Toro Groundsmaster 5900 Series User manual

FormNo.16227SLRevB
Groundsmaster®5900&5910
(Models31698and31699)
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
–2016InitialIssue
A03/2018UpdatedEnginechapter,ElectricalchapterandFoldoutdrawings.Addedrevision
history.
B10/2019UpdatedHydraulic,Electrical,ChassisandOperatorCabchapters.
RevisionHistoryPage2Groundsmaster®5900&5910
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ReaderComments
TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous
efforttoimprovethequalityandusefulnessofitspublications.Todothis
effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,
accuracy,organization,usability,andreadabilityofthismanualbyane-mail
to[email protected]
orMailto:
TechnicalPublicationManager,Commercial
TheToroCompany
8111LyndaleAvenueSouth
Bloomington,MN55420-1196
Phone:[phone]
Groundsmaster®5900&5910Page3ReaderComments
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NOTES
NOTESPage4Groundsmaster®5900&5910
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Preface
Thepurposeofthispublicationistoprovidetheservicetechnicianwith
informationfortroubleshooting,testing,andrepairofmajorsystemsand
componentsontheGroundsmaster5900and5910.
RefertotheOperator’sManualsforinstalling,operating,maintenance,and
adjustmentinstructions.KeepacopyoftheOperator’sManualsandParts
CatalogsforyourmachineanditsaccessorieswiththisServiceManualfor
reference.AdditionalcopiesoftheOperator’sManualsandPartsCatalogsare
availableatwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
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.
Groundsmaster®5900&5910Page5Preface
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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
thanwhatisrecommendedintheStandardTorqueT ables;refertoT orque
Specications(page2–7).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
PrefacePage6Groundsmaster®5900&5910
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TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
SafetyandInstructionalDecals....................................................................1–8
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–7
ShopSupplies............................................................................................2–13
SpecialT ools..............................................................................................2–15
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
GeneralHydraulicSystemProblems............................................................3–3
TractionCircuitProblems..............................................................................3–4
PTOProblems..............................................................................................3–6
Lift/LowerCircuitProblems...........................................................................3–7
SteeringCircuitProblems.............................................................................3–8
StartingProblems.........................................................................................3–9
GeneralRunandTransportProblems.........................................................3–11
CuttingDeck(PTO)OperatingProblems....................................................3–12
CuttingDeckLift/LowerProblems...............................................................3–14
OperatorAdvisories....................................................................................3–16
UsingtheInfoCenterDisplayforTroubleshooting.......................................3–21
MachineFaults...........................................................................................3–23
EngineFaults..............................................................................................3–27
FactorsThatCanAffectQualityofCutandClippingDispersion...................3–29
Chapter4:YanmarDieselEngine....................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs...................................................................................4–11
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
HydraulicSchematic...................................................................................5–12
HydraulicFlowDiagrams............................................................................5–13
Testing........................................................................................................5–36
Adjustments...............................................................................................5–72
ServiceandRepairs...................................................................................5–73
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–3
ElectricalSystemOperation..........................................................................6–7
InfoCenterDisplay........................................................................................6–9
Adjustments................................................................................................6–46
ComponentT esting.....................................................................................6–53
ServiceandRepairs.................................................................................6–138
Chapter7:Chassis..........................................................................................7–1
GeneralInformation.....................................................................................7–2
ServiceandRepairs.....................................................................................7–3
Chapter8:CuttingDecks................................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
Chapter9:OperatorCab................................................................................9–1
GeneralInformation.....................................................................................9–2
ServiceandRepairs.....................................................................................9–4
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
HydraulicSchematic....................................................................................A–3
ElectricalSchematic(machineserialnumbersbelow316000200)................A–4
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ElectricalSchematic(machineserialnumbersbelow316000200)................A–5
ElectricalSchematic(machineserialnumbers316000201to
399999999)..................................................................................................A–6
ElectricalSchematic(machineserialnumbers316000201to
399999999)..................................................................................................A–7
ElectricalSchematic(machineserialnumbers400000000to
403450000)..................................................................................................A–8
