Form No. 08159SL Rev C Groundsmaster 5900 Traction Unit (Models 31598 and 31599) © 2018—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date – 2009 Initial issue. A 2016 Updated Hydraulic and Electrical chapters. B 03/2018 Added revision history. C 05/2018 Added VA02 series planetary information.
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Notes: Notes: Page 4 Groundsmaster 5900 Traction Unit 08159SL Rev C
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components of the Groundsmaster 5900 and 5910 machines (Models 31598 and 31599). Refer to the traction unit Operator’s Manuals for operating, maintenance, and adjustment instructions. Keep a copy of the Operator’s Manuals and Parts Catalogs for your machine with this Service Manual for reference.
g033775 Figure 1 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.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–5 Safety and Instructional Decals .
Electrical Schematic Sheet 1 of 5 (Serial Number Below 313000300) ......................................................................................................................A–7 Electrical Schematic Sheet 2 of 5 (Serial Number Below 313000300) ..................................................................................................A–8 Electrical Schematic Sheet 3 of 5 (Serial Number Below 313000300) ..........................................................................................
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number Above 314000000) ................................................................................................A–36 Rear Wire Harness Drawing (Serial Number Below 313000300) .................A–37 Rear Wire Harness Diagram (Serial Number Below 313000300) ................A–38 Rear Wire Harness Drawing (Serial Number From 313000301 to 313999999) ................................................................................................
Preface Page 10 Groundsmaster 5900 Traction Unit 08159SL Rev C
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ............................................................................................................. 1–2 Maintenance and Service.................
Safety Instructions The Groundsmaster 5900 and 5910 machines are tested and certified by Toro for compliance with the existing safety standards and specifications. Although the hazard control and accident prevention do not fully depend on the design and configuration of the machine, these factors are also dependent on the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
While Operating the Machine (continued) DANGER The exhaust fumes are hazardous and have the potential of injury or death. Do not run the engine in a confined area without adequate ventilation. CAUTION Running the engine causes the engine, radiator, and exhaust system to become hot. Touching a hot engine, radiator, or exhaust system can burn you. Do not touch the engine, radiator, or exhaust system while the engine is running or soon after you stop it.
Maintenance and Service (continued) • Do not overspeed the engine by changing the governor setting. To ensure • • • • • • • • • • • • • Safety: Safety Instructions safety and accuracy, check the maximum engine speed. Disconnect the batteries before servicing the machine. Disconnect the negative battery cable and then the positive cables. If the battery voltage is necessary for troubleshooting or test procedures, temporarily connect the batteries.
Jacking Instructions CAUTION Failing to properly support the machine with jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to raise and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Raising the Rear of the Machine g032123 Figure 3 1. Rear axle jacking point 2. Rear tire 1. Set the parking brake and block the 2 front tires with chocks to prevent the machine from moving. 2. Position the jack correctly under the center of the rear axle. Lift the rear of the machine off the ground. 3. Use appropriate jack stands under the rear axle to support the machine. Safety and Instructional Decals The numerous safety and instruction decals are affixed to your machine.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Decimal and Millimeter Equivalents ................................................................................................... 2–2 U.S. to Metric Conversions ................................................................................................................
Specifications Insert a copy of the Operator’s Manuals and Parts Catalogs for your machine at the end of this chapter. Additionally, if any optional equipment or accessories are installed to your machine, insert the Installation Instructions, Operator’s Manuals, and Parts Catalogs for those options at the end of this chapter. The maintenance procedures and recommended service intervals for your machine are covered in the Operator’s Manual.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.914 Feet Meters 0.305 Feet Centimeters 30.48 Inches Meters 0.025 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.093 Square Inches Square Centimeters 6.452 Acre Hectare 0.405 Cubic Yards Cubic Meters 0.765 Cubic Feet Cubic Meters 0.028 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
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. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Identifying the Fastener (continued) g032125 Figure 5 Calculating the Torque Values When Using a Drive-Adapter Wrench g033777 Figure 6 Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90º and 270º to the frame of the torque wrench will affect the torque value measured by the torque wrench because of the effective length (lever) of the torque wrench changes.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 30 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Thread Size Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Other Torque Specifications (continued) Wheel Bolts and Lug Nuts Thread Size Recommended Torque* 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N∙m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N∙m M12 X 1.25 Class 8.8 80 ± 10 ft-lb 108 ± 14 N∙m M12 X 1.5 Class 8.8 80 ± 10 ft-lb 108 ± 14 N∙m *For steel wheels and non-lubricated fasteners Thread Cutting Screws (Zinc Plated Steel) Thread Size Threads per Inch Baseline Torque** Type A Type B No. 6 18 20 20 ± 5 in-lb No.
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. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
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.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Chapter 3 Diesel Engine Table of Contents Specifications ....................................................................................................................................... 3–2 Diesel Engine..................................................................................................................................... 3–2 General Information ..............................................................................................................................
Specifications Diesel Engine Item Description Make/Designation Cummins, 4-cycle, 4-cylinder, liquid cooled, turbocharged, diesel engine Bore 95 mm (3.74 inches) Stroke 115 mm (4.53 inches) Total displacement 3300 cm³ (201 in³) Firing order 1 (closest to the engine pulley) - 2 - 4 - 3 Direction of rotation Clockwise (viewed from the engine pulley) 17:1 Compression ratio Intake valve clearance 0.35 mm (0.014 inch) Exhaust valve clearance 0.50 mm (0.
Diesel Engine (continued) Engine Fastener Torque Specifications Item Description Alternator adjusting bolt 31 N∙m (23 ft-lb) Alternator mounting bracket bolt (2 each) 31 N∙m (23 ft-lb) Alternator mounting bolt 66 N∙m (49 ft-lb) Crankshaft pulley bolt 372 N∙m (274 ft-lb) Exhaust manifold flange-head screw (8 each) 45 N∙m (33 ft-lb) Front cover flange-head screw (16 each) 19 N∙m (14 ft-lb) Oil drain plug 51 N∙m (38 ft-lb) Oil pan flange-head screw (24 each) 32 to 51 N∙m (24 to 38 ft-lb) Oil
General Information This chapter gives information about specifications of the Cummins B3.3 diesel engine used in the Groundsmaster 5900 and 5910 machines. Additionally, some engine repair procedures are described in this manual. The described adjustments and repairs require tools which are commonly available in many service shops. Some service and repair parts for the engine in your Groundsmaster are supplied through your Authorized Toro Distributor.
Fuel-Injection System The engine fuel-injection system operates at high pressures while the engine is running. Do not loosen any fuel system components, fittings, or hoses while the engine is running. Keep your body and hands away from leaks in fuel-injection lines. Use cardboard or paper to find high pressure fuel leaks if they may exist. Leaking fuel under pressure can penetrate skin and cause injury.
Adjustments Adjusting the Valve Clearance g031354 Figure 7 1. Crankshaft pulley 2. Tone wheel cutout 3. TDC indicator g031355 Figure 8 1. 2. Locknut Adjustment screw 3. 4. Rocker arm Valve clearance g031356 Figure 9 1. 2. 3. 4. Diesel Engine: Adjustments #1 #1 #2 #2 intake exhaust intake exhaust 5. 6. 7. 8.
Adjusting the Valve Clearance (continued) 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift and support the hood. 3. Remove the valve cover from the engine; refer to Removing the Valve Cover (page 3–28). 4. Position the engine crankshaft so that the cylinder #1 is at the top dead center (TDC) at the end of the compression stroke. A.
Service and Repairs Air Filter System g031956 Figure 10 1. Clamp 10. Worm clamp 19. Hose clamp (8 each) 2. 3. Air hose Flange-head screw (6 each) 11. 12. Intake tube U-bolt 20. 21. Tube Air intake tube (4 each) 4. 5. Air cleaner mount Flange nut (8 each) 13. 14. Bolt Mount plate 22. 23. Tube Radiator assembly 6. Air cleaner mounting band (2 each) 15. Tube clamp 24. Airbox 7. Air cleaner assembly 16. Flat washer 25. Shim (as needed) 8. Adapter 17. Flange nut (3 each) 26.
Removing the Air Filter System g031358 Figure 11 1. Radiator 4. Pin clip (8 each) 2. Left cooler bracket 5. Pin (8 each) 3. Charge air cooler 6. Right cooler bracket 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift and support the hood to get access to the engine. 3. Remove the air cleaner components as shown in Figure 10. 4. Examine all the tubes and clamps for wear or damage.
Installing the Air Filter System IMPORTANT Leaks in the air filter system will cause serious engine damage. Ensure that all the air cleaner components are in good condition and are properly secured during installation. 1. Assemble the air cleaner system; refer to Figure 10. A. Ensure that the tabs in the air cleaner mounting bands align fully with the slots in the air cleaner body. B. Align the clamps (item 1) so that there is no interference with hood foam when you close the hood. C.
Exhaust System g031957 Figure 14 1. Exhaust clamp 4. Muffler 7. 2. Exhaust tube 5. Tailpipe 3. Muffler clamp (2 each) 6. Flange-head screw (4 each) Heat shield Removing the Exhaust System CAUTION A hot engine and exhaust system can cause burns. Allow the engine and exhaust system to cool before working on or near them. 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Exhaust System (continued) g031958 Figure 15 1. Exhaust manifold 3. Engine 2. Manifold gasket 4. Flange-head screw (8 each) 4. Remove the muffler and/or exhaust tube from the engine as shown in Figure 14. 5. If necessary, remove the exhaust manifold from the engine; refer to Figure 15. A. Remove the turbocharger from the exhaust manifold; refer to Removing the Turbocharger (page 3–14). B. Support the exhaust manifold to prevent it from falling. C.
Installing the Exhaust System (continued) Note: Ensure that all of the sealing surfaces of the exhaust system are free of unwanted material or damage that can prevent a tight seal. 1. Remove all of the covers and plugs that you placed while removing the exhaust system. 2. If the exhaust manifold was removed, install it onto the engine (Figure 15): A. Apply anti-seize lubricant to the threads of the 8 flange-head screws that are attached to the exhaust manifold. B.
Turbocharger g031959 Figure 17 1. Turbocharger assembly 7. Banjo bolt 13. Flange-head screw (2 each) 2. Flange nut (4 each) 8. Sealing washer 14. Flange-head screw (8 each) 3. Banjo bolt 9. 4. Sealing washer 5. 6. Coupling 15. Oil drain tube 10. O-ring 16. Flange-head screw (2 each) Oil supply tube 11. Exhaust manifold gasket 17. Gasket Exhaust manifold 12. Gasket 18. Turbocharger gasket Removing the Turbocharger CAUTION A hot engine and exhaust system can cause burns.
Removing the Turbocharger (continued) 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift and support the hood to get access to the engine. 3. Clean the turbocharger area to prevent contaminants from entering into the engine. 4. Loosen the clamps that attach the exhaust tube to the turbocharger outlet and muffler inlet, and remove the exhaust tube. 5.
Fuel Tank g031365 Figure 18 1. Fitting cover 2. Socket-head screw (3 each) 9. Fuel hose (2 each) 17. Fuel sender 10. Flange nut (2 each) 18. Lock washer (5 each) 3. Fuel supply standpipe 11. Tank hold-down 19. Screw (5 each) 4. Fuel return standpipe 12. Flange-head screw (2 each) 20. Fuel hose 5. Bushing (2 each) 13. Clamp (2 each) 21. Worm clamp (3 each) 6. Vent elbow fitting 14. Cap 22. Fuel hose 7. Bushing 15. Plug (4 each) 8. Fuel tank 16.
DANGER Diesel fuel is highly flammable and explosive. A fire or explosion from fuel can burn you and others and can damage property. • Use caution whenever you store or handle diesel fuel. • Do not smoke while filling the fuel tank. • Do not fill the fuel tank while the engine is running, hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Removing the Fuel Tank (continued) 5. Remove the 3 socket-head screws that attach the fitting cover (item 1 in Figure 18) to the fuel tank, and remove the fitting cover (item 1 in Figure 18) from the fuel tank. 6. Disconnect the sender power wire (blue/red) and sender ground wire (black) from the fuel sender in the fuel tank (items 1 and 2 in Figure 19). 7. Label the fuel hoses to ensure that the hoses are correctly assembled. 8.
Installing the Fuel Tank (continued) WARNING Failure to maintain proper torque could result in failure or loss of the wheel and may result in personal injury. Maintain the proper torque of the wheel lug nuts. 10. Install the front left wheel assembly onto the machine, and tighten the wheel lug nuts by hand. 11. Remove the jack stands and lower the machine to the ground. Torque the wheel lug nuts to 95 to 122 N∙m (70 to 90 ft-lb) in a crossing pattern. 12. Fill the tank with fuel.
Radiator g031960 Figure 20 1. Radiator assembly 11. Barb fitting 21. Bolt (4 each) 31. Flange nut (14 each) 2. Flange nut (4 each) 12. Drain cock fitting 22. Reservoir hose 32. Clamp (2 each) 3. Support plate (2 each) 13. Fan shroud 23. Radiator cap 33. Carriage screw (14 each) 4. Flange nut (4 each) 14. Air intake tube (4 each) 24. Support rod 34. Lower radiator hose 5. Rubber pad (4 each) 15. Hose clamp (8 each) 25. Flat washer (10 each) 35. Fan motor bracket 6.
Removing the Radiator (continued) 4. Loosen the hose clamps and disconnect the air intake tubes (item 14 in Figure 20) from the charge air cooler. 5. Disconnect the wire harness connector from the coolant level sensor at the right side of the radiator. WARNING Ethylene-glycol antifreeze is poisonous. Discard the coolant correctly. Keep the coolant in a correctly labeled container. Keep coolant away from children and pets.
Removing the Radiator (continued) g031370 Figure 22 1. Radiator 4. Pin clip (8 each) 2. Left cooler bracket 5. Pin (8 each) 3. Charge air cooler 6. Right cooler bracket 6. Open the drain cock fitting and drain the radiator into a suitable container. The drain cock fitting is located near the hydraulic 4-wheel drive manifold (Figure 21). 7. Loosen the hose clamps and disconnect the upper and lower coolant hoses (item 6 in Figure 20) from the radiator. 8.
Installing the Radiator (continued) 4. Assemble the radiator to the fan shroud and support with the 2 carriage screws, 2 flat washers, and 2 flange nuts. 5. Connect the upper and lower radiator hoses to the radiator; attach the hoses with hose clamps (item 6 in Figure 20). 6. Connect the air intake tubes (item 14 in Figure 20) to the charge air cooler, and attach them with the hose clamps. 7. Connect the wire harness connector to the coolant level sensor at the right side of the radiator. 8.
Alternator g031947 Figure 23 1. Alternator 6. Flat washer 11. Water pump 2. Front cover 7. Hex nut 12. Adjusting bracket 3. Belt 8. Flange-head screw (2 each) 13. Alternator bracket 4. Bevel washer (2 each) 5. Flange-head screw 9. 10. Alternator bracket Bolt Removing the Alternator 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Alternator (continued) Note: Replace the belt, if necessary. 9. For assembly purposes, label all the wires that connect to the alternator. Disconnect the wires from the alternator terminals and keep the wires away from the alternator. 10. Support the alternator to prevent the alternator from shifting or falling. 11. Remove the flange-head screw and flat washer that attach the alternator to the adjusting bracket (item 12 in Figure 23). 12.
Starter Motor g031948 Figure 24 1. Engine 2. Starter motor 3. Flange-head screw (2 each) Removing the Starter Motor g031373 Figure 25 1. 2. Starter stud Starter solenoid 3. Screw 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift and support the hood to get access to the engine. 3. Remove the battery access panel; refer to Removing and Installing the Battery (page 5–103). 4.
Removing the Starter Motor (continued) 5. Disconnect the positive battery cable. 6. Label all the wires that connect to the starter. Disconnect the wires from the starter terminals and position them away from starter; refer to Figure 25. A. Remove the nut and lock washer that attach the cable to the starter stud, and remove the cable from the starter stud. B. Loosen the screw used to attach the blue wire of the harness to the starter solenoid, and disconnect the wire from the starter. 7.
Valve Cover g031949 Figure 26 1. Engine 4. Flat washer (3 each) 2. Valve cover 5. Isolation washer (3 each) 3. Locknut (3 each) 6. Oil fill cap 7. Valve cover gasket Removing the Valve Cover 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift and support the hood to get access to the engine. 3. Clean the valve cover and cylinder head to prevent contaminants from entering into the engine.
Installing the Valve Cover (continued) 3. Connect the crankcase breather tube to the valve cover and secure the hose with a hose clamp; refer to Installing the Engine Breather System (page 3–31). 4. Add the specified oil into the crankcase of the engine until the oil level is correct. 5. Lower the hood and secure it.
Engine Breather System g031375 Figure 27 1. 2. Hose Hose clamp 7. 8. Breather outlet hose Latch plate 13. 14. Breather hose Hose barb 3. Spacer 4. Breather mount plate 10. 9. Hose clamp 15. Hose Breather inlet hose 16. 5. Bolt (2 each) Check valve 11. Hose clamp 17. Worm clamp 6. Breather 12. Hose clamp Removing the Engine Breather System 1.
Installing the Engine Breather System g031376 Figure 28 1. Base (gray) 2. Cover (black) 1. Install the breather components, refer to Figure 27. Note: If the check valve (item 16 in Figure 27) is removed, ensure that it is installed with the black side toward the engine oil pan; refer to Figure 28. 2. Lower the hood and secure it.
Thermostat g031950 Figure 29 1. Water pump 3. Thermostat 5. Thermostat housing 2. Seal 4. Gasket 6. Flange-head screw (2 each) Removing the Thermostat 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift and support the hood to get access to the engine. WARNING Ethylene-glycol antifreeze is poisonous. Discard the coolant correctly. Keep the coolant in a correctly labeled container.
Removing the Thermostat (continued) 5. Remove the 2 flange-head screws that attach the thermostat housing to the water pump, and remove the thermostat housing. 6. Remove the thermostat and seal from the water pump housing. 7. Clean the gasket surfaces of the pump and thermostat housing. 8. Inspect the thermostat sealing areas in the pump housing. Clean the sealing surfaces if there is corrosion or contamination. Testing the Thermostat 1.
Water Pump g031951 Figure 31 1. Flange-head screw (4 each) 6. O-ring 11. Thermostat 2. Water pump pulley 7. Gasket 12. Front cover 3. Belt 8. Thermostat housing 13. Seal 4. Flange-head screw 9. Flange-head screw (3 each) 14. Gasket 5. Flange-head screw (2 each) 10. Water pump Removing the Water Pump 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Water Pump (continued) DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. g031380 Figure 32 1. Water pump 2. Temperature sensor 3. Drain the coolant from the radiator and engine; refer to Removing the Radiator (page 3–20). 4. Disconnect the wire harness connector from the temperature sensor at the water pump housing; refer to Figure 32. 5.
Installing the Water Pump (continued) 3. Align the water pump to the engine and secure the pump to the engine with the flange-head screws. 4. If the pulley was removed, assemble the pulley to the water pump shaft with the 4 flange-head screws. Torque the flange-head screws to 31 N∙m (23 ft-lb). 5. If the thermostat was removed, install the thermostat to the water pump; refer to Installing the Thermostat (page 3–33). 6.
Front Cover g031952 Figure 33 1. Belt 8. Flange-head screw (2 each) 15. Alternator 2. Front cover 9. Alternator bracket 16. Flange-head screw 3. Water pump pulley 10. Water pump assembly 17. Oil pan 4. Bevel washer (2 each) 11. Crankshaft pulley with tone wheel 18. Mounting plate 5. Flange-head screw 12. Adjusting bracket 19. Bolt 6. 7. Flat washer Hex nut 13. 14. Alternator bracket Bolt Removing the Front Cover 1.
Removing the Front Cover (continued) g031382 Figure 34 Crankshaft-position sensor 4. Harness clamp 2. Camshaft-position sensor 5. Crankshaft pulley 3. Tone wheel 1. g031953 Figure 35 1. 2. Front cover Flange-head screw 4. 5. Oil seal Alternator bracket 3. Flange-head screw 6. Flange-head screw 6. Remove the electrical components from the front cover (Figure 34) as follows: A. Remove the screws that attach the electrical harness clamps to the front cover. B.
Removing the Front Cover (continued) 8. Remove the locknut and thrust washer that attach the rear axle pivot shaft to the frame. 9. Slide the pivot shaft toward the rear of the machine to give the clearance to remove the engine pulley bolt; refer to Removing the Rear Axle (page 6–27). 10. Remove the crankshaft pulley (Figure 34). IMPORTANT When removing the crankshaft pulley, ensure that you do not damage the tone wheel that is attached to the rear side of the pulley.
Installing the Front Cover (continued) 7. Attach the oil pan to the front cover with the 5 flange-head screws. Torque the screws to 19 N∙m (14 ft-lb). 8. Install the crankshaft pulley: IMPORTANT When installing the crankshaft pulley, ensure that you do not damage the tone wheel that is attached to the rear side of the pulley. A. Insert the woodruff key into the crankshaft slot. B. Carefully slide the pulley onto the crankshaft. Note: Ensure that you do not damage the oil seal in the front cover.
Oil Pan g031954 Figure 36 1. O-ring 4. Flange-head screw (24 each) 7. Oil pan 2. Flat washer 5. Sealing washer 8. Oil suction tube 3. Flange-head screw (2 each) 6. Drain plug Removing the Oil Pan 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift and support the hood to get access to the engine. 3. Drain the oil from the engine. 4.
Installing the Oil Pan 1. If the oil suction tube was removed, install the O-ring on the tube and align the tube with the engine. 2. Use the 2 flange-head screws to secure the oil suction tube to the engine; torque the screws to 19 N∙m (14 ft-lb). 3. Using the Cummins sealant #3164067 (or equivalent), apply a 1 mm (0.039 inch) sealant bead around all the oil pan mounting screw holes. 4. Apply a 3 mm (0.118 inch) sealant bead to the oil pan mounting surface. 5.
Engine g031385 Figure 37 1. Engine assembly 7. Bolt (4 each) 13. Front left engine mount 2. Traction flush manifold 8. Engine isolator mount (4 each) 14. Front right engine mount 3. Bolt (8 each) 9. Snubbing washer (4 each) 15. Flange nut (8 each) 4. Bolt (4 each) 10. Locknut (4 each) 16. 4-wheel drive control manifold 5. Rear engine mount (2 each) 11. Bolt (4 each) 6. Lock washer (4 each) 12. Lock washer (4 each) Removing the Engine 1.
Removing the Engine (continued) WARNING Ethylene-glycol antifreeze is poisonous. Discard the coolant correctly. Keep the coolant in a correctly labeled container. Keep coolant away from children and pets. DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. 7. Drain the coolant from the radiator into a suitable container; refer to Removing the Radiator (page 3–20).
Removing the Engine (continued) g031387 Figure 39 1. Water pump 2. Temperature sensor 8. Disconnect the coolant hoses from the radiator. 9. Remove the exhaust system from the engine; refer to Removing the Exhaust System (page 3–11). 10. Remove the air cleaner system from the engine; refer to Removing the Air Filter System (page 3–9). 11. Remove the intake hoses from the charge air cooler. 12. Note the location of the cable ties used to attach the electrical wires.
Removing the Engine (continued) g031388 Figure 40 1. Positive battery cable 6. Internal lock washer 2. Negative battery cable 7. Flange nut 3. Bolt 8. Negative battery cable 4. Bolt 9. Positive battery cable 5. Internal lock washer 15. Remove the hydraulic pump assembly from the engine; refer to Gear Pump (page 4–108) and Piston (Traction) Pump (page 4–112). 16.
Removing the Engine (continued) g031389 Figure 41 1. Air conditioning compressor 2. Connector 18. Connect the hoist to the front and rear lift tabs on the engine. 19. Remove the locknuts, snubbing washers, and bolts that attach the engine brackets to the engine isolator mounts. IMPORTANT Use 1 person to operate the lift or hoist while the other person to guides the engine into the machine.
Removing the Engine (continued) 22. If necessary, remove the engine isolator mounts (item 8 in Figure 37) from the engine. Note: There is a fastener at the right, front motor mount that is attached to the frame ground cable. 23. Install suitable covers and plugs on all of the engine openings to prevent contamination. Installing the Engine IMPORTANT Ensure that all parts removed from the engine during maintenance or overhaul are correctly installed on the engine. 1.
Installing the Engine (continued) Note: Ensure that the drive belt is correctly tensioned. 9. Use the notes that you recorded while removing the engine to connect the wires and/or electrical connections to the following electrical components: A. The alternator; refer to Figure 38. B. The temperature sensor at the water pump housing; refer to Figure 39. C. The battery, frame, and wire harness ground at the engine block; refer to Figure 40. D.
Flywheel Coupling Assembly g031955 Figure 43 1. Bolt (12 each) 4. Bolt (8 each) 2. Washer (12 each) 5. Washer (8 each) 3. Coupling housing 6. Flywheel coupling 7. Engine assembly Disassembling the Flywheel Coupling 1. If the engine is in the machine, remove the hydraulic pump assembly from the engine to service the coupling; refer to Gear Pump (page 4–108) and Piston (Traction) Pump (page 4–112). 2. Remove the coupling housing and flywheel coupling from the engine; refer to Figure 43.
