Page 1 Form No. 16227SL Rev B Groundsmaster ® 5900 & 5910 (Models 31698 and 31699) © 2019—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision Date Description – 2016 Initial Issue 03/2018 Updated Engine chapter, Electrical chapter and Foldout drawings. Added revision history. 10/2019 Updated Hydraulic, Electrical, Chassis and Operator Cab chapters. Revision History Page 2 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 3 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 servicemanuals@toro.com...
Page 4 NOTES NOTES Page 4 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 5 Catalogs for your machine and its accessories with this Service Manual for reference. Additional copies of the Operator’s Manuals and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
Page 6 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.
Page 7: Table Of Contents
Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Safety and Instructional Decals ..............1–8 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–7 Shop Supplies .................... 2–13 Special Tools ....................2–15 Chapter 3: Troubleshooting ................
Page 8 Electrical Schematic (machine serial numbers below 316000200) ....A–5 Electrical Schematic (machine serial numbers 316000201 to 399999999) ....................A–6 Electrical Schematic (machine serial numbers 316000201 to 399999999) ....................A–7 Electrical Schematic (machine serial numbers 400000000 to 403450000) ....................A–8 Electrical Schematic (machine serial numbers 400000000 to 403450000) ....................A–9 Electrical Schematic (machine serial numbers above 403450001)....A–10 Electrical Schematic (machine serial numbers above 403450001)....A–11...
Page 9 Engine Wire Harness Drawing (machine serial numbers above 403450001) ....................A–35 Cab Power Supply Wire Harness (Machine serial numbers below 316000200) ....................A–36 Cab Headliner Wire Harness Drawing............A–37 Cab Headliner Wire Harness Diagram ............A–38 Wire Harness Diagram − Two−Post ROPS Extension .........A–39 Wire Harness Diagram −...
Page 10 Preface Page 10 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 11: Chapter 1: Safety
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........................1–4 Battery-Disconnect Switch ......................... 1–5 Jacking Instructions ........................... 1–6 Safety and Instructional Decals ......................1–8 Groundsmaster ®...
Page 12: Safety Instructions
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.
Page 13: While Operating The Machine
C. Apply the parking brake. D. Stop engine and remove key from switch. 6. Toro recommends that anytime the machine is parked (short or long term), the cutting decks should be lowered to the ground. This relieves hydraulic pressure from the deck lift circuit and eliminates the risk of the cutting decks unexpectedly lowering to the ground.
Page 14: Maintenance And Service
15. At the time of manufacture, the machine conformed to the safety standards for riding mowers. To assure optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance with the safety standards and the warranty may be voided.
Page 15: Battery-Disconnect Switch
If the battery disconnect switch is set to OFF while the engine is running, the engine will continue to run on the power supplied by the 12 Volt alternator and you may cause damage to electrical components including the Toro Electronic Controllers (TECs). Groundsmaster ®...
Page 16: Jacking Instructions
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.
Page 17 Jacking the Rear End (Figure g008995 Figure 3 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.
Page 18: 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. Safety: Safety and Instructional Decals Page 1–8 Groundsmaster ®...
Page 19: Chapter 2: Specifications And Maintenance
Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine..............................2–3 Hydraulic System ..........................2–4 Chassis .............................. 2–5 Cutting Decks............................. 2–6 Torque Specifications ........................... 2–7 Calculating the Torque Values When Using a Drive-Adapter Wrench ..........2–8 Identifying the Fastener........................
Page 20: Specifications
Specifications Overall Dimensions g287504 Figure 4 Specifications and Maintenance: Specifications Page 2–2 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 21: Engine
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) −...
Page 22: Hydraulic System
Hydraulic System Item Description Piston (Traction) Pump Variable Displacement Axial Piston 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)
Page 23: Chassis
Chassis Item Description Tire pressure 29 x 12.00−15, 6 ply @ 220 kPa (32 psi) Front tire 23 x 10.50−12, 6 ply @ 207 kPa (30 psi) Rear tire Rear wheel toe−in 0 to 3 mm (0.12 in) Wheel lug nut torque (front and 124 to 146 N·m (92 to 108 ft−lb), front and rear) rear in a crossing pattern...
Page 24: Cutting Decks
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 25.4 mm to 152 mm (1 to 6 in) in 12.7 mm (1/2 in) increments. Center RANGE: deck height−of−cut adjustment is achieved by changing spacers on castor wheels and re−positioning the castor wheel axles in the castor...
Page 25: Torque Specifications
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.
Page 26: Calculating The Torque Values When Using A Drive-Adapter Wrench
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 5 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...
Page 27: Identifying The Fastener
Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 28: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, and 8 with Studs, and Sems with Studs, and Sems with Studs, and Sems with Thin Height Regular Height Nuts...
Page 29: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Class 10.9 Bolts, Screws, and Thread Size Studs with Regular Height Nuts Studs with Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 ±...
Page 30: Other Torque Specifications
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 ±...
Page 31: Shop Supplies
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.
Page 32 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.
Page 33: Special Tools
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...
Page 34 Hydraulic Hose Kit K-Line Part No. TOR6007 and Hydraulic Test Fitting Kit K-Line Part No. TOR4079. Hydraulic O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection.
Page 35 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. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12 8 ORFS (13–16–16) TOR4079–4...
Page 36 Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 2–16). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Measuring Container K-Line Part Number: TOR4077 Use this container to test hydraulic motor efficiency (motors with case drain lines only).
Page 37 Remote Starter Switch (purchased) switch connector for circuit protection. A remote stater switch can also be constructed using Toro switch #106−2027, a length of 14 gauge wire, a 20 amp in−line fuse, two (2) alligator clips and necessary connectors. Connecting the...
Page 38 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,...
Page 39: Chapter 3: Troubleshooting
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.......................... 3–2 Repair ..............................3–2 Solution Confirmation......................... 3–2 General Hydraulic System Problems ..................... 3–3 Traction Circuit Problems ........................
Page 40: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
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 •...
Page 41: General Hydraulic System Problems
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.
Page 42: Traction Circuit Problems
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.
Page 43 Problem Possible Cause High range traction speed (transport) will not An electrical problem exists that prevents engage. 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.
Page 44: Pto Problems
PTO Problems Problem Possible Cause An electrical problem exists that prevents None of the cutting decks will operate. solenoid valve operation in deck manifolds (see Chapter 6: Electrical System (page 6–1)). Note: Cutting decks have to be fully lowered Gear pump internal drive shaft failure. and floating, traction speed needs to be in Both gear pump sections for the cutting deck low range (mow), the PTO switch needs to be...
Page 45: Lift/Lower Circuit Problems
Lift/Lower Circuit Problems Problem Possible Cause Engine RPM is too low. Cutting decks will not raise. Note: To raise a cutting deck, the engine must Hydraulic oil level in reservoir is too low (other be running. Also, the operator seat has to be hydraulic systems are affected as well).
Page 46: Steering Circuit Problems
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.
Page 47: Starting Problems
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)).
Page 48 Problem Possible Cause Nothing happens when start attempt is made The key switch or circuit wiring is faulty. (engine does not crank). InfoCenter display Traction pedal position sensor or circuit wiring operates with the key switch in the RUN is faulty. position.
Page 49: General Run And Transport Problems
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 Key switch or circuit wiring is faulty.
Page 50: Cutting Deck (Pto) Operating Problems
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 The seat switch or circuit wiring is faulty.
Page 51 Problem Possible Cause Cutting deck(s) do not operate. Cutting decks The operator is lifting off the seat switch. are able to raise and lower. 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.
Page 52: Cutting Deck Lift/Lower Problems
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.
Page 53 Problem Possible Cause RH wing cutting deck will not raise or lower, RH deck raise/lower switch or circuit wiring is but the front and LH wing cutting decks will faulty. raise and lower. Lift control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty.
Page 54: Operator Advisories
1602, 1603, 1604, Deck Raise Denied 1605 Note: If “Unknown Cause” appears as an advisory description, a controller software issue may exist. If you are unable to clear this type of advisory, contact your Authorized Toro Distributor. Troubleshooting: Page 3–16 Groundsmaster ®...
Page 55: To Start
Engine coolant temperature must be less than 102 ºC (216 ºF) before COOL: PTO will engage. #109 REQUIRES CAN communication between the two (2) Toro Electronic Controllers SERVICE: (TEC) must be reestablished before the PTO will engage. TO SET CRUISE CONTROL The TO SET CRUISE CONTROL advisory identifies that the cruise control will not engage when the cruise control switch is pressed.
Page 56: To Lower Deck
Operator needs to be in seat before cutting decks will lower. MUST BE SEATED: #304 REQUIRES The slave Toro Electronic Controller is inoperable due to CAN SERVICE: communication issues or an internal controller fault. TO FLOAT DECK The TO FLOAT DECK advisory identifies that the cutting decks are not in float mode.
Page 57: To Set Low Range
Ground speed needs to be less than 2 MPH in order to engage low speed GROUND SPEED: range. #604 REQUIRES CAN communication between the two (2) Toro Electronic Controllers SERVICE: (TEC) must be reestablished before low speed range can be engaged. FOR TRACTION The FOR TRACTION advisory identifies that the traction drive will not engage when the traction pedal is pressed.
Page 58: Fuel Level
TRACTION PEDAL neutral position and the parking brake must be engaged before cutting TO NEUTRAL: decks will raise. #1605 REQUIRES The slave Toro Electronic Controller is inoperable due to CAN SERVICE: communication issues or an internal controller fault. Troubleshooting: Page 3–20 Groundsmaster ®...
Page 59: Using The Infocenter Display For Troubleshooting
Input/Output screen should show as ON. If the inputs and qualifiers are properly positioned and the output remains OFF, a problem with controller power (circuit wiring or fuse) may exist, or the Toro Electronic Controller (TEC) or TEC software may require reloading or replacement. Contact your Authorized Toro Distributor for assistance.
Page 60 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.
Page 61: Machine Faults
516.9 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...
Page 62 Traction Current Validation Failure. Test the traction (piston) pump forward and reverse solenoid coils and circuit wiring. Replace master TEC (contact an Authorized Toro Distributor for assistance). Forward Traction Circuit Failure. Test the traction (piston) pump forward and reverse solenoid coils and circuit wiring.
Page 63 (contact an Authorized Toro Distributor for assistance). Master Contention Fault Reprogram system software (contact (two master controllers on CAN your Authorized Toro Distributor for bus). assistance). Slave Contention Fault Reprogram system software (contact (two slave controllers on CAN your Authorized Toro Distributor for bus).
Page 64 Replace slave TEC (contact an Authorized Toro Distributor for assistance). Internal software fault 3. A software fault exists within the Master TEC. Contact an authorized Toro Distributor. Internal software fault 4. A software fault exists within the Master TEC. Contact an authorized Toro Distributor.
Page 65: Engine Faults
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. The faults generated by the TECs are specific to the machine (see Machine Faults (page 3–23) for additional information).
Page 66 IDLE 0X00 ENG HRS − 100 VOLTAGE LOW SPN − 3251 FMI − 4 OCC CNT − 1 g287510 Figure 12 Button 1 Button 4 Button 2 Button 5 Button 3 Engine fault description 3. The fault description will be displayed on the Info- Center (Figure 12).
Page 67: Factors That Can Affect Quality Of Cut And Clipping Dispersion
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.
Page 68 Troubleshooting: Page 3–30 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 69 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........................... 4–2 Engine Electronic Control Unit (ECU) ....................4–3 Yanmar Engine ..........................4–5 Diesel Particulate Filter ........................4–6 Service and Repairs ...........................
Page 70: General Information
Yanmar engine repair facility. Service and repair parts for Yanmar engines are supplied through your Authorized Toro Distributor. If no parts list is available, be prepared to provide your distributor with the Toro model and serial number of your machine.
Page 71: Engine Electronic Control Unit (Ecu)
The Yanmar electronic tool and troubleshooting manual should be used to provide assistance in identifying the cause of the problem and the repairs that are necessary. Contact your Toro distributor for assistance in Yanmar engine troubleshooting.
Page 72 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.
Page 73: Yanmar Engine
During the operation of the engine, if conditions warrant, the engine ECU may generate an engine fault. Use the machine InfoCenter to identify the engine fault; refer to the Yanmar Troubleshooting Manual, or contact an Authorized Toro Distributor for assistance. Groundsmaster ® 5900 & 5910 Page 4–5...
Page 74: Diesel Particulate Filter
• For machines with software 122−0310A thru H: Complete DPF regeneration instructions can be found in the updated traction unit Operator’s Manual for the specific machine. Visit www.toro.com to download the updated traction unit Operator’s Manual for the machine. •...
