Form No. 16227SL Rev D Groundsmaster® 5900 & 5910 (Models 31698 and 31699) © 2021—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date – 2016 A 03/2018 Updated Engine chapter, Electrical chapter and Foldout drawings. Added revision history. B 10/2019 Updated Hydraulic, Electrical, Chassis and Operator Cab chapters. C 07/2020 Updated Electrical chapter and Foldout Drawings. D 04/2021 Updated primary and secondary controller naming.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
NOTES NOTES Page 4 Groundsmaster® 5900 & 5910 16227SL Rev D
Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 5900 and 5910. Refer to the Operator’s Manuals for installing, operating, maintenance, and adjustment instructions. Keep a copy of the Operator’s Manuals and Parts Catalogs for your machine and its accessories with this Service Manual for reference.
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. components) that may have been removed. • Dimensions or settings that must be maintained for proper machine operation. • A specific fastener tightening sequence. • Component orientation that may not be obvious.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Safety and Instructional Decals ....................................................................
Electrical Schematic (machine serial numbers below 316000200) ................A–7 Electrical Schematic (machine serial numbers 316000201 to 399999999) ..................................................................................................A–8 Electrical Schematic (machine serial numbers 316000201 to 399999999) ..................................................................................................A–9 Electrical Schematic (machine serial numbers 400000000 to 403450000) ...................
Rear Wire Harness Drawing (machine serial numbers above 405600001) ................................................................................................A–37 Engine Wire Harness Drawing (machine serial numbers 316000001 to 316999999) ................................................................................................A–38 Engine Wire Harness Drawing (machine serial numbers 316000001 to 316999999) ...........................................................................................
Preface Page 10 Groundsmaster® 5900 & 5910 16227SL Rev D
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ............................................................................................................. 1–3 Maintenance and Service.................
Safety Instructions The Groundsmaster 5900 and 5910 are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
While Operating the Machine 1. Sit on the seat when starting and operating the machine. 2. Before starting the engine: A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). 3. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, there may be a problem with traction pedal calibration or the piston (traction) pump that needs to be corrected before using the machine. 4.
Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the key switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. 4.
Maintenance and Service (continued) 17. When welding on machine, disconnect all battery cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect wire harness connector from both of the TEC controllers, disconnect and remove the engine ECU and disconnect the terminal connector from the alternator. Attach welder ground cable no more than two (2) feet (0.6 meters) from the welding location. 18.
Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine.
Jacking the Rear End (Figure 3) g008995 Figure 3 1. Rear axle jacking point 1. Set parking brake and chock both front tires to prevent the machine from moving. 2. Place jack securely under the center of rear axle. Jack rear of machine off the ground. 3. Once the machine is raised, use jack stands under the axle to support the machine.
Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Overall Dimensions............................................................................................................................ 2–2 Engine................................................................................................................................................
Specifications Overall Dimensions g287504 Figure 4 Specifications and Maintenance: Specifications Page 2–2 Groundsmaster® 5900 & 5910 16227SL Rev D
Engine Item Description Make / Designation Yanmar Model 4TNV98CT−NTRL: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, EPA Tier 4 Diesel Engine Bore 98 mm (3.858 in) Stroke 110 mm (4.331 in) Total Displacement 3319 cc (202.5 in³) Firing Order 1 (closest to flywheel end) − 3 − 4 (farthest from flywheel) − 2 Direction of Rotation Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low Sulfur Content Fuel Tank Capacity 132.5 liters (35 U.S.
Hydraulic System Item Description Variable Displacement Axial Piston Pump Piston (Traction) Pump Maximum Displacement (per revolution) 68 cc (4.15 in³) System Relief Pressure: Forward 350 bar (5080 PSI) System Relief Pressure: Reverse 350 bar (5080 PSI) Charge Pressure 20 bar (290 PSI) Front Wheel Motors Dual Speed, Radial Piston Motor Displacement (per revolution) in Low (Mow) Speed 280.3 cc (17.1 in³) Displacement (per revolution) in High (Transport) Speed 560.5 cc (34.
Chassis Item Description Tire pressure Front tire 29 x 12.00−15, 6 ply @ 220 kPa (32 psi) Rear tire 23 x 10.50−12, 6 ply @ 207 kPa (30 psi) Rear wheel toe−in 0 to 3 mm (0.
Cutting Decks MOUNTING: Cutting decks are supported by lift arms controlled with hydraulic lift cylinders. CONSTRUCTION: Deck chambers are welded steel construction reinforced with channels and plates. HEIGHT−OF−CUT RANGE: 25.4 mm to 152 mm (1 to 6 in) in 12.7 mm (1/2 in) increments. Center deck height−of−cut adjustment is achieved by changing spacers on castor wheels and re−positioning the castor wheel axles in the castor forks.
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.
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 5 Torque Conversion Factor = A / B 1. Torque wrench 3. A (effective length of torque wrench) 2. Drive-adapter wrench (crowsfoot) 4. B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g.
Identifying the Fastener g206088 Figure 6 Inch Series Bolts and Screws 1. Grade 1 2. Grade 5 3. Grade 8 g206089 Figure 7 Metric Bolts and Screws 1. Class 8.8 2. Class 10.9 Fasteners with a Locking Feature IMPORTANT If a fastener with a locking feature or previously applied thread locking compound is reused, clean the fastener threads and apply new thread locker to the fastener during installation. Locking features are designed to create friction and prevent a fastener from loosening.
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 ± 56 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 Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) 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.
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 K-Line 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 K-Line 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 K-Line 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 K-Line Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 LPM or 40 GPM) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bidirectional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction. If a component failure occurs in the closed-loop traction circuit, contamination from the damaged part will remain in the circuit until you remove it.
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, drive motor), it is necessary to prime the hydraulic pumps. A remote starter switch can be used for this purpose. A remote starter switch can be purchased locally or fabricated as follows. IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp in−line fuse between the battery and switch connector for circuit protection.
Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug the connector into the component, unplug the connector, apply the gel to both surfaces again, and connect the harness connector to the component again. The connectors must be fully packed with gel for effective results.
Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ............................. 3–2 Gather Information ............................................................................................................................. 3–2 Evaluate Potential Causes ................................................................................................................. 3–2 Assess Performance.............................................
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis • Narrow down the focus of the problem Assess Performance • Ensure you have all the necessary tools for testing • Test all potential causes of the failure • Reevaluate and create a new hypothesis if nece
General Hydraulic System Problems The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all−inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be useful during the hydraulic troubleshooting process.
Traction Circuit Problems When troubleshooting traction circuit problems, if a problem exists in both low range (mow) and high range (transport) speeds, consider a faulty component that affects the entire traction circuit (e.g. charge circuit, traction circuit relief valves, piston pump). If the problem exists in low range but not in high range (transport), consider a problem that only exists in mow (e.g. solenoid valve in traction manifold, issue with front wheel motor).
Problem Possible Cause High range traction speed (transport) will not engage. An electrical problem exists that prevents solenoid valve (SV) operation in traction manifold (see Chapter 6: Electrical System (page 6–1)). Solenoid valve SV in traction manifold is leaking or faulty. PD cartridge valve(s) in traction manifold is (are) leaking, damaged or sticking. Parking brake cannot be disengaged with engine running.
PTO Problems Problem Possible Cause None of the cutting decks will operate. An electrical problem exists that prevents solenoid valve operation in deck manifolds (see Chapter 6: Electrical System (page 6–1)). Note: Cutting decks have to be fully lowered and floating, traction speed needs to be in low range (mow), the PTO switch needs to be engaged and the engine coolant temperature needs to be below 102 ºC (215 ºF) in order for decks to operate. Gear pump internal drive shaft failure.
Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. Engine RPM is too low. Note: To raise a cutting deck, the engine must be running. Also, the operator seat has to be occupied or the parking brake must be applied with the traction pedal in neutral. Hydraulic oil level in reservoir is too low (other hydraulic systems are affected as well). Lift arm pivots are binding. Lift cylinder is damaged.
Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (Note: Other hydraulic systems are affected as well). Steering relief valve (RV1) in combination manifold is stuck or damaged. Pressure compensator valve (LC) in steering/deck lift manifold is faulty. One or both of the steering cylinders leak internally.
Starting Problems CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Appendix A (page A–1)). If the machine has any interlock switches by−passed, reconnect the switches for proper troubleshooting and safety.
Problem Possible Cause Nothing happens when start attempt is made (engine does not crank). InfoCenter display operates with the key switch in the RUN position. The key switch or circuit wiring is faulty. Traction pedal position sensor or circuit wiring is faulty. The seat switch or circuit wiring is faulty (when trying to start engine in seat). The parking brake switch or circuit wiring is faulty (when trying to start engine out of seat). The start relay or circuit wiring is faulty.
General Run and Transport Problems Check the InfoCenter Display for any operator advisories or faults that may appear. Use the InfoCenter Display Diagnostics feature to help identify the problem (see DIAGNOSTICS SCREENS (page 6–22)). Problem Possible Cause Engine continues to run, but should not, when the key switch is turned off. Key switch or circuit wiring is faulty. The engine, engine ECU or fuel system is malfunctioning (see Yanmar Service Manual). The primary controller is faulty.
Cutting Deck (PTO) Operating Problems Check the InfoCenter Display for any operator advisories or faults that may appear. Use the InfoCenter Display Diagnostics feature to help identify the problem (see DIAGNOSTICS SCREENS (page 6–22)). Problem Possible Cause The cutting decks remain engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty. A hydraulic problem in the mow circuit exists (see Chapter 5: Hydraulic System (page 5–1)). The secondary TEC is faulty.
Problem Possible Cause Cutting deck(s) do not operate. Cutting decks are able to raise and lower. The operator is lifting off the seat switch. The cutting decks are not fully lowered. High temperature of engine coolant or hydraulic oil has disabled the cutting decks. Coolant temperature sender or circuit wiring is faulty. The seat switch or circuit wiring is faulty. The PTO switch or circuit wiring is faulty. The cutting deck position switch or circuit wiring is faulty.
Cutting Deck Lift/Lower Problems Check the InfoCenter Display for any operator advisories or faults that may appear. Use the InfoCenter Display Diagnostics feature to help identify the problem (see DIAGNOSTICS SCREENS (page 6–22)). Problem Possible Cause None of the cutting decks will lower. Operator is not fully depressing the seat switch. Traction unit is not in LOW speed (mow) mode. Secondary TEC fuses (F−A2, F−B2, F−C2, F−D2) are faulty. The seat switch or circuit wiring is faulty.
Problem Possible Cause RH wing cutting deck will not raise or lower, but the front and LH wing cutting decks will raise and lower. RH deck raise/lower switch or circuit wiring is faulty. Lift control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty. Combination control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty. A hydraulic problem in the lift/lower circuit exists (see Chapter 5: Hydraulic System (page 5–1)). Secondary TEC is faulty.
Operator Advisories Operator advisories are automatically displayed by the InfoCenter when a machine function requires additional action. Typically, an advisory can be eliminated with a change in machine controls by the operator. For example, if the operator attempts to start the engine when the traction pedal is depressed, an advisory is identified on the InfoCenter Display that the traction pedal needs to be in neutral. An advisory will not be logged into any fault log.
Advisories are available for the following functions: TO START The TO START advisory identifies that the engine starter will not engage after the key switch is turned to the START position. #5 DISENGAGE PTO: The PTO switch is in the engaged position and must be disengaged before starter will operate. #6 MOVE TRACTION PEDAL TO NEUTRAL: The traction pedal position sensor is not in the neutral position.
TO LOWER DECK The TO LOWER DECK advisory identifies that the cutting deck will not lower when a lower deck switch is pressed. The deck switch must be recycled after the advisory condition has been corrected. #302 SET MACHINE TO LOW SPEED RANGE: Machine is set to high speed range and needs to be in low speed range before decks will lower. #303 OPERATOR MUST BE SEATED: Operator needs to be in seat before cutting decks will lower.
TO SET LOW RANGE The TO SET LOW RANGE advisory identifies that low range traction speed will not engage when the High/Low range traction speed switch is pressed. #602 DISENGAGE CRUISE: Cruise control is engaged and needs to be disengaged in order to engage low speed range. #603 REDUCE GROUND SPEED: Ground speed needs to be less than 2 MPH in order to engage low speed range.
FUEL LEVEL The FUEL LEVEL advisory identifies that the fuel remaining in the tank is low. #1302 LOW ADD FUEL: Less than 5 gallons of fuel remain in the fuel tank. TRACTION PEDAL The TRACTION PEDAL advisory identifies an inaccurate or inconsistent signal from the traction pedal position sensor. #1402 CALIBRATE: The traction pedal position sensor needs to be calibrated (see Traction Pedal Position Sensor Calibration (page 6–51)).
Using the InfoCenter Display for Troubleshooting 1 2 3 4 g287506 Figure 8 1. 2. Machine function Input 3. 4. Qualifiers Outputs The Diagnostics − Input/Output screens of the InfoCenter display can be very helpful when troubleshooting machine operation issues (see DIAGNOSTICS SCREENS (page 6–22)). Some of the electrical components and the circuit wiring involved in various machine operations can be evaluated using the Input/ Output screens prior to testing each component individually.
A faulty output component will not be identified by the Input/ Output screen. If all inputs, qualifiers and outputs are correct for the machine operation selected, yet the operation does not function as it should, the output component may be faulty. In this example, the controller output is occurring but the faulty component is preventing the operation from functioning. Test the specific output and output wiring (see Testing (page 5–36)).
Machine Faults 90 5 92 91 12 97 726.7 708.5 517.1 517.1 516.9 516.9 24 5.4 517.0 517.0 472.7 516.9 27 4 3 4 2 1 g287507 Figure 9 Machine faults are generated by the Toro Electronic Controllers (TEC) to identify an electrical system malfunction (fault) that occurs during machine operation. When an machine fault occurs, an audible alarm will sound and the InfoCenter will display information about the fault logged. Machine faults can be viewed via the InfoCenter Diagnostic Screen Fault Viewer (Figure 9).
Fault Code Fault Description Service Suggestions 3 Pedal Sensor Neutral Switch Issue (receiving Fwd/Neutral/Rev inputs simultaneously). Replace traction pedal position sensor. 5 Traction Current Validation Failure. Test the traction (piston) pump forward and reverse solenoid coils and circuit wiring. Replace the primary TEC (contact an Authorized Toro Distributor for assistance). 6 Forward Traction Circuit Failure.
Fault Code Fault Description Service Suggestions 82 Charging Too High (12 Volt system). Use InfoCenter Display to check 12V system voltage. Test engine alternator (see Yanmar Service Manual). 84 Internal TEC Fault − Master. Replace the primary TEC and reprogram system software (contact an Authorized Toro Distributor for assistance). 85 Internal TEC Fault − Secondary. Replace the primary TEC and reprogram system software (contact an Authorized Toro Distributor for assistance).
Fault Code Fault Description Service Suggestions 98 L Deck PTO Fault. Test left deck manifold PRV solenoid and circuit wiring. Replace the secondary TEC (contact an Authorized Toro Distributor for assistance). 99 C Deck PTO Fault. Test center deck manifold PRV solenoid and circuit wiring. Replace the secondary TEC (contact an Authorized Toro Distributor for assistance). 100 R Deck PTO Fault. Test right deck manifold PRV solenoid and circuit wiring.
Engine Faults g287508 Figure 10 Engine faults are generated by the by the Yanmar engine Electronic Control Unit (ECU) to identify an electrical system malfunction (fault) pertaining to the engine during operation. When an engine fault occurs, an audible alarm will sound and the InfoCenter will display information about the fault. Depending on the severity of the fault, a STOP icon may display as well (Figure 10). The Toro Electronic Controllers (TECs) can also generate electrical faults.
1. IDLE 0X00 ENG HRS − 100 SPN − 3251 OCC CNT − 1 VOLTAGE LOW FMI − 4 6 1 2 3 4 5 g287510 Figure 12 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Engine fault description 3. The fault description will be displayed on the Info- Center (Figure 12). Press button 3 to silence the audible alarm. Press buttons 1 and 2 to scroll through the list of active engine faults. 4.
Factors That Can Affect Quality of Cut and Clipping Dispersion Note: Cutting decks have to be fully lowered and floating, traction speed needs to be in low range (mow), the PTO switch needs to be engaged and the engine coolant temperature needs to be below 102 ºC (215 ºF) in order for decks to operate. There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions.
Troubleshooting: Page 3–30 Groundsmaster® 5900 & 5910 16227SL Rev D
Chapter 4 Yanmar Diesel Engine Table of Contents General Information .............................................................................................................................. 4–2 Operator’s Manuals............................................................................................................................ 4–2 Yanmar Service and Troubleshooting Manuals .................................................................................. 4–2 Stopping the Engine...............
General Information This Chapter gives information about specifications and repair of the Yanmar diesel engine used in the Groundsmaster 5900/5910. General maintenance procedures are described in your Traction Unit Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Yanmar Service Manual and Yanmar Troubleshooting Manual. Most repairs and adjustments require tools which are commonly available in many service shops.
Engine Electronic Control Unit (ECU) 1 2 g287514 Figure 13 1. Engine 2. Engine ECU The Yanmar engine that powers your Groundsmaster uses an Electronic Control Unit (ECU) for engine management and also to communicate with the Toro Electronic Controller (TEC) and the operator InfoCenter display on the machine. All wire harness electrical connectors should be plugged into the ECU before the machine key switch is moved from the OFF position to either the ON or START position.
Engine Electronic Control Unit (ECU) (continued) If the engine ECU is to be disconnected for any reason, make sure that the key switch is in the OFF position with the key removed before disconnecting the engine ECU. Also, to prevent possible ECU damage when welding on the machine, disconnect the engine ECU from the machine before welding. The engine ECU is mounted to the machine using four (4) rubber isolator mounts.
Yanmar Engine 1 2 g287514 Figure 14 1. Engine 2. Engine ECU The engine used on your Groundsmaster is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4 emission regulations.
Diesel Particulate Filter The diesel particulate filter (DPF) used on Yanmar Tier 4F compliant engines is designed to breakdown the hazardous elements in the exhaust and prevent the discharge of unburnt fuel or oil known as particulate matter or soot. The DPF includes a Diesel Oxidation Catalyst (DOC), a Soot Filter (SF), 2 temperature sensors, and a pressure differential sensor.
Regeneration (continued) Types of regeneration that are performed automatically (while the machine is operating) (continued) Assist Occurs because of prolonged operation at low engine speed, low engine load, or when the engine ECU detects the soot filter is becoming obstructed. The engine ECU adjusts the intake throttle to raise the exhaust temperature. For software 122−0310A thru H only: the InfoCenter displays the assist regeneration icon. Reset Occurs every 100 hours of engine operation.
Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. May be caused by prolonged operation at low engine speed, low engine load, or the use of incorrect fuel or engine oil. Manually initiate a parked regeneration as soon as possible.
Soot Accumulation If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addition to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Ash Accumulation Advisories and Engine Faults (continued) Engine Power Rating Engine Speed Reduction Recommended Action Level 2: Engine Warning De-rated to 50% None Service DPF. Level 3: Engine Warning De-rated to 50% Maximum torque +200 rpm Service DPF.
Service and Repairs Air Filter 11 12 4 3 2 6 5 8 10 to 11 N·m (90 to 100 in-lb) 1 6 9 10 7 g287547 Figure 15 1. Air filter assembly 5. Air box 2. Flange nut (2) 6. Flange head screw (2) 9. Intake tube 10. Hose clamp 3. Grommet 7. 4. Flange nut (2) 8. Carriage screw (2) 11. Foam seal Hose clamp 12. Foam seal Air Filter Removal 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Raise the hood to allow access to engine.
Air Filter Installation IMPORTANT Any leaks in the air filter system will cause serious engine damage. Make sure that all air filter components are in good condition and are properly secured during installation. 1. Assemble air filter system (Figure 15): A. Verify that tabs in air filter mounting bands mesh fully with slots in air filter body. B. Tighten intake tube hose clamps from 10 to 112 N·m (90 to 100 in−lb). 1 4 3 2 5 6 VACUATOR VALVE DIRECTION g287548 Figure 16 1. Air filter housing 4.
Exhaust System 39 44 to 54 N·m (32 to 40 ft-lb) 37 36 35 38 3 1 4 8 32 33 32 6 7 5 9 32 10 30 34 28 30 31 30 29 30 2 41 13 40 14 31 24 to 34 N·m (18 to 25 ft-lb) 16 11 12 15 13 20 16 17 15 15 13 10 18 17 26 25 15 10 17 26 27 15 17 13 19 21 3 22 23 24 g287549 Figure 17 Groundsmaster® 5900 & 5910 16227SL Rev D Page 4–13 Yanmar Diesel Engine: Service and Repairs
Figure 17 (continued) 1. Exhaust gasket 15. DPF stiffener (5) 29. Exhaust pressure pipe (DPF outlet) 2. Flange head screw (4) 16. DPF gasket (2) 30. Sensor gasket (4) 3. Flange nut (5) 17. Lock nut (20) 31. Banjo bolt (2) 4. Exhaust elbow 18. DPF stiffener w/lifting lug 32. Hose clip (4) 5. DOC temp sensor (inlet) 19. DPF stiffener 33. Exhaust pressure hose (DPF inlet) 6. DOC temp sensor (outlet) 20. Outlet flange 34. Exhaust pressure hose (DPF outlet) 7. Band 21.
Exhaust System Removal (continued) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Raise the hood and remove side panel from left side of machine to gain access to exhaust system. Allow engine and exhaust to cool before doing any disassembly of exhaust system components. 1 2 3 4 5 6 7 9 8 g287550 Figure 18 1. DOC assembly 6. Lock nut (4) 2. DPF assembly 7. Support bracket 3. Exhaust gasket 8. Flange nut 4. Exhaust pipe 9.
Exhaust System Installation (continued) C. If DPF stiffeners (Figure 17 items 14, 15, 18 and 19) were loosened or removed, tighten fasteners that secure stiffeners before tightening fasteners that secure exhaust system to DPF mounts. D. Position new exhaust gasket and exhaust pipe to engine and secure with four (4) flat washers and hex nuts. E. Position support bracket flat against the engine and the exhaust pipe and secure with flange head screws and flange nut. 4.
Fuel System 14 15 16 3 17 18 2 13 13 21 1 9 8 6 13 12 11 10 10 19 20 23 7 22 25 24 26 4 5 g287551 Figure 19 1. Fuel tank 10. Bushing (2) 19. Fuel hose − to vent tube 2. Fitting cover 11. Standpipe − return 20. Bushing 3. Screw (3) 12. Standpipe − supply 21. Elbow fitting − vent 4. Cap 13. Clamp (3) 22. Clamp (2) 5. Gasket 14. Fuel hose − return from filter 23. Panel fastener (4) 6. Fuel sender 15. Fuel hose − supply to separator 24. Tank hold down 7.
Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recommended in the Operator’s Manual. Also, drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period. To clean fuel tank, flush tank out with clean diesel fuel. Make sure tank is free of contaminates and debris. Check Fuel Lines and Connections Check fuel lines and connections periodically as recommended in the Operator’s Manual.
Fuel Tank Removal (continued) 9. Slide the fuel tank out from the left side of the machine. Note: See Fuel Sender (page 6–109) testing information. 10. If necessary, remove standpipes, vent elbow, bushings and fuel sender from fuel tank. Fuel Tank Installation 1. If removed, install standpipes, vent elbow, bushings and fuel sender into fuel tank (Figure 19). 2. Slide the fuel tank in from the left side of the machine. 3. Position tank hold down (item 24) to fuel tank and machine frame.
Fuel Lines, Filters and Fuel Pump Removal 5 18 14 16 5 5 15 13 9 5 10 11 19 5 5 12 17 6 3 RETURN 5 20 21 5 8 4 1 23 7 22 24 2 25 SUPPLY VENT g287553 Figure 21 10. Flange head screw (2) 19. Fuel hose − return to tank Fuel/water separator element 11. Fuel pump 20. Rivet (2) Fuel/water separator head 12. Grommet 21. Clip (2) 1. Fuel hose − supply from tank 2. 3. 4. Straight barb fitting 13. Fuel hose − filter to injection pump 22. Vent tube (attached to R.O.P.S.
Fuel Lines, Filters and Fuel Pump Removal (continued) 4. Remove fuel system components from the engine as necessary. Note: See Fuel Pump (page 6–111) testing information. See machine Operator’s Manual for fuel/water separator and fuel filter service information. Fuel Lines, Filters and Fuel Pump Installation 1. Install removed system components (Figure 21). 2. If barb fittings were removed from fuel/water separator head, apply thread sealant to fittings prior to installation. 3.
Radiator 13 14 3 to 5 N·m (30 to 45 in-lb) 11 12 11 15 10 8 2 9 18 7 6 1 17 16 20 21 17 22 23 5 3 to 5 N·m (30 to 45 in-lb) 24 25 20 26 25 24 20 3 34 33 7 31 11 27 28 17 4 19 17 32 20 11 29 30 3 to 5 N·m (30 to 45 in-lb) g287539 Figure 22 1. Fan shroud assembly 13. Screw − carriage (2) 25. Washer (4) 2. Foam seal 14. Coolant reservoir 26. Cap screw (2) 3. Foam seal 15. Hose − reservoir overflow 27. Straight barb fitting 4.
Radiator Removal (continued) 5. Remove the lock nut, friction washers and cap screw (item 5) securing the fan shroud prop to the fan shroud and remove the fan shroud prop (Figure 23). 6. Tilt fan shroud assembly toward the rear of the machine and lift the fan shroud assembly from machine (Figure 23). CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene−glycol antifreeze is poisonous.
Radiator Installation (continued) 1 2 5 3 4 3 g287540 Figure 23 1. Fan shroud assembly 4. Lock nut 2. Fan shroud prop 5. Cap screw 3. Friction washer (2) 8. Install the fan shroud assembly and fan shroud prop (Figure 23). Connect the radiator cooling fans to the machine wire harness. Ensure that the fan shroud assembly seals around the radiator when fan shroud prop is latched. Adjust upper radiator mounting brackets forward or rearward for proper seal if necessary. 9.