Assembling the Flywheel Coupling g031392 Figure 44 1. Flywheel housing 4. Coupling hub 2. Engine flywheel 5. Bolt (8 each) 3. Flywheel coupling 1. Align the flywheel coupling with the engine flywheel; refer to Figure 44. Note: Ensure that the coupling hub is aligned away from the flywheel. 2. Apply the Permatex™ Blue Gel medium-strength thread-locking compound (or equivalent) to the threads of the 20 bolts (item 4 in Figure 43). 3.
Diesel Engine: Service and Repairs Page 3–52 Groundsmaster 5900 Traction Unit 08159SL Rev C
Chapter 4 Hydraulic System Table of Contents Specifications ....................................................................................................................................... 4–4 Hydraulic System ............................................................................................................................... 4–4 General Information ..............................................................................................................................
Testing the Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauge and 40 GPM Flow Meter) ...................................................................................................................................... 4–74 Testing the Cutting Deck Motor for Case Drain Leakage (Using Tester with Pressure Gauge and 40 GPM Flow Meter) ........................................................................................................................
Additional Reference Materials DANFOSS D SERIES GEAR PUMP SEAL KIT SERVICE INSTRUCTION BULLETIN REXROTH VARIABLE PUMP A10VG REPAIR INSTRUCTIONS REXROTH VARIABLE PUMP A10VG REPAIR MANUAL DANFOSS H1 CLOSED CIRCUIT AXIAL PISTON PUMPS SERVICE MANUAL DANFOSS H1 CLOSED CIRCUIT AXIAL PISTON PUMPS REPAIR INSTRUCTIONS EATON REPAIR INFORMATION: MODEL 74318 and 74348 PISTON MOTORS PARKER TORQMOTORTM SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES) EATON PARTS AND REPAIR INFORMATION: 5 SERIES STEERING CONTR
Specifications Hydraulic System Item Description Piston (traction) pump (before serial number 313000300) Maximum pump displacement (per revolution) Rexroth Bosch, variable displacement piston pump 63 cm³ (3.84 in³) Piston (traction) pump (after serial number 313000300) Maximum pump displacement (per revolution) Sauer-Danfoss, variable displacement piston pump 68 cm³ (4.
Hydraulic System (continued) Hydraulic reservoir capacity 100 Mesh (in reservoir) Hydraulic fluid Groundsmaster 5900 Traction Unit 08159SL Rev C Refer to the Operator’s Manual Page 4–5 Hydraulic System: Specifications
General Information The Operator’s Manual for the traction unit contains information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Checking the Hydraulic Fluid g031393 Figure 45 1. 2. Hydraulic-fluid cap Tank cover The hydraulic system on your machine is designed to operate on anti-wear hydraulic fluid. The reservoir holds approximately 71.
Towing the Traction Unit g031756 Figure 46 1. Forward bypass valve 2. Reverse bypass valve 3. Reverse test port (MA) g031768 Figure 47 1. 4-wheel drive control manifold reverse test 3. port (G2) 2. Traction pump reverse-pressure test port (MA) Hydraulic hose IMPORTANT If you exceed the towing-speed limit, you can severely damage the piston pump. If you must tow or push the machine, move the machine forward at a speed below 3.2 km/h (2 mph) for a distance of 0.4 km (1/4 mile) or less.
Towing the Traction Unit (continued) IMPORTANT If you must push or tow the machine in the reverse direction, hydraulically bypass the check valve in the 4-wheel drive manifold by performing the following. Parts needed for this procedure: Hydraulic hose (Part No. 95-8843)—1 each, coupler fitting (Part No. 95-0985)—2 each, and hydraulic fitting (Part No. 340-77)—2 each. 1. Connect the hydraulic hose to the reverse pressure-test port (MA) of the traction pump with 1 hydraulic coupler and 1 hydraulic fitting.
Traction Circuit Component Failure (continued) The recommended procedure to remove contamination from the traction circuit is to temporarily install the Toro high-flow hydraulic-fluid filter into the traction circuit; refer to Special Tools (page 4–42). Use a hydraulic-fluid filter when you connect the hydraulic test gauges in order to test the traction circuit components or after you replace a damaged traction circuit component (e.g., traction (piston) pump or wheel motor).
Hydraulic Hoses (continued) For more hydraulic hose information; refer to the Hydraulic Hose Servicing (Part No. 94813SL) in the Toro Service Training Book. WARNING Relieve all pressure in the hydraulic system before performing any work on the system; refer to Releasing Pressure from the Hydraulic System (page 4–6). • Keep your body and hands away from pin-hole leaks or nozzles that eject hydraulic fluid under high pressure. • Do not use your hands to search for leaks; use a piece of paper or cardboard.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (continued) 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Note: Ensure that the O-ring is installed and correctly seated in the groove of the fitting. Lightly lubricate the O-ring with only clean hydraulic fluid. 3. Align the hose/tube against the body of the fitting so that the flat face of the hose/tube sleeve fully touches the O-ring in the fitting; refer to Figure 48. 4.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (continued) Flats From Wrench Resistance Table Size FFWR 4 (1/4 inch nominal hose or tubing) 1/2 to 3/4 6 (3/8 inch) 1/2 to 3/4 8 (1/2 inch) 1/2 to 3/4 10 (5/8 inch) 1/2 to 3/4 12 (3/4 inch) 1/3 to 1/2 16 (1 inch) 1/3 to 1/2 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) Installing the Non-Adjustable Fittings g031755 Figure 50 1. Fitting 2. O-ring 1.
Installing the Non-Adjustable Fittings (continued) Note: Using a drive-adapter wrench in any position other than 90º and 270º to the frame of the torque wrench will affect the torque value measured by the torque wrench because of the effective length (lever) of the torque wrench changes. Using a torque wrench with a drive-adapter wrench lowers the torque value than that of the installation torque listed in the table.
Installing an Adjustable Fitting g031757 Figure 51 1. Locknut 2. Back-up washer 3. O-ring g031758 Figure 52 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. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with only clean hydraulic fluid. Ensure that the threads of the fitting are clean with no lubricant applied. 4.
Installing an Adjustable Fitting (continued) Note: Do not rotate the adjustable fitting more than 1 turn counterclockwise. 7. Hold the fitting in the correct alignment with a wrench and use a torque wrench to tighten the fitting to the recommended torque value within the specified range of torque values; refer to Fitting Installation Torque Table (page 4–13). Note: This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench).
Hydraulic Schematic Note: Download a free copy of the Hydraulic Schematic for your Groundsmaster 5900 or 5910 machine by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.
Hydraulic Flow Diagrams g035143 Figure 53 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–17 Hydraulic System: Hydraulic Flow Diagrams
Traction Circuit: Low Speed A variable displacement, bi-directional piston pump is directly connected to the engine flywheel, the piston pump supplies hydraulic flow to the traction circuit. An electronic proportional-servo assembly controls the movement of the swash plate of the piston pump. Pressing the traction pedal rotates a potentiometer that sends a signal to the machine TEC-5002 controller.
Forward Direction (continued) flush valve spools, allowing a small amount of hydraulic fluid to bleed off to cool the closed loop traction circuit. The charge system replenishes the fluid that is bled from the traction circuit because of the flush valve operation. When you go down a hill, the tractor becomes an over-running load that drives the wheel motors. In this condition, the rear wheel motors can lock up as the fluid is pumped from the motors, increasing the pressure as it returns to the hydrostat.
Reverse Direction (continued) g035144 Figure 54 Hydraulic System: Hydraulic Flow Diagrams Page 4–20 Groundsmaster 5900 Traction Unit 08159SL Rev C
Traction Circuit: High Speed A variable displacement, bi-directional piston pump is directly connected, the piston pump supplies the hydraulic flow to the traction circuit. The movement of the swash plate of the piston pump is controlled by an electronic proportional-servo assembly. Pressing the traction pedal rotates a potentiometer that sends a signal to the machine TEC-5002 controller.
Forward Direction (continued) forward transport operation, a small amount of fluid exits through the shifted PD2 cartridge and returns to the charge circuit. Reverse Direction With the Hi-Lo speed switch in the high-range position, the solenoid valve (S) in the 4-wheel drive control manifold is energized. The solenoid valve spool moves to direct the charge pressure that shifts the PD1 and PD2 control valve spools.
Reverse Direction (continued) g035145 Figure 55 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–23 Hydraulic System: Hydraulic Flow Diagrams
Traction Circuit: Traction Control A flow divider is incorporated into the traction circuit to supply a proportioned flow to the front- and rear-wheel motors for a true 4-wheel drive system. When the Hi-Lo speed switch is in the LOW position and you press the traction pedal in the forward direction, the operator can engage the traction flow divider when low-traction situations could lead to wheel spin.
Traction Assist Switch in the ON Position (continued) g035146 Figure 56 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–25 Hydraulic System: Hydraulic Flow Diagrams
Raising the Cutting Deck A 3-section gear pump is connected to the piston (traction) pump. The gear pump section (P3) farthest from the piston pump supplies hydraulic flow to the lift-control manifold, steering/cooling fan control manifold, and traction charge circuit. The hydraulic flow from the pump section (P3) is divided between the lift/lower circuit and the steering/cooling fan/charge circuit by a proportional flow divider located in the lift-control manifold.
Raising the Right Cutting Deck Press the rear of the right console switch to send an input to the TEC-5001 controller to raise the right cutting deck. The controller gives an electrical output to the solenoid valves S1 and S7 in the lift-control manifold. The energized solenoid valves shift to allow a passage for circuit fluid flow to the rod end of the right deck lift cylinder. The shifted S1 prevents the fluid flow from returning directly to the reservoir.
Raising the Left Cutting Deck (continued) g035147 Figure 58 Hydraulic System: Hydraulic Flow Diagrams Page 4–28 Groundsmaster 5900 Traction Unit 08159SL Rev C
Lowering the Cutting Deck A 3-section gear pump is connected to the piston (traction) pump. The gear pump section (P3) farthest from the piston pump supplies hydraulic flow to the lift-control manifold, steering/cooling fan control manifold, and traction charge circuit. The hydraulic flow from the pump section (P3) is divided between the lift/lower circuit and the steering/cooling fan/charge circuit by a proportional flow divider in the lift-control manifold.
Lowering the Left Cutting Deck (continued) the left deck lift cylinder. The shifted S1 prevents fluid flow that returns directly to the reservoir. The shifted S3 allows a fluid path to the shaft end of the lift cylinder to retract the lift cylinder and lower the left cutting deck. The fluid from the retracting cylinder flows through orifice OR1 to control the drop speed of the cutting deck. Flow is then directed through the shifted S3, counterbalance valve (LC), and returns to the hydraulic reservoir.
Cutting Deck Float (continued) g035148 Figure 59 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–31 Hydraulic System: Hydraulic Flow Diagrams
PTO Mow Circuit A 3-section gear pump is connected to the piston (traction) pump. The hydraulic flow for the PTO mow circuit is supplied by 2 sections of the gear pump. The gear pump section (P1) nearest to the piston pump supplies hydraulic flow in series to the right and left decks, while the next gear pump section (P2) supplies the center deck.
PTO Circuit Relief g031760 Figure 60 A relief valve (RV1) in the hydraulic control manifold limits the maximum mow circuit pressure for each deck. The center and left deck relief valves are set at 20,700 kPa (3,000 psi) and the right deck relief valve is set at 13,800 kPa (2,000 psi). The relief valve (RV1) and logic cartridge (LC1) work together as a 2-stage relief. When there is increased circuit resistance or if a cutting blade hits an object, the relief valve feels the increased pressure.
PTO Mow Circuit Cutting Deck Blade Braking (continued) g031762 Figure 62 g031763 Figure 63 When the operator turns the PTO switch to the OFF position or if the deck is in the raised position with the PTO switch on, the PTO control manifold solenoid valve (S) gets de-energized causing logic cartridge (LC1) to shift; refer to PTO Mow Circuit (page 4–32). This shifted cartridge allows the fluid to return to manifold port P2.
PTO Mow Circuit Cutting Deck Blade Braking (continued) come to a stop. Once the blades stop, the logic cartridge LC2 remains in the NEUTRAL position to keep the deck motor from rotating.
PTO Mow Circuit Cutting Deck Blade Braking (continued) g035149 Figure 64 Hydraulic System: Hydraulic Flow Diagrams Page 4–36 Groundsmaster 5900 Traction Unit 08159SL Rev C
Steering Circuit A 3-section gear pump is connected to the piston (traction) pump. The gear pump section (P3) farthest from the piston pump supplies hydraulic flow to the steering/cooling fan control manifold, lift control manifold, and traction charge circuit. The hydraulic flow from pump section (P3) is divided between the steering/cooling fan/charge circuit and the lift/lower circuit by a proportional flow divider located in the lift-control manifold.
Turning Right (continued) fluid that leaves the cylinders flows back through the steering valve L port, spool valve, out of the T port and then used for traction circuit charge fluid. The steering wheel and steering control valve return to the NEUTRAL position when the turn is complete. Steering Relief Operation While steering, when the steering cylinders are at the end of their stroke or if there is a obstruction in a rear wheel (e.g., a curb), the pressure in the steering circuit increases.
Steering Relief Operation (continued) g035150 Figure 65 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–39 Hydraulic System: Hydraulic Flow Diagrams
Engine Cooling Fan Circuit A 3-section gear pump is connected to the piston (traction) pump. The gear pump section (P3) farthest from the piston pump supplies hydraulic flow to the steering/cooling fan control manifold, the lift-control manifold and the traction charge circuit. The hydraulic flow from pump section (P3) is divided between the steering/cooling fan/charge circuit and the lift/lower circuit by a proportional flow divider located in the lift control manifold.
Reverse Direction Fan Operation (continued) high, the PWM signal to the PRV valve is sent to slow down the cooling fan. The controller then energizes the solenoid valve (S) in the steering/cooling fan control manifold to move the cooling fan motor fluid flow in the reverse direction so that the controller runs in reverse. The controller selects the amount of time that the fan should run in reverse before the fan runs in the forward direction.
Special Tools You can order these special tools from your Toro Distributor. Hydraulic Pressure Testing Kit g031764 Figure 66 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
15 GPM Hydraulic Tester (Pressure and Flow) (continued) 4. Flow Meter: This meter measures the actual fluid flow in the operating circuit with a gauge rated at 5 to 55 L/minute (1 to 15 gallons/minute). 5. Outlet Hose: A hose from the outlet side of the hydraulic tester that connects to the hydraulic system circuit. 6. Fittings: An assortment of hydraulic fittings are included with this kit. Toro Part No.
Hydraulic Hose Kit g035152 Figure 69 This kit includes the fittings and hoses that are used to connect the 40 GPM hydraulic tester (AT40002) or high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components. Toro Part No. TOR6007 High Flow Hydraulic Filter Kit g035050 Figure 70 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities.
High Flow Hydraulic Filter Kit (continued) Note: This kit does not include the hoses; refer to Hydraulic Hose Kit (page 4–44). Note: The replacement filter element is Toro Part No. TOR6012. The filter element cannister tightening torque is 34 N∙m (25 ft-lb). O-Ring Kit g033395 Figure 71 This kit includes O-rings in a variety of sizes for face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection. Toro Part No.
Measuring Container g031767 Figure 73 Use this container to test hydraulic motor efficiency (motors with case drain lines only). Limit the outlet flow from the motor and measure the leakage from the case drain line to measure the efficiency of a hydraulic motor while the hydraulic system pressurizes the motor. The table gives the gallons per minute (gpm) conversion for the measured milliliter or ounce motor case drain leakage. Toro Part No.
Rear Wheel Hub Puller g031769 Figure 74 The rear wheel hub puller allows you to safely remove the wheel hub from the rear wheel motor shaft. Toro Part No.
Troubleshooting The following charts contains information to troubleshoot hydraulic circuit problems. There can be more than 1 cause for a machine malfunction. Refer to Testing the Hydraulic System (page 4–52) for precautions and specific hydraulic test procedures. General Hydraulic System Problems Problem Possible Causes The hydraulic system operates hot. • • • • • • • • • The hydraulic fluid in the reservoir foams. • The hydraulic reservoir fluid level is low.
Traction Problems Problem Possible Causes The machine operates in 1 direction only. • The system charge check valve and/or the system relief valve is not functioning. • The orifice or screen in the piston (traction) pump control assembly is blocked or damaged. • The pilot direction valve in 4-wheel drive control manifold is damaged or does not move freely. • The traction-control potentiometer is not functioning. The traction pedal is sluggish.
PTO Problems Problem Possible Causes The cutting decks do not operate. • An electrical problem exists; refer to the Chapter 5: Electrical System (page 5–1). • The gear pump is worn or damaged. Note: The decks must be fully lowered and the traction speed in the MOW position for the decks to operate. A cutting deck motor does not operate. • An electrical problem exists; refer to the Chapter 5: Electrical System (page 5–1).
Lift/Lower Problem Problem Possible Causes The cutting deck does not raise. • The engine speed is too low. • The hydraulic-fluid level in the reservoir is low. • The lift-arm pivots do not move freely. • A lift cylinder is damaged. • The relief valve in the lift-control manifold does not move freely. • The pilot valve in the lift-control manifold is damaged or does not move freely. • The proportional flow divider in the lift-control manifold is not functioning.
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 4–42). IMPORTANT Before performing the hydraulic tests, check all obvious areas, such as fluid supply, filter, binding linkages, loose fasteners, or improper adjustments before you assume that a hydraulic component is the source of the problem.
WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury. Before you disconnect the hydraulic components or work on the hydraulic system, release the pressure in the system; refer to Releasing Pressure from the Hydraulic System (page 4–6). 1. Clean the machine fully before you disconnect or disassemble the hydraulic components. Note: Cleanliness is required whenever you work on the hydraulic equipment.
Determining which Hydraulic Tests to Perform (continued) 3. If there is a lift circuit problem, perform 1 or more of the following tests: lift/lower circuit relief pressure, counterbalance pressure, and/or gear pump (P3) flow tests. 4. If there is a steering/engine cooling fan circuit problem, perform 1 or more of the following tests: steering circuit relief pressure, steering cylinder internal leakage, and/or gear pump (P3) flow tests.
Testing the Traction Circuit Charge Pressure Note: Machines with serial number below 313000300 have a Rexroth piston (traction) pump. Machines with serial number above 313000300 have a Sauer-Danfoss piston pump. The traction circuit charge pressure testing is similar regardless of the pump brand. Testing differences for both pump brands are included in the following procedure. 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake.
Testing the Traction Circuit Charge Pressure (continued) 2. Connect a 7,000 kPa (1,000 psi) pressure gauge to the charge-pressure test port fitting on the piston pump (Figure 76 or Figure 77). 3. After you install the pressure gauge, start and operate the engine at idle speed. Check for the hydraulic-fluid leaks at the tester connections and correct before continuing the test. 4. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes. 5.
Testing the Traction Circuit Relief Pressure (Using Pressure Gauge) g035156 Figure 78 Perform the traction circuit relief pressure test to ensure that the forward and reverse traction circuit relief pressures are correct. Testing the Traction Circuit Relief Pressure 1. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes. Note: Ensure that the hydraulic tank is full.
Testing the Traction Circuit Relief Pressure (continued) CAUTION Performing the traction circuit relief pressure test on the hydraulic system can cause personal injury and property damage. Perform this test in an open area that is away from people and obstructions. 2. Move the machine to an open area, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment.
Testing the Traction Circuit Relief Pressure (continued) g035208 Figure 80 1. Forward test port 3. Forward relief valve 2. Reverse test port 4. Reverse relief valve 3. Connect a 70,000 kPa (10,000 psi) pressure gauge to the traction circuit test port to check the function (Figure 79 or Figure 80). 4. Start the engine and operate it at idle speed. Check for hydraulic-fluid leaks at the tester connections and correct before continuing the test. 5.
Testing the Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge) g035209 Figure 81 Hydraulic System: Testing the Hydraulic System Page 4–60 Groundsmaster 5900 Traction Unit 08159SL Rev C
Testing the Rear Traction Circuit (RV) Relief Pressure 1. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes. Note: Ensure that the hydraulic tank is full. 2. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment.
Testing the Rear Traction Circuit (RV) Relief Pressure (continued) Note: Relief valve (RV) is located on the rear side of the 4-wheel drive control manifold (Figure 82). 10. Disconnect the pressure gauge from the manifold-test port.
Testing the Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) g035210 Figure 83 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–63 Hydraulic System: Testing the Hydraulic System
Testing the Traction Circuit Reducing Valve (PR) Pressure 1. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes. Note: Ensure that the hydraulic tank is full. 2. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment.
Testing the Traction Circuit Reducing Valve (PR) Pressure (continued) Note: Do not remove the reducing valve from the hydraulic manifold for adjustment. 9. Disconnect the pressure gauge from the test port.
Testing the Counterbalance Pressure 1. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes. Note: Ensure that the hydraulic tank is full. 2. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment. Read all Warning, Cautions, and precautions at the beginning of this section.
Testing the Piston (Traction) Pump Flow (Using Tester with Pressure Gauge and 40 GPM Flow Meter) g035211 Figure 87 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–67 Hydraulic System: Testing the Hydraulic System
Testing the Piston (Traction) Pump Flow This test measures the piston (traction) pump output (flow). During this test, the pump load is created at the flow meter using the adjustable load valve on the tester. Note: Before performing the piston pump flow test, ensure that the traction speed is set to 100% using the InfoCenter settings menu. IMPORTANT At normal engine high-idle speed, the traction circuit flow for the Groundsmaster 5900 or 5910 machines exceeds 150 L/minute (40 gallons/minute).
Testing the Piston (Traction) Pump Flow (continued) g035212 Figure 88 1. Traction control manifold 2. Fitting in the P port 3. Hose from the piston pump 3. Clean the junction of the hydraulic hose from the piston pump and 90° fitting in the P port (item 2 in Figure 88) at the bottom of the traction control manifold which is attached to the bottom of the front axle frame. Disconnect the hose from the 90° fitting.
Testing the Piston (Traction) Pump Flow (continued) 7. Slowly push the traction pedal in fully forward position. Keep the pedal fully pressed in the forward position. 8. Have a second person monitor the pressure gauge on the tester carefully and slowly close the flow control valve until you get 6,900 kPa (1,000 psi) on the gauge. Verify with the InfoCenter display that the engine speed is still at the correct speed as listed above.
Testing the Cutting Deck Circuit Pressure (Using Pressure Gauge) g035213 Figure 89 Perform the cutting deck circuit pressure test to ensure that the cutting deck circuit pressures are correct.
Testing the Cutting Deck Circuit Pressure g031781 Figure 90 1. Center deck circuit-pressure test port G 1. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes. Note: Ensure that the hydraulic tank is full. 2. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment.
Testing the Cutting Deck Circuit Pressure (continued) CAUTION Cutting blades are sharp and may cause personal injury. Stay away from the cutting decks while you perform the test. g031783 Figure 92 1. Left wing deck circuit-pressure test port G 5. Sit on the seat and operate the engine at full speed (2,750 rpm). Release the parking brake and engage the cutting decks. 6. Monitor the pressure gauge carefully while you are mowing with the machine.
Testing the Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauge and 40 GPM Flow Meter) g035214 Figure 93 Perform the cutting deck circuit relief pressure test to ensure that the deck circuit relief pressures are correct. Testing the Cutting Deck Circuit Relief Pressure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for approximately 10 minutes. Note: Ensure that the hydraulic tank is full.
Testing the Cutting Deck Circuit Relief Pressure (continued) 2. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment. Read all Warning, Cautions, and precautions at the beginning of this section. g035215 Figure 94 1. Front deck manifold 2. Left deck manifold 3.
Testing the Cutting Deck Circuit Relief Pressure (continued) CAUTION The cutting deck blades will rotate when you lower the cutting decks with the PTO switch in the ON position. Keep away from the cutting decks during the test to prevent personal injury from the rotating blades. Do not stand in front of the machine. 5. After you install the hydraulic tester, start the engine and run it at idle speed. Check for hydraulic-fluid leaks at the tester connections and correct before continuing the test. 6.
Testing the Cutting Deck Motor for Case Drain Leakage (Using Tester with Pressure Gauge and 40 GPM Flow Meter) g035217 Figure 96 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–77 Hydraulic System: Testing the Hydraulic System
Testing the Cutting Deck Motor for Case Drain Leakage Note: Over a period of time, a deck motor can wear internally. A worn motor may bypass the hydraulic fluid to its case drain that reduces the motor efficiency. After sometime, sufficient fluid loss causes the deck motor to stall under heavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect quality of cut.
Testing the Cutting Deck Motor for Case Drain Leakage (continued) g035218 Figure 97 1. Flow (in) 2. Flow return (out) 3. Case drain 2. Disconnect the hydraulic return hose from the deck motor that you are testing (Figure 97). IMPORTANT Ensure that the oil flow indicator arrow on the flow gauge is showing that the fluid will flow from the motor, through the tester, and into the disconnected hydraulic hose. 3.
Testing the Cutting Deck Motor for Case Drain Leakage (continued) CAUTION The cutting deck blades will rotate when you lower the cutting decks with the PTO switch in the ON position. Keep away from the cutting decks during the test to prevent personal injury from the rotating blades. Do not stand in front of the machine. 7. Sit on the seat, start the engine, and increase the engine speed to full speed (2,750 rpm). Engage the cutting decks. 8.
Testing the Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) g031784 Figure 98 Perform the lift/lower circuit relief valve pressure test to ensure that the lift circuit relief pressure is correct. Testing the Lift/Lower Circuit Relief Pressure 1. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes.