Page 75 Regeneration (continued) Types of regeneration that are performed automatically (while the machine is operating) (continued) Assist Occurs because of prolonged operation The engine ECU adjusts the intake at low engine speed, low engine load, throttle to raise the exhaust temperature. or when the engine ECU detects the soot filter is becoming obstructed.
Page 76 Note: Verify the model and serial number of the engine installed in the machine. 4TNV98CTNTRL engines below serial number 16420 cannot run a recovery regeneration without first reprogramming the engine ECU. Contact an Authorized Toro Distributor for assistance. Yanmar Diesel Engine: General Information Page 4–8 Groundsmaster ®...
Page 77: General Information
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.
Page 78 Ash Accumulation Advisories and Engine Faults (continued) Fault Level Fault Code Engine Engine Speed Recommended Action Power Reduction Rating Level 2: De-rated to None Service DPF. Engine Warning Level 3: De-rated to Maximum torque Service DPF. Engine +200 rpm Warning Yanmar Diesel Engine: General Information Page 4–10 Groundsmaster...
Page 79: Service And Repairs
Service and Repairs Air Filter 10 to 11 N·m (90 to 100 in-lb) g287547 Figure 15 Air filter assembly Air box Intake tube Flange nut (2) Flange head screw (2) Hose clamp Grommet Carriage screw (2) Foam seal Flange nut (2) Hose clamp Foam seal Air Filter Removal...
Page 80 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.
Page 81: Exhaust System
Exhaust System 44 to 54 N·m (32 to 40 ft-lb) 24 to 34 N·m (18 to 25 ft-lb) g287549 Figure 17 Groundsmaster ® 5900 & 5910 Page 4–13 Yanmar Diesel Engine: Service and Repairs 16227SL Rev B...
Page 82 Once the DPF has gone through the reconditioning process, it can be re−installed in the exhaust system. Contact your Toro Distributor for information on reconditioning the DPF. The diesel oxidation catalyst (DOC) has a service life expectancy and requires replacement at recommended intervals.
Page 83 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.
Page 84 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.
Page 85: Fuel System
Fuel System g287551 Figure 19 Fuel tank Bushing (2) Fuel hose − to vent tube Fitting cover Standpipe − return Bushing Screw (3) Standpipe − supply Elbow fitting − vent Clamp (3) Clamp (2) Gasket Fuel hose − return from filter Panel fastener (4) Fuel sender Fuel hose −...
Page 86 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.
Page 87 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.
Page 88 Fuel Lines, Filters and Fuel Pump Removal RETURN SUPPLY VENT g287553 Figure 21 Fuel hose − supply from tank Flange head screw (2) Fuel hose − return to tank Fuel/water separator element Fuel pump Rivet (2) Fuel/water separator head Grommet Clip (2) Straight barb fitting Fuel hose −...
Page 89 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.
Page 90: Radiator
Radiator 3 to 5 N·m (30 to 45 in-lb) 22 23 3 to 5 N·m (30 to 45 in-lb) 3 to 5 N·m (30 to 45 in-lb) g287539 Figure 22 Fan shroud assembly Screw − carriage (2) Washer (4) Foam seal Coolant reservoir Cap screw (2) Foam seal...
Page 91 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).
Page 92 Radiator Installation (continued) g287540 Figure 23 Fan shroud assembly Lock nut Fan shroud prop Cap screw 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.
Page 93: Engine
Engine g287541 Figure 24 Cooler frame assembly Flange not (3) Flange nut (6) Battery−disconnect switch bracket Carriage screw (4) 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.
Page 94 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.
Page 95 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).
Page 96 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.
Page 97 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.
Page 98 Engine Installation (continued) 10. Install the 24 Volt alternator/air conditioning compressor drive belt (see 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.
Page 99: Pump Adapter Plate (Coupler)
Pump Adapter Plate (Coupler) 39 to 45 N·m (29 to 33 ft-lb) 54 to 65 N·m (40 to 48 ft-lb) g287545 Figure 28 Flywheel cover Cap screw (8) Washer head screw (12) Spring coupler Engine Hardened washer (8) Removal Note: The hydraulic pump assembly needs to be removed from engine before coupler can be removed.
Page 100 Installation Pump Side g287546 Figure 29 Coupler Engine flywheel Coupler hub 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.
Page 101: Chapter 5: Hydraulic System
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........................... 5–3 Traction Circuit Component Failure....................5–5 Hydraulic Hoses..........................5–6 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) ..............5–7 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)..........
Page 102 Gear Pump Service.......................... 5–88 Traction Circuit ..........................5–93 Piston (Traction) Pump ........................5–94 Piston (Traction) Pump Service......................5–98 Front Wheel Motors........................5–100 Rear Wheel Motors ........................5–105 Wheel Motor Service........................5–107 Traction Control Manifold ....................... 5–109 Traction Control Manifold Service ....................5–112 Brake Release Manifold .........................
Page 103: General Information
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.
Page 104 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.
Page 105: Traction Circuit Component Failure
Groundsmaster 5900 or 5910, keep engine speed below 2200 RPM. Higher engine speeds may allow excessive hydraulic flow to the filter. Once the Toro high flow hydraulic filter kit has been placed in the circuit, raise and support the machine with all wheels off the ground (see...
Page 106: Hydraulic Hoses
Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).
Page 107: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal)
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 31 Tube or hose Swivel nut 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.
Page 108 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size Installation Torque (inch)—threads per inch) 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 1—14...
Page 109: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 33 Fitting 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.
Page 110 Installing an Adjustable Fitting g212224 Figure 34 Locknut Back-up washer O-ring g212225 Figure 35 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer 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.
Page 111 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;...
Page 112: Hydraulic Schematic
Hydraulic Schematic The hydraulic schematic for Groundsmaster 5900 and 5910 machines is located A Hydraulic Schematic (page A–3). Hydraulic System: Hydraulic Schematic Page 5–12 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 113: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams g287712 Figure 36 Traction Circuit Schematic Groundsmaster ® 5900 & 5910 Page 5–13 Hydraulic System: Hydraulic Flow Diagrams 16227SL Rev B...
Page 114: Traction Circuit Operation
Pushing the traction pedal rotates a potentiometer that provides an input to the machine master Toro Electronic Controller (TEC). The controller in turn sends a corresponding PWM (Pulse Width Modulation) output signal to the piston pump displacement control to rotate the pump swash plate accordingly to control the pump’s output and direction.
Page 115 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.
Page 116: Traction Circuit: Low Range Traction Speed (Mow)
Traction Circuit: Low Range Traction Speed (Mow) Working Pressure Low Pressure (Charge) Return or Suction Flow g287713 Figure 37 Traction Circuit: Low Range Traction Speed (Forward Shown) Hydraulic System: Hydraulic Flow Diagrams Page 5–16 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 117 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.
Page 118 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.
Page 119: Traction Circuit: High Range Traction Speed (Transport)
Traction Circuit: High Range Traction Speed (Transport) Working Pressure Low Pressure (Charge) Return or Suction Flow g287726 Figure 38 Traction Circuit: High Range Traction Speed (Forward Shown) Groundsmaster ® 5900 & 5910 Page 5–19 Hydraulic System: Hydraulic Flow Diagrams 16227SL Rev B...
Page 120 When the high range traction speed (transport) is selected, solenoid valve (SV) in the traction manifold is energized by the slave 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.
Page 121 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.
Page 122: Raise Cutting Deck
Raise Cutting Deck g287727 Figure 39 Raise Cutting Deck Hydraulic System: Hydraulic Flow Diagrams Page 5–22 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 123 (3) deck raise/lower switches on the armrest console (Figure 40). Pressing the rear of a switch provides an input for the slave Toro Electronic Controller (TEC) to raise a cutting deck. The controller provides electrical outputs to solenoids in the steering/deck lift manifold to allow appropriate valve shift to cause a cutting deck to raise.
Page 124 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 slave 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.
Page 125: Lower Cutting Deck
Lower Cutting Deck g287728 Figure 41 Lower Cutting Deck Groundsmaster ® 5900 & 5910 Page 5–25 Hydraulic System: Hydraulic Flow Diagrams 16227SL Rev B...
Page 126 (3) deck lift/lower switches on the armrest console (Figure 40). Pressing the front of a switch provides an input for the slave Toro Electronic Controller (TEC) to lower a cutting deck. The controller provides electrical outputs to solenoids in the steering/deck lift control manifold to allow appropriate valve shift to cause a cutting deck to lower.
Page 127 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 slave 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.
Page 128: Pto Mow Circuit
PTO Mow Circuit g287729 Figure 42 PTO Mow Circuit (All Deck Motors Rotating) A three (3) section gear pump is coupled to the piston (traction) pump. Hydraulic flow for the PTO mow circuit is supplied by two (2) sections of the gear pump. The gear pump section closest to the piston pump supplies hydraulic flow in series to the right and left decks, while the middle gear pump section supplies the front deck.
Page 129 Toro Electronic Controller (TEC). Mow circuit pressure can be measured at port (G1) of the hydraulic manifold for each cutting deck.
Page 130 PTO Circuit Relief .025” 1.5 CID PUMP FLOW 10 PSI 110 PSI 3000 PSI 10 PSI 600 PSI .063” 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.
Page 131: Pto Mow Circuit Cutting Deck Blade Braking
PTO Mow Circuit Cutting Deck Blade Braking .025” 1.5 CID PUMP FLOW 10 PSI 110 PSI 3000 PSI 10 PSI 600 PSI .063” 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...
Page 132 PTO Mow Circuit Cutting Deck Blade Braking (continued) .025” 1.5 CID PUMP FLOW 10 PSI 110 PSI 3000 PSI 600 PSI 10 PSI .063” LEFT DECK RETURN PTO SWITCH OFF V NOT ENERGIZED LC1, RV AND LC2 SHIFTED 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).
Page 133: Steering Circuit
Steering Circuit g287731 Figure 47 Steering Circuit (Left Turn Shown) Groundsmaster ® 5900 & 5910 Page 5–33 Hydraulic System: Hydraulic Flow Diagrams 16227SL Rev B...
Page 134 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.
Page 135 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.
Page 136: Testing
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...
Page 137: Which Hydraulic Tests Are Necessary
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.
Page 138 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.
Page 139: Traction Circuit Charge Pressure Test (Using Pressure Gauge)
Traction Circuit Charge Pressure Test (Using Pressure Gauge) .138” .088” .088” 5 PSI .055” OR4 .046” .055” 1500 TO STEERING UNIT PORT E 340 PSI OR1 .030” TO STEERING UNIT PORT P 80 PSI TO BRAKE 2100 PSI 50 PSI RELEASE MANIFOLD 4 PSI...
Page 140 Procedure for Traction Circuit Charge Pressure Test (continued) g287734 Figure 49 Steering/lift manifold Port CH1 test fitting g287735 Figure 50 Piston pump 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).
Page 141 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−...
Page 142: Traction Circuit Relief Pressure Test (Using Pressure Gauge)
Traction Circuit Relief Pressure Test (Using Pressure Gauge) FORWARD RELIEF PRESSURE TEST SHOWN TO STEERING/DECK LIFT MANIFOLD PORT P1 TO FRONT DECK MANIFOLD P1 PORT FROM STEERING/LIFT MANIFOLD TO LEFT DECK PORT T AND FRONT LIFT CYLINDERS MANIFOLD P1 PORT FROM STEERING/LIFT MANIFOLD PORT CL 10.6 GPM...
Page 143 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.
Page 144 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.
Page 145: Counterbalance Pressure Test (Using Pressure Gauge)
Counterbalance Pressure Test (Using Pressure Gauge) .138” .088” .088” 5 PSI .055” OR4 .046” .055” 1500 TO STEERING UNIT PORT E 340 PSI OR1 .030” TO STEERING UNIT PORT P 80 PSI TO BRAKE 2100 PSI 50 PSI RELEASE MANIFOLD 4 PSI .030”...
Page 146 Procedure for Counterbalance Pressure Test (continued) g287739 Figure 54 Steering/lift manifold Counterbalance valve Test fitting (port G4) 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.
Page 147: Piston (Traction) Pump Flow Test (Using Tester With Pressure Gauge & 40 Gpm Flow Meter)
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 FROM STEERING/DECK LIFT MANIFOLD MANIFOLD CH2 PORT 21.7 GPM 21.7 GPM...
Page 148 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.
Page 149 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.