ElectricalSchematic(machineserialnumbers400000000to
403450000)..................................................................................................A–9
ElectricalSchematic(machineserialnumbersabove403450001)..............A–10
ElectricalSchematic(machineserialnumbersabove403450001)..............A–11
OperatorPlatformWireHarnessDrawing(machineserialnumbersbelow
316000200)................................................................................................A–12
OperatorPlatformWireHarnessDiagram(machineserialnumbersbelow
316000200)................................................................................................A–13
OperatorPlatformWireHarnessDiagram(machineserialnumbersbelow
316000200)................................................................................................A–14
OperatorPlatformWireHarnessDrawing(machineserialnumbers
316000201to316999999)..........................................................................A–15
OperatorPlatformWireHarnessDiagram(machineserialnumbers
316000201to316999999)..........................................................................A–16
OperatorPlatformWireHarnessDiagram(machineserialnumbers
316000201to316999999)..........................................................................A–17
OperatorPlatformWireHarnessDiagram(machineserialnumbers
400000000to403450000)..........................................................................A–18
OperatorPlatformWireHarnessDiagram(machineserialnumbers
400000000to403450000)..........................................................................A–19
OperatorPlatformWireHarnessDiagram(machineserialnumbers
400000000to403450000)..........................................................................A–20
OperatorPlatformWireHarnessDiagram(machineserialnumbersabove
403450001)................................................................................................A–21
OperatorPlatformWireHarnessDiagram(machineserialnumbersabove
403450001)................................................................................................A–22
OperatorPlatformWireHarnessDiagram(machineserialnumbersabove
403450001)................................................................................................A–23
RearWireHarnessDrawing(machineserialnumbersbelow
316000200)................................................................................................A–24
RearWireHarnessDiagram(machineserialnumbersbelow
316000200)................................................................................................A–25
RearWireHarnessDrawing(machineserialnumbers316000201to
403450000)................................................................................................A–26
RearWireHarnessDrawing(machineserialnumbers316000201to
403450000)................................................................................................A–27
RearWireHarnessDrawing(machineserialnumbersabove
403450001)................................................................................................A–28
RearWireHarnessDrawing(machineserialnumbersabove
403450001)................................................................................................A–29
EngineWireHarnessDrawing(machineserialnumbers316000001to
316999999)................................................................................................A–30
EngineWireHarnessDrawing(machineserialnumbers316000001to
316999999)................................................................................................A–31
EngineWireHarnessDrawing(machineserialnumbers400000000to
403450000)................................................................................................A–32
EngineWireHarnessDrawing(machineserialnumbers400000000to
403450000)................................................................................................A–33
EngineWireHarnessDrawing(machineserialnumbersabove
403450001)................................................................................................A–34
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EngineWireHarnessDrawing(machineserialnumbersabove
403450001)................................................................................................A–35
CabPowerSupplyWireHarness(Machineserialnumbersbelow
316000200)................................................................................................A–36
CabHeadlinerWireHarnessDrawing.........................................................A–37
CabHeadlinerWireHarnessDiagram........................................................A–38
WireHarnessDiagram−Two−PostROPSExtension.................................A–39
WireHarnessDiagram−Two−PostROPSExtension.................................A–40
AdditionalReferenceMaterials
YanmarTNV(Tier4)SeriesServiceManual
YanmarTNV(Tier4)SeriesTroubleshootingManual
DanfossH1ClosedCircuitAxialPistonPumpsServiceManual
DanfossH1ClosedCircuitAxialPistonpumpsRepairInstructions
DanfossSteeringUnitTypeOSPMServiceManual
EatonPartsAndRepairInformation:5SeriesSteeringControlUnits
SandenSDCompressorServiceGuide
Groundsmaster®5900&5910Page9Preface
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PrefacePage10Groundsmaster®5900&5910
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Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
BeforeOperatingtheMachine...........................................................................................................1–2
WhileOperatingtheMachine.............................................................................................................1–3
MaintenanceandService...................................................................................................................1–4
Battery-DisconnectSwitch.................................................................................................................1–5
JackingInstructions...........................................................................................................................1–6
SafetyandInstructionalDecals............................................................................................................1–8
Groundsmaster®5900&5910Page1–1Safety
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SafetyInstructions
TheGroundsmaster5900and5910aretestedandcertiedbyT orofor
compliancewithexistingsafetystandardsandspecications.Althoughhazard
controlandaccidentpreventionpartiallyaredependentuponthedesignand
congurationofthemachine,thesefactorsarealsodependentuponthe
awareness,concernandpropertrainingofthepersonnelinvolvedinthe
operation,transport,maintenanceandstorageofthemachine.Improperuseor
maintenanceofthemachinecanresultininjuryordeath.