Testing the Lift/Lower Circuit Relief Pressure (continued) Note: Ensure that the hydraulic tank is full. 2. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment. Read all Warning, Cautions, and precautions at the beginning of this section. g031785 Figure 99 1. Lift circuit test port G3 2. Relief valve RV 3.
Testing the Lift/Lower Circuit Relief Pressure (continued) B. Check the relief pressure and adjust it again as necessary. C. Install and tighten the cap on the relief valve after adjustment. 9. If the relief pressure is too low, do the following steps: A. Check for a restriction in the gear pump intake line or reservoir strainer. B. Check the lift cylinder for internal leakage.
Testing the Steering Circuit Relief Pressure (Using Pressure Gauge) g031786 Figure 100 Perform the steering circuit relief valve pressure test to ensure that the steering circuit relief pressure is correct. Testing the Steering Circuit Relief Pressure 1. Ensure that the hydraulic fluid is at the normal operating temperature by operating the machine for approximately 10 minutes.
Testing the Steering Circuit Relief Pressure (continued) Note: Ensure that the hydraulic tank is full. 2. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment. Read all Warning, Cautions, and precautions at the beginning of this section. g031787 Figure 101 1. Steering circuit-pressure test port G 3.
Testing the Steering Circuit Relief Pressure (continued) g031788 Figure 102 1. Steering/fan manifold 2. Steering relief valve 7. Shut off the engine and record the test results. Note: If steering relief pressure is incorrect and there are a lift/lower problems, check the gear pump (P3) for wear and inefficiency. If the steering wheel continues to turn at the end of the cylinder travel (with less than the normal effort), check the steering cylinder and steering control valve for wear or damage. 8.
Testing the Steering Cylinder for Internal Leakage g031789 Figure 103 Perform the steering cylinder internal leakage test if you identify a steering problem. This test determines if a steering cylinder is not functioning. Note: The operation of the steering circuit is affected by the rear tire pressure, binding of steering cylinders, extra weight on the vehicle, and/or binding of the rear axle steering components. Check these items before proceeding with the steering cylinder internal leakage test.
Testing the Steering Cylinder for Internal Leakage (continued) CAUTION Performing testing on the hydraulic system can cause personal injury and damage to the equipment. Read all Warning, Cautions, and precautions at the beginning of this section. 3. Turn the steering wheel and fully extend the steering cylinder rod to test the cylinder. 4. Clean the area around the hydraulic hose to test at the rod end of the steering cylinder. 5.
Testing the Gear Pump (P3) (PTO, Steering, Cooling Fan, Lift/Lower, and Traction Charge Circuits) Flow (Using Tester with Pressure Gauges and Flow Meter) g035219 Figure 104 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–89 Hydraulic System: Testing the Hydraulic System
g035220 Figure 105 1. First gear pump section (wing decks) 2. Second gear pump section (center deck) 3. Third gear pump section (steering, lift/lower, fan, and charge) Perform the gear pump flow test to ensure that the mow, steering, cutting deck lift/lower, engine cooling fan, and traction charge circuits have sufficient hydraulic-fluid flow. The gear pump sections are shown in Figure 105. The first gear pump section provides hydraulic flow for both the wing cutting decks.
Testing the Gear Pump (P3) Flow (continued) g035221 Figure 106 1. First pump section outlet 4. Second pump section outlet 2. 3. Left deck manifold Manifold P1 port 5. 6. Front deck manifold Manifold P1 port 2. Determine the gear pump section that you are testing. Disconnect the hydraulic hose from appropriate manifold fitting for the gear pump section that you are testing: A.
Testing the Gear Pump (P3) Flow (continued) IMPORTANT To prevent hydraulic tester damage, use a 40 GPM Hydraulic Tester #AT40002 (pressure and flow) and Hose Kit for this test; refer to Special Tools (page 4–42). IMPORTANT Ensure that the oil flow indicator arrow on the flow gauge is showing that the fluid flows from the pump, through the tester, and into the hydraulic hose. 3. Install a 40 GPM tester (flow and pressure) in series with the disconnected hose and hydraulic fitting in the manifold.
Testing the Gear Pump (P3) Flow (continued) refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10). 11. If the hood was opened, lower and secure the hood. Note: Ensure that the hydraulic reservoir is full. Gear Pump Flow Table Groundsmaster 5900 Traction Unit 08159SL Rev C Pump section Normal flow Minimum flow First section 83 L/minute (22 gallons/minute) 74 L/minute (19.6 gallons/minute) Second section 83 L/minute (22 gallons/minute) 74 L/minute (19.
Adjustments Adjusting the Pressure Valve The mow/transport and lift control manifolds include the adjustable pressure valves. If testing indicates that the circuit pressure setting is incorrect, adjust these valves; refer to Testing the Hydraulic System (page 4–52). Note: Do not remove the valve from the hydraulic manifold to adjust the valve.
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, park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Clean the machine before you disconnect, remove, or disassemble the hydraulic components.
After Repairing or Replacing the Components (continued) 4. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10) and Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 4–12). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts. 6.
Flushing the Hydraulic System (continued) CAUTION Pressurized hydraulic fluid can cause injury. Operate all the hydraulic controls to release the system pressure. • Operate the controls with the key switch in the RUN position and the engine shut off. • Actuate all the electrically operated control valves. • Turn the key switch to the OFF position after releasing the pressure. • Remove the key from the key switch. 2. Drain the hydraulic reservoir. 3. Drain the complete hydraulic system.
Flushing the Hydraulic System (continued) g035224 Figure 110 1. Piston pump 2. Charge-pressure test port g035225 Figure 111 1. Piston pump 2. Charge-pressure test port 7. Fill the hydraulic reservoir with the correct quantity of new hydraulic fluid. IMPORTANT Before unplugging the wire harness power connector from the engine ECM, ensure that the key switch is in the OFF position and the key is removed from the switch.
Flushing the Hydraulic System (continued) 10. Connect a 7,000 kPa (1,000 psi) pressure gauge onto the charge-pressure test port fitting on the piston (traction) pump; refer to Figure 110 or Figure 111. 11. Turn the key switch to the START position and engage the starter for 30 seconds to prime the traction and gear pumps. Wait for 2 minutes to allow the starter to cool and then repeat this step. 12.
Charging the Hydraulic System (continued) g031795 Figure 112 1. 2. Engine ECM Power connector g035224 Figure 113 1. Piston pump 2. Charge-pressure test port IMPORTANT Change the hydraulic-fluid filter when you repair or replace the hydraulic components. 1. Position the machine on a level surface, and remove the key from the key switch. 2. Ensure that all of the hydraulic connections, lines, and components are tight.
Charging the Hydraulic System (continued) IMPORTANT Before unplugging the wire harness power connector from the engine ECM, ensure that the key switch is in the OFF position and the key is removed from the switch. Removing the power connector from the engine ECM while the electrical power is on can damage the ECM. 4. Ensure that the key switch is in the OFF position and the key is removed from the switch. 5.
Charging the Hydraulic System (continued) 11. Disconnect the pressure gauge from the charge-pressure test port; refer to Figure 114. WARNING Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–5). 12. Lift 1 front and 1 rear wheel off the ground and place the appropriate jack stands under the frame to support the machine. Block the remaining wheels with chocks to prevent the movement of the machine. 13. Ensure that the traction pedal is in the NEUTRAL position.
Filtering the Closed-Loop Traction Circuit (continued) traction circuit, use the Toro high flow hydraulic filter and hydraulic hose kits ( Special Tools (page 4–42)). 1. Park the machine on a level surface, shut of the engine, and remove the key from the key switch. 2. Lift and support the machine so that all the wheels are off the ground; refer to Jacking Instructions (page 1–5).
Filtering the Closed-Loop Traction Circuit (continued) CAUTION During this procedure, all the wheels will be off the ground and rotating. Ensure that the machine is well supported so it will not move and accidentally fall to prevent injuring anyone around the machine. IMPORTANT While engaging the traction circuit, monitor the indicator on the high flow hydraulic filter.
Hydraulic Reservoir g031978 Figure 116 1. Bushing 12. Reservoir cap 23. Tank strainer 2. Elbow fitting 13. O-ring 24. Flange nut (2 each) 3. Latch plate 14. Stand pipe 25. Tank hold-down 4. Socket-head screw (2 each) 15. Dipstick 26. Flange-head screw 5. Magnetic catch 16. Bushing (4 each) 27. Hose clamp 6. Hinge bracket (2 each) 17. Screen filter 28. Hose 7. Push nut (2 each) 18. Hydraulic reservoir 29. O-ring 8. Socket-head screw (2 each) 19. Bolt 30.
Removing the Hydraulic Reservoir (continued) 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–95). 3. Clean the exterior of the reservoir, fittings, and hoses before removing the hydraulic reservoir to prevent contaminants from entering into the hydraulic system. g031884 Figure 117 1. Stand pipe 3. Hydraulic hose 2. Hose clamp 4. Hydraulic tube 4. Remove the drain plug and drain the reservoir into a suitable container. 5.
Installing the Hydraulic Reservoir (continued) 2. Remove the caps or plugs that were installed during the removal process. 3. Use the tags that you placed during reservoir removal to connect the hydraulic hoses to the reservoir fittings and secure the hoses with the hose clamps. 4. If the hose guard (item 33 in Figure 116) was removed, install the guard with the split oriented up and attach it with 2 cable ties. 5.
Gear Pump g035227 Figure 118 1. Gear pump 11. Hose (from filter) 21. O-ring 2. 90° hydraulic fitting 12. Bolt (2 each) 22. O-ring 3. Piston pump 13. 90° hydraulic fitting 23. Diagnostic fitting 4. Quick fitting 14. O-ring 24. Hose (from hydraulic tank) 5. Dust cap 15. O-ring 25. Washer (2 each) 6. Bolt (2 each) 16. O-ring 26. Tee fitting 7. Hydraulic adapter 17. O-ring 27. Test fitting 8. Flat washer (2 each) 18. O-ring 28. O-ring 9.
Removing the Gear Pump 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the hood to get access to the gear pump; refer to Removing the Hood (page 7–37). 3. Drain the hydraulic reservoir. 4. Clean the exterior of the pump and fittings before removing the pump to prevent contaminants from entering into the hydraulic system. 5. Label all the hydraulic hose connections for assembly purposes. 6.
Servicing the Gear Pump g031893 Figure 119 1. Socket-head screw (8 each) 9. Idler gear 17. Idler gear 2. Seal ring 10. Gear housing 18. Mounting flange 3. Deflecting plate 11. Dowel pin (6 each) 19. Seal 4. Rear cover 12. Drive coupler 20. Idler gear 5. Drive gear 13. Gear housing 21. Drive gear 6. Deflecting plate 14. Bearing plate 22. Bearing plate 7. Load seal 15. Gear housing 8. Pre-load seal 16.
Traction Circuit g031894 Figure 120 1. Piston (traction) pump 4. Traction control manifold 7. Traction flush manifold 2. Gear pump 5. Right front wheel motor 8. Right rear wheel motor 3. Left front wheel motor 6. 4-wheel drive control manifold 9. Left rear wheel motor Refer to Figure 120 for the components that are used in the traction circuit of the machine.
Piston (Traction) Pump g035228 Figure 121 1. Gear pump 11. Hose (from filter) 21. O-ring 2. 90° hydraulic fitting 12. Bolt (2 each) 22. O-ring 3. Piston pump 13. 90° hydraulic fitting 23. Diagnostic fitting 4. Quick fitting 14. O-ring 24. Hose (from hydraulic tank) 5. Dust cap 15. O-ring 25. Washer (2 each) 6. Bolt (2 each) 16. O-ring 26. Tee fitting 7. Hydraulic adapter 17. O-ring 27. Test fitting 8. Flat washer (2 each) 18. O-ring 28. O-ring 9.
Removing the Piston (Traction) Pump g035229 Figure 122 1. Piston pump 7. Adapter fitting 2. Bolt (4 each) 8. Test nipple 3. Washer (4 each) 9. 90° fitting 4. Straight fitting 10. Tee fitting 5. Dust cap 11. Straight fitting 6.
Removing the Piston (Traction) Pump (continued) g035230 Figure 123 1. Hydraulic hose 4. Lock washer (4 each) 2. Flange 5. O-ring 3. Bolt (4 each) Note: Machines with serial number below 313000300 have a Rexroth piston (traction) pump (Figure 121). Machines with serial number above 313000300 have a Sauer-Danfoss piston pump (Figure 122). Removal and installation of the piston pump is very similar regardless of the pump brand. 1.
Removing the Piston (Traction) Pump (continued) CAUTION The weight of the Rexroth piston pump assembly is approximately 39 kg (86 lb). The weight of the Sauer-Danfoss piston pump assembly is approximately 50 kg (110 lb). Ensure that you support the piston pump correctly before removing the pump mounting screws. 11. Attach a hoist to the piston pump to support the pump and safely remove the pump from the machine. 12.
Installing the Piston (Traction) Pump (continued) 9. Fill the hydraulic reservoir with the correct quantity of fluid. Note: Correctly fill the hydraulic system; refer to Charging the Hydraulic System (page 4–99). 10. Shut off the engine and check for hydraulic-fluid leaks. Check the hydraulic-fluid level in the hydraulic reservoir. 11. Install the hood; refer to Installing the Hood (page 7–38).
Servicing the Piston (Traction) Pump (Rexroth) g031896 Figure 124 1. Rotary group 12. Retaining ring 23. Socket-head screw (4 each) 2. Stroking piston assembly 13. Joint pin 24. Plug 3. Port plate assembly 14. Forward traction relief valve 25. Pump housing 4. Pump support plate assembly 15. Reverse traction relief valve 26. Orifice 5. EP control assembly 16. Charge relief valve 27. Plug 6. Gasket 17. Socket-head screw (4 each) 28. O-ring 7.
Servicing the Piston (Traction) Pump The Rexroth piston pump is used on the Groundsmaster machines with serial number below 313000300. For the piston (traction) pump repair procedures on these machines; refer to the Rexroth Variable Pump A10VG Repair Instructions and Repair Manual at the end of this chapter. IMPORTANT If a piston (traction) pump fails; refer to the Traction Circuit Component Failure (page 4–8) for information regarding the importance of removing contamination from the traction circuit.
Servicing the Piston (Traction) Pump (Sauer-Danfoss) g035232 Figure 126 Groundsmaster 5900 Traction Unit 08159SL Rev C Page 4–119 Hydraulic System: Service and Repairs
Figure 126 (continued) 1. Screen (2 each) 19. Coupling 37. Seal 2. Plug with O-ring (2 each) 20. Bearing 38. O-ring 3. Plug with O-ring (2 each) 21. Screw (4 each) 39. Seal carrier 4. Cylinder block assembly 22. Thrust plate 40. Retaining ring 5. Valve plate 23. Reverse relief valve assembly 41. Coil nut (2 each) 6. Servo piston 24. Forward relief valve assembly 42. O-ring 7. Screw (6 each) 25. Swash plate bearing assembly 43. Reverse solenoid coil 8.
Front Wheel Motors g031897 Figure 127 1. Front wheel motor 9. 2. Splined brake shaft 10. O-ring 17. Flange-head screw (4 each brake) 18. Hydraulic fitting (2 each motor) O-ring 3. Internal retaining ring 11. Bolt (2 each motor) 19. Hydraulic tube 4. Planetary assembly 12. Flat washer (2 each motor) 20. Hydraulic tube 5. Gasket 13. Hydraulic fitting 21. Hydraulic tube 6. Front wheel assembly 14. O-ring 22. Traction control manifold 7. Brake assembly (left) 15.
Removing the Front Wheel Motors (continued) 3. Clean the exterior of the motor, hydraulic tubes, and fittings before removing the motor to prevent contaminants from entering into the hydraulic system. 4. To easily access the hydraulic tube fittings at the wheel motor, remove the pin that secures the lift cylinder to the front deck lift arm and lower the front of the lift cylinder; refer to Removing the Front Deck Lift Cylinder (page 4–166). 5. Disconnect the hydraulic tubes from the wheel motor.
Installing the Front Wheel Motors (continued) 3. Position the wheel motor to the brake assembly and ensure that the case drain port is above the supply line ports; refer to Figure 128. 4. Align the splines on the motor shaft and splined brake shaft in the brake assembly. Slide the motor into the brake assembly. 5. Attach the motor to the brake and planetary assemblies with the 2 bolts and 2 flat washers; torque the bolts to 102 to 115 N∙m (75 to 85 ft-lb). 6.
Servicing the Front Wheel Motor g031899 Figure 129 1. Driveshaft 7. Bolt (6 each) 13. 2. Backplate 8. Shaft seal 14. Thrust bearing Roll pin 3. Housing assembly 9. Retaining ring 15. Roll pin 4. Rotating assembly 10. Thrust race 16. Bearing 5. Cam plate insert 11. O-ring 17. Bearing 6. Retaining ring 12. Valve plate 18. Washer Note: The front wheel motors on the 5900 and 5910 machines are the Eaton Model 74348 motors. The front wheel motors are identical.
Servicing the Front Wheel Motor (continued) IMPORTANT If a wheel motor fails; refer to the Traction Circuit Component Failure (page 4–8) for information regarding the importance of removing contamination from the traction circuit.
Rear Wheel Motors g031900 Figure 130 1. Rear tire 9. Right wheel motor 2. Wheel lug nut (6 each wheel) 10. Hex nut 18. Wheel rim 3. Bolt (4 each motor) 11. Square key 19. Steering cylinder (2 each) 4. Lock washer (4 each motor) 12. Wheel stud (6 each wheel) 20. Rear axle 5. Left wheel motor 13. Wheel hub 21. Hydraulic hose 6. Valve stem 14. Hydraulic fitting 22. Hydraulic hose 7. Tie rod assembly 15. O-ring 8. Right steering spindle 16. O-ring 17.
Removing the Rear Wheel Motors (continued) 2. Block the front wheels with chocks to prevent the machine from moving. 3. Loosen, but do not remove the 6 wheel-lug nuts and hex nut (item 10 in Figure 130) that secures the wheel hub to the wheel motor. WARNING Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–5). 4. Lift the machine with a jack and remove the rear wheel. Support the machine with jack stands. 5.
Installing the Rear Wheel Motors (continued) 1. Position the rear wheel motor to the steering spindle. Note: Ensure that the ports in the wheel motor are facing toward the rear of the machine. 2. Attach the wheel motor to the spindle with the 4 bolts and 4 lock washers; torque the bolts to 91 to 112 N∙m (67 to 83 ft-lb). 3. Remove the plugs from the disconnected hydraulic hoses and wheel motor ports. 4. Lubricate and install new O-rings to the hydraulic fittings.
Servicing the Rear Wheel Motor g031901 Figure 131 1. Bolt (7 each) 7. Shaft seal 13. Coupling shaft 2. Commutator assembly 8. Back-up washer 14. Back-up ring 3. Manifold 9. End cover 15. Housing 4. Stator assembly 10. Commutator ring 16. Dirt and water seal 5. Wear plate 11. Body seal (5 each) 6. Drive link 12. Thrust bearing Note: The rear wheel motors of the Groundsmaster 5900 and 5910 machines are the Parker Torqmotor™ TG Series.
Traction Control Manifold g031902 Figure 132 1. Traction control manifold 4. Planetary assembly 7. Frame assembly 2. Flange-head screw (4 each) 5. Left front wheel motor 8. Brake assembly 3. Front PTO control manifold 6. Front wheel assembly Note: The ports on the traction control manifold are marked for easy identification of the components.
Removing the Traction Control Manifold (continued) g031903 Figure 133 1. Dust cap 10. Straight fitting (M2) 2. Quick fitting (G-OR) 11. O-ring 3. O-ring 12. O-ring 4. Orifice (G-OR) 13. Straight fitting (CD) 5. Manifold 14. O-ring 6. O-ring 15. Tee fitting (M1) 7. Straight fitting (CH) 16. O-ring 8. O-ring 17. 90° fitting (P) 9. O-ring 5. Remove the hydraulic manifold from the frame; refer to Figure 132. 6.
Installing the Traction Control Manifold (continued) 4. Use the labels that you attached during removal to correctly connect the hydraulic lines to the manifold; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10). 5. Connect the wire harness connector to the solenoid valve. 6. Ensure that the hydraulic tank is full. Add the correct quantity of fluid if necessary.
Servicing the Traction Control Manifold g031904 Figure 134 1. Dust cap 7. #4 NWD plug (3 each) 13. Manifold body 2. Quick fitting (G-OR) 8. Solenoid valve (S) 14. Check valve (CV) 3. O-ring 9. Solenoid coil 15. #12 NWD plug 4. Orifice (G-OR) 10. Nut 16. O-ring 5. #8 NWD plug 11. Flow divider (FD) 6. O-ring 12. Pilot directional valve (PD) Note: The ports on the traction control manifold are marked for easy identification of the components.
Servicing the Valve Cartridge 1. Ensure that the entire outer surface of the manifold is clean before you remove the valve. 2. If the cartridge is solenoid-operated, remove the nut securing the solenoid coil to the cartridge valve. Carefully slide the solenoid coil off the valve. IMPORTANT Slight bending or distortion of the stem tube can cause binding and malfunction. Carefully handle the valve cartridge. 3. Remove the cartridge valve with a deep socket wrench.
Servicing the Valve Cartridge (continued) IMPORTANT Slight bending or distortion of the stem tube can cause binding and malfunction. Carefully handle the valve cartridge. C. Turn the cartridge valve carefully into the manifold port. The valve should go in easily without binding. D. Use a deep socket and torque the cartridge valve; refer to Figure 134 for the torque value. E. If the cartridge is solenoid-operated, carefully install the solenoid coil to the cartridge valve.
4-Wheel Drive Control Manifold g031905 Figure 135 1. 4-wheel drive control manifold 5. Hydraulic tee fitting 2. O-ring 6. Flange nut 9. 10. Bolt Bolt (2 each) 3. O-ring 7. Bulkhead mount plate 11. Flush manifold 4. Hydraulic tee fitting 8. Flange nut (2 each) 12. Flange screw (4 each) Note: The ports on the 4-wheel drive control manifold are marked for easy identification of the components.
Removing the 4-Wheel Drive Control Manifold (continued) 4. Disconnect all the hydraulic lines from the manifold and install caps or plugs on the open hydraulic lines and fittings. Label the disconnected hydraulic lines for proper assembly. 5. Support the manifold to prevent it from falling. 6. Remove the 4 flange screws that attach the 4-wheel drive control manifold to the frame, and remove the manifold from the frame. 7.
Installing the 4-Wheel Drive Control Manifold (continued) 2. Position the 4-wheel drive control manifold to the frame and attach it with 4 flange screws. 3. Remove the caps and plugs from the fittings and hoses. 4. Correctly connect the hydraulic lines to the manifold; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10). 5. Connect the wire harness connector to the solenoid valve. 6. Ensure that the hydraulic tank is full. Add the correct quantity of fluid if necessary.
Servicing the 4-Wheel Drive Control Manifold g031907 Figure 137 1. Orifice (0.040) (OR2) 6. Solenoid coil 11. Orifice (0.030) (OR1) 2. Plug with O-ring 7. Nut 12. Relief valve (RV) 3. NWD #6 plug with O-ring 8. Check valve (CV) 13. Pressure valve (PR) 4. NWD #8 plug with O-ring 9. NWD #4 plug with O-ring 14. Directional pilot valve (PD1) 5. Solenoid valve (SV) 10.
Servicing the Valve Cartridge (continued) Note: The 4-wheel drive control manifold includes several zero-leak NWD plugs. These plugs have a tapered sealing surface on the plug head, that is designed to resist vibration induced plug loosening. The zero-leak plugs have an O-ring as a secondary seal.
Traction Flush Manifold g031908 Figure 138 1. 4-wheel drive control manifold 6. Flange nut 11. Hydraulic-fluid temperature sender 2. O-ring 7. Bulkhead mount plate 12. O-ring 3. O-ring 8. Flange nut (2 each) 13. Flush manifold assembly 4. Hydraulic tee fitting 9. Bolt 14. Flange screw (4 each) 5. Hydraulic tee fitting 10. Bolt (2 each) Note: The ports on the traction flush manifold are marked for easy identification of the components.
Removing the Traction Flush Manifold (continued) 2. Clean the exterior of the manifold and fittings before removing the manifold to prevent contaminants from entering into the hydraulic system. 3. Disconnect the hydraulic lines from the flush manifold and install caps or plugs on the open hydraulic lines and fittings. Label the disconnected hydraulic lines for proper assembly. 4. Support the flush manifold to prevent it from falling. 5.
Installing the Traction Flush Manifold (continued) 3. Position the flush manifold to the frame, and attach it with 2 bolts and 2 flange nuts. 4. Remove the caps and plugs from the fittings and hoses. Correctly connect the hydraulic lines to the manifold; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10). 5. Ensure that the hydraulic tank is full. Add the correct quantity of fluid if necessary.
PTO Circuit g031910 Figure 140 1. Gear pump 5. Left PTO control manifold 2. Right PTO control manifold 6. Left cutting deck motor 3. Hydraulic hose to oil cooler 7. Filter manifold 4. Hydraulic hose from oil cooler 8. Right cutting deck motor 9. 10. Front cutting deck motor Front PTO control manifold Refer to Figure 140 for the components that are used in the PTO circuit of the machine.