Page 150: Cutting Deck Circuit Pressure Test (Using Pressure Gauge)
Cutting Deck Circuit Pressure Test (Using Pressure Gauge) PRESSURE GAUGE .025” 1.5 CID 10 PSI 110 PSI 3000 10 PSI 600 PSI FROM STEERING UNIT T PORT FRONT DECK .025” 1.5 CID 10 PSI FROM STEERING/LIFT MANIFOLD T PORT AND CENTER DECK LIFT CYLINDERS 110 PSI 3000...
Page 151 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.
Page 152 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.
Page 153: Cutting Deck Circuit Relief Pressure Test (Using Tester With Pressure Gauge And 40 Gpm Flow Meter)
Cutting Deck Circuit Relief Pressure Test (Using Tester with Pressure Gauge and 40 GPM Flow Meter) .025” 1.5 CID 10 PSI 110 PSI 3000 10 PSI 600 PSI FROM STEERING UNIT T PORT FRONT DECK .025” 1.5 CID 10 PSI FROM STEERING/LIFT MANIFOLD T PORT AND CENTER DECK LIFT CYLINDERS...
Page 154 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.
Page 155 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.
Page 156: Cutting Deck Motor Case Drain Leakage Test (Using Tester With Pressure Gauge & 40 Gpm Flow Meter)
Cutting Deck Motor Case Drain Leakage Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter) .025” 1.5 CID 10 PSI 110 PSI 3000 10 PSI 600 PSI FROM STEERING UNIT STEEL MEASURING T PORT CONTAINER FRONT DECK .025” 1.5 CID 10 PSI FROM STEERING/LIFT MANIFOLD...
Page 157 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.
Page 158 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.
Page 159 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.
Page 160: Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge)
Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge) .088” .138” .088” 5 PSI .055” OR4 .046” .055” 1500 TO STEERING UNIT PORT E 340 PSI OR1 .030” TO STEERING UNIT PORT P 80 PSI TO BRAKE 2100 PSI 50 PSI RELEASE MANIFOLD 4 PSI...
Page 161 Procedure for Lift/Lower Circuit Relief Pressure Test (continued) g287779 Figure 67 Steering/lift manifold Relief valve RV2 Test fitting (port G1) 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).
Page 162 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)).
Page 163: Steering Circuit Relief Pressure Test (Using Pressure Gauge)
Steering Circuit Relief Pressure Test (Using Pressure Gauge) STEER CYLINDERS LH WING FRONT RH WING DECK LIFT DECK LIFT DECK LIFT .088” .138” .088” 5 PSI .046” 6.1 CID .055” .055” STEERING 1500 PSI UNIT TO HYDRAULIC RESERVOIR 340 PSI .030”...
Page 164 Procedure for Steering Circuit Relief Pressure Test (continued) g287791 Figure 69 Steering/lift manifold Relief valve RV1 Test fitting (port G1) 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).
Page 165: Steering Cylinder Internal Leakage Test
Steering Cylinder Internal Leakage Test FULLY FULLY EXTENDED RETRACTED STEER CYLINDERS LEAKAGE PLUG STEERING WHEEL TURNED FOR LEFT TURN STEERING 6.1 CID UNIT 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.
Page 166 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.
Page 167: Gear Pump (Pto, Steering, Deck Lift/Lower And Traction Charge Circuits) Flow Test (Using Tester With Pressure Gauges And Flow Meter)
Gear Pump (PTO, Steering, Deck Lift/Lower and Traction Charge Circuits) Flow Test (Using Tester with Pressure Gauges and Flow Meter) THIRD GEAR TO STEERING/DECK LIFT MANIFOLD PORT P1 PUMP SECTION TO FRONT DECK MANIFOLD P1 PORT FLOW TEST SHOWN FROM STEERING/LIFT MANIFOLD PORT T AND FRONT LIFT CYLINDERS TO LEFT DECK MANIFOLD...
Page 168 g287815 Figure 73 First gear pump section (side decks) gear pump section (steering, lift/lower, charge) gear pump section (front deck) 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.
Page 169 Procedure for Gear Pump Flow Test (continued) g287816 Figure 74 pump section hose pump section hose Left deck manifold P1 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.
Page 170 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.
Page 171 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.
Page 172: Adjustments
Adjustments Adjust Manifold Relief Valves g287873 Figure 76 Relief valve Adjustment socket Valve cap 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)).
Page 173: Service And Repairs
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.
Page 174 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.
Page 175: Check Hydraulic Lines And Hoses
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.
Page 176: Priming Hydraulic Pumps
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...
Page 177: Flush Hydraulic System
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.
Page 178 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 through again until oil is clean.
Page 179: Charge Hydraulic System
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.
Page 180 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.
Page 181: Filtering Closed−Loop Traction Circuit
To effectively remove contamination from closed−loop traction circuit, use of the Toro high flow hydraulic filter and hydraulic hose kits are recommended (see Special Tools (page 2–15)).
Page 182 IMPORTANT If using a filter that is not the Toro high flow filter that is bi−directional, do not press the traction pedal in the reverse direction. If flow is reversed when using a filter that is not bi−directional, debris from the filter will re−enter the traction circuit.
Page 183: Hydraulic Reservoir
Hydraulic Reservoir 143 to 155 N·m (105 to 115 ft−lb) 5 to 6 N·m (44 to 55 in−lb) 18 to 19 N·m 155 to 171 in−lb 5 to 6 N·m (44 to 55 in-lb) g287876 Figure 79 Bushing O−ring Flange head screw Elbow fitting Stand pipe (4) Hose clamp...
Page 184 Hydraulic Reservoir Removal (Figure 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.
Page 185 Inspection 1. Clean hydraulic reservoir and suction strainer with solvent. 2. Inspect reservoir for leaks, cracks or other damage. Hydraulic Reservoir Installation (Figure 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.
Page 186: Gear Pump
Gear Pump 5 to 6 N·m (45 to 55 in-lb) 10 N·m (90 in-lb) 112 to 140 N·m (83 to 103 ft-lb) g287889 Figure 81 Gear pump 45 Elbow fitting Hydraulic hose assembly Piston pump Flat washer (2) Hydraulic hose assembly O−ring Cap screw (2) Hose clamp (2)
Page 187 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).
Page 188: Gear Pump Service
Gear Pump Service 140 N·m (103 ft−lb) 45 N·m (33 ft-lb) g287890 Figure 82 Front cover Splined connecting shaft Drive shaft/gear Plug Retaining ring Uni−ring (2) Sleeve bearing (8) Shaft seal (2) Pressure seal (2) Uni−ring (4) Idler shaft/gear (2) Thrust plate (2) Pressure seal (4) Pump body −...
Page 189 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 g287891 Figure 83...
Page 190 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.
Page 191 Gear Pump Assembly (Figure 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.
Page 192 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.
Page 193: Traction Circuit
Traction Circuit g287894 Figure 86 Piston (traction) pump RH front wheel motor Charge return to reservoir − out Gear pump RH rear wheel motor Case drain to reservoir − out LH front wheel motor LH rear wheel motor Brake release manifold Traction manifold Charge pressure −...
Page 194 Piston (Traction) Pump 3 to 5 N·m (30 to 45 in−lb) 112 to 140 N·m (83 to 103 ft−lb) 115 to 120 N·m (85 to 89 ft−lb) g287901 Figure 87 Piston (traction) pump Straight fitting Mounting flange (4) O−ring Diagnostic fitting (3) Hydraulic hose assembly Gear pump assembly Cap (3)
Page 195 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. g287906 Figure 88 Piston pump Reverse solenoid coil (S2) Forward solenoid coil (S1)
Page 196 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 1. If fittings were removed from piston pump, lubricate and place new O−rings onto fittings.
Page 197 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) Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page...
Page 198: Piston (Traction) Pump Service
Piston (Traction) Pump Service g287948 Figure 90 Hydraulic System: Service and Repairs Page 5–98 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 199 Figure 90 (continued) Housing Adapter Plug with O−ring (2) Dowel pin (4) Plug with O−ring (2) Screw (4) Gasket Orifice (2) Screw (2) Valve plate Screen (2) High pressure relief valve (2) Bearing Dowel pin (2) Charge pressure relief valve Swashplate bearing kit Feedback pin Lifting lug...
Page 200: Front Wheel Motors
Front Wheel Motors 183 to 224 N·m (135 to 165 ft−lb) g287959 Figure 91 Front wheel motor Hydraulic straight fitting (2) Hydraulic elbow fitting Hydraulic straight fitting Hydraulic straight fitting Cap screw (8) Front Wheel Motor Removal (Figure 1. Park machine on a level surface, lower cutting decks fully, disengage PTO and stop engine.
Page 201 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. g287960 Figure 92 (LH Wheel Motor)
Page 202 Front Wheel Motor Removal (Figure 91) (continued) 5. Disconnect or remove hydraulic tubes from the desired wheel motor in the order recommended (Figure 92 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.
Page 203 Front Wheel Motor Installation (Figure 91) (continued) g287962 Figure 94 (LH Wheel Motor) Connect/install 1 Connect/install 4 Connect/install 2 Connect/install 5 Connect/install 3 g287963 Figure 95 (RH Wheel Motor) Connect/install 1 Connect/install 4 Connect/install 2 Connect/install 5 Connect/install 3 3. Remove plugs from hydraulic lines and fittings and connect or install hydraulic tubes to the wheel motor being installed in the recommended order (Figure Figure...
Page 204 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. Hydraulic System: Service and Repairs Page 5–104 Groundsmaster...
Page 205: Rear Wheel Motors
Rear Wheel Motors 91 to 112 N·m (67 to 83 ft−lb) g287964 Figure 96 Rear wheel motor Hydraulic straight fitting Hydraulic straight fitting (2) 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...
Page 206 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.
Page 207: Wheel Motor Service
Wheel Motor Service g287965 Figure 97 (Rear Motor Shown) Flange nut(6) Seal kit Rotating group 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.
Page 208 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)
Page 209: Traction Control Manifold
Traction Control Manifold g288015 Figure 98 Traction control manifold Mounting bracket Flange head cap screw (6) Flange nut Note: 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 Hydraulic Schematic (page A–3) to identify the function of the hydraulic lines and...
Page 210 g288016 Figure 99 Manifold block Straight fitting Elbow fitting (2) Straight fitting (7) Dust cap Elbow fitting Straight fitting Diagnostic fitting Straight fitting (2) Elbow fitting Traction Control Manifold Removal (Figure 1. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–73).
Page 211 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.
Page 212: Traction Control Manifold Service
Traction Control Manifold Service (T7) (T7) (T3) (T4) (T3) (T7) (T7) (T3) (T7) (T7) (T3) (T4) (T4) (T8) (T7) (T3) (T7) (T7) (T7) (T7) (T3) (T5) (T7) (T3) (T4) (T6) (T8) (T3) (T1) (T7) (T8) (T3) (T7) (T6) (T7) (T2) (T6) (T7) (T3)
Page 213 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 Hydraulic Schematic (page A–3) to identify the function of the hydraulic lines and cartridge valves at each port).
Page 214: Brake Release Manifold
Brake Release Manifold g288018 Figure 101 Brake release manifold Washer (4) Hydraulic tube − to brake Flat washer (2) Grommet (2) Flange nut (2) Cap screw (2) Spacer (2) Hydraulic tube − from manifold Bulkhead nut (2) Both front wheel motors include a multi−disc parking brake that engages when hydraulic pressure is not present (e.g.
Page 215 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).
Page 216: Brake Release Manifold Service
Brake Release Manifold Service 34 N·m 34 N·m (25 ft−lb) 34 N·m (20 ft−lb) (25 ft−lb) FRONT 34 N·m (20 ft−lb) FRONT 34 N·m 34 N·m (25 ft−lb) (25 ft−lb) g288019 Figure 102 Manifold block #6 zero−leak plug − with O−ring (2) 7. Hydraulic elbow Hand pump −...
Page 217: Cutting Deck Circuit
Cutting Deck Circuit g288020 Figure 103 Piston (traction) pump Left wing deck control manifold Wing case drain to reservoir − out Gear pump Cutting deck motor (3) Front case drain to reservoir − out Front deck control manifold Suction from reservoir − in Right wing deck control manifold Return to oil cooler −...
Page 218: Cutting Deck Motor
Cutting Deck Motor 37 to 44 N·m (27 to 33 ft−lb) g288021 Figure 104 Front Deck Motor Shown Cutting deck motor Hydraulic hose − pressure Washer Flange head screw (2) Hydraulic fitting Spider 45º hydraulic fitting Hydraulic hose − case drain Motor mount Hydraulic hose −...
Page 219 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 g288022 Figure 105 Flow −...