Engine 1 3 4 5 6 6 5 4 6 2 g287541 Figure 24 1. Cooler frame assembly 3. Flange not (3) 5. Flange nut (6) 2. Battery−disconnect switch bracket 4. Carriage screw (4) 6. Cap screw (6) Engine Removal 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. CAUTION The engine, exhaust pipe, radiator and oil cooler may be hot. To avoid possible burns, allow the machine to cool before working on or near these components. 2.
Engine Removal (continued) 8. To prevent contamination of hydraulic system, thoroughly clean exterior of oil cooler, fittings and hydraulic hoses prior to disconnecting hydraulic hoses. 9. Disconnect hydraulic hoses from the oil cooler and install caps or plugs on fittings and hoses. 10. Remove the cooler frame assembly with the radiator and fan assembly, oil cooler and fan assembly, air filter and plenum assembly, coolant reservoir and windshield washer reservoir attached (Figure 24): A.
Engine Removal (continued) D. Remove the cable clamp securing the ground wires to the right rear engine mount bracket and remove bolt securing ground wires to engine block (below starter motor). E. Disconnect the glow plugs from the wire harness (near the fuel/water separator). F. Disconnect the oil pressure switch from the wire harness (near the fuel/water separator). G. Disconnect four (4) wire harness connections at the Yanmar engine wire harness (near the fuel/water separator).
Engine Removal (continued) CAUTION Make sure that hoist or lift used to remove engine can properly support engine. Engine assembly without hydraulic pumps weighs approximately 295 kg (650 lb). 15. Connect suitable hoist or lift to the front and rear lift tabs on engine. Do not allow the lift chains or straps to contact the DPF. 13 1 2 3 9 2 6 7 8 5 10 11 2 6 7 12 9 6 7 8 10 4 8 11 54 to 65 N·m (40 to 48 ft-lb) g287544 Figure 27 1. Engine assembly 6. Engine isolator mounts (4) 11.
Engine Removal (continued) IMPORTANT Make sure to not damage the engine, fuel lines, hydraulic lines, electrical harness or other machine components while removing the engine. 17. Carefully raise engine from the machine. 18. If necessary, remove engine mount brackets from the engine. 19. If necessary, remove engine isolator mounts from frame. Note ground connection at right rear isolator mount. 20. Cover or plug all engine openings to prevent contaminants from entering engine. Engine Installation 1.
Engine Installation (continued) 10. Install the 24 Volt alternator/air conditioning compressor drive belt (see 24 Volt Alternator/Air Conditioning Compressor Drive Belt (page 6–147)). 11. Connect the supply and return fuel hoses to the fuel pump (Figure 26). Secure the clamp supporting the fuel hoses to the fuel pump mounting screw. 12. Connect wires and/or electrical connections to the engine assembly at the following locations: A. Four (4) connections at Yanmar engine harness B. Oil pressure switch C.
Pump Adapter Plate (Coupler) 39 to 45 N·m (29 to 33 ft-lb) 6 5 3 4 1 2 54 to 65 N·m (40 to 48 ft-lb) g287545 Figure 28 1. Flywheel cover 4. Cap screw (8) 2. Washer head screw (12) 5. Spring coupler 3. Hardened washer (8) 6. Engine Removal Note: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. 1. If engine is in machine, remove hydraulic pump assembly (see Piston (Traction) Pump (page 5–94)). 2.
Installation Engine Side Hydraulic Pump Side 1 2 3 g287546 Figure 29 1. Coupler 2. Coupler hub 3. Engine flywheel 1. Position spring coupler to engine flywheel and align mounting holes (Figure 28). Make sure that coupling hub is toward pump (away from engine flywheel) (Figure 29). 2. Apply medium strength thread locker to threads of cap screws (item 4). Secure coupling to engine flywheel with eight (8) cap screws and hardened washers.
Chapter 5 Hydraulic System Table of Contents General Information .............................................................................................................................. 5–3 Operator’s Manual ............................................................................................................................. 5–3 Relieving Hydraulic System Pressure ................................................................................................ 5–3 Towing Traction Unit..........
Gear Pump Service.......................................................................................................................... 5–88 Traction Circuit ................................................................................................................................. 5–93 Piston (Traction) Pump .................................................................................................................... 5–94 Piston (Traction) Pump Service........................................
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved.
Towing Traction Unit (continued) If it becomes necessary to tow or push the machine, move machine in a forward direction at a speed below 2 mph (3.2 kph), and for a very short distance. If the machine needs to be moved more than a short distance, machine should be transported on a trailer. The piston (traction) pump high pressure relief valves include a high pressure relief valve, charge check valve and a bypass valve.
Traction Circuit Component Failure The traction circuit on Groundsmaster 5900 and 5910 machines is a closed loop system that includes the piston (traction) pump and four (4) wheel motors. If a component in the traction circuit should fail, debris and contamination from the failed component will circulate throughout the traction circuit. This contamination can damage other components in the circuit so it must be removed to prevent additional component failure.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others. Examine all of the hydraulic hoses of the machine frequently and repair or replace them as necessary.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 31 1. Tube or hose 2. Swivel nut 3. 4. O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting.
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size (inch)—threads per inch) Installation Torque 4 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 6 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 8 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 10 1—14 82 to 100 N∙m (60 to 74 ft-lb) 12 1–3/16—12 116 to 142 N∙m (85 to 105 ft-lb) 16 1–7/16—12 150 to 184 N∙m (110 to 136 ft-lb) 20 1–11/16—12 190 to 233 N∙m (140 to 172
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 33 1. Fitting 2. O-ring 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 clean hydraulic fluid.
Installing an Adjustable Fitting g212224 Figure 34 1. Locknut 2. Back-up washer 3. O-ring g212225 Figure 35 1. Step 1: clearance the lock nut 3. Step 3: align the fitting 2. Step 2: seat the back-up washer 4. Step 4: tighten the lock nut 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.
Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 35): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 5–11). This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench); refer to Calculating the Torque Values When Using a Drive-Adapter Wrench (page 2–8).
Hydraulic Schematic The hydraulic schematic for Groundsmaster 5900 and 5910 machines is located in A Hydraulic Schematic (page A–5).
Groundsmaster® 5900 & 5910 16227SL Rev D Page 5–13 FROM FRONT DECK MANIFOLD FROM WING DECK MANIFOLDS FROM OIL COOLER 21.7 GPM 21.7 GPM M5 M4 1.03 CID2.11 CID 2.11 CID TO LEFT DECK MANIFOLD TO FRONT DECK MANIFOLD 10.6 GPM TO HYDRAULIC RESERVOIR 6.1 CID L 0.032” BREATHER L2 4.15 CID 0.032” TO OIL COOLER TO HYDRAULIC RESERVOIR T TRACTION PUMP S2 P STEERING UNIT E R STEER CYLINDERS S1 L4 M3 290 PSI M14 LC C3 P1 OR3 .
Traction Circuit Operation A variable displacement, bi−directional piston pump is directly coupled to the engine flywheel to provide hydraulic flow for the traction circuit. The piston pump swash plate movement is controlled by a pump mounted electrical displacement control. Pushing the traction pedal rotates a potentiometer that provides an input to the machine master Toro Electronic Controller (TEC).
Traction Circuit Operation (continued) The final gear pump section supplies oil to the steering, cutting deck lift and traction charge circuits. This gear pump section provides a constant supply of charge oil to the traction circuit to make up for oil that is lost to internal leakage in the traction pump and wheel motors. Charge pump flow is directed through the charge oil filter attached to the steering/deck lift manifold before entering the piston pump.
Hydraulic System: Hydraulic Flow Diagrams Page 5–16 FROM FRONT DECK MANIFOLD FROM FRONT DECK MANIFOLD FROM OIL COOLER TO LEFT DECK MANIFOLD TO FRONT DECK MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow M4 M5 21.7 GPM 21.7 GPM 10.6 GPM TO HYDRAULIC RESERVOIR P 0.032” E L BREATHER TRACTION PUMP S2 6.1 CID STEERING UNIT R STEER CYLINDERS T L2 4.15 CID 0.032” S1 L4 M3 290 PSI M14 TO OIL COOLER 5080 PSI LC AM3 P1 OR3 .
Note: See Traction Circuit Operation (page 5–14) for a description of general function of the traction circuit. With the low range traction speed (mow) selected and the traction pedal in the neutral position, the swash plate in the piston pump is not rotated so there is no oil flow from the pump and no machine traction movement.
Reverse Direction The traction circuit operates essentially the same in reverse low range as it does in the forward direction. However, the flow through the circuit is reversed. Oil flow from piston pump port B is directed to traction manifold port P2. Pump flow is then routed in parallel to both halves of the front wheel motors through port R of the motors. Flow exits the motor sections through motor ports A1 and A2.
Groundsmaster® 5900 & 5910 16227SL Rev D Page 5–19 FROM FRONT DECK MANIFOLD FROM FRONT DECK MANIFOLD FROM OIL COOLER TO LEFT DECK MANIFOLD TO FRONT DECK MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow M4 M5 21.7 GPM 21.7 GPM 10.6 GPM 6.1 CID 0.032” STEERING UNIT BREATHER TRACTION PUMP S2 TO HYDRAULIC RESERVOIR P R E L STEER CYLINDERS T L2 4.15 CID 0.032” S1 L4 290 PSI M14 TO OIL COOLER M3 5080 PSI AM3 5080 PSI E LC OR3 .
Note: See Traction Circuit Operation (page 5–14) for a description of general function of the traction circuit. When the high range traction speed (transport) is selected, solenoid valve (SV) in the traction manifold is energized by the secondary Toro electronic controller. The shifted solenoid valve (SV) spool directs charge pressure in the traction manifold to shift all six (6) pressure differential valves (PD1, PD2, PD3, PD4, PD5 and PD6) in the manifold.
Reverse Direction The traction circuit operates essentially the same in reverse high range traction speed as it does in the forward direction. However, the flow through the circuit is reversed. Oil flow from piston pump port B is directed to traction manifold port P2. Pump flow is then routed in parallel to both halves of the front wheel motors through port R of both motors. Flow exits the motor sections through motor ports A1 and A2.
Hydraulic System: Hydraulic Flow Diagrams Page 5–22 M4 M5 E L 0.032” T BREATHER TRACTION PUMP S2 6.1 CID 21.7 GPM 21.7 GPM 10.6 GPM P 1.03 CID 2.11 CID 2.11 CID FROM FRONT DECK MANIFOLD AND STEERING UNIT FROM LEFT AND RIGHT DECK CIRCUITS RETURN FILTER 36 PSI FROM FRONT AND RIGHT DECK MANIFOLDS TO LEFT DECK MANIFOLD P1 PORT TO FRONT DECK MANIFOLD P1 PORT TO HYDRAULIC RESERVOIR STEERING UNIT R STEER CYLINDERS L2 4.15 CID 0.
A three (3) section gear pump is coupled to the piston (traction) pump. The gear pump section furthest from the piston pump supplies hydraulic flow to the steering, cutting deck lift and traction charge circuits. Hydraulic flow from the final pump section is directed to the appropriate circuits by a pressure compensator valve located in the steering/deck lift manifold.
Right Wing Deck Raise To raise the right wing deck, the rear of the right console switch is pushed to act as an input to the secondary TEC. The controller provides an electrical output to solenoid valves S1 and S7 in the steering/deck lift manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the barrel end of the right deck lift cylinder. Shifted S1 prevents oil flow from returning directly to the traction charge circuit.
Groundsmaster® 5900 & 5910 16227SL Rev D Page 5–25 M4 M5 E L 0.032” T BREATHER TRACTION PUMP S2 6.1 CID 21.7 GPM 21.7 GPM 10.6 GPM P 1.03 CID 2.11 CID 2.11 CID FROM FRONT DECK MANIFOLD AND STEERING UNIT FROM LEFT AND RIGHT DECK CIRCUITS RETURN FILTER 36 PSI FROM FRONT AND RIGHT DECK MANIFOLDS TO LEFT DECK MANIFOLD P1 PORT TO FRONT DECK MANIFOLD P1 PORT TO HYDRAULIC RESERVOIR STEERING UNIT R STEER CYLINDERS L2 4.15 CID 0.032” L4 M14 P1 M3 C3 290 PSI LC OR3 .
A three (3) section gear pump is coupled to the piston (traction) pump. The gear pump section furthest from the piston pump supplies hydraulic flow to the steering, cutting deck lift and traction charge circuits. Hydraulic flow from the final pump section is directed to the appropriate circuits by a pressure compensator valve located in the steering/deck lift control manifold.
Left Cutting Deck Lower To lower the left wing deck, the front of the left console switch is depressed to act as an input to the secondary TEC. The controller provides an electrical output to solenoid valves S1, S3 and S4 in the steering/deck lift control manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the rod end of the left wing deck lift cylinder. Shifted S1 prevents oil flow from returning directly to the traction charge circuit.
Hydraulic System: Hydraulic Flow Diagrams 1.5 CID 1.5 CID 1.5 CID Page 5–28 M2 M1 M2 M1 M2 M1 OR2 SQ OR2 RIGHT DECK LC2 10 PSI 110 PSI LEFT DECK LC2 10 PSI 110 PSI SQ FRONT DECK LC2 10 PSI 110 PSI SQ OR2 OR1 .063” 600 PSI RV .025” .063” OR1 600 PSI RV .025” OR1 600 PSI RV .025” PRV PRV PRV 10 PSI 10 PSI CD 3000 PSI CD 3000 PSI CD 3000 PSI 10 PSI G1 G1 G1 P2 P1 P2 P1 P2 RETURN FILTER 36 PSI LC1 LC1 LC1 P1 1.03 CID 2.11 CID 2.
Each of the three (3) cutting decks is controlled by a hydraulic control manifold equipped with a proportional relief valve (PRV), logic valves (LC1) and (LC2), a sequence valve (SQ) and a brake relief cartridge (RV). The proportional relief valve is a solenoid operated valve that also functions as the circuit relief valve when the valve is energized by the secondary Toro Electronic Controller (TEC). Mow circuit pressure can be measured at port (G1) of the hydraulic manifold for each cutting deck.
PTO Circuit Relief G1 M1 P1 OR2 .025” SQ 1.5 CID 10 PSI LC1 PUMP FLOW RV 110 PSI PRV 3000 PSI 10 PSI 600 PSI M2 P2 LC2 OR1 .063” CD LEFT DECK RETURN PTO SWITCH OFF PRV ENERGIZED LC1 SHIFTED g287730 Figure 43 Maximum mow circuit pressure is limited for each deck by the proportional relief valve (PRV) in the hydraulic control manifold. The front and left deck relief valves are set at 207 bar (3000 PSI) and the right deck relief valve is set at 138 bar (2000 PSI).
PTO Mow Circuit Cutting Deck Blade Braking G1 M1 P1 OR2 1.5 CID .025” SQ 10 PSI 110 PSI RV LC1 PUMP FLOW PRV 3000 PSI 10 PSI 600 PSI M2 P2 LC2 OR1 .063” CD LEFT DECK RETURN PTO SWITCH OFF PRV NOT ENERGIZED LC1 SHIFTED g287723 Figure 44 When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, deck manifold proportional relief valve (PRV) is de−energized causing logic cartridge (LC1) to shift (refer to PTO Mow Circuit (page 5–28)).
PTO Mow Circuit Cutting Deck Blade Braking (continued) G1 M1 P1 OR2 .025” SQ 1.5 CID 10 PSI LC1 PUMP FLOW RV 110 PSI PRV 3000 PSI 10 PSI 600 PSI M2 P2 LC2 OR1 .063” CD LEFT DECK PTO SWITCH OFF PRV NOT ENERGIZED LC1, RV AND LC2 SHIFTED RETURN g287725 Figure 46 The inertia of the rotating cutting blades, however, effectively turns the deck motor into a pump causing an increase in pressure as the flow from the motor comes up against the closed logic cartridge (LC2).
Groundsmaster® 5900 & 5910 16227SL Rev D Page 5–33 M4 M5 E L 0.032” T BREATHER TRACTION PUMP S2 6.1 CID 21.7 GPM 21.7 GPM 10.6 GPM P 1.03 CID 2.11 CID 2.11 CID FROM FRONT DECK MANIFOLD AND STEERING UNIT FROM LEFT AND RIGHT DECK CIRCUITS RETURN FILTER 36 PSI FROM FRONT AND RIGHT DECK MANIFOLDS TO LEFT DECK MANIFOLD P1 PORT TO FRONT DECK MANIFOLD P1 PORT TO HYDRAULIC RESERVOIR STEERING UNIT R STEER CYLINDERS L2 4.15 CID 0.
A three (3) section gear pump is coupled to the piston (traction) pump. The gear pump section furthest from the piston pump supplies hydraulic flow to the steering, cutting deck lift and traction charge circuits. Hydraulic flow from the final pump section is directed to the appropriate circuits by a pressure compensator valve located in the steering/deck lift control manifold. The steering control valve is a closed center, load sensing valve.
Steering Relief Operation When the steering cylinders reach the end of their stroke or if a rear wheel should encounter an obstruction (e.g. a curb) while steering, the pressure in the steering circuit will rise. Relief valve (RV1) in the steering/deck lift manifold senses this pressure increase. When steering circuit pressure builds to approximately 145 bar (2100 PSI), relief valve (RV1) opens and allows hydraulic flow to return to the hydraulic reservoir.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see Special Tools (page 2–15)). Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply, filter, binding linkages, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.
Precautions for Hydraulic Testing (continued) WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved and all rotating machine parts must be stopped. Stop engine; lower or support attachments. 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of hydraulic components. 2.
Which Hydraulic Tests Are Necessary? (continued) 3. If a lift circuit problem exists, consider performing one or more of the following tests: Lift/Lower Circuit Relief Pressure, Counterbalance Pressure and/or Gear Pump Flow Tests. 4. If a steering circuit problem exists, consider performing one or more of the following tests: Steering Circuit Relief Pressure, Steering Cylinder Internal Leakage and/or Gear Pump Flow Tests.
Traction Circuit Charge Pressure Test (Using Pressure Gauge) C3 C4 C2 OR3 .088” C5 OR5 .138” S9 S4 S5 S2 G3 OR2 S6 S3 .055” OR4 .046” RV2 .055” S8 G4 5 PSI CL CV1 1500 PSI RV3 G2 LS CF CH3 340 PSI LC TO STEERING UNIT PORT P S7 OR6 S1 TO STEERING UNIT PORT E C6 OR7 .088” OR1 .030” RV1 80 PSI G1 S10 BRK CV2 50 PSI CV3 OR8 2100 PSI TO BRAKE RELEASE MANIFOLD 4 PSI .
Procedure for Traction Circuit Charge Pressure Test (continued) FRONT 1 2 g287734 Figure 49 1. Steering/lift manifold 2. Port CH1 test fitting 2 FRONT 1 g287735 Figure 50 1. Piston pump 2. Charge relief valve 4. Connect a 70 Bar (1000 PSI) pressure gauge with hydraulic hose attached to test fitting on steering/deck lift manifold port CH1 (Figure 49). Route gauge hose to allow operator to view the gauge. 5. After installing pressure gauge, start engine and run at low idle speed.
Procedure for Traction Circuit Charge Pressure Test (continued) 9. If there is no pressure, or pressure is low, check the following items: A. Restriction in gear pump intake line or reservoir strainer. B. Inspect charge pressure relief valve located in the piston pump and adjust if necessary (see Sauer− Danfoss H1 Closed Circuit Axial Piston Pumps Service Manual). Keep in mind that operating the machine with an elevated charge pressure can reduce swash−plate response time. C.
Traction Circuit Relief Pressure Test (Using Pressure Gauge) FORWARD RELIEF PRESSURE TEST SHOWN TO FRONT DECK MANIFOLD P1 PORT TO STEERING/DECK LIFT MANIFOLD PORT P1 FROM STEERING/LIFT MANIFOLD TO LEFT DECK MANIFOLD P1 PORT PORT T AND FRONT LIFT CYLINDERS FROM STEERING/LIFT MANIFOLD PORT CL 10.6 GPM FROM STEERING/DECK LIFT MANIFOLD CH2 PORT PRESSURE GAUGE M14 21.7 GPM TO TRACTION MANIFOLD P1 PORT S2 S1 21.7 GPM E MA A 0.032” 2.11 CID FORWARD 5080 PSI M5 1.03 CID 42.7 GPM 0.032” 2.
Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature (54 to 66 ºC (130 to 150 ºF)) by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. CAUTION Perform Traction Circuit Relief Pressure Test in an open area, away from people and obstructions. 2. Drive machine to an open area, fully raise cutting decks, engage parking brake and turn the engine off. FRONT 1 3 4 2 g287737 Figure 52 1.
Procedure for Traction Circuit Relief Pressure Test (continued) 9. If traction relief pressure is low, make sure that bypass (tow) valves in traction pump are fully seated. Then, inspect traction pump relief valves (Figure 52). Clean or replace valves as necessary. These cartridge type valves are factory set and are not adjustable. If relief valves are in good condition, piston (traction) pump or wheel motors should be suspected of wear and inefficiency.
C3 C4 C2 OR3 .088” C5 OR5 .138” S9 S5 S2 OR2 S6 S3 .055” OR4 .046” RV2 .055” S8 G4 5 PSI CL CV1 1500 PSI RV3 G2 LS CF CH3 340 PSI LC TO STEERING UNIT PORT P S7 OR6 S1 TO STEERING UNIT PORT E C6 OR7 .088” S4 G3 PRESSURE GAUGE Counterbalance Pressure Test (Using Pressure Gauge) OR1 .030” RV1 80 PSI G1 S10 BRK CV2 50 PSI CV3 OR8 2100 PSI TO BRAKE RELEASE MANIFOLD 4 PSI .
Procedure for Counterbalance Pressure Test (continued) FRONT 3 1 2 g287739 Figure 54 1. Steering/lift manifold 2. Test fitting (port G4) 3. Counterbalance valve 4. Connect a 70 Bar (1000 PSI) pressure gauge to test fitting in port G4 on steering/deck lift control manifold (Figure 54). 5. After installing pressure gauge, start engine and run at low idle speed. Check for hydraulic leakage at tester connections and correct before proceeding with test. 6.
Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter) TO STEERING/DECK LIFT MANIFOLD PORT P1 TO FRONT DECK MANIFOLD P1 PORT 10.6 GPM TO LEFT DECK MANIFOLD P1 PORT TRACTION MANIFOLD FROM STEERING/DECK LIFT MANIFOLD CH2 PORT P1 M14 21.7 GPM S2 TESTER S1 21.7 GPM E MA A 0.032” FORWARD 5080 M5 1.03 CID 2.11 CID 42.7 GPM 0.032” PSI 2.11 CID 4.
CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. Procedure for Piston (Traction) Pump Flow Test 1. Park machine on a level surface, raise and lock the cutting decks, disengage PTO, engage parking brake and stop engine. Remove key from key switch. Make sure hydraulic oil is at normal operating temperature (54 to 66 ºC (130 to 150 ºF)).
Procedure for Piston (Traction) Pump Flow Test (continued) 4. Install 40 GPM tester (flow and pressure) in series between disconnected hose and manifold fitting to allow flow from piston (traction) pump to tester. Use hydraulic hose kit (see Special Tools (page 2–15)) to connect tester to machine. Make sure that fitting and hose connections are properly tightened. Also, make sure the flow control valve on tester is fully open. 5. After installing tester, start engine and run at low idle speed.
Cutting Deck Circuit Pressure Test (Using Pressure Gauge) PRESSURE GAUGE G1 M1 P1 OR2 .025” FRONT DECK CIRCUIT PRESSURE TEST SHOWN SQ 1.5 CID 110 PSI RV PRV LC1 3000 PSI 10 PSI M2 10 PSI P2 600 PSI LC2 OR1 FROM STEERING UNIT T PORT CD FRONT DECK G1 M1 P1 OR2 1.5 CID .025” SQ 10 PSI LC1 FROM STEERING/LIFT MANIFOLD T PORT AND CENTER DECK LIFT CYLINDERS PRV RV 110 PSI 3000 PSI 10 PSI 600 PSI M2 P2 TO STEERING/LIFT MANIFOLD CL PORT LC2 OR1 .
CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature (54 to 66 ºC (130 to 150 ºF)) by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2.
Procedure for Cutting Deck Circuit Pressure Test (continued) 5. After installing pressure gauge, start engine and run at low idle speed. Check for hydraulic leakage at tester connections and correct before proceeding with test. CAUTION Keep away from cutting decks during test to prevent personal injury from the cutting blades. 6. Sit on seat and operate the engine at high idle speed (2530 RPM). Release parking brake and engage the cutting decks. 7.
Cutting Deck Circuit Relief Pressure Test (Using Tester with Pressure Gauge and 40 GPM Flow Meter) TESTER G1 M1 P1 OR2 .025” FRONT CUTTING DECK CIRCUIT RELIEF PRESSURE TEST SHOWN SQ 1.5 CID 110 PSI M2 RV PRV 3000 PSI 10 PSI 600 PSI LC2 10 PSI LC1 P2 OR1 FROM STEERING UNIT T PORT CD FRONT DECK G1 M1 P1 OR2 .025” SQ 1.
CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. Procedure for Cutting Deck Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature (54 to 66 ºC (130 to 150 ºF)) by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2.
Procedure for Cutting Deck Circuit Relief Pressure Test (continued) IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow from the manifold, through the tester and into the disconnected hydraulic hose. 4. Install 40 GPM tester (flow and pressure) in series between the deck manifold port M1 and the disconnected hose. Make sure the flow control valve on tester is fully open.
Cutting Deck Motor Case Drain Leakage Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter) G1 M1 1.5 CID P1 OR2 .025” TESTER SQ 110 PSI RV STEEL CAP 10 PSI LC1 3000 PSI 10 PSI M2 P2 600 PSI LC2 MEASURING CONTAINER PRV TEST FOR FRONT DECK MOTOR SHOWN OR1 FROM STEERING UNIT T PORT CD FRONT DECK G1 M1 P1 OR2 1.5 CID .