Cutting Deck Motor g031911 Figure 141 1. Hydraulic hose 2. O-ring 3. Cutting deck motor 4. 5. 8. 9. Hex nut 15. Mounting shim (if equipped) Spindle assembly 16. O-ring 10. Motor mount 17. Hydraulic fitting Flange-head screw (2 each) 11. Spider 18. O-ring 90° hydraulic fitting 12. Washer 19. Hydraulic hose 6. O-ring 13. Spider hub 7. Hydraulic hose 14. Woodruff key Removing the Cutting Deck Motor 1.
Removing the Cutting Deck Motor (continued) g031912 Figure 142 Deck motor (front) 4. Return hose 2. Flange-head screw 5. Case drain hose 3. Inlet hose 1. 6. Remove the 2 flange-head screws that attach the hydraulic motor to the motor mount; refer to Figure 141. 7. Carefully remove the hydraulic motor from the cutting deck. Note: Do not damage the spider hub that is attached to the motor. 8. Locate and remove the spider and mounting shim(s) (if present) from the deck. 9.
Installing the Cutting Deck Motor (continued) 4. Position the spider into the spindle pulley. If necessary, place the mounting shim(s) on the deck and carefully install the hydraulic motor to the cutting deck. Note: Ensure that you do not damage the spider hub that is attached to the motor. 5. Attach the motor to the cutting deck with the 2 flange-head screws. IMPORTANT For proper hydraulic hose routing, ensure that the cutting decks are fully lowered before installing the hoses to the deck motor. 6.
Servicing the Cutting Deck Motor g031913 Figure 143 1. Rear cover 7. Dust seal 13. Bolt (4 each) 2. Drive gear 8. Pressure seal 14. Front flange 3. Shaft seal 9. 4. Retaining ring 5. 6. Back-up gasket 15. Dowel pin (4 each) 10. O-ring 16. Washer (4 each) Flange washer 11. Body 17. Rear wear plate Front wear plate 12. Idler gear Disassembling the Cutting Deck Motor 1. Plug the motor ports and clean the exterior of the motor.
Disassembling the Cutting Deck Motor (continued) g031914 Figure 144 1. 2. Deck motor Woodruff key 3. Spider hub 4. 5. Washer Nut g031915 Figure 145 2. Remove the nut and washer that attach the spider hub to the motor shaft (Figure 144). Use a suitable puller to remove the hub from the shaft, and remove the woodruff key. 3. Use a marker and make a diagonal line across the front flange, body, and rear cover for assembly purposes; refer to Figure 145.
Disassembling the Cutting Deck Motor (continued) 7. Remove the rear cover from the body. 8. Lift the body straight up and carefully remove it. Note: Ensure that the rear wear plate remains on the drive and idler gear shafts. 9. Remove and discard the O-rings from the body. 10. Locate and retrieve the dowel pins. IMPORTANT Before removing the wear plates, note the position of the open and closed side of the wear plates. Also identify the wear plates (front and rear) with a marker for proper assembly. 11.
Inspecting the Cutting Deck Motor (continued) g031916 Figure 146 1. Gear shaft spline 3. Gear teeth 2. Gear shaft 4. Gear face edge 3. Inspect the drive gears and idler gears for the following; refer to Figure 146. A. Gear shafts must be free from rough surfaces and excessive wear at the bushing points and sealing areas. Replace the gears if you find any scoring, rough surfaces, or wear on the gear shafts. B. Gear teeth must be free from excessive scoring and wear.
Assembling the Cutting Deck Motor (continued) g031917 Figure 147 1. Dust seal 3. Flange washer 2. Retaining ring 4. Shaft seal 2. Install new seals into the front flange (Figure 147) as follows: A. Press the shaft seal into the front flange until it reaches the bottom of the bore. B. Install the flange washer into the front flange and then install the retaining ring into the groove of the front flange. C. Install a new dust seal into the front flange. 3.
Assembling the Cutting Deck Motor (continued) Note: If the wear plate is not below the body, check the assembly for a shifted pressure seal, back-up gasket, or O-ring. Correct the shifting before you proceed. 15. Apply a light coating of petroleum jelly to the exposed side of the rear cover. 16. Use the marker line for proper location and place the rear cover on the assembly, and align the dowels with firm hand pressure. 17. Install the 4 bolts with 4 washers and tighten them by hand.
PTO Control Manifolds g031918 Figure 148 1. 2. Front PTO control manifold Right PTO control manifold 4. 5. Traction control manifold Bolt (2 each manifold) 3. Left PTO control manifold 6. Flange nut (2 each manifold) 7. 8. Main frame Front axle frame The control manifolds for the 3 cutting deck sections are very similar. Note: When servicing the PTO control manifolds, do not interchange the parts from 1 control manifold to another.
Removing the PTO Control Manifolds g031919 Figure 149 1. Front PTO manifold 2. O-ring 3. Quick fitting 8. Hydraulic 45° fitting 9. O-ring 10. O-ring 4. Dust cap 11. O-ring 5. O-ring 12. Hydraulic tee fitting 6. Hydraulic 45° fitting 13. O-ring 7. O-ring 14. Hydraulic 90° fitting 1. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–95). 2.
Installing the PTO Control Manifolds g032282 Figure 150 1. Right PTO manifold 8. O-ring 2. O-ring 9. Hydraulic tee fitting 3. Quick fitting 10. O-ring 4. Dust cap 11. Hydraulic 90° fitting 5. O-ring 12. O-ring 6. Hydraulic 90° fitting 13. O-ring 7. O-ring 14.
Installing the PTO Control Manifolds (continued) g032283 Figure 151 1. Left PTO manifold 8. Hydraulic 90° fitting 2. O-ring 9. O-ring 3. Quick fitting 10. O-ring 4. Dust cap 11. O-ring 5. O-ring 12. Hydraulic 90° fitting 6. Hydraulic 90° fitting 13. O-ring 7. O-ring 14. Straight fitting 1. If the fittings were removed from the manifold, do the following steps: A. Lubricate and install new O-rings with clean hydraulic fluid onto the fittings. B.
Servicing the PTO Control Manifold g031922 Figure 152 1. Manifold body 5. Nut 2. Relief valve (RV2) 6. Relief valve (RV1) 3. Solenoid valve (S) 7. Spool logic element (LC1 and LC2) 4. Solenoid coil 8. Orifice (OR) (right and left only) 9. NWD #4 plug with O-ring 10. NWD #8 plug with O-ring Note: The ports on the PTO control manifolds are marked for easy identification of the components.
Servicing the Valve Cartridge The control manifolds for the 3 cutting deck sections are very similar. The manifold for the right and left side decks include an orifice (item 8 in Figure 152) that is not used on the front deck manifold. Also, the relief valve (RV1) on the right side manifold is set to a lower pressure 13,800 kPa (2,000 psi) than the relief valve (RV1) pressure on the front and left side manifold 20,700 kPa (3,000 psi).
Filter Manifold g031923 Figure 153 1. Bolt and lock washer (4 each) 8. Straight fitting (T) 15. O-ring 2. Split flange 9. O-ring 16. 45° hydraulic fitting (CD1) 3. Fitting 10. Straight fitting (T2) 17. Check valve (CV) 4. O-ring 11. O-ring 18. O-ring 5. Filter manifold 12. 90° hydraulic fitting (CD2) 19. 90° hydraulic fitting (CL) 6. NWD #6 plug with O-ring 13. O-ring 20. O-ring 7. O-ring 14.
Removing the Filter Manifold g031924 Figure 154 1. Flange-head screw (4 each) 3. Oil filter 2. Filter manifold 4. Main frame 1. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–95). 2. Raise the hood to get access to the filter manifold. 3. Clean the exterior of the manifold and fittings before removing the manifold to prevent contaminants from entering into the hydraulic system. 4.
Installing the Filter Manifold (continued) 2. Refer to Figure 153 for the check valve and plug installation torque. 3. Position the filter manifold to the frame and attach it with 4 flange-head screws. Torque the screws to 12.0 to 17.9 N∙m (106 to 159 in-lb); refer to Figure 154. 4. Remove the caps and plugs from the fittings and hoses. Correctly connect the hydraulic lines to the manifold; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10). 5.
Hydraulic Oil Cooler g031925 Figure 155 1. Oil cooler 5. Washer (4 each) 9. Support plate (2 each) 2. O-ring 6. Flange nut (4 each) 10. Bolt (4 each) 3. Clamp (2 each) 7. Hydraulic hose (2 each) 11. Radiator assembly 4. Bolt (2 each) 8. Flange nut (4 each) 12. Bumper (2 each) Removing the Hydraulic Oil Cooler CAUTION A hot radiator and oil cooler can cause burns. Allow the engine and cooling systems to cool before working on or near them. 1.
Removing the Hydraulic Oil Cooler (continued) 4. Clean the exterior of the oil cooler and hydraulic hoses before removing the oil cooler to prevent contaminants from entering into the hydraulic system. 5. Remove the oil cooler; refer to Figure 155. 6. Use a back-up wrench on the oil cooler fittings to remove the hydraulic hoses from the fittings. Install caps or plugs on the oil cooler and hydraulic hose openings to prevent contamination. Inspecting the Hydraulic Oil Cooler 1.
Cutting Deck Raise/Lower Circuit g031926 Figure 156 1. Gear pump 3. Front cutting deck lift cylinder 2. Left cutting deck lift cylinder 4. Right cutting deck lift cylinder 5. Lift control manifold Note: Refer to Figure 156 for the components that are used in the cutting deck raise/lower circuits of the machine. Procedures for removal, installation, and disassembly/assembly of these components are provided in the following pages of this section.
Front Deck Lift Cylinder g031927 Figure 157 1. Lift cylinder 6. Grease fitting 2. Lift arm (left) 7. O-ring 12. Plug 3. Flange nut 8. 90° hydraulic fitting 13. Flat washer (4 each pin) 4. Pin 9. O-ring 5. Flange-head screw 10. 11. Clevis pin Cotter pin (2 each pin) Removing the Front Deck Lift Cylinder 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Front Deck Lift Cylinder (continued) IMPORTANT Ensure that you release the lift system pressure before removing the lift cylinder; refer to Releasing Pressure from the Hydraulic System (page 4–6). Note: For easy assembly, label all the hydraulic hoses to identify their correct position on the lift cylinder. 4. Disconnect the hydraulic hoses from the lift cylinder fittings. Install caps or plugs on the fittings and hoses to prevent contamination. Label the hydraulic lines for proper assembly. 5.
Servicing the Front Deck Lift Cylinder g031928 Figure 158 1. Barrel with clevis 2. Retaining ring 3. Shaft with clevis 4. 5. Dust seal Shaft seal O-ring 11. Piston 7. Back-up ring 12. Locknut 8. Head 13. O-ring 6. 9. 10. Piston seal Wear ring Disassembling the Front Deck Lift Cylinder 1. Slowly pump the cylinder shaft to remove the hydraulic fluid from the lift cylinder into a drain pan. 2. Plug both the ports and clean the outer surface of the cylinder.
Disassembling the Front Deck Lift Cylinder (continued) 3. Mount the lift cylinder in a vise equipped with soft jaws by clamping on the barrel clevis. 4. Remove the retaining ring that secures the head in the barrel as follows: A. Use a spanner wrench to rotate the head clockwise, until the edge of the retaining ring appears in the barrel opening. B. Put a screw driver under the beveled edge of the retaining ring to start moving the retaining ring through the opening. C.
Assembling the Front Deck Lift Cylinder (continued) 3. Mount the shaft correctly in a vise equipped with soft jaws by clamping on the shaft clevis. A. Put a coating of clean hydraulic fluid on the shaft. B. Slide the head and piston onto the shaft. C. Attach the piston to the shaft with the locknut; torque the locknut to 176 N∙m (130 ft-lb). 4. Lubricate the head and piston with clean hydraulic fluid. Slide the shaft assembly carefully into the cylinder barrel.
Wing Deck Lift Cylinder g031929 Figure 159 1. Wing deck lift arm (left) 5. Pin 9. O-ring 2. Pin 6. Bolt 10. O-ring 11. Jam nut (4 each pin) 3. Grease fitting 7. Hydraulic fitting (2 each cylinder) 4. Flange nut 8. Wing deck lift cylinder (left) Removing the Wing Deck Lift Cylinder 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Wing Deck Lift Cylinder (continued) Note: For easy assembly, label all the hydraulic hoses to identify their correct position on the lift cylinder. 4. Disconnect the hydraulic hoses from the lift cylinder fittings. Install caps or plugs on the fittings and hoses to prevent contamination. Label the hydraulic lines for proper assembly. 5. Remove the bolt (item 6 in Figure 159) and flange nut (item 4 in Figure 159) that attach the pin (item 5 in Figure 159) to the lift arm.
Servicing the Wing Deck Lift Cylinder g031930 Figure 160 1. Barrel with clevis 7. Back-up ring 13. Wear ring 2. 3. External collar Shaft with clevis 8. 9. Head O-ring 14. 15. Piston seal Steel ring 4. Dust seal 10. Cushion 16. Wear ring 5. 6. Shaft seal O-ring 11. 12. Piston Locknut Disassembling the Wing Deck Lift Cylinder 1. Slowly pump the cylinder shaft to remove the hydraulic fluid from the lift cylinder. 2.
Disassembling the Wing Deck Lift Cylinder (continued) 4. Use a spanner wrench to loosen and remove the collar from the barrel. 5. Carefully twist and pull the shaft and remove it with head, cushion, and piston. IMPORTANT Clamping the vise jaws against the shaft surface could damage the shaft. When securing the shaft in a vise, clamp the shaft clevis only. 6. Mount the shaft correctly in a vise equipped with soft jaws by clamping on the shaft clevis. 7. Remove the locknut from the shaft.
Assembling the Wing Deck Lift Cylinder (continued) 4. Lubricate the head, cushion, and piston with clean hydraulic fluid. Slide the shaft assembly carefully into the cylinder barrel. IMPORTANT When you clamp the barrel of the cylinder in a vise, clamp the barrel clevis only to prevent damage. Do not close the vise on the barrel. 5. Mount the lift cylinder in a vise equipped with soft jaws by clamping on the barrel clevis. 6. Use a spanner wrench and tighten the collar onto the barrel.
Lift Control Manifold g031931 Figure 161 1. Battery 4. Flange-head screw (3 each) 7. Hydraulic filter 2. Lift control manifold 5. Flange-head screw (4 each) 8. Flange nut (3 each) 3. Water separator assembly 6. Mounting plate 9. Frame Note: The ports on the lift control manifold are marked for easy identification of the components.
Removing the Lift Control Manifold (continued) 6. Remove the hydraulic manifold from the frame; refer to Figure 161. IMPORTANT An orifice is placed below the 90° hydraulic fittings in the control manifold C1-OR1 and C5-OR2 ports. If 1 of these fittings is removed from the manifold, ensure that you remove the orifice and label the orifice position for assembly purposes. 7. If you remove the hydraulic fittings from the manifold, put a mark on the fitting orientation for correct assembly. 8.
Installing the Lift Control Manifold (continued) IMPORTANT When installing the orifice in manifold port C1-OR1 or C5-OR2, ensure that the orifice is flat in the base of the port cavity. Letting the orifice stay cocked in the cavity can damage the manifold. B. If the fitting was removed from the manifold port C1-OR1 or C5-OR2, place the orifice in the port before you install the fitting. C.
Servicing the Lift Control Manifold g031933 Figure 163 1. Lift manifold Solenoid coil (4 each) 11. Solenoid valve (S6) 2. Solenoid valve (S2, S3, S7 and S8) 7. 6. Solenoid nut 12. SAE #6 plug with O-ring 3. Solenoid coil (5 each) 8. Solenoid valve (S1) 13. NWD #6 plug with O-ring 4. Solenoid nut 9. Relief valve (RV) 14. Flow divider (FD) 5. Solenoid valve (S4 and S9) Solenoid valve (S5) 15. SAE #4 plug with O-ring (7 each) 10.
Servicing the Valve Cartridge g031934 Figure 164 1. Lift manifold 3. Logic valve (LC) 2. NWD #8 plug/O-ring 4. SAE #4 plug/O-ring For the cartridge valve service procedures; refer to Servicing the Traction Control Manifold (page 4–133). Refer to Figure 163 and Figure 164 for the lift control manifold cartridge valve and plug installation torque.
Steering and Engine Cooling Fan Circuit g031935 Figure 165 1. Steering control valve 3. 2. Oil filter 4. Steering/cooling fan control manifold Steering cylinder (2 each) 5. Engine cooling fan motor Refer to Figure 165 for the components that are used in the steering and engine cooling fan circuit of the machine. Procedures for removal, installation, and disassembly/assembly of these components are provided in the following pages of this section.
Steering Control Valve g031936 Figure 166 1. Steering tower cover 15. Spacer 29. Locknut 2. Flange-head screw 16. Knob 30. Proximity switch 3. Bolt (2 each) 17. Steering wheel cover 31. Switch plate 4. Pivot hub (3 each) 18. Hex nut 32. Carriage bolt 5. Steering column assembly 19. Flat washer 33. Compression spring 6. Thrust washer (4 each) 20. Steering wheel 34. Parking brake rod 7. Steering tower 21. Foam collar 35. Parking brake rack 8.
Removing the Steering Control Valve 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–95). 3. Remove the steering tower cover (item 1 in Figure 166). 4.
Installing the Steering Control Valve (continued) 4. Remove the caps or plugs that were installed during the removal process. 5. Use the tags that you placed during control valve removal to identify the correct tube placement and correctly connect the hydraulic tubes to the fittings on the steering valve; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10). 6. Install the steering tower cover (item 1 in Figure 166). 7.
Servicing the Steering Control Valve g031938 Figure 168 1. Steering valve housing 2. Dust seal 3. O-ring 4. Spool 5. Spring retaining ring 6. Pin 7. Sleeve 8. Centering springs/spacers 9. Bolt (7 each) 17. Geroter drive 10. End cap 18. Wear plate 11. O-ring 19. Bearing race 12. Seal ring 20. Thrust bearing 13. O-ring 21. Plug 14. Geroter 22. O-ring 15. O-ring 23. Check ball 16.
Steering Cylinders g031939 Figure 169 1. Slotted hex nut 6. Cotter pin 11. Steering cylinder 2. Left steering spindle 7. Tie rod assembly 12. Bolt 3. Cylinder Ball joint 8. Slotted hex nut 13. O-ring 4. Hex nut 9. O-ring 14. 90° hydraulic fitting 5. Grease fitting 45° hydraulic fitting 15. Rear axle 10. Removing the Steering Cylinders 1.
Removing the Steering Cylinders (continued) 4. Disconnect the hydraulic hoses from the steering cylinder fittings. Install caps or plugs on the fittings and hoses to prevent contamination. Label the hydraulic lines for proper assembly. 5. Remove the cotter pins and slotted hex nuts (items 1 and 8 in Figure 169) that attach the cylinder ball joints to the rear axle and steering spindle. 6. Disconnect the ball joints from the rear axle and steering spindle, and remove the steering cylinder from the machine.
Servicing the Steering Cylinder g031940 Figure 170 Rod seal 15. O-ring 9. 10. Head Back-up ring 16. 17. Locknut Barrel Piston rod ball joint 11. O-ring 18. Roll pin Snap ring 12. O-ring 19. Jam nut 6. Piston rod 13. Piston 20. Barrel end ball joint 7. Rod wiper 14. Slipper seal 1. Grease fitting 2. 3. Bolt Locknut 4. 5. 8. Disassembling the Steering Cylinder 1. Slowly pump the piston rod to remove the fluid from the steering cylinder. 2.
Disassembling the Steering Cylinder (continued) IMPORTANT Do not wipe the parts dry with paper towels or a cloth. They let lint accumulate in the hydraulic system, which will damage it. 8. Carefully inspect the internal surface of the barrel for damage (deep scratches, out-of-round, etc.). A. Replace the entire cylinder if the barrel is damaged. B. Inspect the shaft and piston for excessive scoring, pitting, or wear. C. Replace any damaged parts. 9.
Assembling the Steering Cylinder (continued) g031941 Figure 171 9. If the piston rod end ball joint (item 4 in Figure 170) was removed, fully retract the piston rod and thread the ball joint onto the rod so that the center-to-center length is 362.5 to 363.9 mm (14.270 to 14.330 inches); refer to Figure 171. 10. Tighten the bolt (item 2 in Figure 170) and locknut (item 3 in Figure 170).
Engine Cooling Fan Motor g031942 Figure 172 1. Socket-head screw (2 each) 2. Cooling fan motor O-ring 17. Flange nut (4 each) 10. 9. Fan motor bracket 18. Carriage screw (2 each) 3. 90° hydraulic fitting 11. Locknut (2 each) 19. Flat washer (2 each) 4. Fan hub 12. Cooling fan 20. Flange nut (2 each) 5. Flat washer 13. Flange-head screw (6 each) 21. Bolt (4 each) 6. Hex nut 14. Oil cooler 22. Clamp (2 each) 7. O-ring 15. Radiator assembly 8. Woodruff key 16.
Removing the Engine Cooling Fan Motor (continued) 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–95). 3. Unlatch the hood and raise it. CAUTION A hot radiator and oil cooler can cause burns. Allow the engine and cooling systems to cool before working on or near them. IMPORTANT Ensure that you do not damage the radiator, oil cooler, or other machine components while loosening and removing the fan motor. 4.
Installing the Engine Cooling Fan Motor (continued) 2. Carefully position the fan motor to the fan motor bracket. Loosely attach the motor to the bracket with the socket-head screws (item 1 in Figure 172) and locknuts (item 11 in Figure 172). 3. Remove the caps or plugs that were installed during the removal process. Connect the hydraulic hoses to the cooling fan motor; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–10). 4.
Servicing the Engine Cooling Fan Motor g031943 Figure 173 1. Rear cover 7. Dust seal 13. Bolt (4 each) 2. Drive gear 8. Pressure seal 14. Front flange 3. Shaft seal 9. Back-up gasket 15. Dowel pin (4 each) 4. Flange washer 10. O-ring 16. Washer (4 each) 5. Retaining ring 11. Body 17. Rear wear plate 6. Front wear plate 12. Idler gear For the disassembly, inspection, and assembly procedures of the cooling fan motor; refer to Servicing the Cutting Deck Motor (page 4–148).
Steering/Engine Cooling Fan Control Manifold g031944 Figure 174 1. Bulkhead mount plate 5. Flange-head screw (7 each) 2. Flange nut (3 each) 6. Tube mount plate 3. Steering/cooling fan manifold 7. Tube clamp 4. Carriage bolt 8. Flange nut 9. 10. Manifold mount plate Bolt (3 each) Note: The ports on the steering/cooling fan manifold are marked for easy identification of the components.
Removing the Steering/Engine Cooling Fan Control Manifold (continued) 5. Disconnect all the hydraulic lines from the manifold and install caps or plugs on the open hydraulic lines and fittings. Label the disconnected hydraulic lines for proper assembly. 6. Remove the steering/cooling fan manifold from the frame; refer to Figure 174. IMPORTANT An orifice is placed below the hydraulic fitting in the control manifold LS port.
Installing the Steering/Engine Cooling Fan Control Manifold (continued) 1. If the fittings were removed from the manifold, do the following steps: A. Lubricate and install new O-rings with clean hydraulic fluid onto the fittings. IMPORTANT When installing the orifice in manifold port LS, ensure that the orifice is flat in the base of the port cavity. Letting the orifice stay cocked in the cavity can damage the manifold. B.
Servicing the Steering/Engine Cooling Fan Control Manifold g031946 Figure 176 1. Steering/cooling fan manifold 5. Solenoid coil 2. NWD #8 plug with O-ring 6. Proportional relief valve (PRV) 9. Solenoid coil 10. Solenoid nut 3. Relief valve (RV) 7. 4. Solenoid nut 8. NWD #4 plug with O-ring (2 each) 11. Solenoid valve (S) Check valve (CV) 12. Compensator valve (PV) Note: The ports on the steering/cooling fan manifold are marked for easy identification and assembly of the components.
Servicing the Valve Cartridge (continued) Note: The steering/cooling fan control manifold includes several zero-leak NWD plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero-leak plugs also have an O-ring as a secondary seal.
Hydraulic System: Service and Repairs Page 4–200 Groundsmaster 5900 Traction Unit 08159SL Rev C
Chapter 5 Electrical System Table of Contents General Information .............................................................................................................................. 5–3 Toro Electronic Controllers (TEC)....................................................................................................... 5–3 Cummins Engine Electronic Control Module (ECM) ........................................................................... 5–3 CAN-Bus Communications .......................
Main Power, Controller, Start, and Cab (Groundsmaster 5910 Machine Only) Relays .............................................................................................................................................. 5–79 Air Conditioning Relay (Groundsmaster 5910 Machine Only) .......................................................... 5–81 Toro Electronic Controller (TEC) ......................................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Toro Electronic Controllers (TEC) The Groundsmaster 5900 and 5910 machines use 2 Toro Electronic Controllers (TEC) to manage the machine electrical functions.
CAN-Bus Communications (continued) bus. These wires provide the data pathways between the controllers (TEC-5001, TEC-5002 and the Cummins controller) and InfoCenter display used on the machine. The engineering term for these cables are the CAN High and CAN Low. At the ends of the twisted pair of bus cables are the 120-ohm termination resistors. The CAN bus link controls each of the components that requires only 4 wires to operate and communicate to the system: CAN High, CAN Low, B+ (power) and ground.
Electrical Drawings The electrical schematic and wire harness drawings for the Groundsmaster 5900 and 5910 are located in Chapter 10—Foldout Drawings.
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter g032284 Figure 177 The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter.