Page 220: Cutting Deck Motor Service
Cutting Deck Motor Service 45 N·m (33 ft-lb) g288023 Figure 106 Shaft seal (2) Front thrust plate Seal (2) Retaining ring Drive gear Rear cover Flange washer Idler gear Cap screw (4) Front flange Rear thrust plate Washer (4) Pressure seal (5) Body Backup gasket (6) Dowel pin (4)
Page 221 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.
Page 222 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).
Page 223 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.
Page 224 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.
Page 225: Cutting Deck Control Manifolds
Cutting Deck Control Manifolds g288131 Figure 110 Front Deck control manifold Cap screw (6) Main frame RH Deck control manifold Flat washer (6) Front axle frame LH Deck control manifold 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.
Page 226 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 34 N·m (75 ft−lb) (25 ft−lb)
Page 227 Cutting Deck Control Manifold Installation (Figure 110) (continued) 102 N·m (75 ft−lb) 34 N·m (25 ft−lb) 102 N·m (75 ft−lb) 102 N·m (75 ft−lb) 34 N·m (25 ft−lb) g288134 Figure 113 LH Deck Control Manifold LH control manifold Hydraulic 90º fitting (3) Dust cap Straight fitting Diagnostic fitting...
Page 228: Cutting Deck Control Manifold Service
Cutting Deck Control Manifold Service 27 N·m (20 ft−lb) 7 N·m (5 ft−lb) 68 N·m (50 ft−lb) 34 N·m 27 N·m (25 ft−lb) (20 ft−lb) 27 N·m (20 ft−lb) 68 N·m (50 ft−lb) g288145 Figure 114 Manifold body #8 zero−leak plug with O−ring Sequence valve (SQ) Logic element (LC1 &...
Page 229 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.
Page 230: Steering And Cutting Deck Lift Circuits
Steering and Cutting Deck Lift Circuits g288146 Figure 115 Piston (traction) pump Steering cylinder (2) Suction from reservoir − in Gear pump Front deck lift cylinder − RH Return to reservoir − out Steering/lift control manifold Front deck lift cylinder − LH Supply to brake release manifold −...
Page 231: Steering Control Valve (For Machines Serial Number Below 403450000)
Steering Control Valve (For machines serial number below 403450000) 28 to 35 N·m (20 to 26 ft−lb) 47 to 56 N·m (34 to 42 ft−lb) 47 to 56 N·m (34 to 42 ft−lb) g288151 Figure 116 Steering wheel cover Flange head screw (7) Lower mounting plate Hex nut Flange head screw (3)
Page 232 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).
Page 233 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).
Page 234: Steering Control Valve (For Machines Serial Number Above 403450001)
Steering Control Valve (For machines serial number above 403450001) g301554 Figure 118 Steering wheel cover Steering control valve Bolt (2 each) Hex nut Bolt (4 each) Lock washer (2 each) Flat washer Nut (14 each) Speed nut (2 each) Steering wheel Washer (4 each) Bolt (4 each) Foam collar...
Page 235 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.
Page 236 Removal (Figure 118) (continued) g278284 Figure 120 Steering control valve O-ring O-ring 90º hydraulic fitting Straight fitting O-ring O-ring 45º hydraulic fitting O-ring 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.
Page 237: Steering Control Valve Service (For Machines Serial Number Below 40345000)
Steering Control Valve Service (For machines serial number below 40345000) 16 to 18 N·m (140 to 160 in−lb) 17 N·m (150 in−lb) g288163 Figure 121 Steering valve housing Cap screw (7) Gerotor drive Dust seal End cap Wear plate O−ring O−ring Bearing race Spool...
Page 238: Steering Control Valve Service (For Machines Serial Number Above 403450001)
Steering Control Valve Service (For machines serial number above 403450001) g278299 Figure 122 Pin bolt Distributor plate Shaft seal Bolt (4 each) Cardan shaft Thrust washer (2 each) Washer (5 each) Plug Bearing End cover Plug Ring Tube (2 each) spring Spring set Inner gearwheel...
Page 239: Steering Cylinders
Steering Cylinders 40 to 61 N·m (30−to 45 ft−lb) 40 to 61 N·m (30−to 45 ft−lb) g288164 Figure 123 Steering cylinder Cap screw Tie rod assembly Ball joint Slotted hex nut Lock nut Cotter pin Steering Cylinder Removal (Figure 123) 1.
Page 240 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.
Page 241: Steering Cylinder Service
Steering Cylinder Service 54 N·m (40 ft−lb) g288165 Figure 124 Ball joint Barrel O−ring Grease fitting Lock nut Back−up ring Jam nut Piston Rod seal Cotter pin Piston seal Rod wiper Castle nut O−ring Internal collar Roll pin Head Piston rod Steering Cylinder Disassembly (Figure 124)
Page 242 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)
Page 243: Front Cutting Deck Lift Cylinders
Front Cutting Deck Lift Cylinders g288167 Figure 126 Lift cylinder Flange nut Clevis pin Cotter pin (2 per pin) Washer (2 per pin) Flange head screw 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.
Page 244 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.
Page 245: Front Cutting Deck Lift Cylinder Service
Front Cutting Deck Lift Cylinder Service 176 N·m (130 ft−lb) g288168 Figure 127 Barrel with clevis O−ring Piston Retaining ring Back−up ring Lock nut Shaft with clevis Head O−ring Dust seal Piston seal Shaft seal Wear ring Front Cutting Deck Lift Cylinder Disassembly (Figure 127) 1.
Page 246 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.
Page 247 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.
Page 248: Wing Cutting Deck Lift Cylinders
Wing Cutting Deck Lift Cylinders g288170 Figure 128 Wing deck lift cylinder (LH shown) Flange nut Clevis pin Flat washer (4 per clevis pin) Flange head screw Cotter pin (2 per clevis pin) Wing Cutting Deck Lift Cylinder Removal (Figure 128) 1.
Page 249 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.
Page 250: Wing Cutting Deck Lift Cylinder Service
Wing Cutting Deck Lift Cylinder Service 176 N·m (130 ft−lb) g288201 Figure 129 Barrel with clevis Back−up ring Wear ring External collar Head Piston seal Shaft with clevis O−ring Steel ring − cushion Dust seal Cushion Wear ring Shaft seal Piston O−ring Lock nut...
Page 251 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.
Page 252: Steering/Deck Lift Control Manifold
Steering/Deck Lift Control Manifold g288202 Figure 130 Steering/lift control manifold Hydraulic filter 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–3) to identify...
Page 253 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.
Page 254 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.
Page 255: Steering/Deck Lift Control Manifold Service
Steering/Deck Lift Control Manifold Service 7 (T2) 7 (T2) 2 (T1) 7 (T2) FORWARD 4 (T3) 16 (T2) 9 (T4) 10 (T6) 11 (T3) 7 (T2) 9 (T4) 11 (T3) 15 (T6) 7 (T2) 21 (T4) 20 (T4) 7 (T2) 14 (T5) 9 (T4) 12 (T3)
Page 256 4 (T3) 2 (T7) 5 (T4) 4 (T3) 6 (T7) 3 (T6) 4 (T3) 5 (T4) 7 (T3) 5 (T4) 4 (T3) 10 (T3) 3 (T6) 11 (T4) 8 (T3) 3 (T6) 4 (T3) 5 (T4) 11 (T4) 4 (T3) 4 (T3) g288215 Figure 133...
Page 257 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.
Page 258: Cartridge Valve Service
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.
Page 259 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.
Page 260 Hydraulic Oil Cooler g288226 Figure 134 Cooling fan assembly Cap screw (4) Oil Cooler Cap screw (4) Flat washer (4) Hydraulic straight fitting (2) Flat washer (4) Isolator Mount (4) Flange nut (4) Hydraulic Oil Cooler Removal (Figure 133) CAUTION The oil cooler may be hot.
Page 261 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.
Page 262 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.
Page 263: Chapter 6: Electrical System
Table of Contents General Information ..........................6–3 Operator’s Manual ..........................6–3 Operator Cab Components ........................ 6–3 Toro Electronic Controllers (TEC)....................... 6–3 Engine Electronic Control Unit (ECU) ....................6–5 Yanmar Engine Electrical Components....................6–5 Battery−Disconnect Switch ........................ 6–6 Electrical System Operation ........................6–7 12 Volt System ...........................
Page 264 Relays with Four (4) Terminals......................6–99 Relays with Five (5) Terminals ....................... 6–102 Hydraulic Solenoid Valves......................6–105 Air Filter Service Indicator ......................6–108 Fuel Sender ........................... 6–109 Fuel Pump............................6–111 Hydraulic Oil Temperature Sender ....................6–113 CAN−bus Terminator Resistor ....................... 6–115 Resistor Assemblies ........................
Page 265: General Information
(inputs) and directs electrical power to control appropriate machine functions (outputs) based on the state of the inputs. Communication between the two Toro controllers, the Yanmar engine controller and the InfoCenter Display is provided by a CAN bus network.
Page 266 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.
Page 267: Engine Electronic Control Unit (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.
Page 268: Battery−Disconnect Switch
If the battery disconnect switch is set to OFF while the engine is running, the engine will continue to run on the power supplied by the 12 Volt alternator and you may cause damage to electrical components including the Toro Electronic Controllers (TECs). Electrical System: General Information Page 6–6...
Page 269: Electrical System Operation
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. Two 12 Volt batteries located at the rear of the machine are connected together in parallel to support the 12 Volt electrical system.
Page 270: Can−Bus Communications
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).
Page 271: Infocenter Display
(key switch is in the START or RUN position). A 2 Amp fuse (F−B5) protects the Info- Center power circuit. A CAN bus network involving the master and slave Toro Electronic Controllers (TECs), the Yanmar engine ECU and the InfoCenter is used to communicate machine information to and from the Info- Center display.
Page 272: Operator Information Screen
IGNITION SWITCHED 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 B...
Page 273 Operator Information Screen g288304 Figure 140 Button 1 Button 5 Button 2 Left gauge screen (coolant temp shown) Button 3 Right gauge screen (hydraulic oil temp shown) Button 4 Fan speed indicator The InfoCenter replaces traditional gauges by displaying engine and machine status.
Page 274 Operator Information Screen (continued) • PTO (engaged) • Parking brake (engaged) • Engine cooling fan (in reverse) • Cruise control (engaged) g288305 Figure 141 Button 1 Button 4 Button 2 Button 5 Button 3 Display controls InfoCenter display controls can be accessed by pressing button 5 on the display (Figure 141).
Page 275: Main Menu
MAIN MENU g288306 Figure 142 Button 1 Button 4 Button 2 Button 5 Button 3 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.
Page 276: Service
SERVICE g288307 Figure 143 Button 1 Button 4 Button 2 Button 5 Button 3 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 •...
Page 277: Hours
HOURS g288308 Figure 144 Button 1 Button 4 Button 2 Button 5 Button 3 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.
Page 278: Traction Pedal
TRACTION PEDAL g288309 Figure 145 Button 1 Button 4 Button 2 Button 5 Button 3 Traction pedal screen The traction pedal screen lists the calibration values stored in the master controller for different traction pedal positions (traction pedal position sensor). This screen also identifies that the traction pedal position sensor calibration has been completed.
Page 279 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. Groundsmaster ® 5900 &...
Page 280: Fan Override
FAN OVERRIDE g288311 Figure 147 Button 1 Button 4 Button 2 Button 5 Button 3 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.
Page 281: Fan Demo
FAN DEMO g288312 Figure 148 Button 1 Button 4 Button 2 Button 5 Button 3 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.
Page 282: Regeneration
REGENERATION g288313 Figure 149 Button 1 Button 4 Button 2 Button 5 Button 3 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).
Page 283 REGENERATION (continued) g288314 Figure 150 Button 1 Button 4 Button 2 Button 5 Button 3 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.
Page 284: Diagnostics Screens
Return to the previous screen by pressing button 5. INPUT/OUTPUT The input/output screens display the current state of the various Toro Electronic Controller (TEC) inputs, qualifiers and outputs necessary to allow a machine functions to occur. The input/output screens should be used to troubleshoot machine operation issues, and check that necessary components and circuit wiring are functioning correctly (see Troubleshooting chapter).
Page 285 INPUT/OUTPUT (continued) g288315 Figure 152 Button 1 Machine function Button 2 Inputs Button 3 Qualifiers Button 4 Outputs 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.
Page 286 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).
Page 287 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).
Page 288 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).
Page 289 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).
Page 290 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.
Page 291 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): •...
Page 292 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). •...
Page 293 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). •...
Page 294 INPUT/OUTPUT (continued) 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.
Page 295 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...
Page 296 Button 5 Button 3 Machine faults Machine faults are generated by the Toro Electronic Controllers (TEC) to identify an electrical system malfunction (fault) that occurs during machine operation. When a machine fault occurs, an audible alarm will sound and the InfoCenter will display information about the fault.
