Toro Field Pro 6040 User manual

FormNo.22267SLRevA
FieldPro®6040
Model08839

RevisionHistory
RevisionDateDescription
A11/2022InitialIssue
RevisionHistoryPage2FieldPro®6040
22267SLRevA

ReaderComments
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bye-mail:
[email protected]
bymail:
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TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
FieldPro®6040Page3ReaderComments
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ReaderCommentsPage4FieldPro®6040
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Preface
Thisservicemanualwaswrittenexpresslyforservicetechnicians.Basicshop
safetyknowledgeandmechanical/electricalskillsareassumed.TheT oro
Companyhasmadeeveryefforttomaketheinformationinthismanualcomplete
andcorrect.
Thepurposeofthispublicationistoprovidetheservicetechnicianwith
informationabouttroubleshooting,testing,andrepairingmajorsystemsand
components.Thismanualmayalsobespeciedforuseonnumerousproducts.
RefertotheTableofContentsforalistofthesystemsandtherelatedtopics
coveredinthismanual.
RefertothemachineOperator’sManualforadditionalinformationabout
operating,maintaining,andadjustingthemachine.KeepacopyoftheOperator’s
Manuals,InstallationInstructions,andPartsCatalogforyourmachineandits
accessorieswiththisServiceManualforreference.Additionalcopiesofthe
Operator’sManuals,InstallationInstructionsandPartsCatalogsareavailable
atwww.toro.com.
TheT oroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
FieldPro®6040Page5Preface
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ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.
components)thatmayhavebeenremoved
•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation
•aspecicfastenertighteningsequence
•componentorientationthatmaynotbeobvious
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardT orqueT ables;refertoStandard
TorqueforDry,ZincPlated,andSteelFasteners(Inch)(page2–8)orStandard
TorqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)(page2–10).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
PrefacePage6FieldPro®6040
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TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–6
SafetyandInstructionalDecals....................................................................1–6
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–5
ShopSupplies............................................................................................2–12
SpecialTools..............................................................................................2–14
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
Troubleshooting–Hydraulic.........................................................................3–3
GeneralHydraulicSystemProblems............................................................3–4
Troubleshooting–Electrical..........................................................................3–5
StartingProblems.........................................................................................3–6
GeneralOperationProblems........................................................................3–9
Chapter4:Engine...........................................................................................4–1
GeneralInformation.....................................................................................4–2
Adjustments.................................................................................................4–5
ServiceandRepairs.....................................................................................4–7
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
HydraulicSchematics.................................................................................5–13
HydraulicFlowDiagrams............................................................................5–14
TestingtheHydraulicSystem......................................................................5–19
Adjustments...............................................................................................5–40
ServiceandRepairs...................................................................................5–46
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–2
ElectricalSystemQuickChecks....................................................................6–3
TestingtheElectricalComponents................................................................6–5
ServiceandRepairs...................................................................................6–26
Chapter7:Chassis..........................................................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments.................................................................................................7–3
ServiceandRepairs.....................................................................................7–5
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
HydraulicSchematic.....................................................................................A–3
ElectricalSchematic.....................................................................................A–4
WireHarnessDrawing–Main.......................................................................A–5
WireHarnessDiagram–Main......................................................................A–6
WireHarness–LightKit(Optional)...............................................................A–7
WireHarness–WirelessHourMeterKit(Optional).......................................A–8
AdditionalReferenceMaterials
KOHLERCommandCH18-CH25,CH620-CH730,CH740,CH750Service
Manual
Hydro-GearPSeriesHydrostaticPumpsServiceandRepairManual
Hydro-GearHGM-H™SeriesMotorServiceandRepairManual
FieldPro®6040Page7Preface
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PrefacePage8FieldPro®6040
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
ThinkSafetyFirst...............................................................................................................................1–3
JackingInstructions..............................................................................................................................1–6
SafetyandInstructionalDecals............................................................................................................1–6
FieldPro®6040Page1–1Safety
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SafetyInstructions
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldkillorcauseseriouspermanentinjuryordisability.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjury.