Battery Terminal Protector g032130 Figure 179 Use this aerosol spray on the battery terminals and fork terminals to reduce corrosion problems. Apply the terminal protector to the connection after you secure the battery cable, ring terminal, or fork terminal. Toro Part No. 107-0392 Battery Hydrometer g032131 Figure 180 Use the battery hydrometer when measuring the specific gravity of the battery electrolyte. Get this tool locally.
Troubleshooting 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. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine; refer to Chapter 10—Foldout Drawings.
Starting Problems Problem Possible Causes All the electrical power is dead, including the InfoCenter display. • The batteries are discharged. • The battery cables are loose or corroded. • The fuse 1F1 (5 A) to the key switch is damaged. • The key switch or circuit wiring is damaged. The starter solenoid clicks, but the starter does not crank. Note: If the starter solenoid clicks, the problem is not in the interlock circuit. • The batteries are discharged. • The battery cables are loose or corroded.
General Run and Transport Problems Problem Possible Causes The engine continues to run, but should not, when the key switch is turned to the OFF position. • The key switch or circuit wiring is damaged. • The engine or engine controller is malfunctioning; refer to Chapter 3: Diesel Engine (page 3–1). • The TEC-5002 controller is damaged. The engine continues to run, but should not, when the traction pedal is engaged with no operator in the seat. • The seat switch or circuit wiring is damaged.
Cutting Deck (PTO) Operating Problems Problem Possible Causes The PTO remains engaged, but should not, with no operator in the seat. • The seat switch or circuit wiring is damaged. • The TEC–5002 controller is damaged. The cutting decks run, but should not, when raised. The cutting decks shut off with PTO switch. • The up limit switch or circuit wiring is damaged. • The TEC–5002 controller is damaged. The cutting decks run, but should not, when raised.
Cutting Deck Lift/Lower Problems Problem Possible Causes None of the cutting decks lowers. • The mow/transport switch is in the TRANSPORT position. • The operator is not fully pressing the seat switch. • The TEC–5001 fuses (4F1, 4F2, 4F3, 4F4) are damaged. • The seat switch or circuit wiring is damaged. • The mow/transport switch or circuit wiring is damaged. • The lift control manifold solenoid coil S1 or circuit wiring is damaged.
InfoCenter Display The machine InfoCenter display is a LCD device that is located on the steering tower. The InfoCenter provides information to the operator during the operation of the machine, provides the electrical system diagnostic assistance for the technicians, and allows inputs for the adjustable machine settings. The power for the InfoCenter is available when the main power relay is energized (key switch is in the START or RUN position). The fuse 1F3 protects the InfoCenter power circuit.
Operator Information g032132 Figure 181 1. Coolant temperature 6. Parking brake icon 2. Fuel level 7. Cooling fan icon 3. 4. Machine hours Traction speed 8. 9. Cruise icon Intake heater icon 5. PTO icon 10. Traction assist icon The InfoCenter replaces the traditional gauges by displaying the engine and machine status. This information is displayed on the 2 screens and the operator can select this information.
Operator Information (continued) You can access the InfoCenter navigation menu (Figure 182) by pressing and releasing any of the left 4 buttons on the display. The navigation menu automatically closes after a short display time or press the button under the opened door to close it. g032134 Figure 183 1. Engine rpm 3. Battery voltage 2. Hydraulic fluid temperature 4.
Operator Advisories The operator advisories are automatically displayed by the InfoCenter when a machine function requires additional action. For example, if the operator attempts to start the engine when the traction pedal is pressed, an advisory is identified on the InfoCenter display that the traction pedal must be in the NEUTRAL position. An advisory does not log into any fault log. You can clear the displayed advisories from the display by pressing any of the InfoCenter buttons.
Operator Advisories (continued) g032137 Figure 186 2. The TO LOWER DECK advisory identifies that the cutting deck does not lower when you press the lower deck switch; refer to Figure 186. A. SET LOW RANGE: The machine is set to a high speed range and must be in low speed before the decks lower. B. SEAT OPERATOR: The operator must be in the seat to lower the cutting decks. C. SET PARKING BRAKE: Set the parking brake to lower the cutting deck. g032138 Figure 187 3.
Operator Advisories (continued) A. SEAT OPERATOR: The operator must be in the seat to press the traction pedal. B. MOVE TP TO NEUTRAL: The traction pedal is not in the NEUTRAL position. C. RELEASE PARKING BRAKE: The parking brake is set and you must release the brake before the traction drive engages. D. FIX CRITICAL SENSOR ERROR: The critical traction pedal sensor error exists. E. FIX CRITICAL VOLTAGE ERROR: The critical traction pedal voltage error exists. g032139 Figure 188 4.
Operator Advisories (continued) g032141 Figure 190 6. The TO ENGAGE PTO advisory identifies that the PTO does not engage when you pull out the PTO switch; refer to Figure 190. A. SEAT OPERATOR: The operator must be in the seat to engage the PTO. B. MUST BE IN LOW RANGE: The machine is set to high speed range and must be in low speed before the PTO engages. C. LET ENGINE WARM: The engine must reach the operating temperature before the PTO engages. D. LOWER DECKS: No cutting decks are lowered.
Operator Advisories (continued) g032143 Figure 192 8. The TO FLOAT DECK advisory identifies that the cutting decks are not in the floating mode; refer to Figure 192. LOWER DECKS: Press the deck lower switch(es) to fully lower the decks and engage the float position. g032144 Figure 193 9. The TO SET RANGE LOW advisory identifies that the low speed range does not engage when the high-low speed switch is pressed; refer to Figure 193. A.
Operator Advisories (continued) g032146 Figure 195 11. The FOR TEACH advisory identifies that the traction pedal teach function is not accessible; refer to Figure 195. TURN KEY SWITCH OFF THEN ON: To access the traction pedal teach function, turn the key switch to the OFF position and then to RUN position.
Operator Advisories (continued) g032147 Figure 196 12. The TO SET RANGE HIGH advisory identifies that the high speed range does not engage when the high-low speed switch is pressed; refer to Figure 196. A. LIFT LEFT DECK: The left cutting deck is lowered and must be raised before the high speed range can be engaged. B. LIFT LEFT DECK FULLY: The left cutting deck is lowered below the up limit switch and must be raised before the high speed range can be engaged. C.
Operator Advisories (continued) E. LIFT RIGHT DECK: The right cutting deck is lowered and must be raised before the high speed range can be engaged. F. LIFT RIGHT DECK FULLY: The right cutting deck is lowered below the up limit switch and must be raised before the high speed range can be engaged. G. DISENGAGE PTO: The PTO is engaged and must be shut off before the high speed range can be engaged. H.
Engine Faults (continued) g032150 Figure 199 1. Navigation arrows 2. Alarm icon The InfoCenter monitors the critical engine electrical functions (e.g., engine oil pressure, engine operating temperature) and alerts the operator if any potential issues occurs. If the Cummins controller identifies an engine electrical fault, the InfoCenter alternately displays a warning icon and provides information about the fault; refer to Figure 197.
Diagnostics The InfoCenter DIAGNOSTICS screens you allow to test the TEC controller electrical inputs and outputs. The separate code reader or computer is not necessary to access the information. Use the DIAGNOSTICS screens to identify and troubleshoot the machine electrical functions. g032151 Figure 200 1. Navigation arrows 2. Enter (accept) 3.
Diagnostics (continued) For the troubleshooting purposes, use the DIAGNOSTICS screens to identify if a switch and its circuit wiring are functioning correctly. For example, if the ENGINE RUN diagnostic screen is displayed and the key switch is in the RUN position (ON), the PTO switch can be engaged and disengaged while viewing the screen. The PTO ENABLED item must indicate the change in the status of the PTO switch.
Diagnostics (continued) The left or right deck lower (MASTER LIFT SOLENOID O and DECK LOWER ON). Once the deck is fully lowered, the following outputs must occur: The left or right deck in the float mode (DECK FLOAT ON). Note: If the deck is already fully lowered when the key switch is moved from the OFF position to RUN position, the deck will not be in float until the deck lift/lower switch is momentarily pressed to lower.
Diagnostics (continued) g032193 Figure 204 1. 2. Indicator bar Neutral close/open voltage (reverse) 3. Neutral switch state change voltage (reverse) 4. Voltage for pedal in present position 5. Neutral switch state change voltage (forward) 6. Neutral close/open voltage (forward) 7. Neutral center target voltage 3. TRACTION PEDAL sensor function (Figure 204) The traction pedal DIAGNOSTIC screen identifies the state of the traction pedal potentiometer.
Diagnostics (continued) The reverse traction diagnostic inputs and outputs are similar to the forward direction. g032195 Figure 206 5. HIGH/LOW RANGE (Figure 206) To engage the traction high range speed, the following inputs must be initiated: • The PTO must be off (PTO SWITCH OFF). • All the cutting decks must be raised (All DECK DOWN OFF and all DECK FLOAT OFF). • The high-low speed switch is pressed to HI (HIGH RANGE REQUEST ON).
Diagnostics (continued) g032197 Figure 208 7. TRACTION ASSIST (Figure 208) Note: The traction assist engages when the low speed range is selected and the traction pedal is pressed in the forward direction. To engage the forward traction assist, the following inputs must be initiated: • The traction assist switch is pressed to engage the traction assist (TRACTION ASSIST INPUT ON). • The seat must be occupied (SEAT ON). • Ensure that the high-low speed switch must be in Low (HIGH RANGE OFF).
Diagnostics (continued) g032199 Figure 210 9.
Diagnostics (continued) The right hazard and right turn signal diagnostic inputs and outputs are similar to the left direction.
Administration Settings The administration SETTINGS screens provide display choices for the InfoCenter display. g032201 Figure 212 1. Navigation arrows 2. Enter (accept) 3. Exit from menu To access the administration SETTINGS screen; refer to Figure 212 and do the following: • Go to the MAIN MENU screen by pressing and holding the right button on the InfoCenter. • Use the navigation arrows to choose SETTINGS. • Use the navigation arrows to choose the SETTINGS menu items to view or change.
Administration Settings (continued) g032203 Figure 214 2. LANGUAGE options (Figure 214) The LANGUAGE settings allow the InfoCenter display to choose the language. Use the navigation arrows to choose a language and use the enter arrow to accept the chosen language. g032204 Figure 215 3. BLEEP (Figure 215) When the BLEEP is ON, a tone from the InfoCenter sounds whenever a button is pressed on the InfoCenter. When the BLEEP is OFF, the tone does not sound. g032205 Figure 216 4.
Administration Settings (continued) If a PIN is desired for the InfoCenter access, use the navigation buttons to change the PIN ENTRY to ON. To enter the PIN, use the navigation buttons to accept the PIN CHANGE. Use the InfoCenter display buttons to enter the desired 4 digit PIN and accept the PIN. Note: If you choose the PIN (PIN ENTRY ON), ensure that you record the PIN for future use, to access the InfoCenter display. If the PIN reset is necessary (e.g.
Administration Service g032208 Figure 219 To access the administration SERVICE screens; refer to Figure 219. To access the MAIN MENU screen, press and hold the right button on the InfoCenter. To choose SERVICE, use the buttons under the navigation arrows. To select the SERVICE, press the button under the enter (right arrow). To access the administration SERVICE screen; refer to Figure 219 and do the following. • Go to the MAIN MENU screen by pressing and holding the right button on the InfoCenter.
Administration Service (continued) g032210 Figure 221 2. TRACTION PEDAL (Figure 221) The traction pedal screen lists the calibration values stored in the TEC-5002 controller for the different pedal positions. This screen also identifies that the traction pedal calibration is completed. g032211 Figure 222 3. FAN OVERRIDE (Figure 222) The fan override screen allows to test the direction and speed of the cooling fan motor if necessary. The engine must run to allow the fan override option to be available.
Administration About g032213 Figure 224 g032214 Figure 225 The Administration ABOUT screens provide information about the machine, InfoCenter display, 2 Toro controllers, and Cummins engine controller. To access the administration ABOUT screen; refer to Figure 224. • Go to the MAIN MENU screen by pressing and holding the right button on the InfoCenter. • Use the navigation arrows to choose ABOUT.
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 5–39). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F). Ensure that the key is in the OFF position and all the accessories are turned off. Connect the positive (+) meter lead to the positive battery post and negative (-) meter lead to the negative battery post.
Testing the Charging System (continued) Battery Voltage Table At least 0.50 V over the initial battery voltage. Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.55 V Checking the Operation of the Interlock Switches CAUTION Operating the machine with disconnected safety switches could result in injury to the operator or others and damage to property. Do not disconnect the safety switches. They are for the operator’s protection.
Testing the Component For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the wire harness connector from the key switch 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. Key Switch g035233 Figure 226 g035234 Figure 227 The key switch has 3 positions (OFF, RUN, and START ).
Testing the Key Switch 1. Before you disconnect the key switch for testing, ensure that you test the switch and its circuit wiring as a TEC controller input with the InfoCenter diagnostic display; refer to the InfoCenter Display (page 5–13). 2. If the diagnostic display verifies that the key switch and circuit wiring are functioning correctly, then no more switch testing is necessary. 3.
Fuses The fuse blocks are located to the right of the operator seat under the power center console. Identification and Function g032221 Figure 228 g032222 Figure 229 The fuse 1F1 (5 A) supplies power to the key switch terminal B. The fuse 1F2 (30 A) supplies power to the starter solenoid circuit. The fuse 1F3 (1 A) supplies power to the InfoCenter display. The fuse 1F4 (30 A) supplies power to the Cummins engine controller. The fuse 2F1 (15 A) supplies power to the road and brake light circuits.
Identification and Function (continued) The fuse 2F2 (10 A) supplies power to the air ride seat suspension seat compressor. The fuse 2F3 (10 A) supplies power to the power point. The fuse 2F4 (10 A) supplies power to the horn circuit. The fuse 3F1 (2 A) supplies logic power for the TEC-5002 master controller. The fuse 3F2 (7.5 A) supplies power to the TEC-5002 master controller. The fuse 3F3 (7.5 A) supplies power to the TEC-5002 master controller. The fuse 3F4 (7.
Maxi Fuses g032223 Figure 230 1. 2. Maxi fuse #1 Maxi fuse #2 3. Maxi fuse #3 g032224 Figure 231 Three 60 A maxi fuses are used on the machine for protection of the main electrical circuits. The maxi fuse block is located to the right of the operator seat under the power center console; refer to Figure 230. Identification and Function The maxi fuse #1 protects the controller power circuit. The maxi fuse #2 protects the main power circuit. The maxi fuse #3 protects the cab power circuit.
Testing the Maxi Fuses (continued) 4. After you complete the fuse test, install and attach the power center cover. Mega Fuses g032225 Figure 232 1. Alternator mega fuse 2. Intake heater mega fuse g032286 Figure 233 1. Alternator fuse holder 6. Battery cable 2. Heater fuse holder 7. Flange nut 3. 300 A mega fuse 8. Lock washer 4. Jumper strap 9. Alternator cable 5. Contactor 10. 125 A mega fuse Two mega fuses are used on the machine for protection of the high-amperage circuits.
Testing the Mega Fuses (continued) 2. Disconnect the battery cables from the battery terminals; refer to Servicing the Battery (page 5–102). 3. Lift the hood to get access to the fuse holders. 4. Press the latch that keeps the fuse holder cover and lift the cover. 5. Remove the flange nuts and lock washers that attach the fuse to the holder; refer to Figure 233. 6. Remove the fuse for testing. Note: Ensure that the fuse is having continuity across the terminals. 7.
Cab Fuses (Groundsmaster 5910 Machine Only) g032227 Figure 234 g032228 Figure 235 The cab fuse blocks are located in the cab headliner. Identification and Function The fuse 1F1 (15 A) supplies power to the windshield wiper. The fuse 1F2 (15 A) supplies power to the heater circuit. The fuse 1F3 (25 A) supplies power to the air conditioner circuit. The fuse 2F1 (15 A) supplies power to the optional cab work lights. The fuse 2F2 (15 A) supplies power to the cab dome light.
Testing the Cab Fuses Ensure that the key switch is in the OFF position and the key is removed from the key switch, and remove the fuse from the fuse block for testing. Note: Ensure that the fuse is having continuity across the fuse terminals.
PTO Switch g032229 Figure 236 1. Console arm 2. PTO switch g032230 Figure 237 The PTO switch is located on the console arm; refer to Figure 236. Pull up the PTO switch to engage the PTO (cutting decks or implement). The TEC-5002 controller monitors the position of the PTO switch (up or down). Using the inputs from the PTO switch and other switches in the interlock system, the TEC controller controls the energizing of the hydraulic solenoid valves to drive the cutting deck motors.
Testing the PTO Switch (continued) 2. If the diagnostic display verifies that the PTO switch and circuit wiring are functioning correctly, then no more switch testing is necessary. 3. If the diagnostic display determines that the PTO switch and circuit wiring are not functioning correctly, then test the PTO switch. 4. Ensure that the key switch is in the OFF position and the key is removed from the key switch. 5.
Cutting Deck Lift Switches g032231 Figure 238 1. 2. Console arm Left lift switch 3. 4. Front lift switch Right lift switch g032232 Figure 239 The cutting deck lift switches are used as inputs for the TEC-5001 controller to raise or lower the cutting decks. When you press and hold the front of a lift switch, the controlled deck (left, front, or right) lowers. When you press and hold the rear of a lift switch, the controlled deck raises. The deck stays in the position when you release the switch.
Testing the Cutting Deck Lift Switches (continued) 6. The switch terminals are marked as in Figure 239. The circuit logic of the lift switches is in the Circuit Logic Table (page 5–53). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each position. Check the continuity between the switch terminals. Replace the switch if the testing identifies a damaged switch. 7.
Traction Assist Switch g032233 Figure 240 1. 2. Console arm Traction assist switch g032287 Figure 241 The traction-assist switch is used as an input for the TEC-5001 controller to energize the solenoid valve in the traction-control manifold. When you press the traction-assist switch, the hydraulic flow splits equally between the front and rear wheels to enhance the traction. The traction-assist switch functions only when the machine is in the low-speed range and in the forward direction.
Testing the Traction Assist Switch (continued) continuity exists between the various terminals for each position. Check the continuity between the switch terminals. Replace the switch if the testing identifies a damaged switch. 7. Connect the wire harness connector to the switch after testing. 8. If the switch testing is correct and the circuit problem still exists, check the wire harness; refer to the Electrical Schematics and Wire Harness Drawings in Chapter 10—Foldout Drawings. 9.
Cruise Control Switch g032235 Figure 242 1. Console arm 2. Cruise control switch g032236 Figure 243 The cruise control switch is used as an input for the TEC-5002 controller to maintain the ground speed. The cruise control function engages (set) when you press the front of the cruise control switch. The cruise control function disengages when you press the rear of the cruise control switch. The cruise control switch is located on the console arm; refer to Figure 242.
Testing the Cruise Control Switch (continued) continuity exists between the various terminals for each position. Check the continuity between the switch terminals. Replace the switch if the testing identifies a damaged switch. 7. Connect the wire harness connector to the switch after testing. 8. If the switch testing is correct and the circuit problem still exists, check the wire harness; refer to the Electrical Schematics and Wire Harness Drawings in Chapter 10—Foldout Drawings. 9.
Throttle Control Switch g032237 Figure 244 1. 2. Steering tower Throttle control switch g032238 Figure 245 The throttle control switch is used as an input for the engine control module to adjust the engine speed to 1 of 3 rpm settings: low idle (1,350 rpm), mid idle (2,400 rpm), or high idle (2,750 rpm). The throttle control switch is located on the steering tower; refer to Figure 244. Testing the Throttle Control Switch 1.
Testing the Throttle Control Switch (continued) 7. The switch terminals are marked as in Figure 245. The circuit logic of the throttle control switch is in the Circuit Logic Table (page 5–59). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each position. Check the continuity between the switch terminals. Replace the switch if the testing identifies a damaged switch. 8.
Increment/Decrement Switch g032239 Figure 246 1. Steering tower 2. Increment/decrement switch g032240 Figure 247 The increment/decrement switch is used as an input for the engine control module to raise or lower the engine speed in small amounts. When you press and hold the switch in the forward position, the engine speed increases. Conversely, when you press the rear of the switch, the engine speed decreases. The increment/decrement switch is located on the steering tower; refer to Figure 246.
Testing the Increment/Decrement Switch (continued) 5. Remove the front steering tower cover; refer to Disassembling the Steering Tower (page 7–4). 6. Locate the increment/decrement switch and disconnect the wire harness connector from the switch. 7. The switch terminals are marked as in Figure 247. The circuit logic of the increment/decrement switch is in the Circuit Logic Table (page 5–61).
High-Low Speed Switch g032241 Figure 248 1. 2. Steering tower High-Low speed switch g032242 Figure 249 The high-low speed switch is used as an input for the TEC-5001 controller to set the machine traction speed for high-speed range (transport) or low-speed range (mow). To change the speed range settings with the speed switch, stop the machine or move it very slowly. The high-low speed switch is located on the steering tower; refer to Figure 248. Testing the High-Low Speed Switch 1.
Testing the High-Low Speed Switch (continued) 6. Locate the mow/transport switch and disconnect the wire harness connector from the switch. 7. The switch terminals are marked as in Figure 249. The circuit logic of the mow/transport switch is in the Circuit Logic Table (page 5–63). With the use of a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each position. Check the continuity between the switch terminals.
Headlight Switch g032243 Figure 250 1. 2. Console arm Headlight switch g032244 Figure 251 The headlight switch is used as an input for the TEC-5002 controller to provide power for the headlights and taillights. The headlight switch is located on the operator side of the control console; refer to Figure 250. Testing the Headlight Switch 1.
Testing the Headlight Switch (continued) a multimeter (ohms setting), test the switch functions to determine if the continuity exists between the various terminals for each position. Check the continuity between the switch terminals. Replace the switch if the testing identifies a damaged switch. 8. Connect the wire harness connector to the switch after testing. 9.
Turn Signal Switch g032245 Figure 252 1. 2. Steering column Turn signal switch g032246 Figure 253 The turn signal switch is used as an input for the TEC-5002 controller to provide power for the turn signals. The switch is located on the steering tower; refer to Figure 252. Testing the Turn Signal Switch 1.
Testing the Turn Signal Switch (continued) continuity exists between the various terminals for each position. Check the continuity between the switch terminals. Replace the switch if the testing identifies a damaged switch. 8. Connect the wire harness connector to the switch after testing. 9. If the switch testing is correct and the circuit problem still exists, check the wire harness; refer to the Electrical Schematics and Wire Harness Drawings in Chapter 10—Foldout Drawings. 10.
Windshield Wiper/Washer Switch (Groundsmaster 5910 Machine Only) g032247 Figure 254 1. Cab headliner 2. Wiper/washer switch g032248 Figure 255 The windshield wiper/washer switch controls the operation of the windshield wiper and washer pump. The windshield wiper/washer switch is located in the cab headliner; refer to Figure 254. Testing the Windshield Wiper/Washer Switch (Groundsmaster 5910 Machine Only) 1.
Testing the Windshield Wiper/Washer Switch (Groundsmaster 5910 Machine Only) (continued) 7. Install the switch plate to the cab headliner.
Air Conditioning Switch (Groundsmaster 5910 Machine Only) g032249 Figure 256 1. 2. Cab headliner Air conditioning switch g032250 Figure 257 The air conditioning switch controls the operation of the air conditioning system. The switch is located in the cab headliner; refer to Figure 256. Testing the Air Conditioning Switch (Groundsmaster 5910 Machine Only) 1. Ensure that the key switch is in the OFF position and the key is removed from the key switch. 2.
Testing the Air Conditioning Switch (Groundsmaster 5910 Machine Only) (continued) Circuit Logic Table Switch Position Groundsmaster 5900 Traction Unit 08159SL Rev C Closed Circuits Open Circuits AIR CONDITIONING OFF 2+3 5+6 2+1 5+4 AIR CONDITIONING ON 2+1 5+4 2+3 5+6 Page 5–71 Electrical System: Testing the Component
Intake Air Heater Contactor g032251 Figure 258 1. Air heater contactor 2. Mega fuse holder g032252 Figure 259 1. Contactor 2. Main post 3. Coil posts The intake air heater contactor of the Groundsmaster 5900 and 5910 provides current for the engine intake air heater. The contactor is attached to a frame bracket behind the batteries; refer to Figure 258. The engine ECM energizes the contactor when the low temperatures are detected before starting the engine.
Testing the Intake Air Heater Contactor (continued) Note: The contactor must click. With the contactor coil energized, the resistance across the contactor main posts must be less than 1 ohm. 6. Remove the voltage from the contactor coil posts. Note: The contactor must click. With the contactor coil not energized, the resistance across the contactor main posts must be infinite ohms. 7. With the voltage removed from all the contactor posts, measure the resistance across the contactor coil posts.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch is an input for the TEC-5002 controller. If the traction system or PTO switch is engaged when the operator raise out of the seat, the traction system or PTO operation stops. The seat switch and its electrical connector are located in the seat assembly. Testing the Seat Switch 1.
Testing the Seat Switch (continued) 11. If the switch testing is correct and the circuit problem still exists, check the wire harness; refer to the Electrical Schematics and Wire Harness Drawings in Chapter 10—Foldout Drawings.