Page 297 FAULT VIEWER (continued) InfoCenter Fault Viewer (Figure 171). See Machine Faults (page 3–23) 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)).
Page 298 Settings Screens (continued) g288336 Figure 173 Button 1 Button 4 Button 2 Button 5 Button 3 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.
Page 299 DISPLAY g288337 Figure 174 Button 1 Button 4 Button 2 Button 5 Button 3 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.
Page 300 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).
Page 301 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.g. PIN has been forgotten), contact your Authorized Toro Distributor.
Page 302 SPEED LIMITS g288343 Figure 180 Button 1 Button 4 Button 2 Button 5 Button 3 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: •...
Page 303 PRODUCT ID: g288345 Figure 182 The About screens provide information about the machine, the InfoCenter Display, the two (2) Toro Electronic Controllers (TECs) and the Yanmar Engine Control Unit (ECU). The About screens (Figure 182) are accessed from the main menu.
Page 304: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) g287496 Figure 183 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.
Page 305 Battery Test (Open Circuit Test) (continued) 3. Access the batteries (see Battery Removal (page 6–140) 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.
Page 306 Charging System Tests (continued) g288427 Figure 186 12 Volt alternator 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).
Page 307 Replace any malfunctioning switches before operating the machine. Your Groundsmaster is equipped with two (2) Toro Electronic Controllers (TEC) which monitor interlock switch operation. If all of the interlock switches necessary to allow a specific machine operation are not in their desired position, an Operator’s Advisory will appear on the Info- Center Display (see...
Page 308: Adjustments
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 slave controller of the current cutting deck position. Adjustment 2.4 to 3.9 mm (0.095 to 0.155 in)
Page 309 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.
Page 310 Adjustment (continued) Switch to Sensing Plate Clearance 2.4 to 3.9mm (0.095 to 0.155 in) g288432 Figure 189 Wing deck lift arm Switch bracket Position switch Sensing plate 5. For machine serial numbers below 316000200 adjust the wing deck switches as follows (Figure 189): A.
Page 311 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.
Page 312 Traction Pedal Neutral Adjustment (continued) g288435 Figure 192 Traction pedal Lock nut Traction pedal shaft Spring shaft 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.
Page 313 Button 3 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. Make sure the traction pedal neutral position is...
Page 314 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.
Page 315: Component Testing
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 Yanmar Troubleshooting...
Page 316: Fusible Link Harness
Fusible Link Harness g288437 Figure 194 Starter motor shield removed) Fusible link harness TO MAIN HARNESS P22 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...
Page 317 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.
Page 318: Mega Fuses
Mega Fuses 12 to 17 N·m (9 to 13 ft-lb) g288439 Figure 196 12 volt battery 60 Amp mega fuse (traction unit) 100 Amp mega fuse 60 Amp mega fuse (cab) Three (3) mega fuses are used on the machine for protection of high amperage circuits.
Page 319: Fuses
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)).
Page 320 Fuse Identification, Location and Function (continued) g288442 Figure 198 Front power center (behind operator seat) Front fuse block g288443 Figure 199 Front Power Center Fuse Block Remove cover from front power center behind operator seat to access fuses (Figure 198 Figure 199).
Page 321 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.
Page 322 Fuse Identification, Location and Function (continued) 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 Figure 202). • Fuse 1F1 (20 Amp) supplies power to the cab work lights. •...
Page 323: Battery−Disconnect Switch
If the battery disconnect switch is set to OFF while the engine is running, the engine will continue to run on the power supplied by the 12 Volt alternator and you may cause damage to electrical components including the Toro Electronic Controllers (TECs). Testing 1.
Page 324 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.
Page 325: Toro Electronic Controllers (Tecs)
Front power center (behind operator seat) Slave controller Master 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.
Page 326 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 −...
Page 327 Toro Electronic Controllers (TECs) (continued) The slave TEC monitors the states of the following components as inputs: Slave 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 −...
Page 328 A controller may be damaged if an attempt is made to test it with an electrical test device (e.g. digital multimeter or test light). Note: The Toro Electronic Controllers used on the Groundsmaster 5900/5910 are programed for correct machine operation. If either TEC is replaced for any reason, system software needs to be reprogrammed (contact your Authorized Toro Distributor).
Page 329 Toro Electronic Controllers (TECs) (continued) The slave TEC controls electrical output to the following outputs: Master 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)
Page 330: Key Switch
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...
Page 331 Testing (continued) SWITCH POSITION CIRCUITS STOP 1 + 6 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)).
Page 332: Pto Switch
PTO Switch g288505 Figure 210 Operator control console PTO switch The PTO switch is located on the console arm (Figure 210). The PTO switch is pulled up to engage the cutting decks. The slave controller monitors the position of the PTO switch (engage or disengage).
Page 333 Testing (continued) g288506 Figure 211 COM B terminal COM C terminal NO B terminal NO C terminal NC B terminal NC C terminal 5. The switch terminals are marked as shown in Figure 211. 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.
Page 334: Cutting Deck Raise/Lower Switches
Cutting Deck Raise/Lower Switches g288507 Figure 212 Operator control console Front deck raise/lower switch Left deck raise/lower switch Right deck raise/lower switch The three (3) cutting deck raise/lower switches are located on the console arm (Figure 212). When the front of a raise/lower switch is depressed and held, the controlled deck (left, front or right) will lower.
Page 335 Testing (continued) 5. The switch terminals are marked as shown in Figure 213. 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.
Page 336: Throttle Switch
Throttle Switch g288509 Figure 214 Operator control console Throttle switch The throttle switch is located on the console arm (Figure 214). 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.
Page 337 Testing (continued) SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS INCREASE ENGINE RPM 2 + 3 and 5 + 6 2 + 1 and 5 + 4 NEUTRAL NONE DECREASE ENGINE RPM 2 + 1 and 5 + 4 2 + 3 and 5 + 6 6.
Page 338: High/Low Range Traction Speed Switch
High/Low Range Traction Speed Switch g288511 Figure 216 Operator control console High/Low range traction speed switch The High/Low range traction speed switch is located on the console arm (Figure 216). When the front of the High/ Low range traction speed switch is depressed, the traction system will shift to HIGH range traction speed.
Page 339 Testing (continued) 5. The switch terminals are marked as shown in Figure 217. 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.
Page 340: Cruise Control Switch
Cruise Control Switch g288513 Figure 218 Operator control console Cruise control switch The cruise control switch is located on the console arm (Figure 218). 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.
Page 341 Testing (continued) SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS NONE 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)).
Page 342: Headlight Switch
Headlight Switch g288515 Figure 220 Operator control console Headlight switch The headlight switch is located on the operator side of the control console (Figure 220). 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.
Page 343 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. Groundsmaster ®...
Page 344: Turn Signal Switch
Turn Signal Switch g288527 Figure 222 Turn signal switch Operator control console The turn signal switch is located on the console arm (Figure 222). When the turn signal switch is depressed (left or right), power is sent to the flasher module to illuminate the corresponding signal lights.
Page 345 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. Groundsmaster ®...
Page 346: Hazard Switch
Hazard Switch g288529 Figure 224 Hazard switch Operator control console The hazard switch is located on the console arm (Figure 224). 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.
Page 347 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. Groundsmaster ®...
Page 348: Parking Brake Switch
Parking Brake Switch g288531 Figure 226 Operator control console Parking brake switch The parking brake switch is located on the console arm (Figure 226). 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).
Page 349 Testing (continued) 5. The switch terminals are marked as shown in Figure 227. 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.
Page 350: Horn Button
Horn Button g288533 Figure 228 Horn button Operator control console 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 228). With the key switch in the RUN or START position, a continuous supply of voltage is available to the horn button.
Page 351: Contactors
Contactors 4.5 to 5.6 N·m (40 to 50 in-lb) g288534 Figure 229 12 volt battery Cab component contactor 24 Volt cooling fan 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 229).
Page 352 Testing (continued) g288535 Figure 230 Contactor Coil posts Main posts 4. Using jumper wires, apply 12 VDC directly across the contactor coil posts (Figure 230). The contactor should click. With the contactor coil energized, resistance across the contactor main posts should be less than 1 ohm. 5.
Page 353: Seat Switch
Seat Switch g288536 Figure 231 Wire harness connector 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 231).
Page 354: Windshield Wiper/Washer Switch (Groundsmaster 5910)
Windshield Wiper/Washer Switch (Groundsmaster 5910) g288537 Figure 232 Cab headliner (center switch panel) Wiper/washer switch The windshield wiper/washer switch is located in the cab headliner (Figure 232). 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).
Page 355 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.
Page 356: Air Conditioning Switch (Groundsmaster 5910)
Air Conditioning Switch (Groundsmaster 5910) g288539 Figure 234 Cab headliner (left switch panel) Air conditioning switch The air conditioning switch is located in the cab headliner (Figure 234). The switch is used to turn the air conditioning system on and off. Testing 1.
Page 357: Fan Speed Switch (Groundsmaster 5910)
Fan Speed Switch (Groundsmaster 5910) g288541 Figure 236 Cab headliner (left switch panel) Fan speed switch The fan speed switch is located in the cab headliner (Figure 236). The switch is used to select the air conditioning/ heater fan speed (off, low, medium or high). Testing 1.
Page 358 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.
Page 359: Work Light And Beacon Switches (Groundsmaster 5910 − Optional)
Work Light and Beacon Switches (Groundsmaster 5910 − Optional) g288543 Figure 238 Cab headliner (right switch panel) Beacon switch (optional) Work light switch (optional) The switches are located in the cab headliner (Figure 238). The switches are used to turn the optional light kits on and off. Testing 1.
Page 360 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.
Page 361: Relays With Four (4) Terminals
Relays with Four (4) Terminals g288551 Figure 240 Front power center TEC power relay 2 Horn relay TEC power relay 1 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.
Page 362 g288552 Figure 241 Yanmar ECU Glow plug relay Start relay The following relays are located on the left side of the engine near the Yanmar (Figure 241): • The start relay supplies power to the engine starter. The glow plug relay is energized by the Yanmar ECU.
Page 363 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).
Page 364: Relays With Five (5) Terminals
Relays with Five (5) Terminals g288565 Figure 244 Front power center 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.
Page 365 g288567 Figure 246 Rear power center 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 master controller.
Page 366 Testing (continued) 5. Using a multimeter, verify that coil resistance between terminals 85 and 86 is from 71 to 88 ohms (Figure 247). 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.
Page 367 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.
Page 368 Testing (continued) g288590 Figure 249 Cutting Deck manifold front shown) 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.
Page 369 Testing (continued) g288591 Figure 250 Traction control manifold 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 248).
Page 370: Air Filter Service Indicator
Air Filter Service Indicator g288592 Figure 251 Air filter 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 251). A high vacuum condition occurs when the engine is running and the air filter elements become restricted, closing the switch.
Page 371: Fuel Sender
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.
Page 372 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)
Page 373: Fuel Pump
Fuel Pump g288595 Figure 253 Yanmar ECU Fuel pump The electric fuel pump is attached to then left frame rail near the Yanmar ECU (Figure 253). Testing 1. Park machine on a level surface, lower cutting decks and stop engine. 2.
Page 374 Testing (continued) 12. Install and secure side panel to left side of machine. 13. Lower and secure hood. Fuel Pump Specifications Pump Capacity 700 ml/min (23.5 fl oz/min) Pressure 22.8 kPa (3.3 PSI) Current Draw 0.9 amp Electrical System: Component Testing Page 6–112 Groundsmaster ®...
Page 375: Hydraulic Oil Temperature Sender
Hydraulic Oil Temperature Sender g288596 Figure 254 Hydraulic traction manifold Hydraulic oil temperature sender Adapter fitting O−ring The hydraulic oil temperature sender is attached to the hydraulic traction manifold in port TS (Figure 254). Testing 1. Locate hydraulic oil temperature sender and disconnect wire harness connector from temperature sender.
Page 376 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.
Page 377: Can−Bus Terminator Resistor
CAN−bus Terminator Resistor g288602 Figure 256 Termination resistor 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.
Page 378: Resistor Assemblies
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. g288603 Figure 257 Resistor assembly End of resistor body g288604 Figure 258 Front power center (behind operator seat) Diode block 1 Diode block 2 2K ohm resistor...
Page 379 The resistor plugs into the engine wire harness near the starter (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 257).
Page 380: Diode Assemblies
EGR relay circuit. The diode plugs into the engine wire harness near the Yanmar ECU (see Appendix A (page A–1)). The diode can be identified by its black color, diode symbol and Toro part number on the end of the diode body (Figure 260).