IMPORTANT
TheImportantnoticewillgivetheimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
Safety:SafetyInstructionsPage1–2FieldPro®6040
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ThinkSafetyFirst
ToroProductsaretestedandcertiedforcompliancewithexistingsafety
standardsandspecications.Althoughhazardcontrolandaccidentprevention
arepartiallydependentuponthedesignandcongurationofthemachine,
hazardcontrolandaccidentpreventionarealsodependentupontheawareness,
concernandpropertrainingofthepersonnelinvolvedintheoperation,transport,
maintenance,andstorageofthemachine.Improperuseormaintenanceofthe
machinecanresultininjuryordeath.
WARNING
Toreducethepotentialofinjuryordeath,complywiththesafety
instructionsinthismanual,aswellasinformationfoundinthe
Operator’sManualsandtheOperatorandSafetyTrainingVideos
foundonwww.toro.com.
•Avoidunexpectedstartingoftheengine…
Alwaysturnofftheengine,removetheignitionkeyanddisconnectthe
sparkplugwire(s)beforecleaning,adjusting,orrepair.
•Avoidlacerationsandamputations…
Stayclearofallmovingpartswhenevertheengineisrunning.Treatall
normallymovingpartsasiftheyweremovingwhenevertheengineis
runningorhasthepotentialtostart.
•Avoidburns…
Donottouchtheengine,mufer,orothercomponents,whichmaybehot
duringoperation,whiletheunitisrunningorshortlyafterithasbeen
running.
•Avoidresandexplosions…
Useextremecareinhandlingfuel.Fuelisammableanditsvaporsare
explosive.
–Extinguishallcigarettes,cigars,pipes,andothersourcesofignition.
–Avoidspillingfuelandneversmokewhileworkingwithanytypeoffuel
orlubricant.
–Wipeupanyspilledfueloroilimmediately.
–Neverremovethefuelcaporaddfuelwhentheengineisrunning.
–Alwaysuseapproved,labeledcontainersforstoringortransportingfuel
andlubricants.
–Donotaddordrainfuelinanenclosedspace.
–Donotstorethemachineorfuelcontainerwherethereisanopename,
spark,orpilotlight,suchasonawaterheaterorotherappliance.
•Avoidasphyxiation…
Donotoperateanengineinaconnedareawithoutproperventilation.
•Avoidinjuryfrombatteries…
–Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,
eyesandclothing.
–Batterygasescanexplode.Keepcigarettes,sparksandamesaway
fromthebattery.
•Avoidinjuryduetoinferiorparts…
Useonlyoriginalequipmentpartstoensurethatimportantsafetycriteria
aremet.
FieldPro®6040Page1–3Safety:SafetyInstructions
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ThinkSafetyFirst(continued)
•Avoidinjurytobystanders…
Alwayscleartheareaofbystandersbeforestartingortestingpowered
equipment.
•Avoidinjuryduetoprojectiles…
Alwayscleartheareaofsticks,rocksoranyotherdebristhatcouldbe
pickedupandthrownbythepoweredequipment.
•Avoidmodications…
Donotalterormodifyanypartunlessitisafactoryapprovedprocedure.
•Avoidunsafeoperation…
Alwaystestthesafetyinterlocksystemaftermakingadjustmentsor
repairsonthemachine.RefertotheElectricalsectioninthismanual
formoreinformation.
•Avoidelectricalshock…
–Nevertouchelectricalwiresorcomponentswhiletheengineisrunning.
Theycanbesourcesofshock.
–De-energizethesystemifyouarehavingtodorepairs.
–Iftestingelectricalcomponentsensureyouareworkinginadry
environment.
–Donotwearmetaljewelrywhenworkingonornearelectricalcomponents
orwiring.
•Avoidcontactwithpressurizedhydraulicuid...
–Releaseallpressureinthehydraulicsystembeforeperforminganywork
onthesystem.