Note: One method to find a failing or malfunctioning deck motor is to have a second person observe the machine while mowing in dense turf. A bad motor will run slower, produce fewer clippings and may cause a different appearance on the turf. IMPORTANT To prevent hydraulic tester damage, use 40 GPM Hydraulic Tester #AT40002 (pressure and flow) and Hose Kit for this test (see Special Tools (page 2–15)). Note: Two people will be required to complete the following test procedure.
Procedure for Deck Motor Case Drain Leakage Test (continued) 3. Install 40 GPM tester (flow and pressure) in series with the deck motor and the disconnected return hose. Make sure the flow control valve on tester is fully open. 4. Start engine and run at low idle speed. Check for hydraulic leaks at tester connections and make corrections if necessary before proceeding with test. 5.
Procedure for Deck Motor Case Drain Leakage Test (continued) 12. When testing is complete, disconnect tester from motor and hydraulic hose. Reconnect return hose to the deck motor. Remove cap from the PTO manifold tee fitting or hydraulic tube and reconnect case drain hose. 13. Repeat test for additional deck motors if required. 14. When testing is complete, make sure that the hydraulic tank is full before returning machine to operation. Groundsmaster® 5900 & 5910 16227SL Rev D GPM Milliliters in 15 sec.
Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge) C3 C4 C2 OR3 .088” C5 OR5 .138” OR7 .088” S9 S4 S5 S2 G3 OR2 S6 S3 .055” OR4 .046” RV2 LS CF G4 5 PSI CL CV1 1500 PSI CH3 340 PSI LC OR1 .030” RV1 80 PSI G1 PRESSURE GAUGE .055” S8 RV3 G2 TO STEERING UNIT PORT P S7 OR6 S1 TO STEERING UNIT PORT E C6 S10 BRK CV2 50 PSI CV3 OR8 2100 PSI TO BRAKE RELEASE MANIFOLD 4 PSI .
Procedure for Lift/Lower Circuit Relief Pressure Test (continued) FRONT 1 3 2 g287779 Figure 67 1. Steering/lift manifold 2. Test fitting (port G1) 3. Relief valve RV2 5. Connect a 350 Bar (5000 PSI) pressure gauge with hydraulic hose attached to test fitting in port G1 on steering/ deck lift manifold (Figure 67). Route gauge hose to allow operator to view the gauge. 6. After installing pressure gauge, start engine and run at idle speed.
Procedure for Lift/Lower Circuit Relief Pressure Test (continued) 12. If lift/lower relief pressure is too low, check for restriction in gear pump inlet line or reservoir strainer. Also, check the lift cylinder for internal leakage. If cylinder is not leaking, adjust the relief valve (RV2) so that relief pressure is correct (see Adjust Manifold Relief Valves (page 5–72)). The relief valve (RV2) is located on the top of the steering/deck lift manifold (Figure 67).
Steering Circuit Relief Pressure Test (Using Pressure Gauge) STEERING WHEEL TURNED FOR LEFT TURN STEER CYLINDERS LH WING DECK LIFT FRONT DECK LIFT C3 C4 C2 OR3 .088” R RH WING DECK LIFT C5 C6 OR7 .088” OR5 .138” L S9 S4 S5 S2 S6 S3 S7 S8 G4 OR2 .055” 6.1 CID OR4 .046” OR6 .055” G3 STEERING UNIT P E 5 PSI CL CV1 T 1500 PSI S1 RV2 RV3 G2 TO HYDRAULIC RESERVOIR LS CH3 340 PSI OR1 .
Procedure for Steering Circuit Relief Pressure Test (continued) FRONT 1 3 2 g287791 Figure 69 1. Steering/lift manifold 2. Test fitting (port G1) 3. Relief valve RV1 5. Connect a 350 Bar (5000 PSI) pressure gauge with hydraulic hose attached to test fitting in port G1 on steering/ deck lift manifold (Figure 69). Route gauge hose to allow operator to view the gauge. 6. After installing pressure gauge, start engine and run at idle speed.
Steering Cylinder Internal Leakage Test FULLY EXTENDED FULLY RETRACTED STEER CYLINDERS LOOK FOR LEAKAGE PLUG STEERING WHEEL TURNED FOR LEFT TURN R L STEERING UNIT 6.1 CID P E T TO HYDRAULIC RESERVOIR FROM STEERING/DECK LIFT MANIFOLD PORT LS FROM STEERING/DECK LIFT MANIFOLD PORT CF g287792 Figure 70 The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if a steering cylinder is faulty.
Procedure for Steering Cylinder Internal Leakage Test 1. Make sure hydraulic oil is at normal operating temperature (54 to 66 ºC (130 to 150 ºF)). 2. Park machine on a level surface, lower cutting decks fully, disengage PTO, engage parking brake and stop engine. Remove key from key switch. 3. Turn the steering wheel so the steering cylinder rod of the cylinder to be tested is fully extended. 4. Thoroughly clean the area around the hydraulic hose at the rod end of the steering cylinder to be tested.
Gear Pump (PTO, Steering, Deck Lift/Lower and Traction Charge Circuits) Flow Test (Using Tester with Pressure Gauges and Flow Meter) THIRD GEAR PUMP SECTION FLOW TEST SHOWN TO STEERING/DECK LIFT MANIFOLD PORT P1 TESTER TO FRONT DECK MANIFOLD P1 PORT FROM STEERING/LIFT MANIFOLD TO LEFT DECK MANIFOLD P1 PORT PORT T AND FRONT LIFT CYLINDERS FROM STEERING/LIFT MANIFOLD PORT CL 10.6 GPM FROM STEERING/DECK LIFT MANIFOLD CH2 PORT TO TRACTION MANIFOLD M14 21.7 GPM P1 PORT S2 S1 21.7 GPM E MA A 0.
1 2 3 FRONT g287815 Figure 73 1. First gear pump section (side decks) 2. 2nd gear pump section (front deck) 3. 3rd gear pump section (steering, lift/lower, charge) The gear pump flow test should be performed to make sure that the mow, steering, cutting deck lift/lower and traction charge circuits have adequate hydraulic flow. Gear pump sections are illustrated in Figure 73. The first gear pump section provides hydraulic flow for both wing cutting decks.
Procedure for Gear Pump Flow Test (continued) 2 1 X 3 RIGHT FRONT 4 g287816 Figure 74 1. 1st pump section hose 3. 2nd pump section hose 2. Left deck manifold P1 4. Front deck manifold P1 2. Determine which gear pump section is to be tested. Thoroughly clean and then disconnect hydraulic hose from appropriate manifold fitting for gear pump section that is to be tested: A. For 1st gear pump section (side deck flow), disconnect hydraulic hose from fitting in left deck manifold port P1 (Figure 74).
Procedure for Gear Pump Flow Test (continued) IMPORTANT To prevent hydraulic tester damage, use 40 GPM Hydraulic Tester #AT40002 (pressure and flow) and Hose Kit for this test (see Special Tools (page 2–15)). IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow from the hydraulic hose from the pump, through the tester and into the manifold fitting. 3.
Procedure for Gear Pump Flow Test (continued) 10. If a pressure of 69 bar (1000 PSI) cannot be obtained or flow was less than the minimum flow listed in above table, check for restriction in the pump inlet line. If inlet line is not restricted, consider that the tested gear pump section is worn or damaged. 11. After testing is completed, disconnect tester from hydraulic hose and fitting in manifold.
Adjustments Adjust Manifold Relief Valves 1 2 3 g287873 Figure 76 1. Relief valve 2. Valve cap 3. Adjustment socket The steering/deck lift manifold includes adjustable pressure relief valves. An adjustment may be required to these valves if testing determines that the circuit pressure setting is incorrect (see Testing (page 5–36)). Use the following process if a valve adjustment is required. Note: Do not remove the valve from the hydraulic manifold for adjustment. 1.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from the key switch. 2. Read and be familiar with all procedure steps before starting to remove, repair, replace or install hydraulic system components. 3.
After Repair or Replacement of Components (continued) 6. If piston (traction) pump, front wheel motors or rear axle motor was removed from machine for service, fill housing through case drain with new hydraulic oil before starting engine. This will ensure that internal components have adequate lubrication during initial operation. 7. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is out of system (see Charge Hydraulic System (page 5–79)). 8.
Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.
Priming Hydraulic Pumps Whenever the hydraulic system is flushed, the hydraulic system is charged or hydraulic components are installed, it is important to properly prime the hydraulic pumps. Hydraulic pump priming ensures that the gear pump and piston (traction) pump have adequate oil during initial start−up and running. The pumps can be primed by using a remote starter switch (see Special Tools (page 2–15)) to crank engine which allows the pumps to prime.
Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT If a component failure occurred in the closed loop traction circuit (e.g. piston pump or wheel motor), filtering the traction circuit is recommended. See Filtering Closed−Loop Traction Circuit (page 5–81). 1.
Flush Hydraulic System (continued) 8. Fill hydraulic reservoir with new hydraulic fluid. 9. Prime hydraulic pumps (see Priming Hydraulic Pumps (page 5–76)). 10. Charge the hydraulic system (see Charge Hydraulic System (page 5–79)). 11. Check condition of hydraulic oil. If the new fluid shows any signs of contamination, repeat steps 1 through 11 again until oil is clean. 12. Assume normal operation and follow recommended maintenance intervals.
Charge Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system to reduce the chance of component damage. IMPORTANT Change hydraulic oil filters whenever hydraulic components are repaired or replaced. 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from the key switch. 2.
Charge Hydraulic System (continued) 9. After the hydraulic system starts to show signs of fill, actuate a lift switch until the lift cylinder rod moves in and out several times. If the lift cylinder does not move after ten (10) to fifteen (15) seconds, or if the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose filter or suction lines. B. Blocked suction line. C. Faulty charge relief valve. D. Faulty gear pump. 10.
Filtering Closed−Loop Traction Circuit Filtering of a closed−loop hydraulic system after a major traction component failure (e.g. traction (piston) pump or wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed−loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
Filtering Closed−Loop Traction Circuit (continued) IMPORTANT While engaging the traction circuit, monitor the indicator on the high flow hydraulic filter. If the indicator should show red, either reduce pressure on the traction pedal or reduce engine speed to decrease hydraulic flow through the filter. 7. With engine running at low idle speed, slowly move the traction pedal to the forward direction to allow flow through the traction circuit and high flow filter.
Hydraulic Reservoir 8 7 6 9 10 27 5 4 7 6 26 2 3 1 12 13 25 15 24 14 16 143 to 155 N·m (105 to 115 ft−lb) 17 32 31 5 to 6 N·m (44 to 55 in−lb) 18 11 22 19 29 20 18 to 19 N·m 155 to 171 in−lb 28 30 21 29 5 to 6 N·m (44 to 55 in-lb) 33 34 35 23 g287876 Figure 79 1. Bushing 13. O−ring 25. Flange head screw 2. Elbow fitting 14. Stand pipe (4) 26. Hose clamp 3. Latch plate 15. Dipstick 27. Hose 4. Socket head screw (2) 16. Bushing (4) 28. O−ring 5.
Hydraulic Reservoir Removal (Figure 79) 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from key switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–73). 3. To prevent contamination of hydraulic system during hydraulic reservoir removal, thoroughly clean exterior of reservoir, fittings and hoses. IMPORTANT Follow all local codes and regulations when recycling or disposing hydraulic fluid. 4.
Inspection 1. Clean hydraulic reservoir and suction strainer with solvent. 2. Inspect reservoir for leaks, cracks or other damage. Hydraulic Reservoir Installation (Figure 79) 1. Install reservoir: A. Position reservoir in frame and install hold down bracket and cap screws. Install spacer, flat washer and cap screw at front of reservoir. B. Tighten drain plug (item 21) from 18 to 19 N·m (155 to 171 in−lb). C. Tighten suction strainer (item 22) from 143 to 155 N·m (105 to 115 ft−lb). 2.
Gear Pump 2 5 to 6 N·m (45 to 55 in-lb) 21 20 5 4 4 1 10 N·m (90 in-lb) 3 17 11 12 18 13 8 19 7 9 14 6 10 15 11 112 to 140 N·m (83 to 103 ft-lb) 12 13 14 16 g287889 Figure 81 1. Gear pump 8. 45 Elbow fitting 15. Hydraulic hose assembly 2. Piston pump 9. Flat washer (2) 16. Hydraulic hose assembly 3. O−ring 10. Cap screw (2) 17. Hose clamp (2) 4. 90 Elbow barb fitting (2) 11. O−ring (2) 18. Suction hose 5. Straight barb fitting 12. Mounting flange (4) 19.
Gear Pump Removal (Figure 81) (continued) 5. To prevent contamination of hydraulic system during pump removal, thoroughly clean exterior of pump and fittings. 6. Label all hydraulic hose connections for assembly purposes. 7. Disconnect all hydraulic lines from gear pump and two (2) hydraulic hoses from bottom of piston pump (items 15 and 16). Put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper reassembly.
Gear Pump Service 11 10 9 8 4 5 6 3 7 2 3 4 5 6 1 17 16 14 15 9 3 12 13 8 18 19 140 N·m (103 ft−lb) 20 21 6 5 4 14 3 4 5 29 6 27 25 22 23 24 23 16 26 30 28 22 26 45 N·m (33 ft-lb) 24 g287890 Figure 82 1. Front cover 2. Plug 12. Retaining ring 22. Uni−ring (2) 3. Sleeve bearing (8) 13. Shaft seal (2) 23. Pressure seal (2) 4. Uni−ring (4) 14. Idler shaft/gear (2) 24. Thrust plate (2) 5. Pressure seal (4) 15. Pump body − P2 25. Idler shaft/gear 6.
Gear Pump Disassembly (Figure 82) (continued) IMPORTANT Keep bodies, gears, flanges and thrust plates for each pump section together; do not mix parts between pump sections. 1. Plug pump ports and thoroughly clean exterior of pump with cleaning solvent. Make sure work area is clean. DIAGONAL LINE OIL IN P1 OIL OUT P2 P3 g287891 Figure 83 2. Use a marker to make diagonal lines across the gear pump sections for assembly purposes (Figure 83).
Gear Pump Disassembly (Figure 82) (continued) 8. Remove the thrust plates and seals from each pump section. Before removing each gear set, apply marking dye to mating teeth to retain ”timing”. Pump efficiency may be affected if the teeth are not installed in the same position during assembly. Keep the parts for each pump section together; do not mix parts between sections. Gear Pump Inspection 1. Remove any nicks and burrs from all parts with emery cloth.
Gear Pump Assembly (Figure 82) Note: When assembling the pump, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate body seals, pressure seals, uni−rings and thrust plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 1 4 3 2 g287893 Figure 85 1. 2. 3. 4. Drive shaft Shaft seal Dust seal Retaining ring 2.
Gear Pump Assembly (Figure 82) (continued) IMPORTANT Do not dislodge seals during installation. H. Align marker lines and slide the body over the gear assembly. A slight tap with a soft hammer on the pump body should be sufficient to engage the steel sleeves. 5. Repeat step 4 for pump section P2. 6. Install the four (4) cap screws with washers and hand tighten. IMPORTANT Prevent damage when clamping the pump in a vise; clamp on the front flange only. Also, use a vise with soft jaws. 7.
Traction Circuit 6 11 12 8 10 5 1 9 2 7 3 4 g287894 Figure 86 1. Piston (traction) pump 5. RH front wheel motor 9. Charge return to reservoir − out 2. Gear pump 6. RH rear wheel motor 10. Case drain to reservoir − out 3. 4. LH front wheel motor Traction manifold 7. 8. LH rear wheel motor Charge pressure − in 11. 12. Brake release manifold From steering/lift manifold − in Figure 86 illustrates the components that are used in the Groundsmaster traction circuit.
Piston (Traction) Pump 3 to 5 N·m (30 to 45 in−lb) 19 1 112 to 140 N·m (83 to 103 ft−lb) 10 18 7 8 9 2 5 4 5 11 6 115 to 120 N·m (85 to 89 ft−lb) 12 9 9 10 10 14 3 13 12 17 15 16 15 14 13 g287901 Figure 87 1. Piston (traction) pump 2. O−ring 3. Gear pump assembly 8. Straight fitting 15. Mounting flange (4) 9. Diagnostic fitting (3) 16. Hydraulic hose assembly Cap (3) 17. Hydraulic hose assembly 10. 4. Cap screw (2) 11. Straight fitting 18. Hose Clamp 5.
Piston (Traction) Pump Removal (Figure 87) (continued) 3. Remove drain plug from the hydraulic reservoir and drain reservoir into a suitable container. 4. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 2 3 1 g287906 Figure 88 1. Piston pump 2. Forward solenoid coil (S1) 3. Reverse solenoid coil (S2) 5. Label wire harness connectors that attach to the two (2) solenoid coils on left side of piston pump (Figure 88).
Piston (Traction) Pump Removal (Figure 87) (continued) 12. If hydraulic fittings are to be removed from piston pump, mark fitting orientation to allow correct assembly. Remove fittings from pump and discard O−rings. Piston (Traction) Pump Installation (Figure 87) 1. If fittings were removed from piston pump, lubricate and place new O−rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings.
Piston (Traction) Pump Installation (Figure 87) (continued) 8. Remove plugs and caps from disconnected hydraulic hoses and fittings of the pump assembly. Install hydraulic lines to correct location on gear and piston pumps (see Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9) and Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–7)). Tighten suction hose clamp from 3 to 5 N·m (30 to 45 in−lb). 9.
Piston (Traction) Pump Service 58 57 55 60 59 61 56 62 55 59 54 58 53 52 51 21 20 19 18 33 55 56 55 57 27 23 24 26 28 31 49 32 30 50 46 34 29 22 25 23 48 22 4 47 1 46 3 2 18 19 5 20 21 45 36 35 39 41 40 42 44 38 37 8 17 6 9 7 10 11 12 43 13 14 15 15 14 16 g287948 Figure 90 Hydraulic System: Service and Repairs Page 5–98 Groundsmaster® 5900 & 5910 16227SL Rev D
Figure 90 1. Housing 22. (continued) Plug with O−ring (2) 43. Adapter 2. Dowel pin (4) 23. Plug with O−ring (2) 44. Screw (4) 3. Gasket 24. Orifice (2) 45. Screw (2) 4. Valve plate 25. Screen (2) 46. High pressure relief valve (2) 5. Bearing 26. Dowel pin (2) 47. Charge pressure relief valve 6. Swashplate bearing kit 27. Feedback pin 48. Lifting lug 7. Swashplate 28. Shaft 49. Plug with O−ring (2) 8. Piston assembly 29. Roller bearing assembly 50.
Front Wheel Motors 4 3 3 2 1 5 183 to 224 N·m (135 to 165 ft−lb) 6 g287959 Figure 91 1. Front wheel motor 3. Hydraulic straight fitting (2) 5. Hydraulic elbow fitting 2. Hydraulic straight fitting 4. Hydraulic straight fitting 6. Cap screw (8) Front Wheel Motor Removal (Figure 91) 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from key switch.
Front Wheel Motor Removal (Figure 91) (continued) 3. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–73). 4. To prevent contamination of hydraulic system during motor removal, thoroughly clean exterior of motor, hydraulic tubes and fittings. 2 4 3 1 5 g287960 Figure 92 (LH Wheel Motor) 1. 2. 3. Disconnect/remove 1st Disconnect/remove 2nd Disconnect/remove 3rd 4. 5.
Front Wheel Motor Removal (Figure 91) (continued) 5. Disconnect or remove hydraulic tubes from the desired wheel motor in the order recommended (Figure 92 and Figure 93). It may be necessary to completely remove the hydraulic tube or loosen the opposite end of the hydraulic tube to allow wheel motor removal. If removed, mark or tag the tube positions for installation. 6. Put caps or plugs on disconnected hydraulic lines and fittings to prevent contamination.
Front Wheel Motor Installation (Figure 91) (continued) 4 2 3 5 1 g287962 Figure 94 (LH Wheel Motor) 1. 2. 3. Connect/install 1st Connect/install 2nd Connect/install 3rd 4. 5. Connect/install 4th Connect/install 5th 4 5 1 2 3 g287963 Figure 95 (RH Wheel Motor) 1. 2. 3. Connect/install 1st Connect/install 2nd Connect/install 3rd 4. 5. Connect/install 4th Connect/install 5th 3.
Front Wheel Motor Installation (Figure 91) (continued) 4. If previously removed, install the fuel tank (see Fuel System (page 4–17)) and/or the hydraulic reservoir (see Hydraulic Reservoir (page 5–83)). 5. Fill reservoir with new hydraulic fluid as required. 6. Check hydraulic system for leaks before returning the machine to service.
Rear Wheel Motors 3 2 1 2 91 to 112 N·m (67 to 83 ft−lb) 4 g287964 Figure 96 1. Rear wheel motor 3. Hydraulic straight fitting 2. Hydraulic straight fitting (2) 4. Cap screw (10) Note: The rear wheel motors on Groundsmaster 5900 and 5910 machines are identical. IMPORTANT If a wheel motor failure occurred, refer to Traction Circuit Component Failure (page 5–5) for information regarding the importance of removing contamination from the traction circuit. Rear Wheel Motor Removal (Figure 96) 1.
Rear Wheel Motor Removal (Figure 96) (continued) CAUTION Make sure wheel motor is properly supported before removing the mounting screws. The wheel motor assembly weighs approximately 32 kg (70 lb). 7. Remove ten (10) cap screws that secure rear wheel motor to the steering spindle and remove the wheel motor. 8. If necessary, remove fittings from wheel motor and discard fitting O−rings. Rear Wheel Motor Installation (Figure 96) 1.
Wheel Motor Service 3 2 4 4 4 1 5 4 4 g287965 Figure 97 (Rear Motor Shown) 1. Flange nut(6) 4. Seal kit 2. Rotating group 5. Cam 3. Radial clip (6) The front wheel motors on Groundsmaster 5900/5910 machines look identical but contain unique internal components for right side and left side application. To avoid interchanging front wheel motors on the machine, label front wheel motors RIGHT and LEFT for assembly purposes. The right and left rear wheel motors on the machines are identical.
Wheel Motor Service (continued) Note: Contact an Authorized Toro Distributor for wheel motor service and repair. The Poclain MS Series Service Manual is available to Authorized Toro Distributors in the Service Library of Toro Gateway. IMPORTANT If a wheel motor failure occurred, refer to Traction Circuit Component Failure (page 5–5) for information regarding the importance of removing contamination from the traction circuit.
Traction Control Manifold 4 3 2 2 1 g288015 Figure 98 1. Traction control manifold 3. Mounting bracket 2. Flange head cap screw (6) 4. Flange nut Note: The ports on the traction control manifold are marked for easy identification of components.
1 6 1 g288016 Figure 99 1. Manifold block 5. Straight fitting 2. Straight fitting (7) 6. Dust cap 3. Straight fitting 7. Diagnostic fitting 4. Straight fitting (2) 8. Elbow fitting 9. 10. Elbow fitting (2) Elbow fitting Traction Control Manifold Removal (Figure 98) 1. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–73). 2.
Traction Control Manifold Removal (Figure 98) (continued) CAUTION Make sure hydraulic manifold is properly supported before removing the mounting screws. The hydraulic manifold assembly weighs approximately 50 kg (110 lb). 5. Remove hydraulic manifold from the frame. 6. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O−rings. Traction Control Manifold Installation (Figure 98) 1.
Traction Control Manifold Service 1 2 (T7) 3 (T7) 4 (T3) 5 (T4) 6 (T3) 7 (T7) 3 (T7) 6 (T3) 7 (T7) 3 (T7) 8 (T3) FRONT 18 (T4) 17 (T4) 10 (T8) 2 (T7) 6 (T3) 3 (T7) 7 (T7) 3 (T7) 7 (T7) 6 (T3) 12 16 (T5) 3 (T7) 8 (T3) 10 (T8) 11 (T4) 9 (T6) 13 (T3) 15 14 (T1) 3 (T7) 10 (T8) 6 (T3) 1 3 (T7) 19 (T6) 3 (T7) 20 (T2) 21 (T6) 7 (T7) 8 (T3) 6 (T3) 6 (T3) 3 (T7) FRONT 21 (T6) 3 (T7) 6 (T3) g288017 Figure 100 1. Manifold block 8. #4 zero−leak plug with O−ring (3) 15.
The ports on the traction control manifold are marked for easy identification of components. Example: P1 is the piston pump connection port for the forward direction and SV is the location for the high/low speed solenoid valve (see A Hydraulic Schematic (page A–5) to identify the function of the hydraulic lines and cartridge valves at each port). Although not recommended in most situations, relief valve RV1 and check valve CV5 are adjustable (see Adjust Manifold Relief Valves (page 5–72)).
Brake Release Manifold 10 1 3 2 9 6 7 5 8 5 4 g288018 Figure 101 1. Brake release manifold 5. Washer (4) 2. Flat washer (2) 6. Grommet (2) 3. Cap screw (2) 7. Spacer (2) 4. Hydraulic tube − from manifold 8. Bulkhead nut (2) 9. 10. Hydraulic tube − to brake Flange nut (2) Both front wheel motors include a multi−disc parking brake that engages when hydraulic pressure is not present (e.g. engine is running and parking brake switch is set to ON or engine is not running).
Brake Release Manifold Installation (Figure 101) 1. If fittings were removed from manifold, lubricate and place new O−rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. Tighten hydraulic fittings to torque value provided (Figure 102). For information on tightening procedures for hydraulic fittings, see Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9). 2.
Brake Release Manifold Service 34 N·m (25 ft−lb) 34 N·m (25 ft−lb) 34 N·m (20 ft−lb) 6 3 2 4 1 1 FRONT 34 N·m (20 ft−lb) 4 7 FRONT 5 8 34 N·m (25 ft−lb) 34 N·m (25 ft−lb) g288019 Figure 102 1. Manifold block 4. #6 zero−leak plug − with O−ring (2) 7. Hydraulic elbow 2. Hand pump − HP 5. #6 zero−leak plug with O−ring Hydraulic straight fitting 3. Manual valve − MV (pull to open 0) 6. Relief valve − RV 8.