Page 381 g288608 Figure 262 Fuse/Diode holder base Mini diode (24 Volt alternator) Fuse/Diode holder cover Groundsmaster ® 5900 & 5910 Page 6–119 Electrical System: Component Testing 16227SL Rev B...
Page 382 g288609 Figure 263 Front power center (behind operator seat) Radiator fan fault diode Diode block 1 Hydraulic oil cooler fan fault diode Diode block 2 Hydraulic oil cooler fan diode 24 Volt remote sense relay diode Radiator fan diode 24 Volt contactor latch diode TEC power diode Mini Diode Location Mini Diode Function...
Page 383 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.
Page 384: Audible Alarm
Audible Alarm g288610 Figure 264 Front power center 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 slave controller. The audible alarm is located in the front power center behind the operator seat (Figure 264).
Page 385: Traction Pedal Position Sensor
Traction Pedal Position Sensor g288612 Figure 266 Traction pedal Traction pedal position sensor The traction pedal position sensor is connected to the traction pedal assembly (Figure 266). 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.
Page 386: Piston (Traction) Pump Control Solenoid Coils
Piston (Traction) Pump Control Solenoid Coils g288613 Figure 267 Piston pump Reverse solenoid coil Forward solenoid coil 5 N·m (44 in-lb) 5 N·m (44 in-lb) g288614 Figure 268 Solenoid coil Coil nut O−ring The piston (traction) pump uses an electronic control assembly to change the position of the swash plate and the pump displacement.
Page 387 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 268).
Page 388: Cutting Deck Position Switches
Cutting Deck Position Switches g288615 Figure 269 Front deck right lift arm Sensing plate Deck position switch 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.
Page 389 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.
Page 390 24 Volt Cooling Fans g288619 Figure 271 Radiator cooling fan panel Flange head screw (16) Flange head screw (2) Hydraulic oil cooler fan panel Flange nut (16) Flange nut (2) 24 Volt cooling fan (4) 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.
Page 391 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.
Page 392: 24 Volt Alternator
24 Volt Alternator g288620 Figure 272 24 Volt alternator Negative (−) terminal (alternator body) Positive (+) terminal 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.
Page 393 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. Groundsmaster ® 5900 & 5910 Page 6–131...
Page 394: 24 Volt Voltage Divider
24 Volt Voltage Divider g288621 Figure 273 Battery−disconnect switch Voltage divider 24 Volt electrical system activity is monitored as an input to the master TEC. A voltage divider in the circuit reduces the 24 Volt system voltage for the TEC input signal to approximately 4 VDC.
Page 395 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.
Page 396: Fan Speed Switch (Machines With Two−Post Rops Extension Operator Fan Kit)
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit) g288623 Figure 275 Fan speed switch Control panel Control knob The fan speed switch is attached to the overhead control panel (Figure 275). The switch is used to select the fan speed (off, low, medium, or high). Testing 1.
Page 397 Testing (continued) 4. The switch terminals are identified in (Figure 276). 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 B+C+L...
Page 398: Resistor Module (Machines With Two−Post Rops Extension Operator Fan Kit)
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit) g288625 Figure 277 Operator’s fan Fan mount bracket Resistor module The resistor module is attached to the rear of the fan mounting bracket (Figure 277). The resistor module is used for operation of the operator’s fan. Testing 1.
Page 399 Testing (continued) 4. Use a multimeter to check that the resistance values of the resistor module as below (Figure 278). 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...
Page 400: Service And Repairs
Rinse with clear water. B. Coat battery posts and cable connectors with Battery Terminal Protector (Toro Part No. 107−0392) or petroleum jelly to prevent corrosion. 3. Battery cables must be tight on terminals to provide good electrical contact. Electrical System: Service and Repairs Page 6–138...
Page 401 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. Battery Service The batteries are the heart of the electrical system.
Page 402 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)
Page 403 Battery Removal (continued) g288670 Figure 280 Knob (2 per side) 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 279).
Page 404 Battery Removal (continued) g288672 Figure 282 Battery cover Cable assembly (for 24 VDC system) Battery−disconnect switch Cable − jumper (for 24 VDC system) Batteries − 12 volt for 12 VDC system) (2) Ground (−) cable Batteries − 12 volt for 24 VDC system) (2) Battery hold down (2) Positive (+) cable (for 12 VDC system) Battery hold down (2)
Page 405 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.
Page 406 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.
Page 407 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.
Page 408: Hydraulic Solenoid Valve Coils
Hydraulic Solenoid Valve Coils g288684 Figure 283 Cutting Deck Control Manifold Hydraulic manifold Solenoid valve coil Solenoid valve Most hydraulic solenoid valves used on the Groundsmaster 5900/5910 have replaceable coils. The coils can be replaced without opening the hydraulic system. The following solenoid valves DO NOT have replaceable solenoid coils and must be replaced as an assembly (see Cartridge Valve Service (page...
Page 409: 24 Volt Alternator/Air Conditioning Compressor Drive Belt
24 Volt Alternator/Air Conditioning Compressor Drive Belt 95 to 108 N·m (70 to 80 ft-lb) 37 to 45 N·m (27 to 33 ft-lb) 39 to 45 N·m (29 to 33 ft-lb) g288686 Figure 284 24 Volt alternator Engine pulley Cap screw Drive belt (GM 5900) Lock washer (3) Air conditioning compressor (GM...
Page 410 Installation g288687 Figure 285 Drive belt (GM 5900) Large hex (at tensioner base) Drive belt (GM 5910) Roll pin 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 285).
Page 411: 24 Volt Alternator
24 Volt Alternator g298625 Figure 286 24 Volt alternator Hardened washer (4) Cap screw (3) Alternator drive belt Hardened washer (8) Roll pin Alternator pulley Plastic isolator (4) Flange nut (8) Flange nut Front mounting bracket Carriage bolt (8) Tensioner assembly Rear mounting bracket Plastic washer (4) Engine pulley...
Page 412 7. Remove the alternator from the machine. Contact your Authorized Toro Distributor or a Delco Remy authorized Dealer for 24 Volt alternator service information. 8. Remove the pulley from the alternator shaft only if the alternator is being replaced.
Page 413 Installation (continued) g298627 Figure 288 24 Volt alternator Alternator mounting bracket Hardened washer (8) Plastic washer (4) Plastic isolator (4) 2. Install the alternator to the mounting brackets as shown (Figure 286). Make sure the plastic washers fit over the plastic isolators (Figure 288).
Page 414 Electrical System: Service and Repairs Page 6–152 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 415 Chapter 7 Chassis Table of Contents General Information ..........................7–2 Operator’s Manual ..........................7–2 Service and Repairs ..........................7–3 Wheels ............................... 7–3 Steering Column (For machines serial number below 403450000) ............ 7–5 Steering Column (For machines serial number above 403450001) ............ 7–8 Rear Axle ............................
Page 416: General Information
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. Chassis: General Information Page 7–2 Groundsmaster ® 5900 &...
Page 417: Service And Repairs
Service and Repairs Wheels g298659 Figure 289 Front wheel assembly Front wheel motor Lug nut (5 per rear wheel) Lug nut (6 per front wheel) Rear wheel assembly Rear wheel motor Wheel Removal (Figure 289) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch.
Page 418 Wheel Removal (Figure 289) (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.
Page 419: Steering Column (For Machines Serial Number Below 403450000)
Steering Column (For machines serial number below 403450000) g298661 Figure 290 Lower mounting plate Steering wheel cover Flange head screw (7) Hex nut Flange head screw (3) Carriage screw (4) Flat washer Socket head screw Carriage screw (3) Steering wheel Flange nut (7) Alignment bushing Steering column boot...
Page 420 Steering Column Removal and Disassembly (Figure 290) 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.
Page 421 Steering Column Assembly and Installation (Figure 290) 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.
Page 422: Steering Column (For Machines Serial Number Above 403450001)
Steering Column (For machines serial number above 403450001) g301554 Figure 292 Steering wheel cover Steering control valve Bolt (2 each) Hex nut Bolt (4 each) Lock washer (2 each) Flat washer Nut (14 each) Speed nut (2 each) Steering wheel Washer (4 each) Bolt (4 each) Foam collar...
Page 423 Removal (Figure 292) (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.
Page 424 Rear Axle g298742 Figure 294 Rear axle Roll pin Castle nut (4) Flange bushing (4) Thrust washer (3) Cotter pin (6) Retaining ring (2) Lock nut Castle nut (2) Spindle cap (2) Axle support Tie rod assembly Flange head screw (2) Hose guard(2) Elbow Thrust washer (2)
Page 425 Rear Axle Removal (Figure 294) 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)).
Page 426 Rear Axle Installation (Figure 294) (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).
Page 427 Rear Axle Service g298845 Figure 295 Rear axle Cap screw (10 per motor) Washer (2) Flange bushing (4) Flange bushing (2) Cap screw (2) Retaining ring (2) Steering cylinder (2) Elbow Spindle cap (2) Castle nut (4) Grease hose Flange head screw (2) Cotter pin (6) Thrust washer (2) Castle nut (2)
Page 428 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 296 Cap screw (2)
Page 429: Rear Axle
Rear Axle Spindle Bushing Replacement g298848 Figure 298 Rear axle Spindle bushing (4) Pivot bushing (2) 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.
Page 430 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.
Page 431: Front Deck Lift Arms
Front Deck Lift Arms g298853 Figure 299 Lift arm (left shown) Roll pin Front deck position switch (machine serial numbers above 316000200 shown) Lift cylinder Cotter pin Switch bracket Flange head screw Cylinder pin Cap screw Pivot pin Flat washer (2 per cylinder) Flat washer Flange nut Sensing plate...
Page 432 Front Deck Lift Arm Removal (Figure 299) (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.
Page 433 Front Deck Lift Arm Removal (Figure 299) (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 299)
Page 434 Front Deck Lift Arm Installation (Figure 299) (continued) g298852 Figure 301 Operator platform Flange head screw Shim pad Flange nut 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 301).
Page 435: Wing Deck Lift Arms
Wing Deck Lift Arms g298890 Figure 302 Lift arm (LH shown) Lock washer (2) Pivot hub assembly Grease fitting Wing deck position switch (machine Thrust washer (2) serial numbers above 316000200 shown) Grease fitting Lock nut (2) Flange bushing (2) Flange nut Impact arm assembly Shim...
Page 436 Wing Deck Lift Arm Removal (Figure 302) 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)).
Page 437 Wing Deck Lift Arm Removal (Figure 302) (continued) g298892 Figure 304 Lift arm (LH shown) Straight bushing (2) Flange bushing (2) Grease fitting Grease fitting 9. Support lift arm to prevent it from shifting or falling. Remove lift arm pivot shaft and lift arm from machine.
Page 438 Wing Deck Lift Arm Installation (Figure 302) (continued) g298893 Figure 305 (For machines serial number below 403450000) Lift arm (LH shown) Thrust washer Joint yoke Spacer Deck connection Impact arm Hardened washer Slotted hex nut Thrust washer Cotter pin Chassis: Service and Repairs Page 7–24 Groundsmaster ®...
Page 439 Wing Deck Lift Arm Installation (Figure 302) (continued) g301648 Figure 306 (For machines serial number above 403450001) Lift arm (LH shown) Yoke joint LH channel assembly Lock nut Nut (16 each) Nut (4 each) Hardened washer Deck mount Lock washer (2 each) Thrust washer Carriage bolt (10 each) Bolt (2 each)
Page 440 Wing Deck Lift Arm Installation (Figure 302) (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.
Page 441: Wing Deck Lift Arm Joint Yoke
Wing Deck Lift Arm Joint Yoke g298932 Figure 307 (For machines serial number below 403450000) Lift arm (LH shown) Thrust washer Base mount (2) Joint yoke Spacer Shim (2) Deck connection Impact arm Bolt plate (2) Hardened washer Slotted hex nut Hardened washer (8) Thrust washer Cotter pin...
Page 442 g301648 Figure 308 (For machines serial number above 403450001) Yoke joint LH channel assembly Lift arm (LH shown) Lock nut Nut (16 each) Nut (4 each) Hardened washer Deck mount Lock washer (2 each) Thrust washer Carriage bolt (10 each) Bolt (2 each) Thrust washer Spacer plate...
Page 443 Joint Yoke Removal (Figure 307 Figure 308) (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.
Page 444 Joint Yoke Assembly (continued) g298933 Figure 309 Joint yoke Angled edge Base mount 8. Press base mounts onto bearing caps with the angled edge of the mounts away from the joint (Figure 309). The outside of the cross bearing cups should be flush with the base mount surfaces.