Parking Brake Switch g032254 Figure 261 1. Locknut 4. Carriage bolt 2. Parking brake switch 5. Parking brake rod 3. Switch plate 6. Steering tower cover The switch used for the parking brake is normally the open proximity switch that is located under the steering tower cover (Figure 261). The parking brake switch is an input for the TEC-5002 controller. When you do not set the parking brake, a tab on the brake rod is positioned near the switch sense zone that causes the switch to close.
Testing the Parking Brake Switch (continued) 10. With the parking brake set (the brake rod tab close to the brake switch), ensure that there is a continuity (zero resistance) between the switch terminals. 11. Replace the switch if necessary. 12. After you complete the test, correctly connect the wire harness connector to the parking brake switch. 13. Install the front steering tower cover; refer to Assembling the Steering Tower (page 7–4).
provide inputs for the TEC-5002 controller. When you do not press a brake pedal, the brake pedal assembly contacts the switch plunger to close the switch. When you apply a brake, the brake pedal assembly moves away from the switch plunger, allowing the switch plunger to extend and the switch to open. Testing the Service Brake Switches 1.
Main Power, Controller, Start, and Cab (Groundsmaster 5910 Machine Only) Relays g032257 Figure 264 1. Cover attachment screw 2. Relay location The Groundsmaster 5900 and 5910 machines use 3 identical relays to control the electrical power circuits. The Groundsmaster 5910 machine uses an additional relay for the cab electrical components. The relays are attached to the operator platform under the power center cover; refer to Figure 264.
Testing the Main Power, Controller, Start, and Cab (Groundsmaster 5910 Machine Only) Relays (continued) g032258 Figure 265 4. Use a multimeter (ohms setting), measure the coil resistance between the terminals 85 and 86; refer to Figure 265. Note: The resistance must be between 70 and 100 ohms. 5. Check that there is an infinite resistance (no continuity) between the terminals 30 and 87. 6. Connect the multimeter (ohms setting) leads to the relay terminals 30 and 87.
Air Conditioning Relay (Groundsmaster 5910 Machine Only) A relay is used to control the air conditioning electrical power circuit of the Groundsmaster 5910 machine. When the air conditioning switch energizes, the relay provides current for the air conditioning components. The relay is attached to the cab headliner above the switch panel. Testing the Air Conditioning Relay (Groundsmaster 5910 Machine Only) 1. Ensure that the key switch is in the OFF position and the key is removed from the key switch. 2.
Toro Electronic Controller (TEC) g032260 Figure 267 1. Cover attachment point 2. Controller location g032261 Figure 268 1. Flange nut (4 each) 3. Flange screw 2. TEC-5001 4. TEC-5002 Groundsmaster 5900 and 5910 machines use 2 Toro Electronic Controllers (TEC). The controllers are attached to the operator platform under the power center cover; refer to Figure 267.
Toro Electronic Controller (TEC) (continued) relay, and turn signals. The Fuses 3F2, 3F3, and 3F4 provides the circuit protection for TEC-5002 outputs. The TEC-5001 slave controller (upper) monitors the states of the following components as inputs: key switch, cutting deck lift switches, traction assist switch, mow/transport switch, and cutting deck position sensors.
Hydraulic Valve Solenoid Coils g032262 Figure 269 1. Left PTO manifold 2. Solenoid coil (port S) g032263 Figure 270 1. Right PTO manifold 2. Solenoid coil (port S) g032264 Figure 271 1. Center PTO manifold Electrical System: Testing the Component 2.
g032265 Figure 272 1. Traction control manifold 2. Solenoid coil (port S) There are numerous hydraulic valve solenoid coils on the hydraulic manifolds of the machine. When the solenoid coils are energized, the hydraulic-valve shift occurs to control the hydraulic flow. Testing of these solenoid coils can be done with the solenoid coil on the hydraulic valve.
Testing the Hydraulic Valve Solenoid Coils (continued) g032266 Figure 273 1. 4-wheel drive control manifold 2. Solenoid coil (port SV) g032267 Figure 274 1. Lift control manifold 3. 2. Solenoid coil (ports S2, S3, S6, S7, and S8) Solenoid coil (ports S1, S4, S5, and S9) g032268 Figure 275 1. Steering/fan manifold 2. Solenoid coil (port S) 3. Solenoid coil (port PRV) B.
Testing the Hydraulic Valve Solenoid Coils (continued) • Lift manifold ports S2, S3, S6, S7, and S8 (Figure 274) • Steering/cooling fan manifold port PRV (Figure 275) Note: The resistance of these coils must be approximately 7.1 ohms. C. Ensure that the resistance of the solenoid coil at steering/cooling fan manifold port S is approximately 4.6 ohms; refer to Figure 275. 4. If the solenoid coil resistance is incorrect, replace the coil; refer to Hydraulic Valve Solenoid Coils (page 5–84).
Fuel Sender The fuel sender is located on the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The TEC controller uses the fuel sender as an input to generate an output for the InfoCenter fuel gauge. Two styles of fuel senders are used on the Groundsmaster 5900 and 5910 machines. Early production machines were equipped with a pivoting float design that has 2 wire harness terminals.
Testing the Fuel Sender (continued) 7. Use a multimeter to check the resistance of the sender with the float in the full and empty positions. The expected resistance values are shown in the Fuel Sender Resistance Table (page 5–89). Fuel Sender Resistance Table Connector style Resistance (full) Resistance (empty) Two Terminals 27.5 to 39.5 ohms 240 to 260 ohms Single Connector 28 to 33 ohms 240 to 250 ohms g035235 Figure 276 8.
Hydraulic Fluid Temperature Sender g032270 Figure 277 1. Hydraulic flush manifold 2. Oil temperature sender 3. Fuel water separator The hydraulic-fluid temperature sender is attached to the hydraulic-flush manifold in the port TS; refer to Figure 277. Testing the Hydraulic Fluid Temperature Sender 1. Locate the fluid temperature sender on the hydraulic flush manifold. Disconnect the wire harness connector from the temperature sender. 2.
Testing the Hydraulic Fluid Temperature Sender (continued) Note: Before taking the small resistance readings with a digital multimeter, short the multimeter test leads together. The multimeter displays a small resistance value (usually 0.5 ohms or less) that is because of the internal resistance of the multimeter and test leads. Subtract this value from the measured value of the component you are testing. 4.
g032273 Figure 280 1. 2. Diode Male terminal 3. Female terminal Testing the Diode Assembly The diode can be tested by using a digital multimeter (diode test or ohms setting); refer to Diode Test Table (page 5–92).
Audible Alarm g032274 Figure 281 1. Cover attachment screw 2. Audible alarm g032275 Figure 282 1. Top view 3. Positive (+) terminal 2. Bottom view 4. Negative (-) terminal The audible alarm operates to tell the operator when there is a problem in the machine. The electrical current for the alarm is provided as an output from the slave Toro Electronic Controller. The audible alarm is located to the right of the operator’s seat under the power center console; refer to Figure 281.
Traction Pedal Potentiometer g032276 Figure 283 1. Traction pedal 2. Traction potentiometer The traction pedal potentiometer is connected to the traction pedal assembly (Figure 283). This potentiometer determines the neutral band for the traction pedal, direction of travel desired by the operator, and traction speed. The potentiometer is a single analog, dual-digital signal electronic device.
Air Filter Sensor (Machines with Serial Number Above 313000300) The machines with serial number above 313000300 use an air filter sensor to monitor the condition of the air filter. The sensor is normally open and closes when the air filter is restricted. Note: Service the engine air filter only when CHECK AIR FILTER is displayed on the InfoCenter. Changing the air filter before it is necessary only increases the chance of dirt entering into the engine when you remove the air filter.
Up Limit Switches g032277 Figure 285 1. Up limit switch (left) 2. Sensing plate The cutting deck up limit switches are normally open proximity switches that are attached to the brackets located on the traction unit frame (Figure 285). The sensing plates used for the switches are located on the cutting deck lift arms. When a cutting deck is in the lowered position, the sensing plate is near the up limit switch and the switch is closed.
Adjusting the Up Limit Switch Adjust the up limit switch to 1.8 to 3.3 mm (0.070 to 0.130 inch) to have the clearance between the switch and sensing plate on the lift arm.
Adjustments Calibrating the Traction Pedal IMPORTANT A properly installed and calibrated traction pedal potentiometer is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing, and calibrating the traction pedal potentiometer. 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, and set the parking brake. 2. Ensure that you plug the wire harness connector into the traction pedal potentiometer. g032215 Figure 286 1.
Calibrating the Traction Pedal (continued) g032216 Figure 287 1. Traction pedal 4. Spring shaft 2. Pedal potentiometer 5. Hex nut 3. Compression spring C. Slowly rotate the spring shaft while watching the switch icons (Figure 287). When 1 of the switch icons closes, stop rotating the shaft and mark the shaft position. D. Slowly rotate the shaft in the opposite direction until the second switch icon closes and mark the shaft position. E.
Traction Pedal Teach g032217 Figure 288 1. Male teach wire 2. Female teach wire 3. Termination cap g032218 Figure 289 1. Remove the power center console located to the right of the operator seat. 2. Locate the wire harness termination cap that connects the 2 traction pedal teach wires; refer to Figure 288. 3. Remove the termination cap and connect the 2 teach wires together; refer to Figure 289. 4. Turn the key switch to the ON position but do not start the engine.
Service and Repairs Battery Storage If you keep the machine for more than 30 days: 1. Remove the batteries and charge them fully; refer to Servicing the Battery (page 5–102). 2. Either keep the batteries on a shelf or on the machine. 3. Disconnect the cables if the batteries are kept on the machine. 4. Store the batteries in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
Battery Care (continued) WARNING Connecting the cables to the wrong battery post could result in personal injury and/or damage to the electrical system. Ensure that the cables are properly connected to the correct battery posts before operating the machine. 4. If corrosion occurs at the battery terminals, disconnect the cables. Always disconnect the negative (-) cables first. Clean the clamps and terminals separately. Connect the cables again with the positive (+) cables first.
Removing and Installing the Battery g032278 Figure 290 1. Battery strap (2 each) 4. Flange screw (6 each) 2. U-nut (2 each) 5. Battery panel 3. Flange nut (4 each) 6. Battery (2 each) g032279 Figure 291 1. Negative (-) cable 2. Positive (+) cable 3. Battery strap 1. Remove the fasteners that attach the battery panel to the machine. 2. Remove the panel to access the batteries. 3. Loosen and remove the negative cables from the batteries.
Removing and Installing the Battery (continued) Note: Ensure that you connect and tighten the 2 positive cables to the batteries before connecting the negative cables. Note: Before connecting the negative (ground) cables to the battery, connect a digital multimeter (set to DC A) between the negative battery post and the negative (ground) cable connector. Ensure that the reading is less than 0.1 A. If the reading is 0.
Inspecting, Maintaining, and Testing the Battery (continued) C. If the difference between the highest and lowest cell specific gravity is 0.050 or more or the lowest cell specific gravity is less than 1.225, charge the battery. D. Charge at the rate and time given in Charging the Battery (page 5–106) or until all cells specific gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell is less than 0.050.
Inspecting, Maintaining, and Testing the Battery (continued) I. If the test voltage is below the minimum voltage in the Minimum Voltage Table (page 5–106), replace the battery. If the test voltage is at or above the minimum, return the battery to the service. Minimum Voltage Table Minimum Voltage Battery Electrolyte Temperature 9.6 70°F (and up) 21.1°C (and up) 9.5 60°F 15.6°C 9.4 50°F 10.0°C 9.3 40°F 4.4°C 9.1 30°F –1.1°C 8.9 20°F -6.7°C 8.7 10°F -12.2°C 8.5 0°F -17.
Charging the Battery (continued) 3. Follow the battery charger manufacturer’s instructions, connect the charger cables to the battery. Ensure that you make a good connection. 4. Charge the battery following the battery charger manufacturer’s instructions. 5. Occasionally check the temperature of the battery electrolyte. If the temperature is more than 52°C (125°F) or the electrolyte is violently gassing or spewing, lower and temporarily stop the charging rate. 6.
Hydraulic Valve Solenoid Coil g032280 Figure 292 1. Hydraulic manifold 3. Solenoid valve cell 2. Solenoid valve 4. Nut You can replace a hydraulic valve solenoid coil on a hydraulic control manifold without opening the hydraulic system. Removing the Hydraulic Valve Solenoid Coil 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Locate the solenoid valve coil that you replace. 3.
Installing the Hydraulic Valve Solenoid Coil g032281 Figure 293 1. Steering/fan manifold 5. Solenoid valve PRV 2. 3. 4. Solenoid valve S Solenoid valve coil Nut 6. 7. Solenoid valve coil Nut 1. Slide the new coil assembly onto the hydraulic valve. 2. Install the nut onto the valve and torque the nut as follows: A. For the solenoid valve S on the steering/engine cooling fan control manifold, torque the coil retaining nut to 13.5 N∙m (10 ft-lb). B.
Electrical System: Service and Repairs Page 5–110 Groundsmaster 5900 Traction Unit 08159SL Rev C
Chapter 6 Axles, Planetaries, and Brakes Table of Contents Specifications ....................................................................................................................................... 6–2 Axles, Planetaries, and Brakes .......................................................................................................... 6–2 General Information ..............................................................................................................................
Specifications Axles, Planetaries, and Brakes Item Specification Tire pressure Front tire Rear tire 345 kPa (50 psi) 207 kPa (30 psi) Rear wheel toe-in 0 to 3.05 mm (0 to 0.120 inch) Planetary gear drive oil Capacity (each planetary) SAE 85W-140 weight gear lube 0.47 to .
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Adjustments Planetary Drive Assembly Endplay (OPH-2 series planetary drives) A front planetary drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planetary. Check the planetary endplay at the maintenance intervals specified in the Operator’s Manual. Checking the Planetary Drive Assembly Endplay (OPH-2 series planetary drives) g253951 Figure 294 1.
Service and Repairs Wheels g031961 Figure 295 1. Front axle frame 5. Wheel lug nut (8 each front wheel) 2. Front wheel motor 6. Front wheel assembly 10. Rear axle 11. Main frame 3. Brake assembly 7. Rear wheel motor 4. Planetary assembly 8. Rear wheel assembly 9. Wheel lug nut (6 each rear wheel) Removing the Wheel 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Wheel (continued) CAUTION Failing to properly support the machine with jack stands can cause the machine to move or fall and can result in personal injury. Properly support the machine with jack stands. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to lift and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Brake Assembly g253986 Figure 296 1. Front axle frame 2. Splined brake coupler 3. 9. O-ring 17. Clevis pin 10. Flange-head screw (4 each side) OPH-2 planetary = 90 mm lg. VA02 planetary = 80 mm lg 18. Carriage screw Retaining ring 11. Front wheel motor (2 each) 19. Bolt (2 each motor) OPH-2 planetary = 120 mm lg VA02 planetary = 110 mm lg 4. Planetary assembly (2 each) 12. Flat washer (2 each motor) 20. Jam nut 5. Wheel lug nut (8 each wheel) 13. Cotter pin 21.
Removing the Brake Assembly (continued) CAUTION Failing to properly support the machine with jack stands can cause the machine to move or fall and can result in personal injury. Properly support the machine with jack stands. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to lift and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Removing the Brake Assembly (continued) E. Move the brake lever to the center of the machine to disengage the lever slot from the pull rod on the brake assembly. F. Remove the 4 flange-head screws (item 10 in Figure 296) that attach the brake assembly to the machine, and remove the brake assembly from the machine. Note: Do not drop the splined brake coupler (item 2 in Figure 296) while removing the brake assembly. 8. Remove and discard the gasket (item 7 in Figure 296).
Installing the Brake Assembly (continued) g031966 Figure 299 1. Brake assembly 3. Brake pull rod 2. Jam nut (2 each) 4. Brake lever 3. Attach the brake lever (item 14 in Figure 296) to the brake pull rod as follows: A. Position the brake lever so that the brake lever slot fits around the pull rod on the brake assembly; refer to Figure 299. B. Place the 2 washers (item 16 in Figure 296) between the brake lever and the frame bracket; refer to Figure 297. C.
Installing the Brake Assembly (continued) WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel lug nuts. 8. Lower machine to ground. Torque wheel lug nuts from 116 to 135 N∙m (85 to 100 ft-lb).
Servicing the Brake g031967 Figure 300 1. Brake housing (left) 6. Hitch pin (2 each) 11. Rotating actuator 2. Seal 7. Stationary disc (4 each) 12. Extension spring (3 each) 3. Pull rod 8. Rotating disc (3 each) 13. Ball (3 each) 4. Clevis pin (2 each) 9. Retaining ring 14. Plug 5. Link (2 each) Gasket 15. O-ring 10. Disassembling the Brake 1. Discard the gasket material (item 10 in Figure 300) from the brake housing and planetary drive mounting surfaces. 2.
Inspecting the Brake (continued) 2. Check that the stack of 4 stationary and 3 rotating discs have a minimum thickness of 11.2 mm (0.440 inch). Assembling the Brake g031968 Figure 301 1. Brake assembly 2. Jam nut (2 each) 3. Brake pull rod 1. Reverse the 2 through 6 to assemble the brakes, install new parts as necessary. Ensure that you install a new seal (item 2 in Figure 300). 2. When you install the jam nuts onto the brake pull rod, position the inner jam nut so that it is 3.0 mm (0.
Planetary Drive Assembly g253986 Figure 302 1. Front axle frame 2. Splined brake shaft 3. 4. 9. O-ring 17. Clevis pin 10. Flange-head screw (4 each side) OPH-2 planetary = 90 mm lg. VA02 planetary = 80 mm lg 18. Carriage screw Retaining ring 11. Front wheel motor (2 each) 19. Bolt (2 each motor) OPH-2 planetary = 120 mm lg VA02 planetary = 110 mm lg Planetary assembly (2 each) 12. Flat washer (2 each motor) 20. Jam nut 5. Wheel lug nut (8 each wheel) 13. Cotter pin 21.
Removing the Planetary Drive Assembly (continued) 2. Drain oil from the planetary drive/brake assembly. 3. Block the rear wheels with chocks to prevent the machine from moving. CAUTION Failing to properly support the machine with jack stands can cause the machine to move or fall and can result in personal injury. Properly support the machine with jack stands.
Installing the Planetary Wheel Drive Assembly (continued) • For OPH-2 series planetary drives: tighten screws to 81 N∙m (60 ft-lb). • For VA02 series planetary drives: tighten screws from 101 to 115 N∙m (75 to 85 ft-lb). 5. Install the front wheel assembly. 6. Fill planetary drive with gear lube; refer to traction unit Operator's Manual. A portion of the gear lube will pass into the brake assembly automatically. 7. Check for proper brake operation and adjust brake cables if necessary.
Servicing the OPH-2 Series Planetary Drive g254024 Figure 303 1. Spindle 11. Outer bearing cup 21. Thrust plug 2. Boot seal 12. Outer bearing cone 22. Thrust washer 3. Oil seal 13. O-ring 23. Retaining ring 4. Inner bearing cone 14. Thrust washer 24. Primary gear 5. Inner bearing cup 15. Retaining ring (external) 25. Driveshaft 6. Wheel stud (8 each) 16. Ring gear 26. Primary carrier assembly 7. Socket-head screw (16 each) 17. Retaining ring (internal) 27.
Disassembling the OPH-2 Series Planetary Drive (continued) 2. Drain oil from planetary drive/brake assembly; refer to traction unit Operator's Manual. 3. Chock rear wheels and jack up front of machine; refer to Jacking Instructions (page 1–5). Support machine with jack stands and remove the front wheel assembly. g248455 Figure 304 1. Spindle 15. Retaining ring (external) 2. Boot seal 16. Ring gear 3. Oil seal 17. Retaining ring (internal) 4. Inner bearing cone 18. Plug (2) 5.
Disassembling the OPH-2 Series Planetary Drive (continued) IMPORTANT Do not use the retaining ring (item 15) again after removal. 9. Remove the retaining ring (item 15) and thrust washer (item 14). Discard the retaining ring. 10. Carefully remove the housing (item 9) from the spindle (item 1). Remove the outer bearing cone (item 12). 11. Remove and discard the seals (items 2 and 3) and O-rings (item 13) from the housing. 12. Remove the inner bearing cone (item 4) from the housing.
Assembling the OPH-2 Series Planetary Drive (continued) Note: The planetary shim kit includes the retaining ring and several thrust washers with the thickness in incremental steps of 0.10 mm (0.004 inch). I. Measure the thickness of the thrust washer (item 14) that was removed during disassembly. Choose a new thrust washer of equal thickness or the next available thickness from the thrust washers in the shim kit. J.
Assembling the OPH-2 Series Planetary Drive (continued) WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel lug nuts. 13. Remove jack stands and lower machine to ground. Tighten wheel lug nuts in a crossing pattern from 116 to 135 N∙m (85 to 100 ft-lb).
Servicing the VA02 Series Planetary Drive g254037 Figure 305 1. Spindle 11. O-ring 21. End cap 2. Boot seal 12. Spacer 22. Thrust plate 3. Lip seal 13. Locking washer 23. O-ring 4. Inner bearing cup (2 each) 14. Lock nut 24. Retaining ring (2 each) 5. Inner bearing cone (2 each) 15. Ring gear 25. Primary gear 6. Wheel stud (8 each) 16. Retaining ring (internal) 26. Drive shaft 7. Socket-head screw (16 each) 17. Plug 27. Primary carrier assembly 8.
Disassembling the VA02 Series Planetary Drive 1. Park machine on a level surface, stop engine and remove key from the ignition switch. 2. Drain oil from planetary drive and brake assembly; refer to traction unit Operator's Manual. 3. Chock the rear wheels and jack up the front of the machine; refer to Jacking Instructions (page 1–5). Support machine with jack stands and remove rear wheel assembly. g248455 Figure 306 1. Spindle 15. Ring gear 2. Boot seal 16. Retaining ring (internal) 3.
Disassembling the VA02 Series Planetary Drive (continued) 10. Remove and discard seals from housing. 11. If necessary, remove bearing cups from housing. 12. If wheel stud removal is necessary, use a press to remove the stud(s) from the housing. 13. If necessary, remove the ring gear from the housing: Note: High strength thread locking compound was used during assembly. It may be necessary to heat the ring gear near the mounting screws to release the screws. A.
Assembling the VA02 Series Planetary Drive (continued) IMPORTANT Perform the following steps without interruption. Once the thread locking compound is applied, you have only a few minutes before the curing process will influence the bearing lock nut torque. 12. Install the bearing lock nut: A. Apply high strength thread locking compound (Loctite 263 or equivalent) and install the lock nut. B. Tighten the lock nut to 150 N∙m (110 ft-lb). C.
Assembling the VA02 Series Planetary Drive (continued) 20. Install the front wheel assembly. 21. Fill planetary drive with gear lube; refer to traction unit Operator's Manual. A portion of the gear lube will pass into the brake assembly automatically. 22. Test planetary drive operation. WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 23. Remove jack stands and lower machine to ground.
Rear Axle g031973 Figure 307 1. Rear wheel assembly 12. Locknut 23. Wheel hub 2. Wheel lug nut (6 each wheel) 13. Axle pivot shaft 24. Wheel stud (6 each hub) 3. Bolt (4 each motor) 14. Roll pin 25. Square key 4. Lock washer (4 each motor) 15. Axle support 26. Hex nut 5. Left wheel motor 16. Flat washer (4 each) 27. Elbow 6. Rear axle 17. Flange-head screw (4 each) 28. Hose 7. Tie rod 18. Retaining ring 29. Nut 8. Right spindle 19. Thrust washer (3 each) 30.
Removing the Rear Axle (continued) 3. Clean the hydraulic hose ends and fittings on the steering cylinders and rear wheel motors to prevent hydraulic system contamination. Note: For easy assembly, label the hydraulic hoses to locate their correct position on the steering cylinders and rear wheel motors. 4. Disconnect the hydraulic hoses from the steering cylinders and rear wheel motors. Install caps or plugs on all the fittings and hoses to prevent contamination. 5.
Installing the Rear axle (continued) movement of the rear axle. Ensure that the axle can still pivot freely after you tighten the locknut. 4. Lower the machine to the ground. 5. Correctly install the hydraulic hoses to the steering cylinders and rear wheel motors. WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel lug nuts. 6. Torque the wheel-lug nuts to 95 to 122 N∙m (70 to 90 ft-lb). 7.
Servicing the Rear Axle g032288 Figure 308 1. Rear wheel assembly 11. Steering cylinder (2 each) 21. Left spindle 2. Wheel lug nut (6 each wheel) 12. Hose 22. Hydraulic fitting (2 each motor) 3. Bolt (4 each motor) 13. Nut 23. Wheel hub (2 each) 4. Lock washer (4 each motor) 14. Flange-head screw 24. Wheel stud (6 each wheel) 5. Left wheel motor 15. Spindle cap 25. Square key 6. Cotter pin 16. Retaining ring 26. Hex nut 7. Tie rod assembly 17.
Tie Rod Assembly g031975 Figure 309 1. 2. 3. Bolt Tie rod end Tie rod tube 4. 5. 6. Locknut Tie rod end Grease fitting g031976 Figure 310 1. Remove the cotter pin and slotted hex nut that attach the tie rod ends to the steering spindles. Separate the tie rod ends from the spindle and remove the tie rod from the machine. Note: 1 of the tie rod ball joints has left-hand threads. 2. Loosen the bolt and locknut and then unscrew the ball joint from the tie rod. 3.
