
524
Electrical Schematic (Machine Serial Numbers 316000201 to 399999999
525
Electrical Schematic (Machine Serial Numbers 400000000 to 403450000)
526
Electrical Schematic (Machine Serial Numbers 400000000 to 403450000
527
Electrical Schematic (Machine Serial Numbers above 403450001)
528
Electrical Schematic (Machine Serial Numbers above 403450001
529
Operator Platform Wire Harness Drawing (Machine Serial Numbers below 316000200
530
Operator Platform Wire Harness Diagram (Machine Serial Numbers below 316000200
531
Operator Platform Wire Harness Diagram (Machine Serial Numbers below 316000200)
532
Operator Platform Wire Harness Drawing
533
Operator Platform Wire Harness Diagram
534
Operator Platform Wire Harness Diagram (Machine Serial Numbers 316000201 to 316999999)
535
Operator Platform Wire Harness Diagram
536
Operator Platform Wire Harness Diagram
537
Operator Platform Wire Harness Diagram
538
Operator Platform Wire Harness Diagram (Machine Serial Numbers above 403450001
539
Operator Platform Wire Harness Diagram (Machine Serial Numbers above 403450001)
540
Operator Platform Wire Harness Diagram (Machine Serial Numbers above 403450001
541
Rear Wire Harness Drawing (Machine Serial Numbers below 316000200
542
Rear Wire Harness Diagram (Machine Serial Numbers below 316000200
543
Rear Wire Harness Drawing (Machine Serial Numbers 316000201 to 403450000
544
Rear Wire Harness Drawing (Machine Serial Numbers 316000201 to 403450000)
545
Rear Wire Harness Drawing (Machine Serial Numbers above 403450001
546
Rear Wire Harness Drawing (Machine Serial Numbers above 403450001)
547
Engine Wire Harness Drawing (Machine Serial Numbers 316000001 to 316999999
548
Engine Wire Harness Drawing (Machine Serial Numbers 316000001 to 316999999)
549
Engine Wire Harness Drawing (Machine Serial Numbers 400000000 to 403450000
550
Engine Wire Harness Drawing (Machine Serial Numbers 400000000 to 403450000)
551
Engine Wire Harness Drawing (Machine Serial Numbers above 403450001
552
Cab Power Supply Wire Harness (Machine Serial Numbers below 316000200
554
Cab Headliner Wire Harness Drawing
555
Cab Headliner Wire Harness Diagram
556
Wire Harness Diagram − Two−Post ROPS Extension
557

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