Page 445: Wing Deck Impact Arm Assembly
Wing Deck Impact Arm Assembly g299090 Figure 310 (For machines serial number below 403450000) Impact arm housing Cap screw Plastic bearing Pivot hub Flange nut (4) Flat washer Flange bushing (2) Cap screw (4) Jam nut (2) Pivot shaft Housing Rod end Flat washer Spring shaft...
Page 446 g301664 Figure 311 (For machines serial number above 403450001) Impact arm housing Flat washer Thrust washer Pivot hub Lock nut Cap screw Flange bushing (2) Flange bushing Flange nut (4) Bolt Thrust washer Spacer Impact Arm Removal (Figure 310 Figure 311) 1.
Page 447 Impact Arm Assembly (Figure 310) (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.
Page 448 Impact Arm Installation (Figure 310 Figure 311) (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.
Page 449: Console Arm
Console Arm g299122 Figure 313 Console arm Cap screw Switch − high/low range Side cover Lock washer Switch − lift (3) Flange head screw (6) Coupling nut InfoCenter display Front cover Seat belt receptacle Switch − cruise control Flange head screw (4) Seat assembly Button −...
Page 450 Console Arm Disassembly (Figure 313) 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.
Page 451: Traction Pedal
Traction Pedal g299131 Figure 314 Steering cover Lock nut Spacer Traction pedal Flat washer Flange head screw (2) Carriage screw (6) Carriage screw (2) Hub and bushing assembly Cap screw (2) Flange nut (7) Standoff (2) Flange bushing Position sensor Pedal shaft Spring bracket Spring...
Page 452 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 314) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch.
Page 453 Traction Pedal Assembly (Figure 314) (continued) g299132 Figure 315 Traction pedal Spring shaft Traction pedal shaft Lock nut Clamp blocks F. Clamp blocks (Figure 315 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.
Page 454: Operator Seat
Operator Seat g299266 Figure 316 Cap screw Spacer Cap screw Lock washer Seat belt receptacle Carriage screw Cap screw Coupling nut Flange nut Flat washer (4) Retractable seat belt Operator Seat Removal (Figure 316) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch.
Page 455 Operator Seat Installation (Figure 316) g299267 Figure 317 Seat Torx head screw − 12mm (3) Suspension assembly Torx head screw − 16mm 1. Carefully position seat to seat suspension. 2. Secure seat to seat suspension with four (4) Torx head screws (Figure 317).
Page 456: Operator Seat Service
Operator Seat Service g299300 Figure 318 Backrest cushion Torx screw Cap screw (2) Seat cushion Seat frame Torx screw (3) RH support cover Washer (3) LH armrest Handle Spring (2) RH support cover Magnet Flat head screw (3) Bushing (2) Seat switch Adaptor plate Backrest...
Page 457 Operator Seat Disassembly (Figure 318) 1. Remove seat from machine for service (see Operator Seat (page 7–40)). 2. Disassemble operator seat as necessary. Operator Seat Assembly (Figure 318) 1. Assemble operator seat as needed. 2. Install seat to machine (see Operator Seat (page 7–40)).
Page 458: Operator Seat Suspension
Operator Seat Suspension g299319 Figure 319 Wire harness Air control valve Cover assembly Upper suspension Air spring Cover Thrust limiter Shock absorber Compressor Control lever Air tube assembly Bellows Tether Handle Lower suspension Operator Seat Suspension Disassembly (Figure 319) Note: Most of the seat suspension components can be serviced with the lower seat suspension (item 15) mounted to the frame platform.
Page 459 Operator Seat Suspension Disassembly (Figure 319) (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.
Page 460 Operator Seat Suspension Assembly (Figure 319) 1. If previously removed, install lower seat suspension to seat platform as follows (Figure 320): 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.
Page 461 Hood and Lower Shrouds g299332 Figure 321 Hood Panel fastener (42) Hood frame Knob (4) Foam pad (2) Intake screen Gas spring (2) Washer head screw (4) Foam strip Radiator screen Ball stud (4) Pop rivet (8) Rear shroud Handle (2) Hair pin (2) Grommet (4) Side shroud −...
Page 462 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 321) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the key switch. 2.
Page 463: Chapter 8: Cutting Decks
Chapter 8 Cutting Decks Table of Contents General Information ..........................8–2 Operator’s Manual ..........................8–2 Blade Stopping Time.......................... 8–2 Service and Repairs ..........................8–3 Front Cutting Deck ..........................8–3 Front Cutting Deck Winglets ......................8–6 Wing Cutting Decks ........................... 8–9 Drive Belt Idler Assemblies ......................
Page 464: General Information
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.
Page 465: Service And Repairs
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 322 Front cutting deck Damper assembly Thrust washer (1 per lift arm) Hydraulic motor HOC chain (1 per lift arm) Lock nut (2 per lift arm)
Page 466 Drive Belt Idler Assemblies (page 8–11), Blade Spindles (page 8–14), Castor Forks and Wheels (page 8–21) Deck Skids and Front Deck Roller (Figure 339 and Figure 340) (page 8–23) in this chapter for removal, installation and service information. Front Cutting Deck Removal (Figure 322) 1.
Page 467 Front Cutting Deck Installation (Figure 322) 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.
Page 468: Front Cutting Deck Winglets
Front Cutting Deck Winglets g299360 Figure 324 Center deck Grease fitting Lock nut (2 per winglet) LH deck winglet Eccentric (2 per winglet) Hinge pin (2 per winglet) Flange bushing (4 per winglet) Cap screw (2 per winglet) Front Cutting Deck Winglet Disassembly (Figure 324) 1.
Page 469 Front Cutting Deck Winglet Assembly (Figure 324) 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.
Page 470 Front Cutting Deck Winglet Assembly (Figure 324) (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 326). Level the front winglet deck to the front center deck (see machine Operator’s Manual).
Page 471 Wing Cutting Decks g299375 Figure 327 Wing cutting deck (LH) Hose guide − open Impact arm assembly (LH) Hydraulic motor Hose guide − loop (on deck Deck connection (LH) connection) Flange head screw (2) Hose guide − loop (on deck) Flange head screw (8) Drive spider Lift arm (LH)
Page 472 Drive Belt Idler Assemblies (page 8–11), Blade Spindles (page 8–14), Castor Forks and Wheels (page 8–21) Deck Skids and Front Deck Roller (Figure 339 and Figure 340) (page 8–23) for removal, installation and service information. Wing Cutting Deck Removal (Figure 327) 1.
Page 473: Drive Belt Idler Assemblies
Drive Belt Idler Assemblies g299397 Figure 328 Lower belt Idler assy − wing deck Washer (1 per idler) Low belt Idler assy − front deck Upper belt idler assembly (4) Idler pivot (1 per idler) Idler stop bolt Retaining ring (1 per idler) Carriage screw (3 per pivot) Jam nut (2) Torsion spring (1 per idler)
Page 474 Drive Belt Idler Assembly Removal (Figure 328) (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.
Page 475 Drive Belt Idler Assembly Installation (Figure 328) (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 330 High idler arm...
Page 476 Blade Spindles g299689 Figure 331 Driven spindle (double pulley) Driven spindle (high pulley) Drive spindle 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.
Page 477 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 332 Flange screw Blade Hydraulic motor Carriage bolt Drive spindle...
Page 478 Blade Spindle Removal (continued) 8. Lift spindle assembly from deck. See Blade Spindle Service (page 8–17) additional spindle service information. Blade Spindle Installation 1. Position spindle on cutting deck noting orientation of grease fitting (Figure 331). Secure spindle assembly to deck with correct fasteners (Figure 332).
Page 479: Blade Spindle Service
Blade Spindle Service g299693 Figure 333 Spindle housing Spindle spacer Large snap ring Grease fitting Seal (2) Inner bearing spacer Lock nut O−ring Outer bearing spacer Hardened washer Bearing cone (2) Drive Stud Pulley Bearing cup (2) Spindle shaft Spacer ring Blade Spindle Disassembly (Figure 333)
Page 480 Blade Spindle Disassembly (Figure 333) (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.
Page 481 Blade Spindle Assembly (Figure 333) (continued) g299695 Figure 335 Bearing cups Arbor press Large snap ring Support Large outer spacer 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.
Page 482 Blade Spindle Assembly (Figure 333) (continued) IMPORTANT If bearings are being replaced, make sure to use the spacer ring that is included with new bearing set (Figure 334). 7. Slide spacer ring and inner bearing spacer into spindle housing, then install upper bearing cone and greased oil seal into top of housing.
Page 483 Castor Forks and Wheels g299724 Figure 337 Wing Deck (LH shown) Castor arm Cap screw (4) Spring seat (1 per cap) Cap screw (12) Lock nut (4) Spring (1 per cap) Flat washer (12) Flange bushing (2 per castor arm) 15. Cap (1 per cap) Flange nut (12) Thrust washer (4 per castor)
Page 484 g299725 Figure 338 Inner tube Bearing (2) Flange nut (4) Rim half Plate Rim half Bearing spacer Tire Castor Wheel Disassembly (Figure 337 Figure 338) 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.
Page 485 Deck Skids and Front Deck Roller (Figure 339 Figure 340) 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 339 Skid/Bumper...
Page 486 Deck Skids and Front Deck Roller Installation (continued) g299740 Figure 340 Skid/Bumper Inner skid Flange nut (2) Carriage bolt (3) Carriage bolt (2) Lock nut (3) 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).
Page 487 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........................9–2 Cab Heater System..........................9–3 Air Conditioning System Performance ....................9–3 Service and Repairs ..........................9–4 General Precautions for Removing and Installing Air Conditioning System Components............................
Page 488: General Information
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. Electrical Components, Schematics and Wire Harness Drawings Information regarding Groundsmaster 5910 electrical cab components (switches and relays) is included in...
Page 489: Cab Heater System
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.
Page 490: Service And Repairs
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.
Page 491 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.
Page 492: Air Conditioning Compressor
Air Conditioning Compressor g299743 Figure 341 Air conditioning compressor Cap screw (2) Tubing Compressor mount Flat washer (4) Cap screw (4) AC hose Lock washer (2) Mount strap (2) AC hose Hex nut (2) Flange nut (4) Elbow fitting Drive belt Removal (Figure 341)
Page 493 Removal (Figure 341) (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.
Page 494 Installation (Figure 341) (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.
Page 495: Roof Assembly
Roof Assembly g299808 Figure 342 Roof panel Front condenser seal Flat washer (22) Headliner assembly LH condenser seal Flange nut (22) Condenser screen Rear condenser seal Front/rear cab strap (2) Flange head screw (16) Condenser assembly Side cab strap (2) RH condenser seal Shoulder screw (22) To gain access to heater and air conditioning components, the roof panel needs...
Page 496 Removal (Figure 342) 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.
Page 497: Heating And Air Conditioning Components
Heating and Air Conditioning Components g299831 Figure 343 A/C binary switch A/C condenser assembly Heat and A/C mixing box assembly A/C drier−receiver LH intake air filter Wiper motor assembly RH intake air filter A/C expansion valve Groundsmaster ® 5900 & 5910 Page 9–11 Operator Cab : Service and Repairs 16227SL Rev B...
Page 498 Heating and Air Conditioning Components (continued) g299832 Figure 344 Evaporator/heater cores Air diverter assembly Blower fan 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 Figure 344 can be used to identify the components used for heating...
Page 499: A/C Condenser Fan Assembly
A/C Condenser Fan Assembly g299833 Figure 345 Cab frame A/C condenser assembly Condenser fan assembly Cab headliner assembly Knob (2) Groundsmaster ® 5900 & 5910 Page 9–13 Operator Cab : Service and Repairs 16227SL Rev B...
Page 500 Removal (Figure 345) g299834 Figure 346 Condenser fan (2) Fan plug (2) Knob (2) g299835 Figure 347 Fan mount plate Condenser fan (2) Screw (4 per fan) Plastic plug (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.
Page 501 Installation (Figure 345) 1. If condenser fan assembly was disassembled, use Figure 347 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.
Page 502: A/C Condenser Assembly
A/C Condenser Assembly g299873 Figure 348 Cab frame Condenser fan assembly AC hose (from compressor) Cab headliner assembly Flange nut (4) O−ring A/C condenser assembly Strip seal (2) AC hose (to drier−receiver) Knob (2) Edge seal (2) O−ring Removal (Figure 348) 1.
Page 503 Removal (Figure 348) (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.
Page 504 Installation (Figure 348) 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 349 as a guide.