–Keepyourbodyandhandsawayfrompin-holeleaksornozzlesthat
ejecthydraulicuidunderhighpressure.Hydraulicuidescapingunder
pressurecanhavesufcientforcetopenetratetheskinandcauseserious
injury.Usecardboardorpapertondhydraulicleaks;neveruseyour
hands.Ifhydraulicuidisinjectedintoyourskin,theuiddamage
toyourbodymustbesurgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryorgangrenemayresult.
•Usepersonalprotectiveequipment…
–Tiebacklonghair,anddonotwearlooseclothingorjewelry.
–Useappropriatepersonalprotectiveequipment(PPE)forprotecting
yourselffrompotentialhazardsintheenvironmentinwhichyouwillwork.
–EachprocessoutlinedinthismanualmayneeddifferentPPEtoprotect
theserviceperson.UsetheproperPPEforthetaskathand.
•Usingtools…
–Alltoolsshouldbeinproperworkingorder.Donotusetoolsthatare
brokenorindisrepair.
–Usethepropertoolfortheproperapplication.
•Usinglifts,hoists,andjacks…
–Alllifts,hoists,andjacksshouldbeusedinaccordancewiththe
manufacturerinformation.
–Inspectlifts,hoists,andjackspriortouse.
–Donotoverloadlifts,hoists,andjacks.
–Donotworkunderasuspendedload.
–Ensurechockblocksareusedonequipmentthatcanmove.
Safety:SafetyInstructionsPage1–4FieldPro®6040
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ThinkSafetyFirst(continued)
–Useliftsorjacksandjackstandsthatareratedtosupportthetotalweight
ofthemachineandanyattachments.
–Donotrelyonjackstosupportthemachine.
–Ifyouareunfamiliarwithanylifts,hoistsorjacks,donotusethemuntil
youknowhowtooperatethemcorrectly.
•Usingreextinguishers…
Usetheproperclassofreextinguisherincaseofre.
Ensurereextinguishersareservicedregularly,andreplaceanyre
extinguishersthataredischargedorinusebeyondtheirexpirationdates.
–ClassAreextinguishersareforordinarycombustiblematerialssuch
aspaper,wood,cardboard,andmostplastics.Thenumericalratingon
thesetypesofextinguishersindicatestheamountofwateritholdsand
theamountofreitcanextinguish.Geometricsymbol(greentriangle).
–ClassBreextinguishersareforresthatinvolveammableor
combustibleliquidssuchasgasoline,kerosene,greaseandoil.The
numericalratingforclassBextinguishersindicatestheapproximate
numberofsquarefeetofreitcanextinguish.Geometricsymbol(red
square).
–ClassCreextinguishersareforresthatinvolveelectricalequipment
suchasappliances,wiring,circuitbreakersandoutlets.Neverusewater
toextinguishclassCres-theriskofelectricalshockisfartoogreat!
ClassCextinguishersdonothaveanumericalrating.TheCclassication
meanstheextinguishingagentisnon-conductive.Geometricsymbol
(bluecircle).
–ClassABCreextinguishersareadrychemicaltypeusedformultiple
purposes.Seeabovedescriptionsforadditionalinformation.
FieldPro®6040Page1–5Safety:SafetyInstructions
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JackingInstructions
DANGER
Ifthemachineisnotproperlyraisedandsupported,themachine
maymoveorfall,whichmayresultinpersonalinjury.
•Useonlymechanicalorhydraulicjackstoraisethemachine.
•Donotusethehydraulicwheelmotorsasajackingorsupport
location.
•Donotuseanattachmentasajackingorsupportlocation.
•Usejackstandstosupporttheraisedmachine.
Beforeyouliftthemachine,removeanyattachmentthatmayinterferewith
correctlyraisingthemachine.
1.Parkthemachineonalevelsurface,raisetheattachment,engagethe
parkingbrake,setthekeyswitchtotheOFFpositionandremovekeyfrom
theswitch.