WARNING
Toreducethepotentialofinjuryordeath,complywiththefollowing
safetyinstructionsaswellasinformationfoundintheOperator’s
ManualsandtheOperatorandSafetyTrainingVideosfoundon
www.toro.com.
BeforeOperatingtheMachine
•ReviewandunderstandthecontentsoftheOperator’sManualsbefore
startingandoperatingthemachine.Becomefamiliarwiththecontrolsand
knowhowtostopthemachineandenginequickly.Additionalcopiesofthe
Operator’sManualsareavailableatwww.toro.com.
•Neverallowchildrentooperatethemachine.Neverallowadultstooperate
themachinewithoutproperinstructions.
•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand
tractorenginequickly.
•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety
device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating
themachine.
•Alwayswearsubstantialshoes.Donotoperatemachinewhilewearing
sandals,tennisshoesorsneakers.Donotwearloosettingclothingwhich
couldgetcaughtinmovingpartsandcausepersonalinjury.
•Wearingsafetyglasses,safetyshoes,longpantsandahelmetisadvisable
andrequiredbysomelocalsafetyandinsuranceregulations.
•Makesureworkareaisclearofobjectswhichmightbepickedupandthrown
bytheattachments.
•Keepeveryone,especiallychildrenandpets,awayfromtheareasof
operation.
•Ensurethattheinterlockswitchesareadjustedcorrectlysotheengine
cannotbestartedunlesstractionpedalisinNEUTRALandcuttingdecksare
DISENGAGED.
•Sincethefuelishighlyammable;handleitcarefully.
–Useanapprovedfuelcontainer.
–Donotremovecapfromfueltankwhenengineishotorrunning.
–Donotsmokewhilehandlingfuel.
–Fillfueltankoutdoorsandnohigherthantothebottomoflterscreen.Do
notoverllfueltank.
–Wipeupanyspilledfuel.
Safety:SafetyInstructionsPage1–2Groundsmaster®5900&5910
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WhileOperatingtheMachine
1.Sitontheseatwhenstartingandoperatingthemachine.
2.Beforestartingtheengine:
A.Applytheparkingbrake.
B.MakesuretractionpedalisinneutralandthePTOswitchisOFF
(disengaged).
3.Afterengineisstarted,releaseparkingbrakeandkeepfootofftractionpedal.
Machinemustnotmove.Ifmovementisevident,theremaybeaproblem
withtractionpedalcalibrationorthepiston(traction)pumpthatneedstobe
correctedbeforeusingthemachine.
4.Donottouchtheengine,radiatorandmuferorexhaustpipewhileengineis
runningorsoonafterithasstoppedbecausetheseareasarehotenough
tocauseburns.
5.Beforegettingofftheseat:
A.Ensurethattractionpedalisinneutral.
B.Fullyloweranddisengagecuttingdecks.Waitforbladestostop.
C.Applytheparkingbrake.
D.Stopengineandremovekeyfromswitch.
6.Tororecommendsthatanytimethemachineisparked(shortorlongterm),
thecuttingdecksshouldbeloweredtotheground.Thisrelieveshydraulic
pressurefromthedeckliftcircuitandeliminatestheriskofthecuttingdecks
unexpectedlyloweringtotheground.