Page 505: Mixing Box Assembly
Mixing Box Assembly g299905 Figure 350 Mixing box Hairpin Vent hose (2) Mixing box cover Flat washer Tube support (2) Cover insulation Carriage screw (2) Vent hose (2) Rivet (19) Support plate Adapter (2) Heater core A/C evaporator/fan Flange nut (4) Hose clamp (2) assy Expansion valve...
Page 506 Removal (Figure 350) 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.
Page 507 Removal (Figure 350) (continued) g299907 Figure 352 Mixing box assembly O−ring A/C expansion valve Hose (from drier) A/C drier−receiver O−ring Cable tie (2) O−ring A/C binary switch Hose (to compressor) Hose (from condenser) 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.
Page 508 Installation (Figure 350) (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.
Page 509 Heater and A/C Evaporator Cores g299909 Figure 353 Mixing box Freeze switch Condensation catch foam Air diverter assembly Rivet (19) Mount bracket (shown with fan) Mixing box cover Expansion valve A/C hose (from drier−receiver) Cover insulation O−ring (2) O−ring Screw (5) A/C evaporator core A/C hose (to A/C compressor) Mount bracket cover...
Page 510 Removal (Figure 353) (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.
Page 511 Installation (Figure 353) (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).
Page 512: Blower Fan
Blower Fan g299935 Figure 354 Mixing box Expansion valve A/C hose (from drier−receiver) Rivet (19) Blower fan O−ring Mixing box cover Screw (6) A/C hose (to AC compressor) Cover insulation Freeze switch O−ring Heater core A/C evaporator Screw (2) assembly O−ring (2) Air diverter assembly Note: The blower fan can be removed and installed with the mixing box (item 1...
Page 513 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.
Page 514 Installation (Figure 354) 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 355).
Page 515: Windshield Wiper Assembly
Windshield Wiper Assembly g299960 Figure 356 Wiper blade Washer plate Cap screw Wiper bracket Lock washer Cap screw (2) Lock washer (2) Washer head screw (4) Cover Wiper arm assembly Flange nut (4) Jam nut Flange nut (2) Washer head screw (3) Star washer Cab headliner Wiper motor...
Page 516 Disassembly (Figure 356) (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.
Page 517 Assembly (Figure 356) (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 357). D. Secure wiper arm sockets to motor shafts with flange nuts. Torque nuts from 23 to 25 N·m (16 to 18 ft−lb).
Page 518 Operator Cab : Service and Repairs Page 9–32 Groundsmaster ® 5900 & 5910 16227SL Rev B...
Page 519: Appendix A
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Hydraulic Schematic .........................A–3 Electrical Schematic (machine serial numbers below 316000200) .............A–4 Electrical Schematic (machine serial numbers below 316000200) .............A–5 Electrical Schematic (machine serial numbers 316000201 to 399999999).........A–6 Electrical Schematic (machine serial numbers 316000201 to 399999999).........A–7 Electrical Schematic (machine serial numbers 400000000 to 403450000).........A–8 Electrical Schematic (machine serial numbers 400000000 to 403450000).........A–9 Electrical Schematic (machine serial numbers above 403450001)...........A–10...
Page 520: Electrical Drawing Designations
Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).
Page 521: Hydraulic Schematic
Hydraulic Schematic LH WING DECK LIFT CENTER DECK LIFT RH WING DECK LIFT BORE: 2.25” BORE: 2.25” BORE: 2.25” STEER CYLINDERS STROKE: 11.38” STROKE: 4.38” STROKE: 11.38” BORE: 1.25” ROD: 1.12” ROD: 1.12” ROD: 1.12” STROKE: 6.00” EXTEND TO: LIFT EXTEND TO: LIFT EXTEND TO: LIFT ROD: 0.75”...
Page 522: Electrical Schematic (Machine Serial Numbers Below 316000200)
Electrical Schematic (machine serial numbers below 316000200) All relays and solenoids are shown as de−energized. All ground wires are black. SHEET 2 SHEET 2 g299964 Page A–4 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0200 Rev A, Sheet 1 of 2...
Page 523: Electrical Schematic (Machine Serial Numbers Below 316000200
Electrical Schematic (machine serial numbers below 316000200) SHEET 1 SHEET 1 All relays and solenoids are shown as de−energized. All ground wires are black. g299965 Groundsmaster 5900/5910, Drawing 122-0200 Rev A, Sheet 2 of 2 16227SL Rev B Page A–5...
Page 524: Electrical Schematic (Machine Serial Numbers 316000201 To 399999999)
Electrical Schematic (machine serial numbers 316000201 to 399999999) All relays and solenoids are shown as de−energized. All ground wires are black. SHEET 2 SHEET 2 g299966 Page A–6 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0805 Rev A, Sheet 1 of 2...
Page 525: Electrical Schematic (Machine Serial Numbers 316000201 To 399999999
Electrical Schematic (machine serial numbers 316000201 to 399999999) SHEET 1 SHEET 1 All relays and solenoids are shown as de−energized. All ground wires are black. g299967 Groundsmaster 5900/5910, Drawing 122-0805 Rev A, Sheet 2 of 2 16227SL Rev B Page A–7...
Page 526: Electrical Schematic (Machine Serial Numbers 400000000 To 403450000)
Electrical Schematic (machine serial numbers 400000000 to 403450000) All relays and solenoids are shown as de−energized. SHEET 2 All ground wires are black. SHEET 2 g302045 Page A–8 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0073 Rev B, Sheet 1 of 2...
Page 527: Electrical Schematic (Machine Serial Numbers 400000000 To 403450000
Electrical Schematic (machine serial numbers 400000000 to 403450000) SHEET 1 SHEET 1 All relays and solenoids are shown as de−energized. All ground wires are black. g302046 Groundsmaster 5900/5910, Drawing 122-0073 Rev B, Sheet 2 of 2 16227SL Rev B Page A–9...
Page 528: Electrical Schematic (Machine Serial Numbers Above 403450001)
Electrical Schematic (machine serial numbers above 403450001) All relays and solenoids are shown as de−energized. SHEET 2 All ground wires are black. SHEET 2 g302047 Page A–10 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-1553 Rev A, Sheet 1 of 2...
Page 529: Electrical Schematic (Machine Serial Numbers Above 403450001
Electrical Schematic (machine serial numbers above 403450001) SHEET 1 SHEET 1 All relays and solenoids are shown as de−energized. All ground wires are black. g302048 Groundsmaster 5900/5910, Drawing 122-1553 Rev A, Sheet 2 of 2 16227SL Rev B Page A–11...
Page 530: Operator Platform Wire Harness Drawing (Machine Serial Numbers Below 316000200
Operator Platform Wire Harness Drawing (machine serial numbers below 316000200) g299976 Page A–12 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0201 Rev B, Sheet 1 of 1...
Page 531: Operator Platform Wire Harness Diagram (Machine Serial Numbers Below 316000200
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 B Page A–13...
Page 532: Operator Platform Wire Harness Diagram (Machine Serial Numbers Below 316000200)
Operator Platform Wire Harness Diagram (machine serial numbers below 316000200) g299970 Page A–14 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0201 Rev B, Sheet 2 of 2...
Page 533: Operator Platform Wire Harness Drawing
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 B Page A–15...
Page 534: Operator Platform Wire Harness Diagram
Operator Platform Wire Harness Diagram (machine serial numbers 316000201 to 316999999) g299972 Page A–16 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0806 Rev A, Sheet 1 of 2...
Page 535: Operator Platform Wire Harness Diagram (Machine Serial Numbers 316000201 To 316999999)
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 B Page A–17...
Page 536: Operator Platform Wire Harness Diagram
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000) g302224 Page A–18 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0990 Rev C, Sheet 1 of 1...
Page 537: Operator Platform Wire Harness Diagram
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 B Page A–19...
Page 538: Operator Platform Wire Harness Diagram
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000) g302226 Page A–20 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0990 Rev C, Sheet 2 of 2...
Page 539: Operator Platform Wire Harness Diagram (Machine Serial Numbers Above 403450001
Operator Platform Wire Harness Diagram (machine serial numbers above 403450001) g302254 Groundsmaster 5900/5910, Drawing 122-1555 Rev B, Sheet 1 of 1 16227SL Rev B Page A–21...
Page 540: Operator Platform Wire Harness Diagram (Machine Serial Numbers Above 403450001)
Operator Platform Wire Harness Diagram (machine serial numbers above 403450001) g302255 Page A–22 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-1555 Rev B, Sheet 1 of 2...
Page 541: Operator Platform Wire Harness Diagram (Machine Serial Numbers Above 403450001
Operator Platform Wire Harness Diagram (machine serial numbers above 403450001) g302256 Groundsmaster 5900/5910, Drawing 122-1555 Rev B, Sheet 2 of 2 16227SL Rev B Page A–23...
Page 542: Rear Wire Harness Drawing (Machine Serial Numbers Below 316000200
Rear Wire Harness Drawing (machine serial numbers below 316000200) g299974 Page A–24 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0441 Rev B, Sheet 1 of 1...
Page 543: Rear Wire Harness Diagram (Machine Serial Numbers Below 316000200
Rear Wire Harness Diagram (machine serial numbers below 316000200) g299975 Groundsmaster 5900/5910, Drawing 122-0441 Rev B, Sheet 1 of 1 16227SL Rev B Page A–25...
Page 544: Rear Wire Harness Drawing (Machine Serial Numbers 316000201 To 403450000
Rear Wire Harness Drawing (machine serial numbers 316000201 to 403450000) g299990 Page A–26 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0807 Rev A, Sheet 1 of 1...
Page 545: Rear Wire Harness Drawing (Machine Serial Numbers 316000201 To 403450000)
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 B Page A–27...
Page 546: Rear Wire Harness Drawing (Machine Serial Numbers Above 403450001
Rear Wire Harness Drawing (machine serial numbers above 403450001) g302318 Page A–28 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-1554 Rev C, Sheet 1 of 2...
Page 547: Rear Wire Harness Drawing (Machine Serial Numbers Above 403450001)
Rear Wire Harness Drawing (machine serial numbers above 403450001) g302319 Groundsmaster 5900/5910, Drawing 122-1554 Rev C, Sheet 2 of 2 16227SL Rev B Page A–29...
Page 548: Engine Wire Harness Drawing (Machine Serial Numbers 316000001 To 316999999
Engine Wire Harness Drawing (machine serial numbers 316000001 to 316999999) g299992 Page A–30 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0337 Rev B, Sheet 1 of 1...
Page 549: Engine Wire Harness Drawing (Machine Serial Numbers 316000001 To 316999999)
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 B Page A–31...
Page 550: Engine Wire Harness Drawing (Machine Serial Numbers 400000000 To 403450000
Engine Wire Harness Drawing (machine serial numbers 400000000 to 403450000) g302386 Page A–32 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-0993 Rev B, Sheet 1 of 2...
Page 551: Engine Wire Harness Drawing (Machine Serial Numbers 400000000 To 403450000)
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 B Page A–33...
Page 552: Engine Wire Harness Drawing (Machine Serial Numbers Above 403450001
Engine Wire Harness Drawing (machine serial numbers above 403450001) g302426 Page A–34 16227SL Rev B Groundsmaster 5900/5910, Drawing 122-1556 Rev C, Sheet 1 of 2...
Page 553 Engine Wire Harness Drawing (machine serial numbers above 403450001) g302427 Groundsmaster 5900/5910, Drawing 122-1556 Rev C, Sheet 2 of 2 16227SL Rev B Page A–35...
Page 554: Cab Power Supply Wire Harness (Machine Serial Numbers Below 316000200
Cab Power Supply Wire Harness (Machine serial numbers below 316000200) g299994 Page A–36 16227SL Rev B Groundsmaster 5910, Drawing 122-0640 Rev B, Sheet 1 of 1...
Page 555: Cab Headliner Wire Harness Drawing
Cab Headliner Wire Harness Drawing g299995 Groundsmaster 5910, Drawing 122-0723 Rev A, Sheet 1 of 1 16227SL Rev B Page A–37...
Page 556: Cab Headliner Wire Harness Diagram
Cab Headliner Wire Harness Diagram g299996 Page A–38 16227SL Rev B Groundsmaster 5910, Drawing 122-0723 Rev A, Sheet 1 of 1...
Page 557: Wire Harness Diagram − Two−Post Rops Extension
Wire Harness Diagram − Two−Post ROPS Extension g299997 Groundsmaster 5900 (Model 31698), Drawing 122-0892 Rev B, Sheet 1 of 1 16227SL Rev B Page A–39...
Page 558 Wire Harness Diagram − Two−Post ROPS Extension g299998 Page A–40 16227SL Rev B Groundsmaster 5900 (Model 31698), Drawing 122-0892 Rev B, Sheet 1 of 1...

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