Cutting Deck Circuit 6 8 10 4 1 9 5 7 2 6 3 6 g288020 Figure 103 1. Piston (traction) pump 5. Left wing deck control manifold 2. Gear pump 6. Cutting deck motor (3) 3. 4. Front deck control manifold Right wing deck control manifold 7. 8. Suction from reservoir − in Return to oil cooler − out 9. Wing case drain to reservoir − out 10. Front case drain to reservoir − out Figure 103 illustrates the components that are used in the Groundsmaster cutting deck circuit.
Cutting Deck Motor 4 1 3 2 5 7 8 9 6 37 to 44 N·m (27 to 33 ft−lb) 10 11 15 12 13 14 g288021 Figure 104 Front Deck Motor Shown 1. Cutting deck motor 6. Hydraulic hose − pressure 11. Washer 2. Flange head screw (2) 7. Hydraulic fitting 12. Spider 3. 45º hydraulic fitting 8. Hydraulic hose − case drain 13. Motor mount 4. Hydraulic hose − return 9. Woodruff key 14. Spindle assembly 5. Hydraulic fitting 10. Coupler hub 15.
Cutting Deck Motor Removal (Figure 104) (continued) 8. If required, remove hex nut and washer that secure coupler hub to motor shaft. Use suitable puller to remove hub from shaft. Remove woodruff key. Cutting Deck Motor Installation (Figure 104) Rotation Direction 1 2 3 g288022 Figure 105 1. 2. Flow − in Flow − out 3. Case drain 1. If fittings were removed from deck motor, lubricate and place new O–rings onto fittings.
Cutting Deck Motor Service 45 N·m (33 ft-lb) 16 15 11 8 7 5 4 14 12 10 6 13 7 9 1 2 3 1 12 13 6 g288023 Figure 106 1. Shaft seal (2) 7. Front thrust plate 13. Seal (2) 2. Retaining ring 8. Drive gear 14. Rear cover 3. Flange washer 4. Front flange Idler gear 15. Cap screw (4) 10. 5. 6. 9. Rear thrust plate 16. Washer (4) Pressure seal (5) 11. Body Backup gasket (6) 12. Dowel pin (4) Cutting Deck Motor Disassembly (Figure 106) 1.
Cutting Deck Motor Disassembly (Figure 106) (continued) IMPORTANT Prevent damage when clamping the motor into a vise; clamp on the front flange only. Also, use a vise with soft jaws. 3. Clamp front flange of motor in a vise with soft jaws with the shaft end down. 4. Loosen cap screws from the rear cover. 5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. 6. Separate rear cover from body. Lift rear cover from motor.
Cutting Deck Motor Disassembly (Figure 106) (continued) IMPORTANT Make sure to not damage the front flange counter bore when removing the seals from the front flange. 11. Carefully remove outer shaft seal, retaining ring, flange washer and inner shaft seal from the front flange (Figure 108). Discard removed seals. Cutting Deck Motor Inspection 1. Remove any nicks and burrs from all parts with emery cloth. CAUTION Use goggles or other appropriate eye protection when using compressed air for drying parts.
Cutting Deck Motor Assembly (Figure 106) Note: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O–rings, pressure seals, back−up gaskets and thrust plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic fluid. 2. Install new seals into front flange (Figure 108): A. Press inner shaft seal into front flange until it reaches the bottom of the bore. B.
Cutting Deck Motor Assembly (Figure 106) (continued) 16. Place front flange of the motor into a vise with soft jaws and alternately torque the cap screws 45 N·m (33 ft−lb). 17. Remove motor from vise. 18. Place a small amount of clean hydraulic fluid in the inlet of the motor and rotate the drive shaft away from the inlet one revolution. If any binding is noted, disassemble the motor and check for assembly problems.
Cutting Deck Control Manifolds 7 2 4 5 8 4 5 6 3 6 1 5 6 4 g288131 Figure 110 1. Front Deck control manifold 4. Cap screw (6) 7. Main frame 2. RH Deck control manifold 5. Flat washer (6) 8. Front axle frame 3. LH Deck control manifold 6. Flange nut (6) The control manifolds for the three cutting deck sections are very similar. Note: When servicing the control manifolds, DO NOT interchange parts from one control manifold to another.
Cutting Deck Control Manifold Removal (Figure 110) (continued) 7. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O−rings. Cutting Deck Control Manifold Installation (Figure 110) 102 N·m (75 ft−lb) 4 34 N·m (25 ft−lb) 2 3 102 N·m (75 ft−lb) 4 5 102 N·m (75 ft−lb) 6 34 N·m (25 ft−lb) 1 FRONT g288132 Figure 111 Front Deck Control Manifold 1. Front control manifold 4.
Cutting Deck Control Manifold Installation (Figure 110) (continued) 5 102 N·m (75 ft−lb) 2 34 N·m (25 ft−lb) 3 102 N·m (75 ft−lb) 4 4 102 N·m (75 ft−lb) 6 1 FRONT 34 N·m (25 ft−lb) g288134 Figure 113 LH Deck Control Manifold 1. LH control manifold 4. Hydraulic 90º fitting (3) 2. Dust cap 5. Straight fitting 3. Diagnostic fitting 6. Hydraulic 90º fitting 1. If fittings were removed from manifold: A. Lubricate new O−rings with clean hydraulic oil.
Cutting Deck Control Manifold Service 27 N·m (20 ft−lb) 9 8 7 N·m (5 ft−lb) 7 2 68 N·m (50 ft−lb) 6 3 34 N·m (25 ft−lb) 27 N·m (20 ft−lb) 10 4 11 12 27 N·m (20 ft−lb) 68 N·m (50 ft−lb) 5 1 g288145 Figure 114 1. Manifold body 5. #8 zero−leak plug with O−ring 2. Nut 6. Logic element (LC1 & LC2) 10. 9. #6 zero−leak plug with O−ring Sequence valve (SQ) 3. Solenoid coil 7. Relief valve (RV) 11. Orifice 0.063 in. (OR1) − RH and LH control manifolds only 4.
IMPORTANT An orifice is placed beneath the plug in the OR1 port of the LH and RH cutting deck control manifolds only. If the plug is removed, make sure to remove the orifice and label its position for assembly purposes. The front cutting deck control manifold has an additional zero leak plug instead of an orifice in the OR1 port. When servicing the deck control manifolds, DO NOT interchange parts from one control manifold to another. Note: The cutting deck control manifolds include several zero−leak plugs.
Steering and Cutting Deck Lift Circuits 3 12 1 8 2 11 10 9 4 5 6 8 7 g288146 Figure 115 1. Piston (traction) pump 5. Steering cylinder (2) 2. Gear pump 6. Front deck lift cylinder − RH 10. 9. Suction from reservoir − in Return to reservoir − out 3. Steering/lift control manifold 7. Front deck lift cylinder − LH 11. 4. Steering control valve 8. Wing deck lift cylinder (2) 12.
Steering Control Valve (For machines serial number below 403450000) 1 4 2 3 28 to 35 N·m (20 to 26 ft−lb) 5 6 47 to 56 N·m (34 to 42 ft−lb) 47 to 56 N·m (34 to 42 ft−lb) 9 10 8 7 11 12 8 13 14 15 16 17 11 18 19 20 21 g288151 Figure 116 8. Flange head screw (7) 15. Lower mounting plate 9. 1. Steering wheel cover 2. Hex nut 3. Flat washer 4. 5. 6. Steering column assembly 13. Upper mounting plate 20. Hydraulic fitting (5) 7. Steering cover 14. Rubber mount (4) 21.
Steering Control Valve Removal (Figure 116) 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from the key switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–73). 3. Remove the steering cover and slide the steering column boot upward (see Steering Column (For machines serial number below 403450000) (page 7–5)). 4.
Steering Control Valve Installation (Figure 116) (continued) 3. Hold steering column in position on machine and slide steering control valve onto lower end of steering column. Secure steering column and steering control valve to machine with four (4) cap screws. Tighten cap screws from 47 to 56 N·m (34 to 42 ft−lb). 4. Remove hydraulic caps or plugs installed during removal to prevent contamination. 5.
Steering Control Valve (For machines serial number above 403450001) g301554 Figure 118 1. Steering wheel cover 2. Hex nut Steering control valve 17. Bolt (2 each) 10. 3. 4. 9. Bolt (4 each) 18. Lock washer (2 each) Flat washer 11. Nut (14 each) 19. Speed nut (2 each) Steering wheel 12. Washer (4 each) 20. Bolt (4 each) 5. Foam collar 13. Mount (4 each) 21. Clip (2 each) 6. Steering shaft 14. Mount assembly 22. Column support 7. Bolt (4 each) 15.
Removal (Figure 118) (continued) 4. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–73). 5. To prevent contamination of the hydraulic system during steering control valve removal, thoroughly clean the exterior of the control valve and fittings. 6. For assembly purpose, label all the hydraulic connections. Note the port designations on the steering control valve.
Removal (Figure 118) (continued) g278284 Figure 120 1. Steering control valve 6. O-ring 2. O-ring 7. 90º hydraulic fitting 3. Straight fitting 8. O-ring 4. O-ring 9. 5. O-ring 10. 45º hydraulic fitting O-ring Installation (Figure 118) 1. If the hydraulic fitting were removed from the steering valve, lubricate the new O-ring with clean hydraulic fluid, position the O-rings to the fittings.
Steering Control Valve Service (For machines serial number below 40345000) 17 11 18 8 7 5 19 16 3 1 2 4 6 9 20 10 15 21 12 13 23 14 22 17 N·m (150 in−lb) 16 to 18 N·m (140 to 160 in−lb) g288163 Figure 121 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. Cap screw (7) 17. Gerotor drive 10. End cap 18. Wear plate 11. O−ring 19. Bearing race 12. Seal ring 20. Thrust bearing 13.
Steering Control Valve Service (For machines serial number above 403450001) g278299 Figure 122 1. Pin bolt 2. Bolt (4 each) Distributor plate 17. Shaft seal 10. 3. 4. 9. Cardan shaft 18. Thrust washer (2 each) Washer (5 each) 11. Plug 19. Bearing End cover 12. Plug 20. Ring 5. Tube (2 each) 13. spring 21. Spring set 6. Inner gearwheel 14. Relief valve 22. Spool 7. O-ring (3 each) 15. Dust sealing ring 23. Cross pin 8. Outer gearwheel 16. Housing 24.
Steering Cylinders 1 7 5 6 1 3 40 to 61 N·m (30−to 45 ft−lb) 2 4 5 6 40 to 61 N·m (30−to 45 ft−lb) g288164 Figure 123 1. Steering cylinder 4. Cap screw 2. Ball joint 5. Slotted hex nut 3. Lock nut 6. Cotter pin 7. Tie rod assembly Steering Cylinder Removal (Figure 123) 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from the key switch. 2.
Steering Cylinder Removal (Figure 123) (continued) 6. Use a suitable puller (pickle fork) to separate ball joints from rear axle and steering spindle. 7. If hydraulic fittings are to be removed from steering cylinder, mark fitting orientation to allow correct assembly. Remove fittings from steering cylinder and discard O−rings from fittings. Steering Cylinder Installation (Figure 123) 1. If fittings were removed from steering cylinder, lubricate and place new O−rings onto fittings.
Steering Cylinder Service 2 1 3 54 N·m (40 ft−lb) 7 4 5 8 9 13 14 6 15 16 10 11 12 17 18 g288165 Figure 124 1. Ball joint 7. Barrel 13. O−ring 2. Grease fitting 8. Lock nut 14. Back−up ring 3. 4. Jam nut Cotter pin 9. 10. Piston Piston seal 15. 16. Rod seal Rod wiper 5. Castle nut 11. O−ring 17. Internal collar 6. Roll pin 12. Head 18. Piston rod Steering Cylinder Disassembly (Figure 124) 1. Remove oil from steering cylinder by slowly pumping the piston rod.
Steering Cylinder Disassembly (Figure 124) (continued) 9. If necessary, remove barrel end ball joint (item 1) from barrel as follows: A. Loosen jam nut (item 3). B. Drive roll pin (item 6) from barrel. C. Unscrew ball joint from barrel. Steering Cylinder Assembly (Figure 124) 1. Use a complete repair kit when rebuilding the cylinder. Put a coating of clean hydraulic oil on all new seals and O−rings. 2. Install new O−rings and seal to the piston and new O−ring, back−up ring, rod seal and rod wiper to head.
Front Cutting Deck Lift Cylinders 1 3 2 4 8 7 5 6 g288167 Figure 126 1. Lift cylinder 4. Flange nut 7. Clevis pin 8. Washer (2 per pin) 2. Pin 5. Cotter pin (2 per pin) 3. Flange head screw 6. Washer (2 per pin) Front Cutting Deck Lift Cylinder Removal (Figure 126) 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from the key switch. 2.
Front Cutting Deck Lift Cylinder Removal (Figure 126) (continued) WARNING Make sure that cutting decks are fully lowered before loosening hydraulic lines from a lift cylinder. If cutting decks are not fully lowered as hydraulic lines are loosened, a cutting deck may drop unexpectedly. Note: To ease assembly, label all hydraulic hoses to identify their correct position on the lift cylinder. 4. Disconnect hydraulic hoses from lift cylinder fittings.
Front Cutting Deck Lift Cylinder Service 176 N·m (130 ft−lb) 12 13 6 7 1 8 5 2 4 11 3 9 10 13 1 10 5 4 8 12 11 9 3 6 7 2 g288168 Figure 127 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. Lock nut 8. Head 13. O−ring 6. 9. 10. Piston seal Wear ring Front Cutting Deck Lift Cylinder Disassembly (Figure 127) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft.
Front Cutting Deck Lift Cylinder Disassembly (Figure 127) (continued) B. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. C. Rotate the head counter−clockwise to remove retaining ring from barrel and head. 4. Extract shaft with head and piston by carefully twisting and pulling on the shaft. IMPORTANT When securing shaft in vise, clamp on shaft clevis only. Do not clamp vise jaws against the shaft surface. 5.
Front Cutting Deck Lift Cylinder Assembly (Figure 127) (continued) IMPORTANT Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise on barrel. 5. Mount lift cylinder in a vise equipped with soft jaws by clamping on the barrel clevis. 6. Secure head in barrel with retaining ring. A. Align retaining ring hole in the head with the access slot in the barrel. B.
Wing Cutting Deck Lift Cylinders 6 7 5 6 5 3 4 1 2 g288170 Figure 128 1. Wing deck lift cylinder (LH shown) 4. Flange nut 2. Pin 5. Flat washer (4 per clevis pin) 3. Flange head screw 6. Cotter pin (2 per clevis pin) 7. Clevis pin Wing Cutting Deck Lift Cylinder Removal (Figure 128) 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine. Remove key from the key switch. 2.
Wing Cutting Deck Lift Cylinder Removal (Figure 128) (continued) WARNING Make sure that cutting decks are fully lowered before loosening hydraulic lines from a lift cylinder. If cutting decks are not fully lowered as hydraulic lines are loosened, a cutting deck may drop unexpectedly. Note: To ease assembly, label all hydraulic hoses to identify their correct position on the lift cylinder. 4. Disconnect hydraulic hoses from lift cylinder fittings.
Wing Cutting Deck Lift Cylinder Service 16 11 9 14 1 6 7 13 12 5 4 176 N·m (130 ft−lb) 2 15 10 3 8 1 11 12 9 16 10 14 3 13 15 8 5 6 7 4 2 g288201 Figure 129 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 − cushion 4. Dust seal 10. Cushion 16. Wear ring 5. 6. Shaft seal O−ring 11. 12. Piston Lock nut Wing Cutting Deck Lift Cylinder Disassembly (Figure 129) 1.
Wing Cutting Deck Lift Cylinder Disassembly (Figure 129) (continued) IMPORTANT When securing shaft in vise, clamp on shaft clevis only. Do not clamp vise jaws against the shaft surface. 5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut from the shaft. Slide shaft, cushion and head off the shaft. 6. Remove piston seal, wear ring and O−ring from the piston. Remove O−ring, back−up ring, dust seal, wear ring and shaft seal from the head. 7. Wash parts in clean solvent.
Steering/Deck Lift Control Manifold 1 3 2 g288202 Figure 130 1. Steering/lift control manifold 2. Hydraulic filter 3. Flange head screw (4) Note: The ports on the lift control manifold are marked for easy identification of components. Example: P1 is the supply port from the gear pump and S1 is the location for solenoid valve #1 (see A Hydraulic Schematic (page A–5) to identify the function of the hydraulic lines and cartridge valves at each port).
Steering/Lift Control Manifold Removal (Figure 130) (continued) IMPORTANT An orifice is placed beneath the hydraulic fittings in the control manifold LS (OR1), C3 (OR3), C2 (OR5) and C5 (OR7) ports. If any of these fittings are removed from manifold, make sure to remove the orifice, note its orientation and label its position for assembly purposes. 9. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O−rings.
Steering/Lift Control Manifold Installation (Figure 130) (continued) B. If fitting was removed from manifold port LS (OR1) C3 (OR3), C2 (OR5) and C5 (OR7), install appropriate orifice in port before installing fitting. C. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. D. Tighten hydraulic fittings to torque value provided (Figure 131).
Steering/Deck Lift Control Manifold Service 7 (T2) 8 7 (T2) 6 6 2 (T1) 7 (T2) FORWARD 3 8 4 (T3) 5 16 (T2) 9 (T4) 10 (T6) 6 11 (T3) 7 (T2) 9 (T4) 11 (T3) 6 15 (T6) 21 (T4) 7 (T2) 20 (T4) 8 7 (T2) 14 (T5) 6 9 (T4) 7 (T2) 8 12 (T3) 11 (T3) 13 (T4) 12 (T3) 4 (T3) 12 (T3) 9 (T4) 19 (T6) 1 18 17 (T3) g288214 Figure 132 1. Manifold block 8. #8 solenoid coil (4) 2. Socket head screw (2) 9. Solenoid valve − S2, S3, S7 and S8 16. Coil nut 3. 4.
FRONT 1 4 (T3) 2 (T7) 5 (T4) 3 (T6) 4 (T3) 4 (T3) 6 (T7) 5 (T4) 7 (T3) 5 (T4) 4 (T3) 10 (T3) 3 (T6) 11 (T4) 8 (T3) 3 (T6) 4 (T3) 5 (T4) 9 11 (T4) 4 (T3) FRONT 4 (T3) g288215 Figure 133 1. Manifold block 5. #6 zero leak plug with O−ring (6) 2. Pressure compensator − LC 6. #10 zero leak plug with O−ring 10. 9. Orifice − 0.055 in OR2 and OR6 Check valve − CV3 3. #8 zero leak plug with O−ring (4) 7. Check valve − CV2 11. #6 zero leak plug with O−ring (2) 4.
IMPORTANT An orifice is placed beneath the plug in the control manifold OR2, OR4, OR6 and OR8 ports. If the plugs are removed, make sure to remove the orifice, note its orientation and label its position for assembly purposes. Note: The lift control manifold includes several zero− leak 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.
Cartridge Valve Service 1. Make sure the entire outer surface of the manifold is clean before removing the valve. WARNING If cartridge valve service involves any valves in the steering/deck lift manifold, make sure that cutting decks are fully lowered before loosening valves in the manifold. If cutting decks are not fully lowered as valves are loosened in the steering/ deck lift manifold, a cutting deck may drop unexpectedly. 2.
Cartridge Valve Service (continued) IMPORTANT Use care when handling the valve cartridge. Slight bending or distortion of the stem tube can cause binding and malfunction. B. Fit cartridge valve carefully into manifold port. The valve should go in easily without binding. C. Tighten the cartridge valve using a deep socket (valves that thread directly into the manifold block) or an extended hex wrench socket (flange mounted cartridge valves) to the value identified in manifold service illustration. D.
Hydraulic Oil Cooler 1 2 3 2 3 4 4 5 6 5 6 7 8 8 9 g288226 Figure 134 1. Cooling fan assembly 4. Cap screw (4) 7. Oil Cooler 2. Cap screw (4) 5. Flat washer (4) 8. Hydraulic straight fitting (2) 3. Flat washer (4) 6. Isolator Mount (4) 9. Flange nut (4) Hydraulic Oil Cooler Removal (Figure 133) CAUTION The oil cooler may be hot. To avoid possible burns, allow the engine and hydraulic systems to cool before working on the oil cooler. 1.
Hydraulic Oil Cooler Removal (Figure 133) (continued) 4. To prevent contamination of hydraulic system during oil cooler removal, thoroughly clean exterior of oil cooler, fittings and hydraulic hoses. 5. Disconnect the oil cooler hydraulic hoses at the frame bulkhead fitting (right side of machine) and allow the cooler to drain. 6. Disconnect hydraulic hose from oil cooler (left side of machine) Put caps or plugs on oil cooler and hydraulic hose openings to prevent contamination. 7.
Hydraulic Oil Cooler Installation (Figure 133) 1. If fittings were removed from oil cooler, lubricate and place new O−rings onto fittings. Install fittings into oil cooler. Tighten fittings (see Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (page 5–9)). 2. Position oil cooler to cooler frame and loosely install four (4) cap screws, washers and flange nuts. 3. Secure cooling fan assembly to oil cooler with four (4) cap screws and flat washers. 4.
Chapter 6 Electrical System Table of Contents General Information .............................................................................................................................. 6–3 Operator’s Manual ............................................................................................................................. 6–3 Operator Cab Components ................................................................................................................
Relays with Four (4) Terminals......................................................................................................... 6–99 Relays with Five (5) Terminals ....................................................................................................... 6–102 Hydraulic Solenoid Valves.............................................................................................................. 6–105 Air Filter Service Indicator ...........................................................
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Operator Cab Components Information regarding Groundsmaster 5910 cab components (blowers, fans, pressure switches, washer pump and windshield wipers) is included in Chapter 9: Operator Cab (page 9–1).
Toro Electronic Controllers (TEC) (continued) IMPORTANT Before performing any welding on the machine, turn the battery−disconnect switch to the OFF position, disconnect the wire harness connectors from both Toro Electronic Controllers, disconnect the wire harness connectors from the engine controller and disconnect the terminal connector from the alternator to prevent damage to the machine electrical system.
Engine Electronic Control Unit (ECU) 1 g288258 Figure 136 1. Yanmar engine ECU The Yanmar engine that powers your Groundsmaster uses an Electronic Control Unit (ECU) for engine management. The engine ECU communicates with the Toro Electronic Controller (TEC) and the InfoCenter display on the machine. The engine ECU is located on the left side of the machine frame near the engine.
Battery−Disconnect Switch 1 g287496 Figure 137 1. Battery−Disconnect switch The machine includes a battery−disconnect switch located under the hood in the right rear corner of the engine compartment (Figure 137). Turning the battery disconnect switch to the OFF position opens the 12 Volt and 24 Volt battery ground circuit. The battery disconnect switch should be set to OFF when servicing the machine. The switch can be locked in the ON or OFF position if desired.
Electrical System Operation Groundsmaster 5900/5910 machines use two (2) separate electrical systems. Most machine functions operate on a typical 12 VDC system. The second system exists to operate the electric cooling fans and is 24 VDC. 12 Volt System Engine electrical components, machine operation switches, hydraulic solenoid coils, the machine Toro electronic controllers (TECs), the Yanmar engine Engine Control Unit (ECU) and the InfoCenter display are all included in the 12 VDC system.
24 Volt System (continued) In normal operating mode, the radiator fans will not operate until the engine coolant reaches the minimum temperature. Once the minimum coolant temperature is reached, the fans will begin to turn at low speed in the forward direction (pulling outside air through the radiator). The Hydraulic oil cooler fans will always run when the engine is running.
InfoCenter Display 2 1 g288346 Figure 138 1. Operator control console 2. InfoCenter Display The Groundsmaster InfoCenter Display is a LCD device that is located in the Operator control console. The Info- Center display provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings.
IGNITION SWITCHED ON OPERATOR INFORMATION SCREEN AFTER 4 SECONDS ABOUT Software version 122−0310E shown g288347 Figure 139 InfoCenter Display Screens Electrical System: InfoCenter Display Page 6–10 Groundsmaster® 5900 & 5910 16227SL Rev D
Operator Information Screen 6 7 8 8 1 2 3 4 5 g288304 Figure 140 1. 2. Button 1 Button 2 5. 6. Button 5 Left gauge screen (coolant temp shown) 3. Button 3 7. Right gauge screen (hydraulic oil temp shown) 4. Button 4 8. Fan speed indicator The InfoCenter replaces traditional gauges by displaying engine and machine status. The operator information screen is the default InfoCenter screen and is displayed when the key switch is in either the RUN or START position.
Operator Information Screen (continued) • PTO (engaged) • Parking brake (engaged) • Engine cooling fan (in reverse) • Cruise control (engaged) 6 1 2 3 4 5 g288305 Figure 141 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Display controls InfoCenter display controls can be accessed by pressing button 5 on the display (Figure 141). When the display controls appear, use buttons 1 or 2 to adjust the display screen brightness, and buttons 3 or 4 to adjust the display screen contrast.
MAIN MENU 6 1 2 3 4 5 g288306 Figure 142 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Main Menu screen The main menu (Figure 142) provides access to the following screens: • Service • Diagnostics • Settings • About The main menu screen is accessed by pressing an holding button 5 on the display for approximately 4 seconds. Note: Access to the main menu screens may require entering a Personal Identification Number (PIN). The default PIN is either 1234 or 5900.
SERVICE 6 1 2 3 4 5 g288307 Figure 143 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Service screen The service screen (Figure 143) is accessed from the main menu and provides access to the following screens: • Hours • Traction Pedal • Fan Override • Fan Demo • Regeneration Access the service screens by pressing buttons 1 or 2 to highlight the desired screen and button 4 to select the highlighted screen. Return to the previous screen by pressing button 5.
HOURS 6 1 2 3 5 4 g288308 Figure 144 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Hours screen The hours screen contains a variety of machine hour meters (Figure 144). Use the Service Due In hour meter to notify the operator via the InfoCenter Display when scheduled maintenance is due. To reset the service due in hour meter, press button 3 from the hours screen. Use buttons 1 or 2 to highlight the desired time increment and button 4 to select the highlighted item.