Tie Rod Assembly (continued) 9. After you complete the assembly and adjustments, ensure that there is no contact between the machine components while the rear wheels move from steering lock to lock. Adjust if necessary. Rear Axle Spindle Bushings g031977 Figure 311 1. Rear axle 3. Spindle bushing 2. Pivot bushing 4. Grease fitting The rear wheel spindles must fit snugly to the rear axle.
Rear Axle Spindle Bushings (continued) 11. Apply grease to the inner and outer surfaces of new bushings. Use a press to install the bushings into the top and bottom of the axle tube. Press the bushings into the tube until the bushing flange shoulder contacts the tube. 12. Clean the steering spindle shaft. Inspect the spindle for wear and replace it if worn or damaged. 13. Install the thrust washer (item 20 in Figure 310) onto the spindle shaft and slide the shaft up through the axle tube.
Axle Pivot Bushings (continued) 1. Loosen, but do not remove the wheel-lug nuts that attach the rear wheels to the axle. 2. Remove the rear axle from the machine; refer to Removing the Rear Axle (page 6–27). 3. Remove the rear wheels from the axle; refer to Removing the Wheel (page 6–5). 4. Use a bushing removal tool to remove the 2 axle pivot bushings from the axle pivot tube. Note: Ensure that you do not damage the bore of the pivot tube during the bushing removal. 5.
Chapter 7 Chassis Table of Contents General Information .............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Steering Tower ...................................................................................................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Steering Tower g031980 Figure 312 1. Steering tower cover 15. Spacer 29. Locknut 2. Flange-head screw 16. Knob 30. Proximity switch 3. Bolt (2 each) 17. Steering wheel cover 31. Switch plate 4. Pivot hub (3 each) 18. Hex nut 32. Carriage bolt 5. Steering column assembly 19. Flat washer 33. Compression spring 6. Thrust washer (4 each) 20. Steering wheel 34. Parking brake rod 7. Steering tower 21. Foam collar 35. Parking brake rack 8.
Disassembling the Steering Tower 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Disassemble the steering tower; refer to Figure 312. Assembling the Steering Tower Assemble the steering tower; refer to Figure 312. 1. If the steering wheel was removed, torque the hex nut (item 18 in Figure 312) to 28 to 35 N∙m (20 to 26 ft-lb). 2.
Wing Deck Rear Impact Arm Assembly g031981 Figure 313 1. Pivot hub 13. Thrust washer (as required) 25. Plain bushing 2. Thrust washer 14. Hardened washer 26. Housing 3. 4. 5. Bolt Flat washer Locknut 15. 16. 17. Locknut Lock washer Rear impact arm housing 27. 28. 29. Jam nut Rod end Spacer 6. Bolt 18. Flange nut (4 each impact arm) 30. Deck connection 7. 8. Shim Base mount 19. 20. Jam nut Flat washer 31. 32. Bolt Lift arm (left) 9. Joint yoke 21. Plain washer 33.
Removing the Wing Deck Rear Impact Arm Assembly (continued) 2. Remove the bolt (item 6 in Figure 313) and locknut (item 5 in Figure 313) that secures the rod end of the rear impact arm to the cutting deck connection. 3. Locate and remove the spacer (item 29 in Figure 313) from each side of the rod end. 4. Remove the locknut (item 15 in Figure 313) and lock washer (item 16 in Figure 313) that secures the rear impact arm pivot shaft (item 12 in Figure 313). 5.
Assembling the Wing Deck Rear Impact Arm Assembly (continued) g031982 Figure 314 10. Hold the first jam nut with a wrench to prevent it from turning, torque the second jam nut to 184 to 223 N∙m (135 to 165 ft-lb) to attach the spring adjustment. 11. Fully fill the spring with grease. Apply approximately 1.1 kg (40 oz) of grease to a clean spring. 12.
Lift Arm Joint Yoke g032052 Figure 315 1. Pivot hub 2. Thrust washer 9. 10. Joint yoke 17. Rear impact arm assembly Spacer 18. Lift arm (left) 3. Bolt (8 each yoke) 11. Thrust washer 19. Spacer 4. Flat washer (8 each yoke) 12. Pivot shaft 20. Deck connection 5. Locknut 13. Thrust washer (as required) 21. Bolt 6. 7. Bolt Shim 14. 15. Hardened washer Locknut 22. 23. Slotted hex nut Cotter pin 8. Base mount 16. Lock washer Removing the Joint Yoke 1.
Removing the Joint Yoke (continued) 3. Remove the 8 bolts (item 3 in Figure 315) and 8 flat washers (item 4 in Figure 315) that attach the base mounts (item 8 in Figure 315) to the cutting deck connection. 4. Raise the lift arm enough to free the joint yoke from the lift arm. Remove the thrust washer (item 11 in Figure 315) and spacer (item 10 in Figure 315) from the yoke shaft. 5. Lift the joint yoke and base mounts from the deck mount. 6.
Assembling the Joint Yoke (continued) g032053 Figure 316 1. Joint yoke 2. Base mount 3. Angled edge 4. Hold the cross to align and press the bearing in until it hits the yoke. 5. Carefully position the second bearing into the yoke bore and onto the cross shaft. Press the bearing into the yoke. 6. Install the snap rings to the bearings to attach the bearings in place. 7. Press the base mounts to the joint yoke with the angled edge of the mounts assembled away from the joint (Figure 316).
Installing the Joint Yoke (continued) 4. Apply grease to the joint yoke and lift arm bushing after you install it on the machine. 5. After you complete the assembly, raise and lower the cutting deck to ensure that the hydraulic hoses and fittings do not contact anything. Front Deck Lift Arms g032054 Figure 317 1. Lift cylinder (left) 12. Plug 23. Carriage screw 2. Lift arm (2 each) 13. Flat washer (4 each pin) 24. Locknut 3. Lift arm pin 14. U-bolt (2 each) 25. Plate 4.
Note: If the lift cylinder (item 1 in Figure 317) requires removal; refer to the Front Deck Lift Cylinder (page 4–166). Removing the Front Deck Lift Arms 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the front cutting deck; refer to Removing the Front Cutting Deck (page 8–7).
Installing the Front Deck Lift Arms g032055 Figure 318 1. Lift arm (left) 11. Flange nut 2. Grease fitting 12. U-bolt 3. Flange bushing 13. HOC chain 4. Retaining ring 14. Locknut 5. Tapered stud 15. Support hub 6. Spherical bearing 16. Thrust washer 7. Jam nut (2 each) 17. Flat washer 8. Flange nut 18. Locknut (2 each) 9. Carriage screw 19. Flat washer (4 each) 10. Trigger sensor 1. If removed, install the components to the lift arm (Figure 318). A.
Installing the Front Deck Lift Arms (continued) 4. Install the front wheel assembly; refer to Installing the Wheel (page 6–6). 5. Lower the machine to the ground. WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Maintain the proper torque of the wheel lug nuts. 6. Torque the wheel-lug nuts equally to 95 to 122 N∙m (70 to 90 ft-lb) in a crossing pattern. 7. Install the cutting deck; refer to Installing the Front Cutting Deck (page 8–9). 8.
Wing Deck Lift Arms g032057 Figure 320 1. Lift arm (left) 12. Carriage bolt 23. Bolt 2. Grease fitting 13. Aluminum plate 24. Thrust washer 3. Grease fitting 14. Rivet (3 each plate) 25. Lift arm pivot shaft 4. Flange nut 15. Proximity sensor 26. Carriage screw (2 each plate) 5. Lift cylinder pin 16. Switch plate 27. Screw (2 each pad) 6. Bolt 17. Locknut 28. Pivot hub assembly 7. Hydraulic fitting 18. Impact arm assembly 29. Thrust washer 8. Lift cylinder 19.
Removing the Wing Deck Lift Arms g032058 Figure 321 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the wing deck from the lift arm; refer to the Wing Cutting Deck (page 8–10). 3. Remove the wing deck impact arm assembly from the pivot hub; refer to the Wing Deck Rear Impact Arm Assembly (page 7–5). 4.
Removing the Wing Deck Lift Arms (continued) g032059 Figure 322 1. Lift arm (left) 4. Straight bushing 2. Flange bushing 5. Grease fitting 3. Grease fitting 6. Remove the bolt (item 23 in Figure 320) and thrust washer (item 24 in Figure 320) from the lift arm pivot shaft. 7. Slide the wing deck impact arm pivot hub and thrust washer (item 29 in Figure 320) from the lift arm pivot shaft. 8. Remove the roll pin (item 22 in Figure 320) that retains the lift arm pivot shaft to the frame.
Installing the Wing Deck Lift Arms (continued) g032060 Figure 323 1. Lift arm (left) 6. Thrust washer 2. Joint yoke 7. Spacer 3. Deck connection 8. 4. 5. Hardened washer Thrust washer 9. 10. Rear impact arm Slotted hex nut Cotter pin 6. Apply the Permatex™ Blue Gel medium-strength thread-locking compound (or equivalent) to the threads of the bolt (item 23 in Figure 320).
Installing the Wing Deck Lift Arms (continued) 9. Position and install the wing cutting deck to the machine; refer to the Wing Cutting Deck (page 8–10). 10. After you complete the assembly, lubricate the lift arm grease fittings. 11. After you complete the assembly, raise and lower the cutting deck to check that the hydraulic hoses and fittings do not contact anything. 12.
Console Arm g032062 Figure 325 1. Headlight switch 11. Cruise switch 2. Locknut 12. 4-wheel drive traction assist switch 22. Flange-head screw (5 each) 3. Left cover 13. Lift/lower switch (3 each) Flange nut (2 each) 4. Console arm panel 14. Lock washer 24. Flange-head screw (2 each) 5. Key switch 15. Arm rest 25. Washer-head screw (10 each) 21. 23. PTO switch 6. Right cover 16. Arm panel 26. Switch guard 7. Screw 17. Flange nut (3 each) 27. Clip (2 each) 8.
Disassembling the Console Arm (continued) g032063 Figure 326 1. Flat washer 10. Flange nut 2. Seat belt buckle 11. Support channel 3. Coupling nut 12. Flange nut (2 each) 4. Spacer 13. Support bracket 5. Carriage screw (5 each) 14. Bolt 6. 7. Lock washer Bolt 15. 16. Manual tube R-clamp (2 each) 8. Arm support 17. Screw (2 each) 9. Bolt 4.
Traction Pedal g032064 Figure 327 1. Carriage screw (6 each) 13. Spring retainer 25. Clip (2 each) 2. Traction pedal 14. Flange-head screw (2 each) 26. Traction pedal cover 3. Pedal abrasive 15. Spring cover 27. Cover plate 4. Pedal abrasive 16. Locknut (2 each) 28. Flange mount bearing (2 each) 5. Traction pedal shaft 17. Capture plate 29. Locknut 6. Slotted roll pin 18. Traction pedal potentiometer 30. Rod end bearing 7. Roll pin 19. Mounting plate 31.
IMPORTANT A correctly installed and calibrated traction pedal potentiometer is critical to accurate traction system response and for reliable potentiometer life. Use care when removing, installing, and calibrating the traction pedal potentiometer. Disassembling the Traction Pedal 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. g032065 Figure 328 1. Traction pedal 4. Pedal hub bracket 2.
Assembling the Traction Pedal (continued) D. To install the traction pedal potentiometer (item 18 in Figure 327), slightly press and hold the traction pedal in reverse. Align the slot at the end of the pedal shaft with the slot in the potentiometer. Slide the potentiometer onto the screws and release the pedal. Hold the potentiometer in position while you install the capture plate (item 17 in Figure 327) and locknuts (item 16 in Figure 327). E. Torque the locknuts (item 16 in Figure 327) to 1.5 to 1.
Operator Seat g032066 Figure 329 1. Seat assembly 9. R-clamp (2 each) 17. Bolt 2. Flat washer (4 each) 10. Manual tube 18. Console arm support 3. 4. Seat belt Bolt 11. 12. Bolt Flange nut 19. 20. Bolt Lock washer 5. Seat platform 13. Support bracket 21. Spacer 6. Flange nut (4 each) 14. Flange nut (2 each) 22. Coupling nut 7. Carriage screw (4 each) 15. Support channel 23. Seat belt buckle 8. Screw (2 each) 16. Carriage screw (5 each) Removing the Operator Seat 1.
Removing the Operator Seat (continued) 3. Support the control arm assembly to prevent it from shifting. g032067 Figure 330 1. Seat 3. Torx-head screw (M8x12) (3 each) 2. Suspension assembly 4. Torx-head screw (M8x16) 4. Remove the flange nut (item 12 in Figure 329) and carriage screw (item 16 in Figure 329) that attach the support bracket (item 13 in Figure 329) to the support channel (item 15 in Figure 329). 5.
Installing the Operator Seat (continued) A. Attach the support bracket (item 13 in Figure 329) and support channel (item 15 in Figure 329) with flange nut (item 12 in Figure 329) and carriage screw (item 16 in Figure 329). B. Attach the console arm support (item 18 in Figure 329) to the coupling nut with the bolt (item 19 in Figure 329) and lock washer (item 20 in Figure 329). C.
Servicing the Operator Seat g035223 Figure 331 1. Backrest cushion 13. Bolt (2 each) 25. Torx-head screw 2. Seat cushion 14. Seat 26. Torx-head screw (3 each) 3. Left support cover 15. Nut 27. Washer (3 each) 4. Left armrest 16. Spring (2 each) 28. Handle 5. Right support cover 17. Magnet 29. Flat-head screw (3 each) 6. Bushing (2 each) 18. Seat switch 30. Adaptor plate 7. Backrest 19. Rivet (4 each) 31. Headscrew 8. Plug (2 each) 20. Mounting plate 32.
Disassembling the Operator Seat 1. Remove the seat from the machine for service; refer to Removing the Operator Seat (page 7–25). 2. Disassemble the operator seat as shown in Figure 331. Assembling the Operator Seat 1. Assemble the operator seat; refer to Figure 331. 2. Install the seat to the machine; refer to Installing the Operator Seat (page 7–26).
Operator Seat Suspension (Machine with Serial Number Below 315000200) g032069 Figure 332 1. Cover 14. Washer (2 each) 27. Clamp (2 each) 2. Cover 15. Tether 28. Hose nipple 3. Level control 16. Rivet (2 each) 29. Screw 4. Air control valve 17. Washer (4 each) 30. Handle C-clip (4 each) 31. Bumper 5. Shock absorber 18. 6. Air spring assembly 19. Pin (2 each) 32. Nut 7. Air tube assembly 20. Rivet (2 each) 33. Plastic plug (23 each) 8. Wire harness 21.
Note: You can service most of the seat suspension components with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6 in Figure 332) requires removal, remove the seat suspension base from the seat platform. Disassembling the Operator Seat Suspension 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. g035299 Figure 333 1. Operator seat assembly 3. Screw (4 each) 2.
Assembling the Operator Seat Suspension (continued) 2. If the seat suspension is removed from the seat platform (Figure 333), do the following: A. Position the seat suspension onto the seat platform. B. Attach the seat suspension to the seat platform with the 4 screws and 4 flange nuts. C. Slide the fuel tank toward the right side of the machine; refer to Installing the Fuel Tank (page 3–18). Note: Ensure that the fuel tank and front wheel are attached correctly. 3.
Operator Seat Suspension (Machine with Serial Number Above 315000200) g035300 Figure 334 6. Wire harness 11. Air control valve 7. Air spring assembly 12. Cover 8. Shock absorber 13. Compressor Air tube assembly 14. Bellows Handle 15. Lower seat suspension 1. Cover assembly 2. Upper suspension 3. Thrust limiter 4. Control lever 9. 5. Tether Groundsmaster 5900 Traction Unit 08159SL Rev C 10.
Note: You can service most of the seat suspension components with the lower seat suspension (item 15 in Figure 334) mounted to the frame platform. If the air spring assembly (item 7 in Figure 334) requires removal, remove the lower seat suspension from the seat platform. Disassembling the Operator Seat Suspension g035301 Figure 335 1. Operator seat assembly 3. Screw (4 each) 2. Flange nut (4 each) 4. Seat platform 1.
Assembling the Operator Seat Suspension (continued) B. Attach the seat suspension to the seat platform with the 4 screws and 4 flange nuts. Tighten the 4 flange nuts to 41 to 49 N∙m (30 to 36 ft-lb). C. Slide the fuel tank back into its position and install the fuel tank; refer to Installing the Fuel Tank (page 3–18). Note: Ensure that the fuel tank and front wheel are attached correctly. 2. Install all the seat suspension components that were removed; refer to Figure 334. 3.
Hood g032071 Figure 336 1. Hood 2. Rear hood foam seal 3. Left rear foam seal 8. Clip (3 each) 15. Side foam seal (2 each) 9. Hex nut (2 each cylinder) 16. Gas spring (2 each) Right rear foam seal 17. Ball stud (2 each cylinder) 10. 4. Flange nut (8 each) 11. Support plate 18. Hair pin (2 each) 5. Flange-head screw (3 each) 12. Hood frame 19. Clevis pin (2 each) 6. Washer (8 each) 13. Top foam seal 20. Bolt (8 each) 7. Heat shield 14.
Removing the Hood g032072 Figure 337 1. Top screen 8. Screw (4 each) 2. Plug 9. Washer (4 each) 3. Rear screen 10. Handle (2 each) 4. Flat washer (2 each) 11. Screw (4 each) 5. Screw (2 each) 12. Latch (2 each) 6. Hood strap 13. Flat washer (4 each) 7. Flange nut (2 each) 14. Locknut (2 each) 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. 3.
Installing the Hood g032073 Figure 338 1. Flange nut (2 each) 3. Shim (as needed) 2. Air box 4. Carriage screw (2 each) 1. Replace all the hood components that were removed; refer to Figure 336 and Figure 337. 2. While supporting the hood on both sides, position the hood to align the clevis pin holes in the hood and machine frames. Install the 2 clevis pins to attach the hood to the machine. 3. Have a person support the rear of the raised hood. 4.
Chapter 8 Cutting Decks Table of Contents Specifications ....................................................................................................................................... 8–2 Cutting Decks..................................................................................................................................... 8–2 General Information ..............................................................................................................................
Specifications Cutting Decks g032074 Figure 339 Mounting: The cutting decks are supported by the lift arms controlled with the hydraulic-lift cylinders. Construction: The deck chambers are welded steel construction reinforced with the channels and plates. Height-of-cut range: 25.4 to 152 mm (1 to 6 inches) adjustable in 12.7 mm (1/2 inch) increments.
Cutting Decks (continued) Discharge: The clippings are discharged from the rear of the cutting deck. Suspension system: A fully floating suspension with the hydraulic counterbalance. The front deck is suspended from the lift arms and has 2 castor wheels, 2 adjustable skids, and 3 anti-scalp rollers. The wing decks are suspended from the lift arms and have 4 castor wheels, 2 adjustable skids, and 2 anti-scalp rollers.
General Information CAUTION Do not install or work on the cutting deck or lift arms with the engine running. Always shut off the engine and remove the key from the key switch. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. The turf conditions such as the excessive thatch, uneven ground conditions, sponginess or attempting to cut off the excessive grass height may not always be overcome by adjusting the machine. Remember that the effective or actual height-of-cut depends on the cutting unit weight, tire pressures, hydraulic counterbalance settings, and turf conditions.
Service and Repairs CAUTION Do not install or work on a cutting deck or lift arm with the engine running. Always shut off the engine and remove the key from the key switch.
Front Cutting Deck g032075 Figure 340 1. Lift cylinder (left) 7. U-bolt (1 each lift arm) 13. Front cutting deck 2. Hydraulic deck motor 8. HOC chain (1 each lift arm) 14. Locknut (2 each lift arm) 3. Flat washer (2 each lift arm) 9. Thrust washer (1 each lift arm) 15. Plate (1 each lift arm) 16. Center deck cover 4. Bolt (2 each lift arm) 10. Damper assembly 5. Lift arm assembly (left) 11. Hairpin (1 each lift arm) 6. Support hub (1 each lift arm) 12.
Removing the Front Cutting Deck (continued) g032076 Figure 341 1. 6. Carriage screw (2 each) Bolt 2. Damper mount 7. Bearing rod end 3. Spring pin 8. Flange nut (3 each) 4. Spacer 9. Damper 5. Clevis rod end 6. Remove the hairpins (item 11 in Figure 340) and clevis pins (item 12 in Figure 340) that attach the height-of-cut chains to the rear of the cutting deck. 7. Remove the spring pin and spacer that attach the damper to the damper mount on the deck (Figure 341 and Figure 342).
Installing the Front Cutting Deck g032077 Figure 342 1. Damper 2. Clevis rod end 3. Bearing rod end 1. Position the machine on a clean, level surface. Lower the front lift arms, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Position the cutting deck to the lift arms. 3. Align the lift arm support hub to the cutting deck. Note: Ensure that the slotted hole in the support hub is toward the rear of the deck. 4.
Wing Cutting Deck g032078 Figure 343 1. Wing cutting deck (left) 4. Locknut (8 each) 2. Lift arm (left) 5. Flange-head screw (8 each) 3. Rear impact arm assembly 6. Deck connection (left) 7. Deck outer cover Removing the Wing Cutting Deck 1. Position the machine on a clean, level surface. Lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the cutting deck outer cover to access the hydraulic deck motor.
Removing the Wing Cutting Deck (continued) g032079 Figure 344 1. Wing deck (right) 5. Flange nut (4 each) 2. Carriage screw (2 each) 6. Loop guide 3. Flange nut (2 each) 7. Bolt (4 each) 4. Hose guide 3. Remove the 3 hose guides from the cutting deck (Figure 344). Keep the 2 loop guides (item 6 in Figure 344) on the hydraulic hoses. 4. Remove the hydraulic motor from the cutting deck; refer to Removing the Cutting Deck Motor (page 4–145). 5.
Idler Assembly g032080 Figure 345 1. Drive spindle assembly 10. Torsion spring 19. Low idler arm 2. Driven spindle assembly (double) 11. Torsion spring 20. Stop bolt 3. Driven spindle assembly (single) 12. Washer 21. Jam nut 4. Idler pulley 13. Snap ring 22. Idler pivot post 5. Flange bushing 14. Grease fitting 23. Carriage screw (3 each post) 6. Flat washer 15. Low idler arm 24. Locknut (3 each post) 7. Idler spacer 16. V-belt 25. Flat washer 8. 9.
Removing the Idler Assembly g032081 Figure 346 1. 2. 3. Screw Flat washer Idler pulley 4. Idler spacer 5. 6. 7. Low idler arm Locknut High idler arm 1. Park the machine on a level surface, lower the cutting deck. Shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the deck covers from the top of the cutting deck. 3.
Installing the Idler Assembly 1. Install the idler components that were removed; refer to Figure 345. Attach the idler arm assembly to the cutting deck with the snap ring. 2. Insert a nut driver or small piece of pipe onto the end of the torsion spring for the idler arm. CAUTION Be careful when applying the tension to the idler arm torsion spring. The spring is under heavy load and can cause personal injury. 3.
Front Deck Winglets g032083 Figure 348 1. Center deck 5. Bumper pad (2 each) 9. Eccentric (2 each winglet) 2. Right deck winglet 6. Screw (4 each) 10. Bolt (2 each winglet) 3. Left deck winglet 7. Flange nut (4 each) 11. Locknut (2 each winglet) 4. Flange bushing (4 each winglet) 8. Grease fitting 12. Hinge pin (2 each winglet) Disassembling the Front Deck Winglets 1.
Disassembling the Front Deck Winglets (continued) g032084 Figure 349 1. Eccentric 3. Marker/paint line 2. Deck bracket 4. Eccentric removal hole 4. For assembly alignment purposes, use a marker or paint pen on the eccentric and deck brackets to identify the location of the eccentric; refer to Figure 349. 5. Remove the locknut, bolt, eccentric, and hinge pin from the front and rear winglet hinges. Use the hole in the deck bracket to remove the eccentric from the deck.
Blade Spindle g032085 Figure 350 1. Driven spindle (double pulley) 3. Driven spindle (high pulley) 2. Drive spindle 4. Grease fitting Removing the Blade Spindle 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the covers from the cutting deck to get access to the blade spindle. 3.
Removing the Blade Spindle (continued) g032086 Figure 351 1. Flange-head screw 2. Hydraulic motor 4. Position the motor away from the spindle. 5. Use an appropriate socket wrench to loosen the idler pulley to release the tension of the belt. Remove the drive belt from the spindle for servicing. 6. Start the engine and raise the cutting deck. Shut off the engine and remove the key from the key switch. Latch or block up the cutting deck so that it cannot fall accidentally. g032087 Figure 352 1.
Removing the Blade Spindle (continued) 7. Remove the cutting blade, anti-scalp cup, and blade bolt from the spindle for servicing. 8. Remove the spindle housing assembly from the deck as follows: A. For the driven spindle assemblies, remove the 8 flange-head screws with the flange nuts that attach the spindle to the deck. B.
Servicing the Blade Spindle Disassembling the Blade Spindle g032088 Figure 353 1. Locknut 7. Spacer set 2. Hardened washer 8. Spindle housing 3. Pulley 9. Grease fitting 4. O-ring 10. Shaft spacer 5. Oil seal 11. Spindle shaft 6. Bearing set 1. Loosen and remove the locknut from the top of the spindle shaft. Remove the hardened washer and pulley from the spindle. For drive spindle, remove the hydraulic motor mount. 2.