2.Chockthewheelsthatremainonthegroundtopreventthemachinefrom
moving.
3.Positionthejacksecurelyundertheframe,orliftthemachinefromoverhead
bytheframe.
4.Carefullyraisethemachine.
5.Positionjackstandsunderthemachineframetosupportthemachineand
lowerthemachineontothejackstands.
SafetyandInstructionalDecals
NumeroussafetyandinstructiondecalsareafxedtotheFieldPro6040.Ifany
decalbecomesillegibleordamaged,installanewdecal.Decalpartnumbers
arelistedinyourPartsCatalog,Operator’sManual,andaccessoryInstallation
Instructions.OrderreplacementdecalsfromAuthorizedToroDistributor.
Safety:JackingInstructionsPage1–6FieldPro®6040
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Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
EngineSpecications.........................................................................................................................2–3
HydraulicSystemSpecications........................................................................................................2–4
ChassisSpecications.......................................................................................................................2–4
TorqueSpecications...........................................................................................................................2–5
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–6
IdentifyingtheFastener......................................................................................................................2–7
StandardT orqueforDry,ZincPlated,andSteelFasteners(Inch)......................................................2–8
StandardTorqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–10
OtherTorqueSpecications.............................................................................................................2–11
ConversionFactors..........................................................................................................................2–11
ShopSupplies....................................................................................................................................2–12
SpecialT ools......................................................................................................................................2–14
FieldPro®6040Page2–1SpecicationsandMaintenance
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Specications
OverallDimensions
g395755
Figure1
SpecicationsandMaintenance:SpecicationsPage2–2FieldPro®6040
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EngineSpecications
ItemDescription
Make/DesignationKohlerCH740–3136,2-cylinder,aircooled,
OHVgasolineengine
BorexStroke83x67mm(3.27x2.64inches)
Totaldisplacement725cm3(44in3)
GovernorMechanical
Lowidlespeed1,575to1,725rpm
Highidlespeed3,575to3,725rpm
CarburetorFloatfeed,xedmainjet,andsolenoidfuelshut-off
ChoketypeManual
FuelRefertotheOperator’sManual
FuelpumpPulsetype
Fueltankcapacity30.2L(8USgallons)
AircleanerSingleelement,remote
LubricationsystemPressurelubrication
Crankcase-oilcapacity2L(2.1USquarts)
EngineoilRefertotheOperator’sManual
IgnitionsystemFlywheelmagneto,twinelectronicarmatures
withignitionadvance
SparkplugChampion®C12YCorequivalent
Sparkpluggap0.76mm(0.030inch)
Starter12VDC,solenoidshift
Alternator12VDC,15A
Engineweight(dry)43kg(94lb)
FieldPro®6040Page2–3SpecicationsandMaintenance:Specications
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HydraulicSystemSpecications
ItemDescription
Piston(traction)pumpsRightside:Hydro-GearPR,manuallycontrolled
variabledisplacementaxialpistonpumpwith
chargepumpandcoolingfan
Leftside:Hydro-GearPR,manuallycontrolled
variabledisplacementaxialpistonpump
Maximumtractionpumpdisplacement(per
revolution)
16.0cm3(0.97in3)
Maximumchargepumpdisplacement(per
revolution)
3.1cm3(0.19in3)
Tractioncircuitreliefpressure(forwardand
reverse)
20,000kPa(2900psi)
LiftpumpCasappapositivedisplacementgeartypepump
Maximumpumpdisplacement(per
revolution)
6.6cm3(0.4in3)
Chargecircuitreliefpressure620kPa(90psi)
Liftcircuitreliefpressure6000kPa(870psi)
WheelmotorsHydro-GearHGM-Hseriesxeddisplacement
axialpistonmotor
Displacement(perrevolution)295cm3(18in3)
HydraulicreturnlterSpin-oncartridgetypewith172kPa(25psi)relief
HydraulicuidRefertotheOperator’sManual
Hydraulicreservoircapacity28L(7.5USgallons)
ChassisSpecications
ItemDescription
Reartires24×12-12,4ply,TurfMaster,tubeless
Recommendedoperatingpressure=159
to172kPa(23to25psi)
Front(casterwheel)tires15×6.00-6,4ply,ribbed,tubeless
Recommendedoperatingpressure=
172kPa(25psi)
Rearwheellugnuttorque122to125N∙m(90to95ft-lb)inacrossingpattern
Rearwheelhubnuttorque373to474N·m(275to350ft-lbs)
SpecicationsandMaintenance:SpecicationsPage2–4FieldPro®6040
22267SLRevA

TorqueSpecications
Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For
criticalapplications,asdeterminedbyT oro,eithertherecommendedtorqueora
torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthis
ServiceManual.