TRACTION PEDAL 6 1 3 2 5 4 g288309 Figure 145 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Traction pedal screen The traction pedal screen lists the calibration values stored in the primary controller for different traction pedal positions (traction pedal position sensor). This screen also identifies that the traction pedal position sensor calibration has been completed.
TRACTION PEDAL (continued) Access the Neutral screen (Figure 146) to check or adjust the traction pedal neutral position by pressing button 2 (see Traction Pedal Neutral Adjustment (page 6–49)). Return to the previous screen by pressing button 5.
FAN OVERRIDE 6 1 2 3 4 5 g288311 Figure 147 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Fan override screen The fan override screen (Figure 147) allows the direction and speed of the radiator and hydraulic oil cooler cooling fans to be operated manually for testing purposes only.
FAN DEMO 6 1 2 3 4 5 g288312 Figure 148 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Fan demo screen The fan demo screen (Figure 148) allows the cooling fans to be put into a demonstration cycle for testing or demonstration purposes only. Note: The engine must be running, no coolant or hydraulic oil temperature warnings can be active and the parking brake needs to be engaged or an operator must be in the seat for fan demo to be operational.
REGENERATION 6 1 2 3 4 5 g288313 Figure 149 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Regeneration screen Regeneration provides the necessary procedure for performing a regeneration of the exhaust system DPF (diesel particulate filter). If the engine ECU identifies that a DPF regeneration is necessary, an engine fault will occur on the InfoCenter display (Figure 149). See Engine Faults (page 3–27).
REGENERATION (continued) 1 2 3 5 4 g288314 Figure 150 1. 2. 3. Button 1 Button 2 Button 3 4. 5. Button 4 Button 5 Park the machine on a hard level surface in a well ventilated area where it can remain until the process is complete. Make sure the machine has an adequate supply of fuel before beginning the automated regeneration process. When ready, access the regeneration screen and press button 4 (Figure 150).
DIAGNOSTICS SCREENS 6 1 3 2 4 5 g288373 Figure 151 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Diagnostics screen The Diagnostic screen (Figure 151) is accessed from the main menu and provides access to the following screens: • Input / Output • Fault Viewer Access the diagnostics screens by pressing buttons 1 or 2 to highlight the desired screen and button 4 to select the highlighted screen. Return to the previous screen by pressing button 5.
INPUT/OUTPUT (continued) 6 7 8 9 1 2 3 5 4 g288315 Figure 152 1. 2. Button 1 Button 2 6. 7. Machine function Inputs 3. 4. Button 3 Button 4 8. 9. Qualifiers Outputs 5. Button 5 Each screen (with exception of air filter service indicator) is separated into four (4) areas of information (Figure 152). The first area identifies the machine function. The second area identifies the inputs that are necessary for the machine function to occur.
INPUT/OUTPUT (continued) To lower the left wing deck, the following inputs and qualifiers are required (Figure 153): • Operator seat needs to be occupied (SEAT ON). • High/Low traction speed range switch in LO position (HIGH RANGE REQUEST OFF). • Hydraulic solenoid valve SV should be de−energized (HIGH RANGE OFF). • Left wing deck raise/lower switch pressed to lower (LEFT DECK LOWER ON).
INPUT/OUTPUT (continued) g288318 Figure 155 (Raise) To raise the left wing cutting deck, the following inputs and qualifiers are required (Figure 155): • Operator seat needs to be occupied (SEAT ON). • High/Low traction speed range switch in LO position (HIGH RANGE REQUEST OFF). • Hydraulic solenoid valve SV should be de−energized (HIGH RANGE OFF). • Left wing deck raise/lower switch pressed to raise (LEFT DECK RAISE ON).
INPUT/OUTPUT (continued) • Hydraulic solenoid valve SV should be de−energized (HIGH RANGE OFF). • Front deck raise/lower switch pressed to lower (CENTER DECK LOWER ON). If the proper inputs and qualifiers exist, the following outputs should occur (Figure 156): • Hydraulic solenoid valve S1 should be energized (MASTER LIFT SOLENOID ON). • Hydraulic solenoid valve S6 should be energized (CENTER DECK LOWER/FLOAT ON).
INPUT/OUTPUT (continued) • Hydraulic solenoid valve SV should be de−energized (HIGH RANGE OFF). • Front deck raise/lower switch pressed to raise (CENTER DECK RAISE ON). If the proper inputs exist, the following outputs should occur (Figure 158): • Hydraulic solenoid valve S1 should be energized (MASTER LIFT SOLENOID ON). • Hydraulic solenoid valve S5 should be energized (CENTER DECK RAISE ON).
INPUT/OUTPUT (continued) g288323 Figure 160 (Float) Once the deck is fully lowered, the deck should float and following outputs should occur (Figure 160): • Hydraulic solenoid valve S9 should be energized (RIGHT DECK FLOAT ON). Note: If a deck is already fully lowered when the key switch is moved from OFF to RUN, the deck will not be in float until the deck raise/lower switch is momentarily pressed to lower.
INPUT/OUTPUT (continued) Traction g288325 Figure 162 (Forward) Note: The traction system will not engage if the operator is not in the seat or if the parking brake is engaged. To engage forward traction, the following inputs and qualifiers are required (Figure 162): • Operator seat needs to be occupied (SEAT ON). • Parking brake must be disengaged (PARKING BRAKE OFF). • Traction pedal pushed to forward (FORWARD RANGE ON).
INPUT/OUTPUT (continued) g288326 Figure 163 (Reverse) To engage reverse traction, the following inputs and qualifiers are required (Figure 163): • • • • Operator seat needs to be occupied (SEAT ON). Parking brake must be disengaged (PARKING BRAKE OFF). Traction pedal pushed to reverse (REVERSE RANGE ON). Traction pedal position sensor voltage should be within the range determined during traction pedal calibration (TRACTION PEDAL (V) between REV MAX and REV NEUTRAL on Traction Pedal Screen).
INPUT/OUTPUT (continued) To engage high range traction speed, the following inputs and qualifiers are required (Figure 164): • PTO switch needs to be disengaged (PTO SWITCH OFF). • No cutting decks can be lowered (LEFT DECK DOWN OFF), (CENTER DECK DOWN OFF) and (RIGHT DECK DOWN OFF). • No cutting decks can be floating (LEFT DECK FLOAT OFF), (CENTER DECK LOWER/FLOAT OFF) and (RIGHT DECK FLOAT OFF). • High/Low range traction speed switch pressed to HI (HIGH RANGE REQUEST ON).
INPUT/OUTPUT (continued) PTO g288329 Figure 166 Note: The PTO will not engage if the operator is not in the seat, the high/low range traction speed switch is in HIGH or the engine coolant temperature is above 102 ºC (215 ºF). Also, one or more cutting decks must be floating before the PTO will engage. The PTO will only engage the floating cutting deck(s). To engage the PTO, the following inputs and qualifiers are required (Figure 166): • Operator seat needs to be occupied (SEAT ON).
INPUT/OUTPUT (continued) • Cruise control switch in the ON position (CRUISE ON/OFF ON). • Cruise control switch depressed to engage cruise control (CRUISE ENGAGE ON). If the proper inputs exist, the following outputs should occur (Figure 167): • Cruise control will be engaged (CRUISE ACTIVE ON). Engine Run g288331 Figure 168 (RUN) When the key switch is in the RUN position (KEY RUN ON), the following output should occur (Figure 168): • The electric fuel pump should be energized (OK RUN ON).
INPUT/OUTPUT (continued) If the proper inputs and qualifiers exist, the following outputs should occur (Figure 169): • The start relay should be energized, the starter motor should engage and the electric fuel pump should be energized (START ON) and (OK RUN ON). Air Filter g288333 Figure 170 The air filter diagnostic screen identifies the state of the engine air filter service indicator (Figure 170). • During normal operating conditions (AIR FILTER OFF) should display.
FAULT VIEWER (continued) InfoCenter Fault Viewer (Figure 171). See Machine Faults (page 3–23) for additional information about specific machine faults. The Yanmar Engine Control Unit (ECU) can also generate electrical faults. The faults generated by the ECU are specific to the engine and cannot be viewed via the fault viewer (see Engine Faults (page 3–27)). The fault viewer displays the following information about a machine fault: • CODE: Fault code number.
Settings Screens (continued) 1 2 3 4 5 g288336 Figure 173 1. 2. 3. Button 1 Button 2 Button 3 4. 5. Button 4 Button 5 The Settings screen (Figure 172) is accessed from the main menu and provides access to the following screens: • Display • Engine • Speed Limits Access the various settings screens by pressing buttons 1 or 2 to highlight the desired screen and button 4 to select the highlighted screen.
DISPLAY 1 2 3 5 4 g288337 Figure 174 1. 2. 3. Button 1 Button 2 Button 3 4. 5. Button 4 Button 5 The display settings are accessed from the settings screen and provide access to the following screens (Figure 174): • Units • Language • Alarms • PIN Settings Access the various items by pressing buttons 1 or 2 to highlight the desired item and button 4 to scroll through the display options. Return to the previous screen by pressing button 5.
DISPLAY (continued) Language g288339 Figure 176 The LANGUAGE setting allows the InfoCenter Display language to be chosen (Figure 176). Alarms g288340 Figure 177 When DISPLAY is ON, a tone will sound whenever a button on the InfoCenter is pressed. When DISPLAY is OFF, no tone will sound (Figure 177). An optional Backup Alarm is available for Groundsmaster 5900/5910 machines. When the alarm is installed and REV is ON, a tone will sound from the backup alarm.
DISPLAY (continued) Use of a PIN allows the ability to password protect access to all screens other than the Operator’s Information Screen. Use the PIN settings screen for turning the PIN protection feature ON or OFF (PIN ENTRY) and entering a custom PIN (PIN CHANGE) (Figure 178). See the machine Operator’s Manual for additional information. Note: If PIN use is chosen (PIN ENTRY ON), and a custom PIN is entered, make sure to record the PIN for future InfoCenter Display access. If PIN reset is necessary (e.
SPEED LIMITS 1 2 3 4 5 g288343 Figure 180 1. 2. 3. Button 1 Button 2 Button 3 4. 5. Button 4 Button 5 Use the speed limits settings to limit the maximum ground speed for the machine in the desired direction and speed range. The speed limits settings are accessed from the settings screen and provide access to the following screens: • Mow Forward • Transport Forward • Mow Reverse • Transport Reverse 1 2 3 4 5 g288344 Figure 181 1. 2. 3. Button 1 Button 2 Button 3 4. 5.
SPEED LIMITS (continued) Adjust the speed limit by pressing buttons 1 or 2 (− or +) (Figure 181). Return to the previous screen by pressing button 5. About Screens MODEL NUMBER: 31698 SERIAL NUMBER: 316000101 CE MODE: OFF SW VERSION: 122−0311 B DATE: 12−18−2015 TIME: 15:40 CHECKSUM: 0x2D1E PART NUMBER: 114−3321 SERIAL NUMBER: 00012345 MODEL NUMBER: 31698 SERIAL NUMBER: 316000101 VERSION: A1 DATE: 12−16−2015 TIME: 13:23 CHECKSUM: 0x258A −OK LIB ID: 01.
Electrical System Quick Checks Battery Test (Open Circuit Test) 1 g287496 Figure 183 1. Battery−disconnect switch The Groundsmaster 5900/5910 uses four (4) 12 Volt maintenance free batteries (Figure 183). Two batteries are connected together in parallel to support the 12 Volt electrical system and two (2) batteries are connected together in series to support the 24 Volt cooling fan circuit. Note: The InfoCenter display can be used to monitor the 12 Volt and 24 Volt systems.
Battery Test (Open Circuit Test) (continued) 3. Access the batteries (see Battery Removal (page 6–140) and Battery Installation (page 6–142)) and disconnect the battery to be tested as follows (Figure 184): A. 12 Volt system batteries: Disconnect the positive (+) red battery cable from either of the 12 Volt system batteries. B. 24 Volt cooling fan system batteries: Disconnect either end of the red jumper cable between the two (2) 24 Volt system batteries.
Charging System Tests (continued) FRONT 2 1 g288427 Figure 186 1. 12 Volt alternator 2. 24 Volt alternator The Groundsmaster 5900/5910 uses four (4) 12 Volt maintenance free batteries. Two batteries are connected together in parallel to support the 12 Volt electrical system and two (2) batteries are connected together in series to support the 24 Volt cooling fan circuit (Figure 185).
Charging System Tests (continued) 24 Volt System Check: • Use the InfoCenter display to enter Fan Demo Mode (see InfoCenter SERVICE (page 6–14) Screens). The cooling fans should begin to operate at maximum speed. • The 24 Volt system voltage should be at least 0.5 volt higher than the initial voltage recorded in step 3. • If the 24 Volt charging system performance is less than desired, see 24 Volt Alternator (page 6–130) for additional information.
Adjustments Cutting Deck Position Switch Adjustment A normally open proximity switch is located near the frame pivot of the front right lift arm and each wing deck lift arm to inform the secondary controller of the current cutting deck position. Adjustment 1 3 4 2 2.4 to 3.9 mm (0.095 to 0.155 in) g288430 Figure 187 1. 2. Front lift arm Position switch 3. 4. Switch bracket Sensing plate 1. Park machine on a level surface with the cutting decks lowered.
Adjustment (continued) 3. For machine serial numbers below 316000200 adjust the front deck switch as follows (Figure 187): A. Raise the front deck to a 17 degree angle and safely support the deck to prevent it from lowering during the adjustment procedure. B. Loosen fasteners securing switch bracket to frame. C. Set the position switch so the sensing eye of the switch is at the lower edge of the sensing plate and the correct clearance exists between the target eye and the sensing plate. D.
Adjustment (continued) 3 1 2 4 Switch to Sensing Plate Clearance 2.4 to 3.9mm (0.095 to 0.155 in) g288432 Figure 189 1. Wing deck lift arm 3. Switch bracket 2. Position switch 4. Sensing plate 5. For machine serial numbers below 316000200 adjust the wing deck switches as follows (Figure 189): A. Raise the wing deck to a 12 degree angle and safely support the deck to prevent it from lowering during the adjustment procedure. B.
Adjustment (continued) 6. For machine serial numbers above 316000200 adjust the wing deck switches as follows (Figure 190): A. Raise the wing deck to a 12 degree angle and safely support the deck to prevent it from lowering during the adjustment procedure. B. The center of the switch sensing eye should be 6.3 mm (0.25 in) above the upper edge of the sensing plate. Loosen the sensing plate mounting fasteners to adjust the plate as needed. C.
Traction Pedal Neutral Adjustment (continued) 1 2 5 4 3 g288435 Figure 192 1. Traction pedal 4. Lock nut 2. Traction pedal shaft 5. Spring shaft 3. Clamp blocks 5. On the bar graph in the screen, the position indicator bar should be between NR and the NF. Also, the reverse switch and forward switch icons should both be open. To adjust the position indicator bar location: A.
Traction Pedal Position Sensor Calibration 6 1 2 3 4 5 g288436 Figure 193 1. 2. 3. Button 1 Button 2 Button 3 4. 5. 6. Button 4 Button 5 Traction pedal screen Calibration of the traction pedal position sensor ensures that the Toro Electronic Controller (TEC) can identify the traction neutral, forward, full forward, reverse and full reverse positions.
Traction Pedal Position Sensor Calibration (continued) F. Slowly press traction pedal in the reverse direction until “Neutral Rev Capture Passed” appears on the InfoCenter display. G. Continue to press and hold traction pedal to the full reverse position until “Max Rev Capture Passed” appears on the InfoCenter display. H. Allow traction pedal to return to the neutral position. I.
Component Testing 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). Note: For engine component testing information, see the Yanmar Model 4TNV98CT−NTRL Yanmar Service Manual or Yanmar Troubleshooting Manual.
Fusible Link Harness 2 1 FRONT g288437 Figure 194 1. 2. Starter motor shield removed) Fusible link harness P02 TO MAIN HARNESS P22 P01 STARTER B+ FUSIBLE LINK (14 GAUGE) FUSIBLE LINK (16 GAUGE) g288438 Figure 195 Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Figure 195). If either of these links should fail, current to the protected circuits will be interrupted.
Testing (continued) 7. After fusible link testing is complete, make sure that fusible link harness is securely attached to starter B+ terminal and wire harness. 8. Turn the battery−disconnect switch to the ON position before returning the machine to service. 9. Lower and secure hood.
Mega Fuses FRONT 2 4 12 to 17 N·m (9 to 13 ft-lb) 3 1 g288439 Figure 196 1. 12 volt battery 3. 60 Amp mega fuse (traction unit) 2. 100 Amp mega fuse 4. 60 Amp mega fuse (cab) Three (3) mega fuses are used on the machine for protection of high amperage circuits. The mega fuse blocks are attached to the rear power center in the right rear corner of the engine compartment (Figure 196). • A 100 Amp mega fuse protects the 24 Volt cooling fan circuit.
Fuses Circuit protection for the 24 VDC system includes a 100 Amp mega fuse (see Mega Fuses (page 6–56)) and a 5 Amp fuse located on the rear power center. The entire 12 VDC system is protected by a 60 Amp mega fuse (see Mega Fuses (page 6–56)). The individual 12 Volt traction unit control circuits are protected by a variety of smaller amperage fuses located at the front or rear power centers.
Fuse Identification, Location and Function (continued) 2 FRONT 1 g288442 Figure 198 1. Front power center (behind operator seat) 2. Front fuse block A B C D 7.5 7.5 7.5 2 7.5 7.5 7.5 2 10 15 10 10 10 10 30 10 2 2 1 FRONT g288443 Figure 199 Front Power Center Fuse Block Remove cover from front power center behind operator seat to access fuses (Figure 198 and Figure 199). • Fuse F−A1 (7.5 Amp) supplies power to primary TEC outputs 11 to 14. • Fuse F−B1 (7.
Fuse Identification, Location and Function (continued) • Fuse F−C4 (30 Amp) supplies power to the horn. • Fuse F−D4 (10 Amp) supplies power to the US hazard lights. • Fuse F−A5 (2 Amp) supplies power to the telematics connector. • Fuse F−B5 (2 Amp) supplies power to the InfoCenter display. • Fuse F−C5 is unused and available for optional equipment. • Fuse F−D5 is unused and available for optional equipment. 1 2 FRONT g288444 Figure 200 1. Cooler frame (right side) 2.
Fuse Identification, Location and Function (continued) 4 3 2 1 15 A 15 A 20 A 25 A 30 A 1F 2F FRONT g288446 Figure 202 Loosen the knobs and remove the cover at the front of the cab headliner to access the operator cab fuses (Groundsmaster 5910) (Figure 201 and Figure 202). • Fuse 1F1 (20 Amp) supplies power to the cab work lights. • Fuse 1F2 (25 Amp) supplies power to the heater/air conditioner fan circuit. • Fuse 1F3 (30 Amp) supplies power to the air conditioner circuit.
Battery−Disconnect Switch 1 g287496 Figure 203 1. Battery−Disconnect switch The machine includes a battery−disconnect switch located under the hood in the right rear corner of the engine compartment (Figure 203). Turning the battery disconnect switch to the OFF position opens the 12 Volt and 24 Volt battery ground circuit. The battery disconnect switch should be set to OFF when servicing the machine. The switch can be locked in the ON or OFF position if desired.
Testing (continued) g288457 Figure 204 Back of Switch 3. The switch terminals are marked as shown in Figure 204. The circuit logic of the battery−disconnect switch is shown in below table. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals.
Toro Electronic Controllers (TECs) 1 FRONT 2 3 g288500 Figure 205 1. Front power center (behind operator seat) 2. Primary controller 3. Secondary controller Groundsmaster 5900 and 5910 machines use two (2) Toro Electronic Controllers (TEC). The controllers contain a microcontroller that monitors the condition of various switches and senders (inputs). The controllers then direct electrical power to control appropriate machine functions (outputs) based on the input conditions.
Toro Electronic Controllers (TECs) (continued) IN 9 Engine Speed Switch − Increase IN 10 Engine Speed Switch − Decrease IN 11 Electric Radiator Fan Controllers − Fault IN 12 Electric Hydraulic Oil Cooler Fan Controllers − Fault ANALOG IN 3 Traction Pedal Position Switch − Position Signal ANALOG IN 4 24 Volt Bus Monitor ANALOG IN 5 Hydraulic Oil Temperature Sender ANALOG IN 6 Fuel Level Sender The primary TEC controls electrical output to the following outputs: Primary TEC Input Number Descr
Toro Electronic Controllers (TECs) (continued) The secondary TEC monitors the states of the following components as inputs: Secondary TEC Input Number Description IN 1 Front Deck Raise/Lower Switch − Raise IN 2 Front Deck Raise/Lower Switch − Lower IN 3 Left Wing Deck Raise/Lower Switch − Raise IN 4 Left Wing Deck Raise/Lower Switch − Lower IN 5 Right Wing Deck Raise/Lower Switch − Raise IN 6 Right Wing Deck Raise/Lower Switch − Lower IN 7 Front Deck Position Sensor IN 8 Left Wing Deck Posi
Toro Electronic Controllers (TECs) (continued) 12V POWER (7.5A FUSES) OUTPUTS (PWR 2) 12V LOGIC POWER (2 AMP FUSE) +5 VOLTAGE OUT IGNITION SWITCH INPUTS OUTPUTS (PWR 3) OUTPUTS (PWR 4) DIGITAL INPUTS (OPEN/ CLOSED) COMM PORT CAN BUS GROUND ANALOG INPUTS (VARIABLE) NOT USED g288502 Figure 207 Fifty (50) pin wire harness connectors attach to the controllers (Figure 206). The connection terminal functions for the controllers and the wire harness connector pins are identified in Figure 207.
Toro Electronic Controllers (TECs) (continued) The secondary TEC controls electrical output to the following outputs: Primary TEC Input Number Description OUT 1 Front Deck Raise Solenoid (S5) OUT 2 Front Deck Float Solenoid (S6) OUT 3 Left Wing Deck Raise Solenoid (S2) OUT 4 Left Wing Deck Lower Solenoid (S3) OUT 5 Front Deck PTO (PRV) OUT 6 Left Wing Deck PTO (PRV) OUT 7 Right Wing Deck PTO (PRV) OUT 8 Deck Raise/Lower Enable Solenoid (S1) OUT 9 High/Low Range Traction Speed Solenoid (SV
Key Switch 2 1 g288503 Figure 209 1. 2. Operator control console Key switch The key switch on the console arm has three (3) positions − OFF, ON and START. The key switch is an input used by the master Toro Electronic Controller (TEC) to manage various machine functions. Testing The key switch and its circuit wiring can be tested as a TEC input using the InfoCenter Display (see InfoCenter Display (page 6–9)).
Testing (continued) SWITCH POSITION CIRCUITS STOP 1 + 6 RUN 1 + 3 + 4 + 5 + 6 START 1 + 2 + 4 + 5 + 6 6. Replace key switch if testing determines that it is faulty. 7. If key switch tests correctly and a circuit problem still exists, check the wire harnesses (see Appendix A (page A–1)). 8. After testing is complete, connect machine wire harness connector to key switch. 9. Assemble console arm (see Console Arm (page 7–35)). 10.
PTO Switch 1 2 g288505 Figure 211 1. Operator control console 2. PTO switch The PTO switch is located on the console arm (Figure 211). The PTO switch is pulled up to engage the cutting decks. The secondary controller monitors the position of the PTO switch (engage or disengage).
Testing (continued) 4 5 1 6 2 3 g288506 Figure 212 1. 2. 3. COM B terminal NO B terminal NC B terminal 4. 5. 6. COM C terminal NO C terminal NC C terminal 5. The switch terminals are marked as shown in Figure 212. The circuit logic of the PTO switch is shown in below table. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals.
Cutting Deck Raise/Lower Switches 1 3 4 2 g288507 Figure 213 1. Operator control console 3. Front deck raise/lower switch 2. Left deck raise/lower switch 4. Right deck raise/lower switch The three (3) cutting deck raise/lower switches are located on the console arm (Figure 213). When the front of a raise/lower switch is depressed and held, the controlled deck (left, front or right) will lower.
Testing (continued) 5. The switch terminals are marked as shown in Figure 214. The circuit logic of the raise/lower switches are shown in below table. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals.
Throttle Switch 1 2 g288509 Figure 215 1. Operator control console 2. Throttle switch The throttle switch is located on the console arm (Figure 215). When the front of the throttle switch is depressed and held, the engine rpm will increase to its HIGH idle setting. When the rear of the throttle switch is depressed and held, the engine rpm will decrease to its LOW idle setting. If the throttle switch is depressed momentarily, the engine speed will increase or decrease in 100 RPM increments accordingly.
Testing (continued) SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS INCREASE ENGINE RPM 2 + 3 and 5 + 6 2 + 1 and 5 + 4 NEUTRAL NONE ALL DECREASE ENGINE RPM 2 + 1 and 5 + 4 2 + 3 and 5 + 6 6. Replace the switch if testing determines that it is faulty. 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses (see Appendix A (page A–1)). 8. After testing is complete, connect machine wire harness connector to the switch. 9.
High/Low Range Traction Speed Switch 1 2 g288511 Figure 217 1. Operator control console 2. High/Low range traction speed switch The High/Low range traction speed switch is located on the console arm (Figure 217). When the front of the High/ Low range traction speed switch is depressed, the traction system will shift to HIGH range traction speed. When the rear of the High/Low range traction speed switch is depressed, the traction system will shift to LOW range traction speed.
Testing (continued) 5. The switch terminals are marked as shown in Figure 218. The circuit logic of the throttle switch is shown in below table. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals.
Cruise Control Switch 1 2 g288513 Figure 219 1. Operator control console 2. Cruise control switch The cruise control switch is located on the console arm (Figure 219). When the top of the cruise control switch is depressed, the cruise control feature is off. When the switch is moved to the center position, the cruise control feature is enabled but no speed is set.
Testing (continued) SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS OFF NONE ALL CRUISE ENABLE 2 + 3 5 + 6 CRUISE ENGAGE 2 + 3 and 5 + 6 NONE 6. Replace the switch if testing determines that it is faulty. 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses (see Appendix A (page A–1)). 8. After testing is complete, connect machine wire harness connector to the switch. 9. Assemble console arm (see Console Arm (page 7–35)). 10.