Disassembling the Blade Spindle (continued) g032089 Figure 354 1. Bearing 4. Inner bearing spacer 2. Spacer ring 5. Outer bearing spacer 3. Large snap ring Assembling the Blade Spindle Note: A replacement spindle bearing set contains 2 bearings, a spacer ring, and a large snap ring (items 1, 2, and 3 in Figure 354). You cannot purchase these parts separately. Also, do not mix the bearing set components from 1 deck spindle to the another.
Assembling the Blade Spindle (continued) g032090 Figure 355 1. Bearing cups 4. Arbor press 2. Large snap ring 5. Support 3. Large outer spacer 6. Arbor press base 3. Use an arbor press and push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer that is previously installed, and the bottom bearing cup must contact the snap ring.
Assembling the Blade Spindle (continued) Note: Ensure that the bottom seal must have the lip facing out (down). This seal installation allows grease to purge from the spindle during the lubrication process; refer to Figure 356. IMPORTANT If you are replacing the bearings, ensure that you use the spacer ring that is included with a new bearing set; refer to Figure 354. 6.
Castor Forks and Wheels g032092 Figure 357 1. Castor arm (wing deck) 5. Locknut 9. Grease fitting 2. Cap 6. Castor spacer 10. Compression spring 3. Castor fork 7. Thrust washer 11. Retaining ring 4. Castor wheel bolt 8. Castor wheel 12.
Disassembling the Castor Forks and Wheels g032093 Figure 358 1. Bearing 6. Inner tube 2. Flange nut (4 each) 7. Rim half 3. 4. Plate Rim half 8. 9. Hub Bearing spacer 5. Tire Disassemble the castor forks and wheels; refer to Figure 357 and Figure 358. Assembling the Castor Forks and Wheels 1. Assemble the castor forks and wheels; refer to Figure 357 and Figure 358. A. Install the castor wheels so that the valve stem extends toward the left side of the machine. B.
Deck Skids and Rollers g032094 Figure 359 1. Bolt 7. Bumper skid (2 each) 2. Roller 8. Carriage screw 3. 4. 5. Locknut Washer-head screw Carriage screw 6. Flange nut 9. 10. 11. Roller Roller shaft Flange nut g032289 Figure 360 1. Locknut 5. Carriage screw 2. Roller 6. Flange nut 3. Bolt 7. Bumper skid 4.
Removing the Deck Skids and Rollers Remove the skids and rollers from the deck; refer to Figure 359 and Figure 360. Installing the Deck Skids and Rollers Install the skids and rollers to the deck; refer to Figure 359 and Figure 360. 1. Ensure that you install the skids (item 7 in Figure 359) in the same mounting hole height position (lower, middle, or upper). 2. Ensure that you install all the deck rollers (items 2 and 9 in Figure 359) in the same mounting hole height position (lower or upper). 3.
Cutting Decks: Service and Repairs Page 8–28 Groundsmaster 5900 Traction Unit 08159SL Rev C
Chapter 9 Operator Cab Table of Contents General Information .............................................................................................................................. 9–2 Operator’s Manual ............................................................................................................................. 9–2 Electrical Components and Schematic............................................................................................... 9–2 Air Conditioning System.............
General Information The information in this chapter pertains to the operator cab of the Groundsmaster 5910 machine. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Air Conditioning System Performance There are a number of factors that can affect the performance of the air conditioning system of your Groundsmaster 5910 machine. To ensure the best system operation, inspect the following components: 1. Ensure that the heater control fully closes the heater valve in the cab headliner. 2. Ensure that the evaporator fins are clean. 3. Check that the refrigerant charge quantity and system operating pressures are correct. 4.
Service and Repairs General Precautions for Removing and Installing the Air Conditioning System Components CAUTION Loosening any system fitting or component allows the pressurized air to escape, causing possible injury. Do not loosen any system fitting or component until a certified air conditioning service technician discharges the system completely. WARNING Do not let the refrigerant contact your skin or eyes as there is a possibility of serious injury.
General Precautions for Removing and Installing the Air Conditioning System Components (continued) 8. Always use a DOT approved tank to store the used and recycled refrigerants. 9. The Groundsmaster 5910 air conditioning system uses R134a refrigerant. Do not use other refrigerants in the system. Note: The capacity of the air conditioning system is 0.57 kg (1.25 lb) of R134a refrigerant. 10. The refrigerant containers (either full or empty) are under pressure and the pressure increases if you heat them.
Air Conditioning Compressor g032096 Figure 361 1. Flange-head screw (4 each) 6. Belt 11. Tensioner arm 2. Pivot plate 7. Button-head screw (2 each) 12. Carriage screw (2 each) 3. Bolt 8. Flange-head screw (3 each) 13. Mount plate 4. Air conditioning compressor 9. Mount plate 14. Spacer (3 each) 5. Locknut Flange nut (4 each) 15. Conduit 10. Removing the Air Conditioning Compressor 1.
Removing the Air Conditioning Compressor (continued) g032097 Figure 362 3. Loosen the carriage screws and flange nuts that attach the air conditioning compressor and tensioner arm (Figure 362). Rotate the compressor to loosen the drive belt. Remove the belt from the air conditioning compressor pulley. 4. Inspect the compressor drive belt for glazing or damage. Replace the belt if necessary. 5. Disconnect the compressor electrical connector from the machine wire harness. 6.
Removing the Air Conditioning Compressor (continued) IMPORTANT To prevent the compressor oil from filling the compressor cylinders, keep the compressor in the same orientation as it was in the installed position. 11. Carefully remove the compressor from the engine and machine. 12. If necessary, remove the compressor mounting brackets from the engine. Note: Replace the drier-receiver whenever you remove the air conditioning compressor from the system; refer to Heater and Evaporator Assembly (page 9–16).
Installing the Air Conditioning Compressor (continued) 9. Have a certified air conditioning service technician evacuate the air conditioning system completely, correctly recharge the system with R134a refrigerant, and perform the leak test on the system. Note: The capacity of the air conditioning system is 0.57 kg (1.25 lb) of R134a refrigerant. 10. Lower the hood and secure it. Servicing the Air Conditioning Compressor g032098 Figure 363 1. Armature bolt 11. Snap ring 21. Rear gasket 2.
Servicing the Air Conditioning Compressor (continued) Note: The air conditioning compressor used on the Groundsmaster 5910 machine is an International Components Engineering (ICE) model TM—16. For the air conditioning compressor repair procedures; refer to the ICE Compressor Service Manual at the end of this chapter. Roof Assembly g032099 Figure 364 1. Roof 7. Panel nut 13. Front fastener (2 each) 2. Screw (2 each) 8. Roof mount 14. Rubber washer 3. Flat washer (6 each) 9. 4. Bushing 5.
Removing the Roof Assembly g032100 Figure 365 1. Heater evaporator assembly 2. 3. Heater valve Air conditioning hose: evaporator to compressor 4. 5. Air duct hose Air conditioning hose: compressor to condenser 6. Air conditioning hose: condenser to drier 7. 8. Heater hose: thermostat to heater valve Heater hose: heater core to water pump 9. 10. Heater hose: heater valve to heater core Condensation drain hose (2 each) 11. Air conditioning hose: drier to evaporator 1.
Removing the Roof Assembly (continued) g032101 Figure 366 1. Heater evaporator 3. Drain hose 2. Air duct hose 4. Drier-receiver Installing the Roof Assembly 1. Ensure that all the components in the headliner and roof are installed and attached. 2. Remove the support and carefully tilt the roof into its position. 3. Attach the roof to the headliner with all the fasteners that were removed.
Air Conditioning Condenser Assembly g032102 Figure 367 1. Condenser cover 4. Condenser coil assembly 7. Roof 2. Flange nut (4 each) 5. Flange nut (2 each) 8. Bushing (4 each) 3. Condenser fan 6. Flat washer (4 each) 9. Flange-head screw (2 each) Removing the Air Conditioning Condenser Assembly 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Air Conditioning Condenser Assembly (continued) CAUTION Loosening any system fitting or component allows the pressurized air to escape, causing possible injury. Do not loosen any system fitting or component until a certified air conditioning service technician discharges the system completely. 7. Have a certified air conditioning service technician evacuate the refrigerant from the air conditioning system. 8. Label and remove the hoses from the condenser coil.
Installing the Air Conditioning Condenser Assembly (continued) 6. Ensure that all the machine air conditioning components are installed and attached. 7. Have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant, and perform the leak test on the system. Note: The capacity of the air conditioning system is 0.57 kg (1.25 lb) of R134a refrigerant. 8.
Heater and Evaporator Assembly g032104 Figure 369 1. Heater and evaporator assembly 5. Bottom cover 9. Drier-receiver 2. Top cover 6. Hose clamp (2 each) 10. Screw (8 each) 3. Flange-head screw (2 each) 7. Speed nut (8 each) 11. Screw (5 each) 4. Drier-receiver mount 8. Panel nut (4 each) Removing the Heater and Evaporator Assembly 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Heater and Evaporator Assembly (continued) CAUTION Loosening any system fitting or component allows the pressurized air to escape, causing possible injury. Do not loosen any system fitting or component until a certified air conditioning service technician discharges the system completely. g032105 Figure 370 1. Heater evaporator assembly 2. 3. Heater valve Air conditioning hose: evaporator to compressor 4. 5. Air duct hose Air conditioning hose: compressor to condenser 6.
Removing the Heater and Evaporator Assembly (continued) g032106 Figure 371 1. Heater evaporator 3. Drain hose 2. Air duct hose 4. Drier-receiver 7. Loosen the hose clamp that secures the air duct hose to the heater and evaporator assembly covers. Slide the hose from the covers. 8. Remove the screws that attach the top cover to the bottom cover. Remove the top cover to access the heater and evaporator assembly. g032107 Figure 372 1. Fan motor 6. Resistor guard 2. Blower wheel 7.
Installing the Heater and Evaporator Assembly (continued) 2. Position the heater and evaporator assembly into the bottom cover in the headliner. Attach the top cover to the bottom cover with the screws that were removed. 3. Slide the air duct hose onto the heater and evaporator assembly covers and secure the air duct hose with a hose clamp. 4. Remove the caps that you placed on the hoses and fittings during the removal process.
Operator Cab: Service and Repairs Page 9–20 Groundsmaster 5900 Traction Unit 08159SL Rev C
Appendix A Foldout Drawings Table of Contents Appendix A ...........................................................................................................................................A–1 Electrical Drawing Designations ........................................................................................................A–3 Hydraulic Schematic (Serial Number Below 313000300) ...................................................................
Cab Wire Harness Diagram (Serial Number Above 315000000) ......................................................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Foldout Drawings Page A–4 Groundsmaster 5900 Traction Unit 08159SL Rev C
Hydraulic Schematic (Serial Number Below 313000300) Groundsmaster 5900/5910 Hydraulic Schematic (Serial Number Below 313000300) g254537 , Drawing Rev , Sheet 08159SL Rev C Page A–5
Hydraulic Schematic (Serial Number Above 313000300) STEERING CYLINDERS 1.25 x 6 INCH STROKE 0.75 INCH ROD G M1 P1 600 PSI RV2 1.61 FRONT TRACTION 3000 PSI RV1 0.025 FRONT DECK CONTROL VALVE 1.80 11.96 : 1 REAR TRACTION 1.80 14.5 11.96 : 1 14.5 17 PSI OR 0.050 0.025 4WD CONTROL VALVE TRACTION CONTROL VALVE M1 M1 OR1 0.030 S 17 PSI R L LC1 S P2 M2 OR 0.020 LC2 G1 PD1 STEERING CONTROL VALVE 6.
Electrical Schematic Sheet 1 of 5 (Serial Number Below 313000300) POWER CONNECTOR GND GND +12 VDC +12 VDC 01 02 03 04 58- B BK BK OR OR OEM CONNECTOR B+ Start 43 53 47 30 DECREMENT 19 INCREMENT GY T 53- D 1 53- C 3 ENGINE STARTER 2 4 53- B PK 1 2 BK 5 6 07 JUNCTION BLOCK ENGINE GROUND BK/R INCREMENT/DECREMENT SWITCH BU 3 4 5 BK/R 6 41 05 LOW 16 30% 18 HIGH BK/R Y/R 54- A 54 - B GY/R 54- C W/R 54- D PK DIAGNOSTIC SWITCH BK/R 1 PK 2 3 4 5 6 COOLANT LEVEL (-
Electrical Schematic Sheet 2 of 5 (Serial Number Below 313000300) ENGINE DIAGNOSTIC LINE 09 LINE 07 LINE 06 LINE 05 LINE 04 LINE 02 LINE 01 SHEET 1 GND +12 VDC CAN+ CAN- CANtrak 2600 INFO CENTER BK/W VIO PK OR BK RS485A RS485B SWITCHED O/P NOT USED R GROUND PWR+ RS232 TX + RS232 TX RS232 RX RS232 RX + CANCAN+ 1 2 3 4 5 6 7 8 9 10 11 12 R/W A B C D E F G H J CAP T/BK T/BK A B C 120 OHM CAN+ CAN- 54- G 54- H CAN- bus TERMINATION RESISTOR 1F 2 R/W BK/W R/W BK/W VIO 30A CUMMINS CONTR
Electrical Schematic Sheet 3 of 5 (Serial Number Below 313000300) R/Y LINE 11 LINE 10 SHEET 1 R/BK SHEET 3 3F 2 LINE 12 7.
Electrical Schematic Sheet 4 of 5 (Serial Number Below 313000300) SHEET 1 LINE 24 R/BK LINE 25 R/W LINE 26 BK/W LINE 21 BK LINE 22 R SHEET 2 4F 2 7.5 A 4F 3 4F 4 T/BK 7.5 A 4F 1 LINE 23 BN/BK 7.5 A GY/BK 2A R W/BK R/BK 1 2 PK/W 3 5 4 6 2 3 1 5 6 4 T/W VIO/W BK BN/Y LH DECK R/L OR/W W/OR 1 BU/W BN/Y 2 W/OR 3 5 Y 4 6 LH UP LIMIT SW. 55- C W/BU PK/BU CTR UP LIMIT SW.
Electrical Schematic Sheet 5 of 5 (Serial Number Below 313000300) ROPS GY 05- B VIO BU 05- E 05- D GY BRAKE/TURN A GROUND B BK TAIL VIO WARNING/TURN BU VIO C D TURN SIGNAL OR BK GY GN TAIL LIGHT RH BRAKE/TURN A GROUND B OR 05- A OR BK 05- F BK TAIL VIO WARNING/TURN BN 05- C BN C D OR BK GY GN TAIL LIGHT LH RH HEAD LIGHT HEAD LIGHT VIO BK BK LH HEAD LIGHT VIO BK BK RH TAIL/BRAKE LIGHT BRAKE LIGHT C B 1 LINE 28 Y VIO 53- E VIO A 53- F GY/T C B 53- A BK A 2
Electrical Schematic Sheet 1 of 5 Serial Number From 313000301 to 313999999) SHEET 6 SHEET 2 SHEET 3 SHEET 3 SHEET 2 Groundsmaster 5900/5910 Electrical Schematic Sheet 1 of 5 (Serial Number From 313000301 to 313999999) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 2 of 5 (Serial Number From 313000301 to 313999999) SHEET 1 SHEET 3 SHEET 6 SHEET 4 SHEET 5 Groundsmaster 5900/5910 Electrical Schematic Sheet 2 of 5 (Serial Number From 313000301 to 313999999) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 3 of 5 (Serial Number From 313000301 to 313999999) SHEET 1 SHEET 2 SHEET 2 SHEET 5 SHEET 2 SHEET 5 Groundsmaster 5900/5910 Electrical Schematic Sheet 3 of 5 (Serial Number From 313000301 to 313999999) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 4 of 5 (Serial Number From 313000301 to 313999999) SHEET 2 SHEET 2 Groundsmaster 5900/5910 Electrical Schematic Sheet 4 of 5 (Serial Number From 313000301 to 313999999) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 5 of 5 (Serial Number From 313000301 to 313999999) SHEET 2 SHEET 3 Groundsmaster 5900/5910 Electrical Schematic Sheet 5 of 5 (Serial Number From 313000301 to 313999999) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 1 of 5 (Serial Number Above 314000000) SHEET 6 SHEET 2 SHEET 3 SHEET 3 SHEET 2 Groundsmaster 5900/5910 Electrical Schematic Sheet 1 of 5 (Serial Number Above 314000000) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 2 of 5 (Serial Number Above 314000000) SHEET 1 SHEET 3 SHEET 6 SHEET 4 SHEET 5 Groundsmaster 5900/5910 Electrical Schematic Sheet 2 of 5 (Serial Number Above 314000000) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 3 of 5 (Serial Number Above 314000000) SHEET 5 SHEET 2 SHEET 2 SHEET 5 SHEET 2 SHEET 5 Groundsmaster 5900/5910 Electrical Schematic Sheet 3 of 5 (Serial Number Above 314000000) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 4 of 5 (Serial Number Above 314000000) SHEET 2 SHEET 2 Groundsmaster 5900/5910 Electrical Schematic Sheet 4 of 5 (Serial Number Above 314000000) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Sheet 5 of 5 (Serial Number Above 314000000) SHEET 2 SHEET 3 Groundsmaster 5900/5910 Electrical Schematic Sheet 5 of 5 (Serial Number Above 314000000) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Operator Cab (Serial Number Below 313000300) 1F 3 30 A A/C BU BN BN -1 VIO -2 OR -7 OR -8 BK -5 BK -6 VIO 15 A HEATER PK L 2 B 3 -3 OR -4 BK/W PWR C 4 OR Y 2 1 3 5 4 6 30 BU 85 OR CONDENSER FAN BK 87a 87 86 BK/W OR/BK BK BINARY SWITCH AIR CONDITIONING (PRESSURE SWITCH) P05- H W 56- E W 56- D BU AIR CONDITIONER CLUTCH P05- G BU SHEET 1 LINE 40 2 3 GN R 6 BU 5 GN R W/BK BK P11- 1 P11- 2 P11- 3 P11- 4 P11- 5 VIO PWR WINDSHIELD WASHE
Electrical Schematic Operator Cab (Serial Number From 313000301 to 313999999) SHEET 1 SHEET 2 SHEET 5 Groundsmaster 5900/5910 Electrical Schematic Operator Cab (Serial Number From 313000301 to 313999999) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Electrical Schematic Operator Cab (Serial Number Above 314000000) SHEET 1 SHEET 5 Groundsmaster 5900/5910 Electrical Schematic Operator Cab (Serial Number Above 314000000) NOTE: THE ELECTRICAL SCHEMATIC IS SHOWN ON SIX (6) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, THE SHEET NUMBER AND A LINE NUMBER WILL BE IDENTIFIED. All relays and solenoids are shown as de- energized. All ground wires are black.
Platform Wire Harness Drawing (Serial Number Below 310000000) NOTE CLOCK POSITION 10 1 20 11 30 21 40 50 31 41 41 50 40 31 30 21 20 11 1 10 NOTE CLOCK POSITION Groundsmaster 5900/5910 Platform Wire Harness Drawing (Serial Number Below 310000000) g254557 , Drawing Rev , Sheet 08159SL Rev C Page A–25
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number Below 310000000) P04 P79 P05 P07 P54 P53 P55 P56 P57 P58 J10 P60 P16 P13 P64 P63 P62 P61 P83 P08 J03 J04 VIOLET GREEN PINK BROWN P41 BLUE RED WHITE BLACK RED VIOLET RED/WHITE BLACK/WHITE BLACK/RED YELLOW/RED GRAY/RED WHITE/RED VIOLET RED/BLACK RED/WHITE BLACK/WHITE TAN VIOLET BLACK BLUE WHITE VIOLET BLACK VIOLET BLACK ORANGE P48 YELLOW RED RED VIOLET GREEN/BLACK P49 PINK BLACK ORANGE/ BLACK PINK YELLOW
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number Below 310000000) PINK TAN VIOLET BLACK PINK BLACK WHITE GREEN/WHITE YELLOW/RED GRAY/RED PINK BLACK/RED BLACK WHITE/RED WHITE/ORANGE BLACK GRAY BLACK BLACK BLUE/WHITE BLACK YELLOW BLACK PINK/GREEN BLACK ORANGE/WHITE BLACK VIOLET/WHITE BROWN/YELLOW PINK/WHITE BLACK VIOLET/WHITE YELLOW VIOLET TAN/WHITE BLACK NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS.
Platform Wire Harness Drawing (Serial Number From 310000001 to 313000300) NOTE CLOCK POSITION 10 1 20 11 30 21 40 31 50 41 41 50 40 31 30 21 20 11 1 10 NOTE CLOCK POSITION Groundsmaster 5900/5910 Platform Wire Harness Drawing (Serial Number From 310000001 to 313000300) g254560 Page A–28 08159SL Rev C , Drawing Rev , Sheet
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number From 310000001 to 313000300) NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number From 310000001 to 313000300) NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Platform Wire Harness Drawing (Serial Number From 313000301 to 313999999) NOTE CLOCK POSITION 10 1 20 11 30 21 40 31 50 41 41 50 40 31 30 21 20 11 1 10 NOTE CLOCK POSITION Groundsmaster 5900/5910 Platform Wire Harness Drawing (Serial Number From 313000301 to 313999999) g254563 , Drawing Rev , Sheet 08159SL Rev C Page A–31
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number From 313000301 to 313999999) NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number From 313000301 to 313999999) NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Platform Wire Harness Drawing (Serial Number Above 314000000) NOTE CLOCK POSITION 10 1 20 11 30 21 40 31 50 41 41 50 40 31 30 21 20 11 1 10 NOTE CLOCK POSITION Groundsmaster 5900/5910 Platform Wire Harness Drawing (Serial Number Above 314000000) g254566 Page A–34 08159SL Rev C , Drawing Rev , Sheet
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number Above 314000000) Groundsmaster 5900/5910 Platform Wire Harness Diagram NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number Above 314000000) NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED.
Rear Wire Harness Drawing (Serial Number Below 313000300) 51 41 31 60 50 40 21 11 1 30 20 10 NOTE CLOCK POSITION Groundsmaster 5900/5910 Rear Wire Harness Drawing (Serial Number Below 313000300) g254569 , Drawing Rev , Sheet 08159SL Rev C Page A–37
BLACK BLACK BLUE BLUE BLACK BLACK BLACK RED/WHITE BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK/YELLOW BLACK WHITE/YELLOW BLACK YELLOW/GREEN BLACK RED/WHITE BLACK BLACK BLACK YELLOW/RED BLACK PINK BLACK/WHITE WHITE/GREEN BLACK Rear Wire Harness Diagram (Serial Number Below 313000300) BLACK GRAY/RED WHITE/RED TAN BLACK/WHITE GREEN/WHITE GRAY WHITE/BLUE BLACK BLACK BLACK BLACK/RED YELLOW/BLUE ORANGE BLACK BLACK BROWN GRAY/WHITE BLACK YELLOW/WHITE BLACK BLACK ORANGE ORANGE
Rear Wire Harness Drawing (Serial Number From 313000301 to 313999999) 51 41 31 21 11 1 60 50 40 30 20 10 NOTE CLOCK POSITION Groundsmaster 5900/5910 Rear Wire Harness Drawing (Serial Number From 313000301 to 313999999) g254571 , Drawing Rev , Sheet 08159SL Rev C Page A–39
Rear Wire Harness Diagram (Serial Number From 313000301 to 313999999) Groundsmaster 5900/5910 Rear Wire Harness Diagram (Serial Number From 313000301 to 313999999) g254572 Page A–40 08159SL Rev C , Drawing Rev , Sheet
Rear Wire Harness Drawing (Serial Number Above 314000000) 51 41 31 21 11 1 60 50 40 30 20 10 NOTE CLOCK POSITION Groundsmaster 5900/5910 Rear Wire Harness Drawing (Serial Number Above 314000000) g254573 , Drawing Rev , Sheet 08159SL Rev C Page A–41
Rear Wire Harness Diagram (Serial Number Above 314000000) Groundsmaster 5900/5910 Rear Wire Harness Diagram (Serial Number Above 314000000) g254574 Page A–42 08159SL Rev C , Drawing Rev , Sheet
Cab Wire Harness Drawing (Serial Number Below 314999999) Groundsmaster 5910 Cab Wire Harness Drawing (Serial Number Below 314999999) g254575 , Drawing Rev , Sheet 08159SL Rev C Page A–43
YELLOW BLACK/WHITE ORANGE/BLACK ORANGE RED WHITE/BLACK Cab Wire Harness Diagram (Serial Number Below 314999999) GRAY ORANGE BROWN VIOLET PINK ORANGE/BLACK BLUE BLACK BLACK ORANGE ORANGE ORANGE BLUE BLACK WHITE/BLACK BLACK RED ORANGE/BLACK VIOLET RED/WHITE BLACK RED RED BLACK GREEN RED RED WHITE/BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK WHITE VIOLET VIOLET ORANGE VIOLET GRAY BROWN BROWN BLUE BLUE VIOLET VIOLET BROWN VIOLET BLACK BLAC
Cab Wire Harness Drawing (Serial Number Above 315000000) 30 AMP FUSE 25 AMP FUSE 20 AMP FUSE 15 AMP FUSE Groundsmaster 5910 Cab Wire Harness Drawing (Serial Number Above 315000000) g254577 , Drawing Rev , Sheet 08159SL Rev C Page A–45
Cab Wire Harness Diagram (Serial Number Above 315000000) Groundsmaster 5910 Cab Wire Harness Diagram (Serial Number Above 315000000) g254578 Page A–46 08159SL Rev C , Drawing Rev , Sheet