Thesetorquespecicationsfortheinstallationandtighteningofthefastenerswill
applytoallthefastenerswhichdonothaveaspecicrequirementidentiedin
thisServiceManual.Thefollowingfactorsmustbeconsideredwhenapplying
thetorque:cleanlinessofthefastener,useofathreadsealant(e.g.,Loctite),
degreeoflubricationonthefastener,presenceofaprevailingtorquefeature
(e.g.,Nylocknut),hardnessofthesurfaceunderneaththeheadofthefastener,
orsimilarconditionwhichaffectstheinstallation.
Asnotedinthefollowingtables,thetorquevaluesshouldbereducedby25%
forlubricatedfastenersorfastenerswithawetthreadlockingcompound
appliedtoachievethesimilarstressasadryfastener.Thetorquevaluesmust
bereducedwhenthefasteneristhreadedintothealuminumorbrass.The
specictorquevalueshouldbedeterminedbasedonthealuminumorbrass
materialstrength,fastenersize,lengthofthreadengagement,etc.
Thestandardmethodofcheckingthetorquecanbeperformedbymarkingaline
onthefastener(headornut)andmatingpart,thenbackoffthefastener1/4
ofaturn.Measurethetorquenecessarytotightenthefasteneruntilthelines
matchup.
FieldPro®6040Page2–5SpecicationsandMaintenance:TorqueSpecications
22267SLRevA

CalculatingtheTorqueValuesWhenUsingaDrive-AdapterWrench
g205924
Figure2
TorqueConversionFactor=A/B
1.Torquewrench3.A(effectivelengthoftorquewrench)
2.Drive-adapterwrench(crowsfoot)4.B(effectivelengthoftorquewrenchand
drive-adapterwrench)
Usingadrive-adapterwrench(e.g.,crowfootwrench)inanypositionotherthan
90°and270°totheframeofthetorquewrenchwillaffectthetorquevalue
measuredbythetorquewrenchbecauseoftheeffectivelength(lever)ofthe
torquewrenchchanges.Whenusingatorquewrenchwithadrive-adapter
wrench,multiplythelistedtorquerecommendationbythecalculatedtorque
conversionfactor(Figure2)todeterminepropertighteningtorque.Whenusinga
torquewrenchwithadrive-adapterwrench,thecalculatedtorquewillbelower
thanthelistedtorquerecommendation.
Example:Themeasuredeffectivelengthofthetorquewrench(distancefrom
thecenterofthehandletothecenterofthesquaredrive)is457mm(18inches).
Themeasuredeffectivelengthofthetorquewrenchwiththedrive-adapter
wrenchinstalled(distancefromthecenterofthehandletothecenterofthe
drive-adapterwrench)is483mm(19inches).
Thecalculatedtorqueconversionfactorforthistorquewrenchwiththis
drive-adapterwrenchwouldbe18/19=0.947.
Ifthelistedtorquerecommendationforafasteneris103to127N∙m(76to94
ft-lb),thepropertorquewhenusingthistorquewrenchwithadrive-adapter
wrenchwouldbe98to121N∙m(72to89ft-lb).
SpecicationsandMaintenance:TorqueSpecicationsPage2–6FieldPro®6040
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