Headlight Switch 1 2 g288515 Figure 221 1. 2. Operator control console Headlight switch The headlight switch is located on the operator side of the control console (Figure 221). When the top of the switch is depressed, the headlights should illuminate. The headlight switch receives power from fuse F−B3 (15 Amp). Testing 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from key switch. 2. Turn battery−disconnect switch to the OFF position. 3.
Testing (continued) 8. After testing is complete, connect machine wire harness connector to the switch. 9. Assemble console arm (see Console Arm (page 7–35)). 10. Turn the battery−disconnect switch to the ON position before returning the machine to service.
Turn Signal Switch 1 2 g288527 Figure 223 1. 2. Operator control console Turn signal switch The turn signal switch is located on the console arm (Figure 223). When the turn signal switch is depressed (left or right), power is sent to the flasher module to illuminate the corresponding signal lights. The signal lights will continue to flash until the switch is returned to the OFF (center) position. The turn signal switch receives power from fuse F−B3 (15 Amp). Testing 1.
Testing (continued) 8. After testing is complete, connect machine wire harness connector to the switch. 9. Assemble console arm (see Console Arm (page 7–35)). 10. Turn the battery−disconnect switch to the ON position before returning the machine to service.
Hazard Switch 1 2 g288529 Figure 225 1. 2. Operator control console Hazard switch The hazard switch is located on the console arm (Figure 225). When the forward end of the hazard switch is depressed, power is sent to the flasher module to illuminate the hazard lights. The hazard lights will continue to flash until the switch is returned to the OFF (rearward) position. The hazard switch receives power from fuse F−D4 (10 Amp). Testing 1.
Testing (continued) 8. After testing is complete, connect machine wire harness connector to the switch. 9. Assemble console arm (see Console Arm (page 7–35)). 10. Turn the battery−disconnect switch to the ON position before returning the machine to service.
Parking Brake Switch 1 2 g288531 Figure 227 1. Operator control console 2. Parking brake switch The parking brake switch is located on the console arm (Figure 227). The parking brake comes on automatically when the engine is not running. For service or towing, the parking brake can be released while the engine is not running by using the hydraulic bypass valve and plunger (see machine Operator’s Manual).
Testing (continued) 5. The switch terminals are marked as shown in Figure 228. The circuit logic of the throttle switch is shown in below table. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals.
Horn Button 1 2 g288533 Figure 229 1. Operator control console 2. Horn button The horn button is a momentary push button switch used to sound the horn. The horn button is located on the outside of the control console (Figure 229). With the key switch in the RUN or START position, a continuous supply of voltage is available to the horn button. When pressed the horn button energizes the horn relay, sounding the horn. Testing 1. Park machine on a level surface, lower cutting decks and stop engine.
Contactors 2 FRONT 4.5 to 5.6 N·m (40 to 50 in-lb) 3 1 g288534 Figure 230 1. 12 volt battery 2. 24 Volt cooling fan contactor 3. Cab component contactor A contactor is used on all Groundsmaster 5900 and 5910 machines to provide current to the 24 volt cooling fans. The contactor is attached to the rear power center in the right rear corner of the engine compartment (Figure 230). The contactor is energized by the primary controller when the key switch is in the START or RUN position.
Testing (continued) 1 2 2 3 g288535 Figure 231 1. Contactor 2. Main posts 3. Coil posts 4. Using jumper wires, apply 12 VDC directly across the contactor coil posts (Figure 231). The contactor should click. With the contactor coil energized, resistance across the contactor main posts should be less than 1 ohm. 5. Remove voltage from contactor coil posts. The contactor should click. With the contactor coil not energized, resistance across the contactor main posts should be infinite ohms. 6.
Seat Switch 1 2 FRONT g288536 Figure 232 1. Wire harness connector 2. Seat switch connector The seat switch and its electrical connector are located in the seat assembly. The seat switch is a normally open proximity switch that closes when the operator is on the seat. Testing of the switch can be done without seat removal by disconnecting the switch wire from the machine wire harness (Figure 232). The primary controller monitors the position of the seat switch.
Windshield Wiper/Washer Switch (Groundsmaster 5910) 1 2 g288537 Figure 233 1. Cab headliner (center switch panel) 2. Wiper/washer switch The windshield wiper/washer switch is located in the cab headliner (Figure 233). The windshield wiper/washer switch is used to control operation of the windshield wiper and washer pump. The windshield wiper/washer switch receives power from fuse 2F−1 (15 Amp). For windshield wiper service information, see Windshield Wiper Assembly (page 9–29).
Testing (continued) 6. Replace the switch if testing determines that it is faulty. 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses (see Appendix A (page A–1)). 8. After testing is complete, connect machine wire harness connector to the switch and install switch panel and vent hoses. 9. Install cab roof (see Roof Assembly (page 9–9)).
Air Conditioning Switch (Groundsmaster 5910) 2 1 g288539 Figure 235 1. 2. Cab headliner (left switch panel) Air conditioning switch The air conditioning switch is located in the cab headliner (Figure 235). The switch is used to turn the air conditioning system on and off. Testing 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from key switch. 2. To access the switch, remove roof panel from top of cab (see Roof Assembly (page 9–9)). 3.
Fan Speed Switch (Groundsmaster 5910) 2 1 g288541 Figure 237 1. Cab headliner (left switch panel) 2. Fan speed switch The fan speed switch is located in the cab headliner (Figure 237). The switch is used to select the air conditioning/ heater fan speed (off, low, medium or high). Testing 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from key switch. 2. To access the switch, remove roof panel from top of cab (see Roof Assembly (page 9–9)). 3.
Testing (continued) 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses (see Appendix A (page A–1)). 8. After testing is complete, connect machine wire harness connector to the switch and install switch panel. 9. Install cab roof (see Roof Assembly (page 9–9)).
Work Light and Beacon Switches (Groundsmaster 5910 − Optional) 2 3 1 g288543 Figure 239 1. Cab headliner (right switch panel) 2. Work light switch (optional) 3. Beacon switch (optional) The switches are located in the cab headliner (Figure 239). The switches are used to turn the optional light kits on and off. Testing 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from key switch. 2.
Testing (continued) 7. If the switch tests correctly and a circuit problem still exists, check the wire harnesses (see Appendix A (page A–1)). 8. After testing is complete, connect machine wire harness connector to the switch and install switch panel. 9. Install cab roof (see Roof Assembly (page 9–9)).
Relays with Four (4) Terminals 1 2 3 4 5 g288551 Figure 241 1. Front power center 4. TEC power relay 2 2. Horn relay 5. TEC power relay 1 3. Main power relay The Groundsmaster 5900 and 5910 use a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay.
1 3 2 g288552 Figure 242 1. Yanmar ECU 2. Start relay 3. Glow plug relay The following relays are located on the left side of the engine near the Yanmar ECU (Figure 242): • The start relay supplies power to the engine starter. The glow plug relay is energized by the Yanmar ECU. • The glow plug relay supplies power to the engine glow plugs. The glow plug relay is energized by the Yanmar ECU. 2 1 g288553 Figure 243 1. Cab headliner (roof removed) 2.
Testing (continued) 4. Disconnect the machine wire harness connector from the relay. Remove relay from mounting bracket for testing. Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value for the tested component.
Relays with Five (5) Terminals 1 2 g288565 Figure 245 1. Front power center 2. Brake light relay The Groundsmaster 5900 and 5910 use a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay. The brake light relay supplies power to the brake lights. The brake light relay is energized by the primary controller. The brake light relay is located in the front power center behind the operator’s seat (Figure 245).
2 1 g288567 Figure 247 1. Rear power center 2. Remote sense relay The remote sense (24 Volt enable) relay provides power to the 24 volt alternator sense terminal. The 24 volt alternator with internal voltage regulator use this circuit to monitor the 24 volt system battery voltage. The remote sense relay is energized by the primary controller. The remote sense relay is attached to the rear power center in the right rear corner of the engine compartment (Figure 247). Testing 1. 2. 3. 4.
Testing (continued) 5. Using a multimeter, verify that coil resistance between terminals 85 and 86 is from 71 to 88 ohms (Figure 248). 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 7. Disconnect voltage from terminal 85 and multimeter lead from terminal 87. 8.
Hydraulic Solenoid Valves There are numerous coil actuated hydraulic solenoid valve on the Groundsmaster hydraulic manifolds. When the coils are energized, hydraulic valve shift occurs to control hydraulic flow. Note: A faulty solenoid coil or solenoid circuit wiring problem will not be identified by the Info Center Display.
Testing (continued) 2 1 g288590 Figure 250 1. Cutting Deck manifold front shown) 2. Solenoid valve PRV 2. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid coil. The resistance for the solenoid coils is identified below: A. The coils of the solenoid valves at the following locations are the same. Resistance of these coils should be approximately 8.8 ohms when tested at 20 ºC (68 ºF): Steering/Lift manifold S4, S5, S6 and S9 (Figure 249) B.
Testing (continued) 1 2 g288591 Figure 251 1. Traction control manifold 2. Solenoid valve SV C. The coils of the solenoid valves at the following locations are the same. Resistance of these coils should be approximately 7.25 ohms when tested at 20 ºC (68 ºF): Steering/Lift manifold S10 (Figure 249). Traction manifold SV (Figure 251). Note: Hydraulic solenoid valve SV (traction manifold) and S10 (steering/lift manifold) do not have replaceable coils.
Air Filter Service Indicator 1 2 g288592 Figure 252 1. Air filter 2. Air filter service indicator The air filter service indicator is a normally open (N.O.) vacuum actuated switch attached to the air filter body (Figure 252). A high vacuum condition occurs when the engine is running and the air filter elements become restricted, closing the switch.
Fuel Sender The fuel sender is attached to the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The fuel sender is an input to the Toro Electronic Controller (TEC) and provide information for the InfoCenter fuel gauge. The fuel sender is a sliding float design with a single wire harness connector. Testing 1. Make sure key switch is OFF. Remove key from key switch. 2. Turn battery−disconnect switch to the OFF position. 3.
Testing (continued) CAUTION Make sure fuel sender is completely dry (no fuel on it) before testing. Perform test away from the fuel tank to prevent an explosion or fire from sparks. 8. Using a multimeter and check resistance of the sender with the float in the full and empty positions shown in below table: SLIDING FLOAT SENDER RESISTANCE (FULL) RESISTANCE (EMPTY) Single Harness Connector 28 to 33 Ohms 240 to 250 Ohms 9. Replace sender if testing determines that it is faulty. 10.
Fuel Pump 2 1 g288595 Figure 254 1. 2. Yanmar ECU Fuel pump The electric fuel pump is attached to then left frame rail near the Yanmar ECU (Figure 254). Testing 1. Park machine on a level surface, lower cutting decks and stop engine. 2. Raise the hood and remove side panel from left side of machine to gain access to fuel pump. Allow engine and exhaust to cool before doing any disassembly of fuel system components. 3. Make sure fuel hoses attached to the fuel pump are free of obstructions. 4.
Testing (continued) 12. Install and secure side panel to left side of machine. 13. Lower and secure hood. Fuel Pump Specifications Electrical System: Component Testing Pump Capacity 700 ml/min (23.5 fl oz/min) Pressure 22.8 kPa (3.3 PSI) Current Draw 0.
Hydraulic Oil Temperature Sender 3 4 2 1 g288596 Figure 255 1. Hydraulic traction manifold 3. Hydraulic oil temperature sender 2. Adapter fitting 4. O−ring The hydraulic oil temperature sender is attached to the hydraulic traction manifold in port TS (Figure 255). Testing 1. Locate hydraulic oil temperature sender and disconnect wire harness connector from temperature sender. 2. Thoroughly clean hydraulic traction manifold around temperature sender. Remove sender from the adapter fitting.
Testing (continued) Note: Prior to taking resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value of the component you are testing. 4. Check resistance of the sender with a multimeter (ohms setting) as the oil temperature increases. A. The meter should indicate from 11.6 to 13.
CAN−bus Terminator Resistor A B 1 2 C g288602 Figure 257 1. Termination resistor 2. Keyway System communication between electrical components on Groundsmaster 5900/5910 machines is accomplished on a CAN−bus communication system. Two (2) specially designed, twisted cables form the bus for the network used on the machine. These wires provide the data pathways between machine components. All Groundsmaster 5900/5910 machines have two (2) 120 ohm termination resistors.
Resistor Assemblies Three (3) different resistors are used on all Groundsmaster 5900/5910 machines. Each resistor has a different resistance rating and location on the machine. 1 2 g288603 Figure 258 1. Resistor assembly 2. 2 3 End of resistor body 1 4 2 g288604 Figure 259 1. Front power center (behind operator seat) 3. Diode block 1 2. Diode block 2 4. 2K ohm resistor 1 2 g288605 Figure 260 1. Mini resistor Electrical System: Component Testing 2.
• A 75 ohm resistor assembly is used for proper key switch operation. The resistor plugs into the console wire harness near the key switch (see Appendix A (page A–1)). The resistor can be identified by its gray color, resistor symbol and Toro part number on the end of the resistor body (Figure 258). • A 1.6K ohm (1600 ohm) resistor assembly is used for proper 12 Volt alternator operation. The resistor plugs into the engine wire harness near the starter (see Appendix A (page A–1)).
Diode Assemblies 4 1 2 3 g288606 Figure 261 1. Diode 3. Terminal B (male) 2. End of diode body 4. Terminal A (female) 4 3 1 2 5 g288607 Figure 262 1. 2. Mini diode End of diode body 3. Key 4. 5. Terminal A Terminal B Ten (10) different diodes are used on all Groundsmaster 5900/5910 machines. The maximum current allowed through any of the diodes is 6 amps. • A diode assembly (D1) is used for circuit protection from voltage spikes that occur when the starter solenoid is de−energized.
2 3 1 g288608 Figure 263 Groundsmaster® 5900 & 5910 16227SL Rev D 1. Fuse/Diode holder base 2. Fuse/Diode holder cover Page 6–119 3.
3 6 2 1 7 10 2 5 3 4 9 8 g288609 Figure 264 1. Front power center (behind operator seat) 6. Radiator fan fault diode 2. Diode block 1 7. Hydraulic oil cooler fan fault diode 3. Diode block 2 8. Hydraulic oil cooler fan diode 4. 24 Volt remote sense relay diode 9. Radiator fan diode 5. 24 Volt contactor latch diode 10.
Testing (continued) 2. Test the diode as follows: Use a multimeter to check for voltage drop across the diode terminals (diode test setting). Contact the multimeter red (+) lead to diode terminal A and the black (−) lead to diode terminal B. A reading of less than 0.7 volts should be displayed on the multimeter. OR Use the following table and a multimeter (ohms setting) to measure the resistance across the diode terminals.
Audible Alarm 2 1 g288610 Figure 265 1. Front power center 2. Audible alarm The audible alarm sounds to notify the operator when a machine problem exists. Electrical current for the alarm is provided as an output from the secondary controller. The audible alarm is located in the front power center behind the operator seat (Figure 265). Testing 1. Make sure key switch is OFF. Remove key from key switch. 2.
Traction Pedal Position Sensor 1 2 g288612 Figure 267 1. Traction pedal 2. Traction pedal position sensor The traction pedal position sensor is connected to the traction pedal assembly (Figure 267). This sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the traction speed. The sensor is a single analog, dual digital signal electronic device.
Piston (Traction) Pump Control Solenoid Coils 2 3 1 g288613 Figure 268 1. Piston pump 2. Forward solenoid coil 3. 2 1 Reverse solenoid coil 2 5 N·m (44 in-lb) 3 3 5 N·m (44 in-lb) 2 1 2 g288614 Figure 269 1. 2. Solenoid coil O−ring 3. Coil nut The piston (traction) pump uses an electronic control assembly to change the position of the swash plate and the pump displacement. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump control.
Solenoid Coil Testing 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Turn battery−disconnect switch to the OFF position. 3. Locate piston pump solenoid coil to be tested and disconnect wire harness connector from solenoid coil (Figure 269). Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less).
Cutting Deck Position Switches 3 2 1 g288615 Figure 270 1. Front deck right lift arm 2. Deck position switch 3. Sensing plate The cutting deck position switches are normally open proximity switches that interact with sensing plates as the cutting deck lift arms raise and lower. When a cutting deck is in the lowered position, the sensing plate will be near the position switch and the switch will be closed.
2 1 3 g288616 Figure 271 1. Wing deck lift arm 2. Deck position switch 3. Sensing plate Testing The cutting deck position switches and their circuit wiring can be tested as TEC inputs using the InfoCenter Display (see InfoCenter Display (page 6–9)). If testing determines that the switch and its circuit wiring are not functioning correctly, proceed with the following test procedure: 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2.
24 Volt Cooling Fans 2 5 3 4 4 1 5 3 8 6 7 g288619 Figure 272 1. Radiator cooling fan panel 4. Flange head screw (16) 7. Flange head screw (2) 2. Hydraulic oil cooler fan panel 5. Flange nut (16) 8. Flange nut (2) 3. 24 Volt cooling fan (4) 6. Harness cover plate (2) Groundsmaster 5900/5910 machines include two (2) panels of cooling fans. One panel cools the radiator and the other cools the hydraulic oil cooler.
Testing CAUTION Be aware of and keep away from rotating parts during test. Do not wear loose clothing while working near rotating parts as these may become entangled and cause personal injury. 1. Park machine on a level surface, lower cutting decks, engage the parking brake, leave the engine running and open the hood.
24 Volt Alternator 3 2 1 g288620 Figure 273 1. 24 Volt alternator 2. Positive (+) terminal 3. Negative (−) terminal (alternator body) The Groundsmaster 5900/5910 uses two (2) batteries connected together in series to support the 24 Volt cooling fan circuit. The 24 Volt system is charged by an 105 Amp 24 Volt alternator driven by a multi−row V−belt. The 24 Volt alternator is mounted to the machine frame with isolation washers to prevent the alternator body from contacting the frame.
Testing (continued) The total system loss (both circuits) should not exceed 1.0 Volt. Clean and tighten cable connections and replace damaged cables if the voltage loss is too high. 3. Remove the alternator for additional testing if necessary (see 24 Volt Alternator (page 6–149)). 4. Contact your Authorized Toro Distributor or a Delco Remy authorized Dealer for further assistance.
24 Volt Voltage Divider 1 2 g288621 Figure 274 1. Battery−disconnect switch 2. Voltage divider 24 Volt electrical system activity is monitored as an input to the primary TEC. A voltage divider in the circuit reduces the 24 Volt system voltage for the TEC input signal to approximately 4 VDC. The TEC uses the reduced signal voltage to calculate the 24 Volt system voltage. The voltage divider is located in the rear power center in the right rear corner of the engine compartment (Figure 274). Testing 1.
Testing (continued) Terminals Resistor 1 + 3 R1 − 12K (12,000) ohms 6 + 3 R2 − 2K (2,000) ohms 4 + 3 R3 − 2K (2,000) ohms 6. After testing is complete, make sure that voltage divider is fully inserted into wire harness connector. 7. If the voltage divider tests correctly and a circuit problem still exists, check the wire harness (see Appendix A (page A–1)). 8. Turn the battery−disconnect switch to the ON position before returning the machine to service.
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit) 1 2 3 g288623 Figure 276 1. Fan speed switch 2. Control knob 3. Control panel The fan speed switch is attached to the overhead control panel (Figure 276). The switch is used to select the fan speed (off, low, medium, or high). Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2.
Testing (continued) 4. The switch terminals are identified in (Figure 277). With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between only the terminals listed for each switch position. Check the continuity between the switch terminals. Switch Position Closed Circuits OFF L+H LOW B+C+L MEDIUM B+C+M HIGH B+C+H 5. Replace the fan speed switch if testing determines that the switch is damaged. 6.
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit) 1 2 3 g288625 Figure 278 1. 2. Operator’s fan Fan mount bracket 3. Resistor module The resistor module is attached to the rear of the fan mounting bracket (Figure 278). The resistor module is used for operation of the operator’s fan. Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2.
Testing (continued) 4. Use a multimeter to check that the resistance values of the resistor module as below (Figure 279). Test Point 1 Test Point 2 Expected Reading Motor Pin Pin 1 Less than 9 ohms Motor Pin Pin 2 Less than 6 ohms Motor Pin Pin 3 Less than 3 ohms 5. Replace the resistor module if it fails the test. 6.
Service and Repairs Batteries Groundsmaster 5900/5910 machines use two (2) separate electrical systems. Most machine functions operate on a typical 12 VDC system. Two 12 Volt batteries located at the rear of the machine are connected together in parallel to support the 12 Volt electrical system. The second system exists to operate the electric cooling fans and is 24 VDC. Two 12 Volt batteries located at the rear of the machine are connected together in series to support the 24 Volt cooling fan circuit.
Battery Care (continued) WARNING Connecting cables to the wrong battery post could result in personal injury and/or damage to the electrical system. 4. If corrosion occurs at battery terminals, turn battery− disconnect switch to the OFF position and disconnect cables. Clean clamps and terminals separately. Reconnect cables with positive (+) cables first. Coat battery posts and cable connectors with Battery Terminal Protector (Toro Part No. 107−0392) or petroleum jelly to prevent corrosion.
24 Volt System Battery Specifications Quantity: 2 BCI Group Size UI 340 CCA at −17.8 ºC (0 ºF) Reserve Capacity of 38 minutes at 26.7 ºC (80 ºF) Dimensions Length 198 mm (7.8 in) Width 132 mm (5.2 in) Height (including terminals) 183 mm (7.2 in) Weight 8.8 Kg (19.5 lb) Electrolyte Specific Gravity Fully charged: 1.265 corrected to 26.7 ºC (80 ºF) Discharged: less than 1.240 Battery Removal 2 1 3 g288669 Figure 280 1. Rear bumper 2.
Battery Removal (continued) 2 1 g288670 Figure 281 1. Knob (2 per side) 2. Side shroud − LH 1. Open hood and turn battery−disconnect switch to the OFF position. 2. Remove three (3) flange head screws from each side of the rear bumper as shown (Figure 280). Loosen the remaining flange head screws securing the bumper to the frame and pivot the bumper downward. 3. Loosen the knobs and remove both side shrouds (Figure 281). 4.
Battery Removal (continued) 1 5 2 7 10 6 9 8 4 3 g288672 Figure 283 1. Battery cover 6. Cable assembly (for 24 VDC system) 2. Battery−disconnect switch 7. Cable − jumper (for 24 VDC system) 3. Batteries − 12 volt for 12 VDC system) (2) 8. Ground (−) cable 4. Batteries − 12 volt for 24 VDC system) (2) 9. Battery hold down (2) 5. Positive (+) cable (for 12 VDC system) 10. Battery hold down (2) Battery Installation 1. Secure batteries with hold downs. 2. Install battery cables. 3.
Battery Inspection, Maintenance, and Testing 1. Perform following inspections and maintenance: A. Check battery case for cracks. Replace battery if cracked or leaking. B. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts. IMPORTANT Before cleaning the battery, tape or block vent holes. C. Check for signs of wetness or leakage on the top of the battery which might indicate overcharging or a loose terminal post. Also, check battery case for dirt and oil.
Battery Inspection, Maintenance, and Testing (continued) G. If the test voltage is below the minimum voltage shown in the chart, replace the battery. If the test voltage is at or above the minimum, return the battery to service. Battery Charging To minimize possible damage to the battery and to allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available.
Battery Charging (continued) CAUTION Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 16 ºC (60 ºF) before connecting to a charger. Charge the battery in a well−ventilated place to dissipate gases produced from charging. These gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke. Nausea may result if the gases are inhaled.
Hydraulic Solenoid Valve Coils 7 N·m (5 ft-lb) 4 1 3 2 g288684 Figure 284 Cutting Deck Control Manifold 1. Hydraulic manifold 3. Solenoid valve coil 2. Solenoid valve 4. Nut Most hydraulic solenoid valves used on the Groundsmaster 5900/5910 have replaceable coils. The coils can be replaced without opening the hydraulic system.
24 Volt Alternator/Air Conditioning Compressor Drive Belt 1 95 to 108 N·m (70 to 80 ft-lb) 37 to 45 N·m (27 to 33 ft-lb) 2 3 11 4 10 12 9 5 6 13 8 7 39 to 45 N·m (29 to 33 ft-lb) g288686 Figure 285 1. 24 Volt alternator 6. Engine pulley 11. Cap screw 2. Drive belt (GM 5900) 7. Lock washer (3) 12. Air conditioning compressor (GM 5910) 3. Alternator pulley 8. Cap screw (3) 13. Drive belt (GM 5910) 9. Roll pin 4. Flange nut 5. Tensioner assembly 10. Lock washer Removal 1.
Installation 2 1 3 4 5 g288687 Figure 286 1. Drive belt (GM 5900) 4. Large hex (at tensioner base) 2. Drive belt (GM 5910) 5. Roll pin 3. Tensioner assembly 1. Install drive belt over pulleys. 2. Rotate the large hex at the base of the drive belt tensioner until the base contacts the roll pin (Figure 286). Tighten the cap screw securing the drive belt tensioner to the frame (item 11) from 37 to 45 N·m (27 to 33 ft−lb). 3.
24 Volt Alternator g298625 Figure 287 1. 24 Volt alternator 8. Hardened washer (4) 15. Cap screw (3) 2. Alternator drive belt 9. Hardened washer (8) 16. Roll pin 3. Alternator pulley 10. Plastic isolator (4) 17. Flange nut (8) 4. Flange nut 11. Front mounting bracket 18. Carriage bolt (8) 5. Tensioner assembly 12. Plastic washer (4) 19. Rear mounting bracket 6. Engine pulley 13. Flange nut (4) 20. Cap screw 7. Cap screw (4) 14. Lock washer (3) 21.
Removal (continued) g298626 Figure 288 1. 24 Volt alternator 4. Negative (−) terminal (alternator body) 2. Positive (+) terminal 5. Remote sense relay (violet) 3. Circuit diode (green) 4. Disconnect the four (4) wire harness connectors from the alternator (Figure 288). 5. Remove the alternator drive belt (see 24 Volt Alternator/Air Conditioning Compressor Drive Belt (page 6–147)). 6.