7.Donotparkonslopesunlesswheelsarechockedorblocked.
Groundsmaster®5900&5910Page1–3Safety:SafetyInstructions
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MaintenanceandService
1.Beforeservicingormakingadjustments,lowerdecks,stopengine,apply
parkingbrakeandremovekeyfromthekeyswitch.
2.Makesuremachineisinsafeoperatingconditionbykeepingallnuts,bolts
andscrewstight.
3.Neverstorethemachineorfuelcontainerinsidewherethereisanopen
ame,suchasnearawaterheaterorfurnace.
4.Makesureallhydraulicconnectorsaretightandallhydraulichosesandlines
areingoodconditionbeforeapplyingpressuretothehydraulicsystem.
5.Keepbodyandhandsawayfrompinholeleaksinhydrauliclinesthateject
highpressurehydraulicuid.Usecardboardorpapertondhydraulicleaks.
Hydraulicuidescapingunderpressurecanpenetrateskinandcauseinjury.
Fluidaccidentallyinjectedintotheskinmustbesurgicallyremovedwithina
fewhoursbyadoctorfamiliarwiththisformofinjuryorgangrenemayresult.
6.Beforedisconnectingorperforminganyworkonthehydraulicsystem,all
pressureinsystemmustberelievedbyloweringcuttingdeckstotheground
andstoppingengine.
7.Ifmajorrepairsareeverneededorassistanceisdesired,contactan
AuthorizedT oroDistributor.
8.Toreducepotentialrehazard,keepengineareafreeofexcessivegrease,
grass,leavesanddirt.Cleanprotectivescreenonmachinefrequently.
9.Ifenginemustberunningtoperformmaintenanceoranadjustment,keep
hands,feet,clothingandotherpartsofthebodyawayfromcuttingdecksand
othermovingparts.Keepbystandersaway.
10.Toassuresafetyandaccuracy,checkmaximumenginespeed.
11.Shutofftheenginebeforecheckingoraddingoiltothecrankcase.
12.Disconnectbatterybeforeservicingthemachine.Disconnectnegativecable
rstandpositivecablelast.Ifbatteryvoltageisrequiredfortroubleshooting
ortestprocedures,temporarilyconnectthebattery.Reconnectpositivecable
rstandnegativecablelast.
13.Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,
eyesandclothing.Protectyourface,eyesandclothingwhenworkingwitha
battery.
14.Batterygasescanexplode.Keepcigarettes,sparksandamesawayfrom
thebattery.
15.Atthetimeofmanufacture,themachineconformedtothesafetystandards
forridingmowers.T oassureoptimumperformanceandcontinued
safetycerticationofthemachine,usegenuineTororeplacementparts
andaccessories.Replacementpartsandaccessoriesmadebyother
manufacturersmayresultinnon-conformancewiththesafetystandardsand
thewarrantymaybevoided.
16.Whenchangingattachments,tiresorperformingotherservice,usecorrect
supports,hoistsandjacks.Makesuremachineisparkedonasolidlevel
surfacesuchasaconcreteoor.Priortoraisingthemachine,remove
anyattachmentsthatmayinterferewiththesafeandproperraisingofthe
machine.Alwayschockorblockwheels.Useappropriatejackstandsto
supporttheraisedmachine.Ifthemachineisnotproperlysupportedbyjack
stands,themachinemaymoveorfall,whichmayresultinpersonalinjury
(seeJackingInstructions(page1–6)).
Safety:SafetyInstructionsPage1–4Groundsmaster®5900&5910
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MaintenanceandService(continued)
17.Whenweldingonmachine,disconnectallbatterycablestopreventdamage
tomachineelectronicequipment.Disconnectnegativebatterycablerstand
positivecablelast.Also,disconnectwireharnessconnectorfrombothofthe
TECcontrollers,disconnectandremovetheengineECUanddisconnectthe
terminalconnectorfromthealternator.Attachweldergroundcablenomore
thantwo(2)feet(0.6meters)fromtheweldinglocation.
