Toro Groundsmaster 5900 User manual

FormNo.3429-577RevA
ContactorKit
Groundsmaster®5900or5910RotaryMower
ModelNo.139-1030
InstallationInstructions
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Disconnectthebattery.
3Nopartsrequired–Removethesidepanels.
4Nopartsrequired–Removethe28-Vsolenoid.
Contactor1
Contactormount1
Cable1
Nut(1/4inch)4
Nut(5/16inch)2
Flangebolt2
5
Carriagebolt2
Installthecontactor.
Wirecap1
Wirelabel1
Vinylcap1
Nut(M5)1
6
Cabletie1
RemovetheI-terminalwirefromthe
alternator.
7Moldedcap1Removethediode.
8Fuse(60A)1Installthe60-Afuse.
9Fusedecal(PartNo.139-1031)1Installthedecal.
10Nopartsrequired–Connectthebattery.
11Nopartsrequired–Installthesidepanelsandclosethe
hood.
12Nopartsrequired–Verifythatthe28-Vsystemandcab
power(ifequipped)arefunctioning.
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3429-577*A

1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Lowerthecuttingunits.
4.Shutofftheengineandremovethekey.
2
DisconnectingtheBattery
NoPartsRequired
Procedure
1.Openthehood(Figure1).
g251777
Figure1
2.RotatethebatterydisconnectswitchtotheOFF
position,refertotheOperator’sManualforyour
machine.
3
RemovingtheSidePanels
NoPartsRequired
Procedure
1.Loosenthe2knobsthatsecuretheleftandright
sidepanelstothemachine(Figure2).
g251780
Figure2
Rightsidepanelshown
1.Sidepanel2.Knobs
2.Removethesidepanelsfromthemachine
(Figure2).
4
Removingthe28-V
Solenoid
NoPartsRequired
Procedure
Note:Yourmachinemayhaveupto3fusesonthe
fusebrackettowardstherearendofthemachine.For
thisprocedure,removethe28-Vsolenoidunderthe
fuseholdershowninFigure3.
2

g285045
Figure3
1.Openthefuse-holdercover(Figure4).
2.Removethe2ringterminalsfromtheleftpostof
thefuseholder(Figure4).
g282709
Figure4
1.Fusecover4.Nut
2.Ringterminal—28V+FUSE5.Wireconnectors(labeled
COIL+[28VMASTER
CONTACTOR]andCOIL-
[28VMASTERCONTACTOR])
3.Ringterminal—battery
cable
3.Removethewireconnectors(labeledCOIL+[28V
MASTERCONTACTOR]andCOIL-[28VMASTER
CONTACTOR])fromthesolenoid(Figure4).
4.Removetheredinsulatorandringterminal
(labeledSOLENOIDLINEOUT[28VMASTER
CONTACTOR])fromthesolenoid(Figure5).
g282710
Figure5
1.Nut3.Redinsulator
2.Ringterminal—SOLENOID
LINEOUT[28VMASTER
CONTACTOR]
5.Removeanddiscardthejumperstrapand
insulator(Figure6).
g282711
Figure6
1.Nuts3.Bolt
2.Jumperstrapandinsulator4.Solenoid
6.Removetheboltsandnutsthatsecurethe
solenoidtothebracket(Figure6).
7.Removeanddiscardthesolenoidfromthe
bracket(Figure6).
3

5
InstallingtheContactor
Partsneededforthisprocedure:
1Contactor
1Contactormount
1Cable
4Nut(1/4inch)
2Nut(5/16inch)
2Flangebolt
2Carriagebolt
Procedure
1.Use2carriageboltsand2nuts(1/4inch)to
securethecontactormounttothebracket
(Figure7).
g282536
Figure7
1.Carriagebolt3.Nut(1/4inch)
2.Contactormount
2.Use2angeboltsand2nuts(1/4inch)tosecure
thecontactortothecontactormount(Figure8).
g282537
Figure8
1.Contactor3.Nut(1/4inch)
2.Flangebolt
3.Useanut(5/16inch)tosecuretheendofthe
cablewiththebootattachedtothecontactor
(Figure9).
g282535
Figure9
1.Nut(5/16inch)3.Nut(5/16inch)
2.Cable
4.Useanut(5/16inch)tosecuretheotherend
ofthecabletotherightpostofthefuseholder
(Figure9).
5.InstallthewireconnectorlabeledCOIL+[28V
MASTERCONTACTOR]totheleftpostatthetopof
thecontactor(Figure10).
4

g282538
Figure10
1.Ringterminal—28V+FUSE
andringterminal—battery
cable
3.Wireconnector—COIL+
[28VMASTERCONTACTOR]
2.Nut4.Wireconnector—COIL-
[28VMASTERCONTACTOR]
6.InstallthewireconnectorlabeledCOIL-[28V
MASTERCONTACTOR]totherightpostatthetop
ofthecontactor(Figure10).
7.Assembletheringterminallabeled28V+FUSE
ofthemachinewireharnessontotheleftpostof
thefuseholder(Figure10).
8.Assembletheringterminalofthebatterycable
ontotheleftpostofthefuseholderandusethe
previouslyremovednuttosecuretheterminals
tothepost(Figure10).
9.Torquethenutsthatsecuretheconnectorsto
thefuse-holderpoststo14N∙m(10ft-lbs).
10.Installtheredinsulatorandringterminallabeled
SOLENOIDLINEOUT[28VMASTERCONTACTOR]
(Figure11)totheleftpostofthecontactor.
g282534
Figure11
1.Fuse-holdercover2.Ringterminal(SOLENOID
LINEOUT[28VMASTER
CONTACTOR])
11.Torquethenutsthatsecuretheconnectorsto
thecontactorpoststo5to6N∙m(40to50in-lb).
12.Closethecoverofthefuse-holder(Figure11)
untilthecoversnapsclosedsecurely.
5