Installation (continued) g298627 Figure 289 1. 24 Volt alternator 4. Alternator mounting bracket 2. Hardened washer (8) 5. Plastic washer (4) 3. Plastic isolator (4) 2. Install the alternator to the mounting brackets as shown (Figure 287). Make sure the plastic washers fit over the plastic isolators (Figure 289). 3. Use the clearance in the alternator mounting holes to align the alternator drive pulleys and tighten the four (4) alternator mounting screws from 41 to 49 N·m (30 to 36 ft−lb). 4.
Electrical System: Service and Repairs Page 6–152 Groundsmaster® 5900 & 5910 16227SL Rev D
Chapter 7 Chassis Table of Contents General Information .............................................................................................................................. 7–2 Operator’s Manual ............................................................................................................................. 7–2 Service and Repairs ............................................................................................................................. 7–3 Wheels ...................
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs Wheels g298659 Figure 290 1. Front wheel assembly 3. Front wheel motor 5. Lug nut (5 per rear wheel) 2. Lug nut (6 per front wheel) 4. Rear wheel assembly 6. Rear wheel motor Wheel Removal (Figure 290) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Chock wheels to prevent machine from shifting. 3. Loosen, but do not remove, lug nuts that secure wheel to machine.
Wheel Removal (Figure 290) (continued) CAUTION Make sure machine is parked on a solid level surface such as a concrete floor prior to raising machine. Use appropriate hoists and jacks to raise the machine. Chock or block wheels to prevent the machine from shifting. Use appropriate jack stands to support the machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. 4.
Steering Column (For machines serial number below 403450000) g298661 Figure 291 1. Steering wheel cover 8. Flange head screw (7) 15. Lower mounting plate 2. Hex nut 9. Flange head screw (3) 16. Carriage screw (4) 3. Flat washer 10. Socket head screw 17. Carriage screw (3) 4. Steering wheel 11. Flange nut (7) 18. Alignment bushing 5. Steering column boot 12. Flat washer (4) 19. Steering control valve 6. Steering column assembly 13. Upper mounting plate 20.
Steering Column Removal and Disassembly (Figure 291) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Remove the steering wheel cover, hex nut, flat washer and steering wheel. 3. Remove the bearing cover from the steering column. 4. Remove the seven (7) flange head screws and remove the steering cover (item 8). 5. Remove the steering column boot (item 5): A. Set the steering column tilt to the fully rearward position. B.
Steering Column Assembly and Installation (Figure 291) 1. Apply anti−seize lubricant to upper and lower splines of steering column shaft. 2. Hold steering column in position on machine and slide steering control valve onto lower end of steering column. Secure steering column and steering control valve to machine with four (4) cap screws. Tighten cap screws from 47 to 56 N·m (34 to 42 ft−lb). 3. Install the steering column boot (item 5): A. Carefully pull the boot down over the steering column. B.
Steering Column (For machines serial number above 403450001) g301554 Figure 293 1. Steering wheel cover 2. Hex nut Steering control valve 17. Bolt (2 each) 10. 3. 4. 9. Bolt (4 each) 18. Lock washer (2 each) Flat washer 11. Nut (14 each) 19. Speed nut (2 each) Steering wheel 12. Washer (4 each) 20. Bolt (4 each) 5. Foam collar 13. Mount (4 each) 21. Clip (2 each) 6. Steering shaft 14. Mount assembly 22. Column support 7. Bolt (4 each) 15. Carriage bolt (4 each) 8.
Removal (Figure 293) (continued) 4. Use a suitable puller to remove the steering tower to get access to the fasteners that secure the steering tower to the machine. 5. Slide the rubber bellows up the steering tower to get access to the fasteners that secure the steering tower to the machine. 6. Support the steering control valve to prevent it from falling during the steering tower removal. Note: Do not allow the steering control valve to hang from the hydraulic lines. 7.
Rear Axle g298742 Figure 295 1. Rear axle 11. Roll pin 21. Castle nut (4) 2. Flange bushing (4) 12. Thrust washer (3) 22. Cotter pin (6) 3. Retaining ring (2) 13. Lock nut 23. Castle nut (2) 4. Spindle cap (2) 14. Axle support 24. Tie rod assembly 5. Flange head screw (2) 15. Hose guard(2) 25. Elbow 6. Thrust washer (2) 16. Flange head screw (4) 26. Grease hose 7. Spindle − LH 17. Lock nut (2) 27. Nut 8. Wheel motor − LH 18. Washer (2) 28. Grease fitting 9.
Rear Axle Removal (Figure 295) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Chock front wheels to prevent machine from shifting. 3. Safely raise the machine and remove rear wheels (see Wheels (page 7–3)). 4. Thoroughly clean hydraulic hose ends at fittings on steering cylinders and the hydraulic hose ends at the frame hard lines for the rear wheel motors to prevent hydraulic system contamination.
Rear Axle Installation (Figure 295) (continued) 7. Check oil level in hydraulic reservoir and add if necessary (see machine Operator’s Manual). 8. Lubricate the rear axle pivot bushings and spindle pivot bushings through the grease fittings provided. 9. Check rear wheel toe−in and adjust as necessary (see machine Operator’s Manual). 10. Check to make sure that no contact is made between any machine components (including hydraulic hoses) as the rear wheels are moved from steering lock to steering lock.
Rear Axle Service g298845 Figure 296 1. Rear axle 2. Flange bushing (4) 3. Retaining ring (2) 9. 10. 11. Cap screw (10 per motor) 17. Washer (2) Flange bushing (2) 18. Cap screw (2) Steering cylinder (2) 19. Elbow 4. Spindle cap (2) 12. Castle nut (4) 20. Grease hose 5. Flange head screw (2) 13. Cotter pin (6) 21. Nut 6. Thrust washer (2) 14. Castle nut (2) 22. Grease fitting 7. Spindle − LH 15. Tie rod assembly 8. Wheel motor − LH 16.
Tie Rod Disassembly and Assembly 1. Remove cotter pins and slotted hex nuts from tie rod ends. Discard cotter pins. 2. Use a suitable puller (pickle fork) to separate tie rod ends from the steering spindles. Note: One of the tie rod ball joints has left hand threads. g298846 Figure 297 1. Cap screw (2) 4. Lock nut (2) 2. 3. Tie rod end − LH thread Tie rod tube 5. 6. Tie rod end − RH thread Grease fitting (2) 3.
Rear Axle Spindle Bushing Replacement g298848 Figure 299 1. Rear axle 3. Spindle bushing (4) 2. Pivot bushing (2) 4. Grease fitting (2) The rear wheel steering spindles must fit snugly in the rear axle. Excessive movement of the spindle in the axle might indicate that the steering spindle bushings are worn and should be replaced. 1. Remove rear axle from machine (see Rear Axle (page 7–10)). 2. Remove the tie rod assembly (see Tie Rod Disassembly and Assembly (page 7–14)). 3.
Rear Axle Spindle Bushing Replacement (continued) 12. Install the tie rod assembly (see Tie Rod Disassembly and Assembly (page 7–14)). 13. If removed, install the rear wheel motor to the steering spindle. Tighten the cap screws from 91 to 112 N·m (67 to 83 ft−lb). 14. Install rear axle to machine (see Rear Axle (page 7–10)). 15. Lubricate the steering spindles through the grease fittings on the rear axle. 16. Check rear wheel toe−in and adjust if necessary (see machine Operator’s Manual). 17.
Front Deck Lift Arms g298853 Figure 300 1. Lift arm (left shown) 8. Roll pin 15. Front deck position switch (machine serial numbers above 316000200 shown) 2. Lift cylinder 9. Cotter pin 16. Switch bracket 3. Flange head screw 10. Cylinder pin 17. Cap screw 4. Pivot pin 11. Flat washer (2 per cylinder) 18. Flat washer 5. Flange nut 12. Sensing plate 19. Thrust washer 6. Lift arm pin 13. Carriage bolt (2) 20. Washer (4 per cylinder) 7. Lock nut 14.
Front Deck Lift Arm Removal (Figure 300) (continued) CAUTION Make sure machine is parked on a solid level surface such as a concrete floor prior to raising machine. Use appropriate hoists and jacks to raise the machine. Chock or block wheels to prevent the machine from shifting. Use appropriate jack stands to support the machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. 3. Chock rear wheels and jack up front of machine.
Front Deck Lift Arm Removal (Figure 300) (continued) C. Remove retaining ring that secures spherical bearing in lift arm. Remove tapered stud with spherical bearing from lift arm. Separate flange nut and spherical bearing from stud. D. Press flange bushings from lift arm. Thoroughly clean lift arm bore. Front Deck Lift Arm Installation (Figure 300) 1. If removed, install components to lift arm (Figure 301): A. Assemble height−of−cut chain u−bolt so that there is 46 mm (1.
Front Deck Lift Arm Installation (Figure 300) (continued) g298852 Figure 302 1. Operator platform 4. Flange head screw 2. Shim pad 5. Flange nut 3. Bumper pad 9. When lift arms are fully raised, check that gap between lift arms and bumper pads on bottom of operator platform is no greater than 1.5 mm (0.06 in) (Figure 302). If necessary, add or remove shim pads so that gap is correct. 10.
Wing Deck Lift Arms g298890 Figure 303 27. Pivot hub assembly 1. Lift arm (LH shown) 14. Lock washer (2) 2. Grease fitting 15. Wing deck position switch (machine 28. serial numbers above 316000200 shown) Thrust washer (2) 3. Grease fitting 16. Lock nut (2) 29. Flange bushing (2) 4. Flange nut 17. Impact arm assembly 30. Shim 5. Cylinder pin 18. Pivot shaft 31. Bumper pad (2) 6. Cap screw 19. Lock washer 32. Bushing (2) 7. Hydraulic fitting 20. Lock nut 33.
Wing Deck Lift Arm Removal (Figure 303) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Remove wing deck from lift arm (see Wing Cutting Decks (page 8–9)). 3. Remove wing deck impact arm assembly from pivot hub (see Wing Deck Impact Arm Assembly (page 7–31)). 4. Remove joint yoke and cutting deck connection from lift arm (Figure 306 and Figure 307): A. Support cutting deck connection to prevent it from falling. B.
Wing Deck Lift Arm Removal (Figure 303) (continued) g298892 Figure 305 1. Lift arm (LH shown) 4. Straight bushing (2) 2. Flange bushing (2) 5. Grease fitting 3. Grease fitting 9. Support lift arm to prevent it from shifting or falling. Remove lift arm pivot shaft and lift arm from machine. Locate and remove thrust washer (item 29) during pivot shaft removal. Note: If pivot shaft is difficult to remove, fabricate a puller (Figure 304).
Wing Deck Lift Arm Installation (Figure 303) (continued) g298893 Figure 306 (For machines serial number below 403450000) Chassis: Service and Repairs 1. Lift arm (LH shown) 6. 2. Joint yoke 7. Spacer 3. Deck connection 8. Impact arm 4. 5. Hardened washer Thrust washer 9. 10.
Wing Deck Lift Arm Installation (Figure 303) (continued) g301648 Figure 307 (For machines serial number above 403450001) 1. Lift arm (LH shown) 8. Yoke joint 15. LH channel assembly 2. Lock nut 9. Nut (16 each) 16. Nut (4 each) 3. Hardened washer 10. Deck mount 17. Lock washer (2 each) 4. Thrust washer 11. Carriage bolt (10 each) 18. Bolt (2 each) 5. Thrust washer 12. Spacer plate 19. Deck stop 6. Grease fitting 13. Left cutting deck 20. Bumper pad (2 each) 7.
Wing Deck Lift Arm Installation (Figure 303) (continued) B. Raise joint yoke, cutting deck connection and wing deck impact arm assembly to lift arm. Slide joint yoke into lift arm bore. C. Place second thrust washer onto joint yoke shaft and then place washer(s) (item 5) as needed to remove as much clearance as possible between thrust washer and hardened washer (item 4) location. D. Install slotted hex nut to secure joint yoke to lift arm. Torque hex nut from 204 to 244 N·m (150 to 180 ft−lb).
Wing Deck Lift Arm Joint Yoke g298932 Figure 308 (For machines serial number below 403450000) 1. Lift arm (LH shown) 6. Thrust washer 11. Base mount (2) 2. Joint yoke 7. Spacer 12. Shim (2) 3. Deck connection 8. Impact arm 13. Bolt plate (2) 4. Hardened washer 9. Slotted hex nut 14. Hardened washer (8) 5. Thrust washer Cotter pin 15. Cap screw (8) Groundsmaster® 5900 & 5910 16227SL Rev D 10.
g301648 Figure 309 (For machines serial number above 403450001) 1. Lift arm (LH shown) 8. Yoke joint 15. LH channel assembly 2. Lock nut 9. Nut (16 each) 16. Nut (4 each) 3. Hardened washer 10. Deck mount 17. Lock washer (2 each) 4. Thrust washer 11. Carriage bolt (10 each) 18. Bolt (2 each) 5. Thrust washer 12. Spacer plate 19. Deck stop 6. Grease fitting 13. Left cutting deck 20. Bumper pad (2 each) 7. Spacer 14. Carriage bolt (6 each) 21.
Joint Yoke Removal (Figure 308 and Figure 309) (continued) 3. Remove eight (8) cap screws (item 15), hardened washers and two (2) bolt plates that secure base mounts (item 11) to cutting deck connection. 4. Raise lift arm enough to free joint yoke and base mounts from lift arm and deck connection. Remove thrust washer and spacer (item 7) from yoke shaft. 5. Locate and retrieve shim (item 12) from between each base mount and deck connection. Joint Yoke Disassembly 1. Remove snap rings from yoke.
Joint Yoke Assembly (continued) g298933 Figure 310 1. Joint yoke 2. Base mount 3. Angled edge 8. Press base mounts onto bearing caps with the angled edge of the mounts away from the joint (Figure 310). The outside of the cross bearing cups should be flush with the base mount surfaces. 9. Make sure that assembled joint yoke moves without binding. Slight binding can usually be eliminated by lightly rapping the yoke lugs with a soft faced hammer.
Wing Deck Impact Arm Assembly g299090 Figure 311 (For machines serial number below 403450000) 1. Impact arm housing 10. Cap screw 19. Plastic bearing 2. Pivot hub 11. Flange nut (4) 20. Flat washer 3. Flange bushing (2) 12. Cap screw (4) 21. Jam nut (2) 4. Pivot shaft 13. Housing 22. Rod end 5. Flat washer 14. Spring shaft 23. Spacer (2) 6. Lock nut 15. Pipe plug 24. Jam nut 7. Flange bushing 16. Bushing 25. Lock nut 8. Thrust washer 17. Washer 26.
g301664 Figure 312 (For machines serial number above 403450001) 1. Impact arm housing 5. Flat washer 2. Pivot hub 6. Lock nut 9. 3. Flange bushing (2) 7. Flange bushing 11. Flange nut (4) 4. Bolt 8. Thrust washer 12. Spacer 10. Thrust washer Cap screw Impact Arm Removal (Figure 311 and Figure 312) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2.
Impact Arm Assembly (Figure 311) (continued) IMPORTANT All endplay must be removed from spring shaft assembly to allow proper operation and ensure long life. 4. Grasp end of spring shaft. Push inward and pull outward on shaft to determine if endplay exists between spring shaft assembly and impact arm housing assembly. 5. If endplay in spring shaft assembly exists, insert a 3/4” socket onto jam nut (item 21) on spring shaft. Access to jam nut can be obtained through the open end of impact arm housing.
Impact Arm Installation (Figure 311 and Figure 312) (continued) Note: Due to changes in the counterbalance setting of the traction unit, it is recommended to test cut grass and check the after−cut appearance before returning the machine to regular service. Refer to machine Operator’s Manual for correcting cutting deck mismatch procedures if necessary.
Console Arm g299122 Figure 314 1. Console arm 15. Cap screw 29. Switch − high/low range 2. Side cover 16. Lock washer 30. Switch − lift (3) 3. Flange head screw (6) 17. Coupling nut 31. InfoCenter display 4. Front cover 18. Seat belt receptacle 32. Switch − cruise control 5. Flange head screw (4) 19. Seat assembly 33. Button − horn 6. Console gate 20. Support strap 34. Cover plate 7. Flange head screw (2) 21. Flange nut (2) 35. Power port 8. Console support 22.
Console Arm Disassembly (Figure 314) 1. Park machine on a level surface, lower cutting units, and stop engine. Remove key from key switch. 2. Remove six (6) flange head screws and side cover (item 2) from outside of console arm. 3. Remove four (4) flange head screws that secure front cover (item 4) to console arm panel. 4. Loosen two (2) flange head screws (item 7) to open console gate (item 6). 5. Remove electrical components from console arm as needed. 6.
Traction Pedal g299131 Figure 315 1. Steering cover 13. Lock nut 25. Spacer 2. Traction pedal 14. Flat washer 26. Flange head screw (2) 3. Carriage screw (6) 15. Carriage screw (2) 27. Hub and bushing assembly 4. Cap screw (2) 16. Flange nut (7) 28. Standoff (2) 5. Pedal shaft 17. Flange bushing 29. Position sensor 6. Spring bracket 18. Spring 30. Cover plate 7. Hex nut 19. Flat washer 31. Socket head screw (2) 8. Clamp block (2) 20. Spring shaft 32.
IMPORTANT A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. Traction Pedal Disassembly (Figure 315) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2.
Traction Pedal Assembly (Figure 315) (continued) g299132 Figure 316 1. Traction pedal 4. Spring shaft 2. Traction pedal shaft 5. Lock nut 3. Clamp blocks F. Clamp blocks (Figure 316 item 3) must be square (at 90º angles) to traction pedal shaft after tightening. 2. Plug machine wire harness connector into traction pedal position sensor. 3. After assembling the traction pedal, calibrate the traction pedal position sensor (see Traction Pedal Position Sensor Calibration (page 6–51)). 4.
Operator Seat g299266 Figure 317 1. Cap screw 5. Spacer 2. Lock washer 6. Seat belt receptacle 10. 9. Carriage screw 11. Flange nut 3. Cap screw 7. Coupling nut 4. Flat washer (4) 8. Retractable seat belt Cap screw Operator Seat Removal (Figure 317) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Disconnect seat electrical connector from machine wire harness. 3.
Operator Seat Installation (Figure 317) g299267 Figure 318 1. Seat 3. Torx head screw − 12mm (3) 2. Suspension assembly 4. Torx head screw − 16mm 1. Carefully position seat to seat suspension. 2. Secure seat to seat suspension with four (4) Torx head screws (Figure 318). Make sure that longer screw is positioned near the seat adjustment handle. Tighten screws from 25 N·m (18 ft−lb). 3. Position and secure console arm assembly to seat. Install all fasteners before fully tightening them. A.
Operator Seat Service g299300 Figure 319 1. Backrest cushion 13. Cap screw (2) 25. Torx screw 2. Seat cushion 14. Seat frame 26. Torx screw (3) 3. RH support cover 15. Nut 27. Washer (3) 4. LH armrest 16. Spring (2) 28. Handle 5. RH support cover 17. Magnet 29. Flat head screw (3) 6. Bushing (2) 18. Seat switch 30. Adaptor plate 7. Backrest 19. Rivet (4) 31. Screw 8. Plug (2) 20. Mounting plate 32. Lever 9. Cable tie (3) 21. Return spring 33.
Operator Seat Disassembly (Figure 319) 1. Remove seat from machine for service (see Operator Seat (page 7–40)). 2. Disassemble operator seat as necessary. Operator Seat Assembly (Figure 319) 1. Assemble operator seat as needed. 2. Install seat to machine (see Operator Seat (page 7–40)).
Operator Seat Suspension g299319 Figure 320 6. Wire harness 11. Air control valve 1. Cover assembly 2. Upper suspension 7. Air spring 12. Cover 3. Thrust limiter 8. Shock absorber 13. Compressor 4. Control lever 9. Air tube assembly 14. Bellows 5. Tether Handle 15. Lower suspension 10. Operator Seat Suspension Disassembly (Figure 320) Note: Most of the seat suspension components can be serviced with the lower seat suspension (item 15) mounted to the frame platform.
Operator Seat Suspension Disassembly (Figure 320) (continued) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Remove operator seat from seat suspension (see Operator Seat (page 7–40)). 3. Disconnect seat suspension electrical connector from machine wire harness. 4. Remove seat suspension components as needed. g299320 Figure 321 1. Operator seat assembly 4. Retaining washer (4) 2. Flange nut (4) 5. Seat platform 3. Screw (4) 5.
Operator Seat Suspension Assembly (Figure 320) 1. If previously removed, install lower seat suspension to seat platform as follows (Figure 321): A. If removed, install mounting screws and secure with retaining washers. B. Position seat suspension onto seat platform. C. Secure lower seat suspension to seat platform with four (4) screws and flange nuts. Tighten flange nuts from 41 to 49 N·m (30 to 36 ft−lb). D. Move fuel tank back into position and install (see Fuel Tank Installation (page 4–19)).
Hood and Lower Shrouds g299332 Figure 322 1. Hood 2. Foam pad (2) 3. Foam strip 4. 5. 8. Panel fastener (42) 9. 15. Hood frame 22. Knob (4) Intake screen 16. Gas spring (2) 23. Washer head screw (4) 10. Radiator screen 17. Ball stud (4) 24. Pop rivet (8) Rear shroud 11. Handle (2) 18. Hair pin (2) 25. Grommet (4) Side shroud − LH 12. Flat washer (2) 19. Clevis pin (2) 26. Grommet plate (4) 6. Front shroud − LH 13. Latch rubber (2) 20. Lanyard (2) 27.
CAUTION Due to the size and weight of the hood assembly, two people are required to remove and install the hood assembly. Hood Removal (Figure 322) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Unlatch and raise hood. 3. Have one person support the rear of the raised hood. 4. Have a second person remove the flange head cap screw and flange nut at the machine frame end of each lanyard (item 20) and disconnect the lanyards from the machine frame.
Chapter 8 Cutting Decks Table of Contents General Information .............................................................................................................................. 8–2 Operator’s Manual ............................................................................................................................. 8–2 Blade Stopping Time.......................................................................................................................... 8–2 Service and Repairs ....
General Information CAUTION Never install or work on the cutting deck or lift arms with the engine running. Always stop engine and remove ignition key first. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine.
Service and Repairs CAUTION Never install or work on a cutting deck or lift arm with the engine running. Always stop engine and remove ignition key first. Front Cutting Deck g299333 Figure 323 1. Front cutting deck 5. Damper assembly 2. Hydraulic motor 6. HOC chain (1 per lift arm) 10. Lock nut (2 per lift arm) 3. Lift arm assembly − LH 7. Cap screw (2 per lift arm) 11. Plate (1 per lift arm) 4. Clevis pin (1 per lift arm) 8. Flat washer (2 per lift arm) 12.
See Drive Belt Idler Assemblies (page 8–11), Blade Spindles (page 8–14), Castor Forks and Wheels (page 8–21) and Deck Skids and Front Deck Roller (Figure 340 and Figure 341) (page 8–23) in this chapter for removal, installation and service information. Front Cutting Deck Removal (Figure 323) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine and remove key from the key switch. 2. Remove center deck cover to access hydraulic deck motor. 3.
Front Cutting Deck Installation (Figure 323) 1. Position machine on a clean, level surface. Lower front lift arms, stop engine and remove key from the key switch. 2. Position the cutting deck to the lift arms. 3. Align lift arm support hub to cutting deck. Make sure that slotted hole in the support hub is toward the rear of the deck. 4.
Front Cutting Deck Winglets g299360 Figure 325 1. Center deck 4. Grease fitting 7. Lock nut (2 per winglet) 2. LH deck winglet 5. Eccentric (2 per winglet) 8. Hinge pin (2 per winglet) 3. Flange bushing (4 per winglet) 6. Cap screw (2 per winglet) Front Cutting Deck Winglet Disassembly (Figure 325) 1. Park machine on a level surface, lower front cutting deck, stop engine and remove key from the key switch. 2. Remove covers from front cutting deck. 3.
Front Cutting Deck Winglet Assembly (Figure 325) 1. Position winglet to front deck. Note: Install previously used eccentric spacers in their original locations. 2. Install eccentric spacers in winglet and center frame brackets. Secure front deck winglet to center deck with hinge pins, cap screws and lock nuts. Do not fully tighten fasteners. 3. Use a ⅜” or ½” drive ratchet or breaker bar to relieve idler pulley tension and install upper (winglet) drive belt.
Front Cutting Deck Winglet Assembly (Figure 325) (continued) B. If new eccentric spacers are being used, initially orient the eccentric spacers with the eccentric lobe downward (notch across hex point upward − Figure 327). Level the front winglet deck to the front center deck (see machine Operator’s Manual). 5. Tighten cap screws and lock nuts securing eccentric spacers from 56 to 75 N·m (41 to 55 ft−lb). 6. Check front cutting deck pitch and adjust as needed (see machine Operator’s Manual). 7.
Wing Cutting Decks g299375 Figure 328 1. Wing cutting deck (LH) 5. Hose guide − open 2. Hydraulic motor 6. Hose guide − loop (on deck connection) 10. Deck connection (LH) 3. Flange head screw (2) 7. Hose guide − loop (on deck) 11. Flange head screw (8) 4. Drive spider 8. Lift arm (LH) 12. Lock nut (8) 9.
See Drive Belt Idler Assemblies (page 8–11), Blade Spindles (page 8–14), Castor Forks and Wheels (page 8–21) and Deck Skids and Front Deck Roller (Figure 340 and Figure 341) (page 8–23) for removal, installation and service information. Wing Cutting Deck Removal (Figure 328) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine and remove key from the key switch. 2. Remove cutting deck outer cover to access hydraulic deck motor. 3. Remove three (3) hose guides from cutting deck.