18.Makesuretodisposeofpotentiallyharmfulwaste(e.g.fuel,oil,engine
coolant,lters,battery)inanenvironmentallysafemanner.Followalllocal
codesandregulationswhenrecyclingordisposingofwaste.
Battery-DisconnectSwitch
1
g287496
Figure1
1.Battery−Disconnectswitch
Themachineincludesabattery−disconnectswitchlocatedunderthehoodin
therightrearcorneroftheenginecompartment.Turningthebatterydisconnect
switchtotheOFFpositionopensthe12Voltand24Voltbatterygroundcircuit.
ThebatterydisconnectswitchshouldbesettoOFFwhenservicingthemachine.
TheswitchcanbelockedintheOFFpositionifdesired.
CAUTION
DoNotturnthebattery−disconnectswitchtotheOFFposition
whiletheengineisrunning.Thebattery−disconnectswitchisnot
anemergencyshutoff.IfthebatterydisconnectswitchissettoOFF
whiletheengineisrunning,theenginewillcontinuetorunonthe
powersuppliedbythe12Voltalternatorandyoumaycausedamage
toelectricalcomponentsincludingtheToroElectronicControllers
(TECs).
Groundsmaster®5900&5910Page1–5Safety:SafetyInstructions
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JackingInstructions
CAUTION
Whenchangingattachments,tiresorperformingotherservice,use
correctjacksandsupports.Makesuremachineisparkedonasolid,
levelsurfacesuchasaconcreteoor.Priortoraisingmachine,
removeanyattachmentsthatmayinterferewiththesafeandproper
raisingofthemachine.Alwayschockorblockwheels.Usejack
standstosupporttheraisedmachine.Ifthemachineisnotproperly
supportedbyjackstands,themachinemaymoveorfall,whichmay
resultinpersonalinjury.
JackingtheFrontEnd(Figure2)
g008996
Figure2
1.Framejackingpoint
1.Setparkingbrakeandchockbothreartirestopreventthemachinefrom
moving.
2.Positionjacksecurelyundertheframe,justtotheinsideofthefronttire.
Makesurethatthejackdoesnotcontacthydraulicliftcylinder.Jackfront
wheelofftheground.
3.Oncethemachineisraised,positionjackstandundertheframeascloseto
thewheelaspossibletosupportthemachine.
Safety:SafetyInstructionsPage1–6Groundsmaster®5900&5910
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JackingtheRearEnd(Figure3)
g008995
Figure3
1.Rearaxlejackingpoint
1.Setparkingbrakeandchockbothfronttirestopreventthemachinefrom
moving.
2.Placejacksecurelyunderthecenterofrearaxle.Jackrearofmachineoff
theground.
3.Oncethemachineisraised,usejackstandsundertheaxletosupportthe
machine.
Groundsmaster®5900&5910Page1–7Safety:SafetyInstructions
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SafetyandInstructionalDecals
Numeroussafetyandinstructiondecalsareafxedtothetractionunitand
cuttingunitsofyourGroundsmaster.Ifanydecalbecomesillegibleordamaged,
installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog.Order
replacementdecalsfromAuthorizedT oroDistributor.
Safety:SafetyandInstructionalDecalsPage1–8Groundsmaster®5900&5910
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Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
OverallDimensions............................................................................................................................2–2
Engine................................................................................................................................................2–3
HydraulicSystem...............................................................................................................................2–4
Chassis..............................................................................................................................................2–5
CuttingDecks.....................................................................................................................................2–6
TorqueSpecications...........................................................................................................................2–7
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–8
IdentifyingtheFastener......................................................................................................................2–9
StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)..........................................2–10
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–11
OtherTorqueSpecications.............................................................................................................2–12
ConversionFactors..........................................................................................................................2–12
ShopSupplies....................................................................................................................................2–13
SpecialTools......................................................................................................................................2–15
Groundsmaster®5900&5910Page2–1SpecicationsandMaintenance
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Specications
OverallDimensions
g287504
Figure4
SpecicationsandMaintenance:SpecicationsPage2–2Groundsmaster®5900&5910
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