6
RemovingtheI-Terminal
WirefromtheAlternator
Partsneededforthisprocedure:
1Wirecap
1Wirelabel
1Vinylcap
1Nut(M5)
1Cabletie
Procedure
1.LocateandremovetheI-terminalwire(green
wire)onthealternator(Figure12).
g283948
Figure12
1.Nut4.Alternatorpost—Remote
senseterminal
2.Ringterminal(I-terminal
wire)
5.Alternatorpost—Iterminal
3.I-terminalwire(greenwire)6.Alternatorpost—R
terminal
2.Cutoffanddiscardtheringterminalfromthe
wire(Figure12).
3.Installthewirecapontheendofthecutgreen
wireandcrimp(Figure13).
g284893
Figure13
1.Vinylcap4.Alternatorpost—Iterminal
2.Wirecap5.Nut(M5)
3.Wirelabel
4.Installthewirelabelontothewire(Figure13).
5.Useacabletietosecurethewiretothewire
harness.
6.Installanut(M5)ushwiththetopofthe
alternatorpost(Figure13).
7.Installavinylcapoverthealternatorpost(Figure
13).
Note:Thenut(M5)helpstosecurethevinyl
capoverthepost.
6

7
RemovingtheDiode
Partsneededforthisprocedure:
1Moldedcap
Procedure
Formachineswithaserialnumberof403444961
orbelow:
1.Locatethefuseblockontherightsideofthe
machine(Figure14).
g283947
Figure14
1.Diode3.Fuseblock
2.Fuse-blockcover
2.Accessthefuseblockbypullingthefuseblock
downfromthecover(Figure14).
3.Removethediodefromthefuseblock(Figure
14)anddiscardit.
4.Installthefuseblockintothecover.
Formachineswithaserialnumberof403444962
orabove:
1.Removethemoldeddiodefromtheconnector
labeledP103ontherightsideofthemachine
(Figure15).
g285043
Figure15
1.Diode3.Moldedplug
2.Connector—P103
2.Discardthediode.
3.Installthemoldedplugintotheconnector
(Figure15).
7

8
Installingthe60-AFuse
Partsneededforthisprocedure:
1Fuse(60A)
Procedure
Performthisprocedureonlyifyourmachineis
equippedwithacaborcabpowersupply(i.e.,
2-PostROPSExtensionKitorPowerHarnessKit).
Figure16illustratesthefusesasseenfromtherearof
themachine.Forthisprocedure,replacetheexisting
cabpowerfuse(100A)withthe60Afusefromthiskit.
g285820
Figure16
1.24-V-system-powerfuse
(100A)
3.Platform-powerfuse(60
A)
2.Cab-powerfuse(100A)
1.Openthecoverofthecabpowerfuse(Figure
17).
2.Removethenutsfromthepostsofthefuse
holder(Figure17).
g285335
Figure17
1.Ringterminal(yellow)3.Fuse
2.Nut4.Post(fuseholder)
3.Removetheringterminalfortheyellowwireof
themachinewireharnessfromtheleftpostof
thefuseholder(Figure17).
4.Removethefuse(100A)fromthefuseholder
(Figure17)anddiscardit.
5.Installthefuse(60A)tothefuseholder(Figure
17).
6.Assembletheringterminalfortheyellowwireof
themachinewireharnessontotheleftpostof
thefuseholder(Figure17).
7.Assemblethe2nutsontotheleftandrightposts
ofthefuse-holder(Figure17).
8.Torquethenutsto14N∙m(10ft-lbs).
9.Closethecoverofthefuse-holderuntilthecover
snapsclosedsecurely(Figure18).
g285334
Figure18
1.Cover(fuseholder)
8

9
InstallingtheDecal
Partsneededforthisprocedure:
1Fusedecal(PartNo.139-1031)
Procedure
1.Removeanydustanddebrisfromtheexisting
fuse-decalsurface;refertoFigure19forthe
decallocation.
g282717
Figure19
1.Contactor2.Decallocation
2.Installthefusedecal(PartNo.139-1031)over
theexistingfusedecal(Figure19).
10
ConnectingtheBattery
NoPartsRequired
Procedure
RotatethebatterydisconnectswitchtotheON
position;refertotheOperator’sManualforyour
machine.
11
InstallingtheSidePanels
andClosingtheHood
NoPartsRequired
Procedure
1.Aligntheholesinsidepanelswiththeholes
inthepanelsupportsofthemachine;referto
Figure2in3RemovingtheSidePanels(page
2).
2.Securethesidepanelstothemachinewiththe
2knobsthatyouremovedin3Removingthe
SidePanels(page2).
3.Closethehoodandsecureit.
9

12
Verifythe28-VSystemand
Cab-PowerFunction
NoPartsRequired
Procedure
Important:Ensurethatallwiringisroutedaway
fromanyhot,sharp,ormovingpartsonthe
machine.
1.Ensurethatthemachinesoftwareisupdatedto
thelatestversion(i.e.,RevKorhigher).
2.UsetheInfoCentertoconrmthatthe28-V
systemandcabpower(ifequipped)are
charging.
Note:Youcandeterminethatthesesystems
arechargingbytogglingtothevoltageindicators
inthestartupscreen;refertothemachine
SoftwareGuide.
3.Verifythattheradiatorandhydrauliccoolerfans
arefunctioningbyperformingthefollowingsteps
torunthefandemointheInfoCenter:
A.FromtheMainMenuscreen,selectthe
Serviceoption.
B.FromtheServicescreen,selecttheFan
Demooption.
C.FollowtheInfoCenterpromptstoperform
thefandemo.
10