Drive Belt Idler Assemblies g299397 Figure 329 1. Lower belt Idler assy − wing deck (2) 5. Washer (1 per idler) 2. Upper belt idler assembly (4) 6. Idler pivot (1 per idler) 10. Idler stop bolt 11. Jam nut (2) 3. Retaining ring (1 per idler) 7. Carriage screw (3 per pivot) 4. Torsion spring (1 per idler) 8. Lock nut (3 per pivot) 9. Low belt Idler assy − front deck Drive Belt Idler Assembly Removal (Figure 329) 1. Park machine on a level surface with cutting deck lowered.
Drive Belt Idler Assembly Removal (Figure 329) (continued) 4. Use a ⅜” or ½” drive ratchet or breaker bar to relieve idler pulley tension and remove drive belt. 5. Remove the retaining ring that secures the idler assembly to the idler pivot. CAUTION Be careful when removing the idler arm assembly. The idler torsion spring is under heavy load and may cause personal injury. 6. For additional leverage, slide a nut driver or small piece of pipe onto either end of the idler arm torsion spring.
Drive Belt Idler Assembly Installation (Figure 329) (continued) 4. Use a ⅜” or ½” drive ratchet or breaker bar to relieve idler pulley tension and install drive belt. Make sure that idler pulley applies tension against the back side of the belt. g299399 Figure 331 1. High idler arm 2. Stop bolt 3. Jam nut 5. On front deck, make sure that clearance between lower belt (center) idler arm and stop bolt head is 2.5 to 4.0 mm (0.10 to 0.16 in) (Figure 331). Adjust as necessary. 6.
Blade Spindles g299689 Figure 332 1. Driven spindle (double pulley) 3. Driven spindle (high pulley) 2. Drive spindle 4. Grease fitting Blade Spindle Removal 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2. Remove covers from cutting deck to allow access to blade spindle. 3. If drive spindle is to be serviced, record motor orientation and remove hydraulic motor from cutting deck.
Blade Spindle Removal (continued) 5. Start the engine and raise the cutting deck. Stop engine and remove key from the key switch. Latch or block up the cutting deck so it cannot lower accidentally. g299690 Figure 333 1. Flange screw 6. Blade 2. Hydraulic motor 7. Carriage bolt 3. Drive spindle 8. Flange nut 9. Cap screw 10. Flat washer 4. Blade bolt 5. Anti−scalp cup 6. Remove cutting blade, anti−scalp cup and blade bolt from spindle to be serviced (Figure 333). 7.
Blade Spindle Removal (continued) 8. Lift spindle assembly from deck. See Blade Spindle Service (page 8–17) for additional spindle service information. Blade Spindle Installation 1. Position spindle on cutting deck noting orientation of grease fitting (Figure 332). Secure spindle assembly to deck with correct fasteners (Figure 333). 2. Install cutting blade, anti−scalp cup and blade bolt to spindle. Tighten blade bolt from 119 to 146 N·m (88 to 108 ft−lb). 3.
Blade Spindle Service g299693 Figure 334 1. Spindle housing 7. Spindle spacer 13. Large snap ring 2. Grease fitting 8. Seal (2) 14. Inner bearing spacer 3. Lock nut 9. O−ring 15. Outer bearing spacer 4. Hardened washer 10. Bearing cone (2) 16. Drive Stud 5. Pulley 11. Bearing cup (2) 6. Spindle shaft 12. Spacer ring Blade Spindle Disassembly (Figure 334) 1. Loosen and remove lock nut from top of spindle shaft. Remove hardened washer and pulley from spindle.
Blade Spindle Disassembly (Figure 334) (continued) 3. Remove and discard the oil seals from spindle housing. 4. Remove the bearing cones, inner bearing spacer, spacer ring and spindle shaft O− ring from the spindle housing. Discard the spindle shaft O−ring. 5. Using an arbor press, remove both of the bearing cups and the outer bearing spacer from the housing. 6. The large snap ring (item 13) can remain inside the spindle housing. Removal of this snap ring can be very difficult. 7.
Blade Spindle Assembly (Figure 334) (continued) g299695 Figure 336 1. Bearing cups 4. Arbor press 2. Large snap ring 5. Support 3. Large outer spacer 6. Arbor press base 4. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring.
Blade Spindle Assembly (Figure 334) (continued) IMPORTANT If bearings are being replaced, make sure to use the spacer ring that is included with new bearing set (Figure 335). 7. Slide spacer ring and inner bearing spacer into spindle housing, then install upper bearing cone and greased oil seal into top of housing. Note: The upper seal must have the lip facing in (down) (Figure 337). Make sure upper seal is flush to 1.5 mm (0.060 in) below the housing surface. 8.
Castor Forks and Wheels g299724 Figure 338 Wing Deck (LH shown) 1. Castor arm 7. Cap screw (4) 13. Spring seat (1 per cap) 2. Cap screw (12) 8. Lock nut (4) 14. Spring (1 per cap) 3. Flat washer (12) 9. Flange bushing (2 per castor arm) 15. Cap (1 per cap) 4. Flange nut (12) 10. Thrust washer (4 per castor) Grease fitting (1 per castor arm) 5. Castor wheel (4) 11. Spacer (6 per castor) 6. Castor fork (4) 12.
g299725 Figure 339 1. Bearing (2) 6. Inner tube 2. Flange nut (4) 7. Rim half 3. 4. Plate Rim half 8. 9. Hub Bearing spacer 5. Tire Castor Wheel Disassembly (Figure 338 and Figure 339) Disassemble castor forks and wheels as needed. Castor Wheel Assembly 1. If the caster arm was removed form cutting deck, insert castor arm bolts with bolt head toward the outside of the cutting deck. 2. Assemble castor forks and wheels as needed. A.
Deck Skids and Front Deck Roller (Figure 340 and Figure 341) Deck Skids and Front Deck Roller Removal 1. Remove skids from cutting decks as needed. 2. Remove roller from front cutting deck as needed. Deck Skids and Front Deck Roller Installation g299739 Figure 340 Groundsmaster® 5900 & 5910 16227SL Rev D 5. Roller 1. Skid/Bumper 2. Flange nut (4) 6. Roller shaft 3. Carriage bolt (4) 7. Carriage screw 4. Flange head screw (2) 8.
Deck Skids and Front Deck Roller Installation (continued) g299740 Figure 341 1. Skid/Bumper 5. Inner skid 2. Flange nut (2) 6. Carriage bolt (3) 3. Carriage bolt (2) 7. Lock nut (3) 4. Flange head screw 1. Install skids and rollers to deck. A. Make sure to install all the skid/bumpers on all the cutting decks in the same mounting hole height position (lower, middle or upper). B. The flange head screw at the front of each deck skid/bumper threads into the skid/bumper.
Chapter 9 Operator Cab Table of Contents General Information .............................................................................................................................. 9–2 Operator’s Manual ............................................................................................................................. 9–2 Electrical Components, Schematics and Wire Harness Drawings ...................................................... 9–2 Air Conditioning System.............................
General Information The information in this chapter pertains to the operator cab on the Groundsmaster 5910. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine.
Cab Heater System The cab heater system used on the Groundsmaster 5910 consists of the following components: 1. A heater core mounted in the headliner of the cab. 2. Hoses to allow a circuit for engine coolant to circulate through the heater core. 3. A blower fan motor that provides air movement through the heater core and into the cab. The fan motor is a component of the mixing box located in the cab headliner. The fan motor is also used for the air conditioning system. 4.
Service and Repairs General Precautions for Removing and Installing Air Conditioning System Components CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. WARNING Always wear safety goggles or a face shield when working with air conditioning system components.
General Precautions for Removing and Installing Air Conditioning System Components (continued) 9. The Groundsmaster 5910 air conditioning system uses R134a refrigerant. DO NOT use other refrigerants in the system. A/C system capacity is 3.43 lb of R134a refrigerant. 10. Refrigerant containers (either full or empty) are under pressure that will increase if the containers are heated. DO NOT expose refrigerant containers to high heat sources or flame. 11.
Air Conditioning Compressor g299743 Figure 342 1. Air conditioning compressor 6. Cap screw (2) 11. Tubing 2. Compressor mount 7. Flat washer (4) 12. Cap screw (4) 3. AC hose 8. Lock washer (2) 13. Mount strap (2) Hex nut (2) 14. Flange nut (4) 4. AC hose 5. Elbow fitting 9. 10. Drive belt Removal (Figure 342) 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from the key switch. 2.
Removal (Figure 342) (continued) CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 6. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 7. Label and remove hoses from compressor. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 8.
Installation (Figure 342) (continued) 6. Remove caps that were placed on hoses and fittings during the removal process. Using labels placed during removal, properly secure hoses to compressor. 7. Connect compressor electrical connector to machine wire harness. 8. Have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. A/C system capacity is 3.43 lb of R134a refrigerant. 9.
Roof Assembly g299808 Figure 343 1. Roof panel 6. Front condenser seal 11. Flat washer (22) 2. Headliner assembly 7. LH condenser seal 12. Flange nut (22) 3. Condenser screen 8. Rear condenser seal 13. Front/rear cab strap (2) 4. Flange head screw (16) 9. Condenser assembly 14. Side cab strap (2) 5. RH condenser seal 10. Shoulder screw (22) To gain access to heater and air conditioning components, the roof panel needs to be removed.
Removal (Figure 343) 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from the key switch. 2. Release swell latches and lift condenser screen (item 3) from roof assembly. 3. Remove flange head screws that secure condenser seals (items 5, 6, 7 and 8) to roof and A/C condenser assembly. 4. Remove shoulder screws, washers and flange nuts that secure the roof and cab straps to the headliner. 5. Carefully lift roof from headliner and cab. Installation (Figure 343) 1.
Heating and Air Conditioning Components g299831 Figure 344 1. A/C binary switch 4. A/C condenser assembly 7. Heat and A/C mixing box assembly 2. A/C drier−receiver 5. LH intake air filter 8. Wiper motor assembly 3. RH intake air filter 6.
Heating and Air Conditioning Components (continued) g299832 Figure 345 1. Evaporator/heater cores 3. Air diverter assembly 2. Blower fan 4. A/C freeze switch Access to cab heating and air conditioning components can be obtained by removing the cab roof. Once the cab roof is removed, the illustrations in Figure 344 and Figure 345 can be used to identify the components used for heating and cooling the operator cab.
A/C Condenser Fan Assembly g299833 Figure 346 1. Cab frame 3. A/C condenser assembly 2. Cab headliner assembly 4. Knob (2) Groundsmaster® 5900 & 5910 16227SL Rev D Page 9–13 5.
Removal (Figure 346) g299834 Figure 347 1. Condenser fan (2) 2. Knob (2) 3. Fan plug (2) g299835 Figure 348 1. Fan mount plate 4. Condenser fan (2) 2. Screw (4 per fan) 5. Plastic plug (3) 3. Fan tab (4 per fan) 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from the key switch. 2. Locate A/C condenser fan assembly which is secured to the frame under the rear of the cab headliner. 3.
Installation (Figure 346) 1. If condenser fan assembly was disassembled, use Figure 348 as a guide to secure fans to fan mount plate. 2. Raise and support fan assembly to cab frame. 3. Secure fan assembly to machine with two (2) knobs. 4. Connect the two (2) condenser fan plugs to the wire harness connectors attached to the cab frame.
A/C Condenser Assembly g299873 Figure 349 1. Cab frame 5. Condenser fan assembly 9. AC hose (from compressor) 2. Cab headliner assembly 6. Flange nut (4) 10. O−ring 3. A/C condenser assembly 7. Strip seal (2) 11. AC hose (to drier−receiver) 4. Knob (2) 8. Edge seal (2) 12. O−ring Removal (Figure 349) 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from the key switch. 2.
Removal (Figure 349) (continued) 4. Read the General Precautions for Removing and Installing Air Conditioning System Components (page 9–4). CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 5. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 6. Label and disconnect hoses from condenser core.
Installation (Figure 349) 1. If condenser assembly was disassembled: A. To properly seal condenser core, apply RTV sealant to all mating surfaces of walls, lower legs and condenser core before assembly. B. Assemble all condenser assembly components using Figure 350 as a guide. Make sure that strip and edge seals are in good condition after assembly. 2. Carefully lower the A/C condenser assembly through headliner and onto cab frame. 3. Secure A/C condenser assembly to cab frame with four (4) flange nuts. 4.
Mixing Box Assembly g299905 Figure 351 1. Mixing box 12. Hairpin 23. Vent hose (2) 2. Mixing box cover 13. Flat washer 24. Tube support (2) 3. Cover insulation 14. Carriage screw (2) 25. Vent hose (2) 4. Rivet (19) 15. Support plate 26. Adapter (2) 5. Heater core A/C evaporator/fan assy 16. Flange nut (4) 27. Hose clamp (2) 6. Expansion valve 17. Flat washer (2) 28. Vent hose 7. O−ring (2) 18. Button head screw (2) 29. Vent hose 8. 9.
Removal (Figure 351) 1. Park machine on a level surface, lower cutting decks and stop engine. Remove key from the key switch. 2. To access mixing box assembly, remove roof panel from top of cab (see Roof Assembly (page 9–9)). 3. Remove cover from mixing box assembly: A. Carefully use a small pry−bar to raise head of pin in center of each rivet that secures mixing box cover. B. Lift rivets from cover and mixing box. C. Remove mixing box cover.
Removal (Figure 351) (continued) g299907 Figure 353 1. Mixing box assembly 7. O−ring 2. A/C expansion valve 8. Hose (from drier) 3. A/C drier−receiver 4. Cable tie (2) 9. O−ring 10. O−ring 5. A/C binary switch 11. Hose (to compressor) 6. Hose (from condenser) 12. O−ring CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 6.
Installation (Figure 351) (continued) Then, have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. A/C system capacity is 3.43 lb of R134a refrigerant. 5. Secure cover to mixing box assembly: A. Position mixing box cover to mixing box. Make sure that wire harness is routed through recess in side of mixing box. B.
Heater and A/C Evaporator Cores g299909 Figure 354 1. Mixing box 9. Freeze switch 17. Condensation catch foam 2. Rivet (19) 10. Mount bracket (shown with fan) 18. Air diverter assembly 3. Mixing box cover 11. Expansion valve 19. A/C hose (from drier−receiver) 4. Cover insulation 12. O−ring (2) 20. O−ring 5. Screw (5) 13. A/C evaporator core 21. A/C hose (to A/C compressor) 6. Mount bracket cover 14. Heater core 22. O−ring 7. Cover gasket 15. Double sided tape (2) 8.
Removal (Figure 354) (continued) CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 4. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 5. Disconnect both evaporator core swivel fittings from front ports of expansion valve.
Installation (Figure 354) (continued) 7. Remove caps that were placed on evaporator core tubes and expansion valve ports during the removal process. Position expansion valve with attached hoses to the evaporator core tubes. Properly secure evaporator core swivel fittings to front ports of expansion valve. Torque fittings from 21 to 27 N·m (15 to 20 ft−lb). 8. Make sure that all machine air conditioning components are installed and secure. 9.
Blower Fan g299935 Figure 355 1. Mixing box 7. Expansion valve 13. A/C hose (from drier−receiver) 2. Rivet (19) 8. Blower fan 14. O−ring 3. Mixing box cover 9. Screw (6) 15. A/C hose (to AC compressor) 4. Cover insulation 10. Freeze switch 16. O−ring 5. Heater core A/C evaporator assembly 11. Screw (2) 6. O−ring (2) 12. Air diverter assembly Note: The blower fan can be removed and installed with the mixing box (item 1 in Figure 355) attached to the cab headliner.
Removal (Figure 355) (continued) CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 4. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 5. Disconnect both evaporator core swivel fittings from front ports of expansion valve.
Installation (Figure 355) 1. Position blower fan to heater core/AC evaporator assembly and secure with six (6) screws. 2. Carefully lower heater core/AC evaporator assembly with attached blower fan into mixing box. 3. Connect wire harness connectors to freeze switch and blower fan assembly (Figure 356). 4. Secure mixing box cover: A. Position mixing box cover to mixing box. Make sure that wire harness is routed through recess in side of mixing box. B.
Windshield Wiper Assembly g299960 Figure 357 1. Wiper blade 7. Washer plate 13. Cap screw 2. Cap screw (2) 8. Wiper bracket 14. Lock washer 3. Lock washer (2) 9. Washer head screw (4) 15. Cover 4. Wiper arm assembly 10. Flange nut (4) 16. Jam nut 5. Flange nut (2) 11. Washer head screw (3) 17. Star washer 6. Cab headliner 12. Wiper motor 18. Wiper motor plate Disassembly (Figure 357) 1. Park machine on a level surface, lower cutting decks and stop engine.
Disassembly (Figure 357) (continued) 3. If necessary, remove wiper arm assembly: A. Disconnect washer hose from wiper assembly. B. Lift caps at top of wiper arms and remove flange nuts that secure wiper arms to wiper motor. C. Use suitable puller to remove tapered wiper arm sockets from wiper motor shafts. 4. If access to wiper motor is necessary, remove roof panel from top of cab to allow access to wiper motor assembly (see Roof Assembly (page 9–9)).
Assembly (Figure 357) (continued) C. Slide wiper arm sockets onto wiper motor shafts so that the bottom of the wiper blade is 76 mm (3 in) from the right side window trim (Figure 358). D. Secure wiper arm sockets to motor shafts with flange nuts. Torque nuts from 23 to 25 N·m (16 to 18 ft−lb). E. Install wiper arm caps over flange nuts. F. Connect washer hose to wiper assembly.
Operator Cab : Service and Repairs Page 9–32 Groundsmaster® 5900 & 5910 16227SL Rev D
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–3 Hydraulic Schematic .........................................................................................................................A–5 Electrical Schematic (machine serial numbers below 316000200) .....................................................
Engine Wire Harness Drawing (machine serial numbers above 403450001) ...................................A–43 Cab Power Supply Wire Harness (Machine serial numbers below 316000200)................................A–44 Cab Headliner Wire Harness Drawing..............................................................................................A–45 Cab Headliner Wire Harness Diagram .............................................................................................
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 & 5910 16227SL Rev D
Hydraulic Schematic LH WING DECK LIFT BORE: 2.25” STROKE: 11.38” ROD: 1.12” EXTEND TO: LIFT STEER CYLINDERS BORE: 1.25” STROKE: 6.00” ROD: 0.75” CENTER DECK LIFT BORE: 2.25” STROKE: 4.38” ROD: 1.12” EXTEND TO: LIFT C3 G1 M1 C4 C2 C5 OR5 .138” OR3 .088” P1 OR2 RH WING DECK LIFT BORE: 2.25” STROKE: 11.38” ROD: 1.12” EXTEND TO: LIFT C6 OR7 .088” .025” R L S9 S4 1.5 CID S5 SQ S2 10 PSI S6 S3 S7 S8 LC1 110 PSI RV 10 PSI LC2 3000 PSI 600 PSI M2 G4 PRV OR4 .046” OR2 .055” 6.
Electrical Schematic (machine serial numbers below 316000200) All relays and solenoids are shown as de−energized. 2 1 All ground wires are black.
Electrical Schematic (machine serial numbers below 316000200) 1 SHEET 1 3 5 2 4 SHEET 1 6 All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic (machine serial numbers 316000201 to 399999999) All relays and solenoids are shown as de−energized. 1 All ground wires are black.
Electrical Schematic (machine serial numbers 316000201 to 399999999) 1 SHEET 1 3 5 2 4 SHEET 1 6 All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic (machine serial numbers 400000000 to 403450000) All relays and solenoids are shown as de−energized. 1 All ground wires are black.
Electrical Schematic (machine serial numbers 400000000 to 403450000) 1 SHEET 1 3 5 2 4 7 SHEET 1 6 All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic (machine serial numbers 403450001 to 405600000) All relays and solenoids are shown as de−energized. 1 All ground wires are black.
Electrical Schematic (machine serial numbers 403450001 to 405600000) 1 SHEET 1 3 5 2 4 7 SHEET 1 6 All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic (machine serial numbers above 405600001) All relays and solenoids are shown as de−energized. All ground wires are black.
Electrical Schematic (machine serial numbers above 405600001) 1 SHEET 1 3 5 2 4 7 SHEET 1 6 All relays and solenoids are shown as de−energized. All ground wires are black.
Operator Platform Wire Harness Drawing (machine serial numbers below 316000200) g299976 Page A–16 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0201 Rev B, Sheet 1 of 1
Operator Platform Wire Harness Diagram (machine serial numbers below 316000200) g299969 Groundsmaster 5900/5910, Drawing 122-0201 Rev B, Sheet 1 of 2 16227SL Rev D Page A–17
Operator Platform Wire Harness Diagram (machine serial numbers below 316000200) g299970 Page A–18 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0201 Rev B, Sheet 2 of 2
Operator Platform Wire Harness Drawing (machine serial numbers 316000201 to 316999999) g299971 Groundsmaster 5900/5910, Drawing 122-0806 Rev A, Sheet 1 of 1 16227SL Rev D Page A–19
Operator Platform Wire Harness Diagram (machine serial numbers 316000201 to 316999999) g299972 Page A–20 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0806 Rev A, Sheet 1 of 2
Operator Platform Wire Harness Diagram (machine serial numbers 316000201 to 316999999) g299973 Groundsmaster 5900/5910, Drawing 122-0806 Rev A, Sheet 2 of 2 16227SL Rev D Page A–21
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000) CV g302224 Page A–22 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0990 Rev C, Sheet 1 of 1
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000) g302225 Groundsmaster 5900/5910, Drawing 122-0990 Rev C, Sheet 1 of 2 16227SL Rev D Page A–23
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000) g302226 Page A–24 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0990 Rev C, Sheet 2 of 2
Operator Platform Wire Harness Diagram (machine serial numbers 403450001 to 405600000) CV g302254 Groundsmaster 5900/5910, Drawing 122-1555 Rev B, Sheet 1 of 1 16227SL Rev D Page A–25
Operator Platform Wire Harness Diagram (machine serial numbers 403450001 to 405600000) g302255 Page A–26 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-1555 Rev B, Sheet 1 of 2
Operator Platform Wire Harness Diagram (machine serial numbers 403450001 to 405600000) g302256 Groundsmaster 5900/5910, Drawing 122-1555 Rev B, Sheet 2 of 2 16227SL Rev D Page A–27
Operator Platform Wire Harness Drawing (machine serial numbers above 405600001) CV g329182 Page A–28 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-1640 Rev A, Sheet 1 of 2
Operator Platform Wire Harness Diagram (machine serial numbers above 405600001) g329183 Groundsmaster 5900/5910, Drawing 122-1640 Rev A, Sheet 2 of 2 16227SL Rev D Page A–29
Rear Wire Harness Drawing (machine serial numbers below 316000200) g299974 Page A–30 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0441 Rev B, Sheet 1 of 1
Rear Wire Harness Diagram (machine serial numbers below 316000200) g299975 Groundsmaster 5900/5910, Drawing 122-0441 Rev B, Sheet 1 of 1 16227SL Rev D Page A–31
Rear Wire Harness Drawing (machine serial numbers 316000201 to 403450000) g299990 Page A–32 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0807 Rev A, Sheet 1 of 1
Rear Wire Harness Drawing (machine serial numbers 316000201 to 403450000) g299991 Groundsmaster 5900/5910, Drawing 122-0807 Rev A, Sheet 1 of 1 16227SL Rev D Page A–33
Rear Wire Harness Drawing (machine serial numbers 403450001 to 405600000) CV g302318 Page A–34 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-1554 Rev C, Sheet 1 of 2
Rear Wire Harness Drawing (machine serial numbers 403450001 to 405600000) g302319 Groundsmaster 5900/5910, Drawing 122-1554 Rev C, Sheet 2 of 2 16227SL Rev D Page A–35
Rear Wire Harness Drawing (machine serial numbers above 405600001) CV g329180 Page A–36 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-1639 Rev A, Sheet 1 of 2
Rear Wire Harness Drawing (machine serial numbers above 405600001) g329181 Groundsmaster 5900/5910, Drawing 122-1639 Rev A, Sheet 2 of 2 16227SL Rev D Page A–37
Engine Wire Harness Drawing (machine serial numbers 316000001 to 316999999) g299992 Page A–38 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0337 Rev B, Sheet 1 of 1
Engine Wire Harness Drawing (machine serial numbers 316000001 to 316999999) g299993 Groundsmaster 5900/5910, Drawing 122-0337 Rev B, Sheet 1 of 1 16227SL Rev D Page A–39
Engine Wire Harness Drawing (machine serial numbers 400000000 to 403450000) CV g302386 Page A–40 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-0993 Rev B, Sheet 1 of 2
Engine Wire Harness Drawing (machine serial numbers 400000000 to 403450000) g302387 Groundsmaster 5900/5910, Drawing 122-0993 Rev B, Sheet 2 of 2 16227SL Rev D Page A–41
Engine Wire Harness Drawing (machine serial numbers above 403450001) CV g302426 Page A–42 16227SL Rev D Groundsmaster 5900/5910, Drawing 122-1556 Rev C, Sheet 1 of 2
Engine Wire Harness Drawing (machine serial numbers above 403450001) g302427 Groundsmaster 5900/5910, Drawing 122-1556 Rev C, Sheet 2 of 2 16227SL Rev D Page A–43
Cab Power Supply Wire Harness (Machine serial numbers below 316000200) g299994 Page A–44 16227SL Rev D Groundsmaster 5910, Drawing 122-0640 Rev B, Sheet 1 of 1
Cab Headliner Wire Harness Drawing g299995 Groundsmaster 5910, Drawing 122-0723 Rev A, Sheet 1 of 1 16227SL Rev D Page A–45
Cab Headliner Wire Harness Diagram g299996 Page A–46 16227SL Rev D Groundsmaster 5910, Drawing 122-0723 Rev A, Sheet 1 of 1
Wire Harness Diagram − Two−Post ROPS Extension 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g299997 Groundsmaster 5900 (Model 31698), Drawing 122-0892 Rev B, Sheet 1 of 1 16227SL Rev D Page A–47
Wire Harness Diagram − Two−Post ROPS Extension 6 5 4 3 2 1 D D C C B B A A 6 5 4 3 2 1 g299998 Page A–48 16227SL Rev D Groundsmaster 5900 (Model 31698), Drawing 122-0892 Rev B, Sheet 1 of 1
