Toro Groundsmaster 5900, 5910 (Model 31698, 31600 – Tier 4) Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Groundsmaster 5900, 5910 (Model 31698, 31600 – Tier 4)

Title Page
Revision History
Reader Comments
NOTES
Preface
Service Procedure Icons

Chapter 1 : Safety

Safety Instructions
Before Operating the Machine
While Operating the Machine
Maintenance and Service
Battery-Disconnect Switch
Jacking Instructions
Safety and Instructional Decals

Chapter 2 : Specifications and Maintenance

Specifications
Overall Dimensions
Engine
Hydraulic System
Chassis
Cutting Decks
Torque Specifications
Calculating the Torque Values When Using a Drive-Adapter Wrench
Identifying the Fastener
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
Shop Supplies
Special Tools

Chapter 3 : Troubleshooting

GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems
Gather Information
Evaluate Potential Causes
Assess Performance
Repair
Solution Confirmation
General Hydraulic System Problems
Traction Circuit Problems
PTO Problems
Lift, Lower Circuit Problems
Steering Circuit Problems
Starting Problems
General Run and Transport Problems
Cutting Deck (PTO) Operating Problems
Cutting Deck Lift, Lower Problems
Operator Advisories
TO START
TO ENGAGE PTO
TO SET CRUISE CONTROL
TO LOWER DECK
TO FLOAT DECK
TO SET HIGH RANGE
TO SET LOW RANGE
FOR TRACTION
ENGINE
FUEL LEVEL
TRACTION PEDAL
TO RAISE DECK
Using the InfoCenter Display for Troubleshooting
Machine Faults
Engine Faults
Factors That Can Affect Quality of Cut and Clipping Dispersion

Chapter 4 : Yanmar Diesel Engine

General Information
Operator’s Manuals
Yanmar Service and Troubleshooting Manuals
Stopping the Engine
Engine Electronic Control Unit (ECU)
Yanmar Engine
Diesel Particulate Filter
Service and Repairs
Air Filter
Exhaust System
Fuel System
Radiator
Engine
Pump Adapter Plate (Coupler)
Yanmar TNV (Tier 4) Series Service Repair Manual
Yanmar TNV (Tier 4) Series Troubleshooting Manual

Chapter 5 : Hydraulic System

General Information
Operator’s Manual
Relieving Hydraulic System Pressure
Towing Traction Unit
Traction Circuit Component Failure
Hydraulic Hoses
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)
Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit Operation
Traction Circuit: Low Range Traction Speed (Mow)
Traction Circuit: High Range Traction Speed (Transport)
Raise Cutting Deck
Lower Cutting Deck
PTO Mow Circuit
PTO Mow Circuit Cutting Deck Blade Braking
Steering Circuit
Testing
Before Performing Hydraulic Tests
Precautions for Hydraulic Testing
Which Hydraulic Tests Are Necessary?
Traction Circuit Charge Pressure Test (Using Pressure Gauge)
Traction Circuit Relief Pressure Test (Using Pressure Gauge)
Counterbalance Pressure Test (Using Pressure Gauge)
Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter)
Cutting Deck Circuit Pressure Test (Using Pressure Gauge)
Cutting Deck Circuit Relief Pressure Test (Using Tester with Pressure Gauge and 40 GPM Flow Meter)
Cutting Deck Motor Case Drain Leakage Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter)
Lift, Lower Circuit Relief Pressure Test (Using Pressure Gauge)
Steering Circuit Relief Pressure Test (Using Pressure Gauge)
Steering Cylinder Internal Leakage Test
Gear Pump (PTO, Steering, Deck Lift, Lower and Traction Charge Circuits) Flow Test (Using Tester with Pressure Gauges and Flow Meter)
Adjustments
Adjust Manifold Relief Valves
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Priming Hydraulic Pumps
Flush Hydraulic System
Charge Hydraulic System
Filtering Closed−Loop Traction Circuit
Hydraulic Reservoir
Gear Pump
Gear Pump Service
Traction Circuit
Piston (Traction) Pump
Piston (Traction) Pump Service
Front Wheel Motors
Rear Wheel Motors
Wheel Motor Service
Traction Control Manifold
Traction Control Manifold Service
Brake Release Manifold
Brake Release Manifold Service
Cutting Deck Circuit
Cutting Deck Motor
Cutting Deck Motor Service
Cutting Deck Control Manifolds
Cutting Deck Control Manifold Service
Steering and Cutting Deck Lift Circuits
Steering Control Valve (For machines serial number below 403450000)
Steering Control Valve (For machines serial number above 403450001)
Steering Control Valve Service (For machines serial number below 40345000)
Steering Control Valve Service (For machines serial number above 403450001)
Steering Cylinders
Steering Cylinder Service
Front Cutting Deck Lift Cylinders
Front Cutting Deck Lift Cylinder Service
Wing Cutting Deck Lift Cylinders
Wing Cutting Deck Lift Cylinder Service
Steering, Deck Lift Control Manifold
Steering, Deck Lift Control Manifold Service
Cartridge Valve Service
Hydraulic Oil Cooler
Danfoss H1 Closed Circuit Axial Piston Pumps Service Repair Manual
Danfoss H1 Closed Circuit Axial Piston pumps Repair Instructions
Danfoss Steering Unit Type OSPM Service Repair Manual
Eaton Parts And Repair Information: 5 Series Steering Control Units

Chapter 6 : Electrical System

General Information
Operator’s Manual
Operator Cab Components
Toro Electronic Controllers (TEC)
Engine Electronic Control Unit (ECU)
Yanmar Engine Electrical Components
Battery−Disconnect Switch
Electrical System Operation
12 Volt System
24 Volt System
CAN−bus Communications
Electrical Drawings
InfoCenter Display
Operator Information Screen
MAIN MENU
SERVICE
HOURS
TRACTION PEDAL
FAN OVERRIDE
FAN DEMO
REGENERATION
DIAGNOSTICS SCREENS
Electrical System Quick Checks
Adjustments
Cutting Deck Position Switch Adjustment
Component Testing
Fusible Link Harness
Mega Fuses
Fuses
Battery−Disconnect Switch
Toro Electronic Controllers (TECs)
Key Switch
PTO Switch
Cutting Deck Raise, Lower Switches
Throttle Switch
High, Low Range Traction Speed Switch
Cruise Control Switch
Headlight Switch
Turn Signal Switch
Hazard Switch
Parking Brake Switch
Horn Button
Contactors
Seat Switch
Windshield Wiper, Washer Switch (Groundsmaster 5910)
Air Conditioning Switch (Groundsmaster 5910)
Fan Speed Switch (Groundsmaster 5910)
Work Light and Beacon Switches (Groundsmaster 5910 − Optional)
Relays with Four (4) Terminals
Relays with Five (5) Terminals
Hydraulic Solenoid Valves
Air Filter Service Indicator
Fuel Sender
Fuel Pump
Hydraulic Oil Temperature Sender
CAN−bus Terminator Resistor
Resistor Assemblies
Diode Assemblies
Audible Alarm
Traction Pedal Position Sensor
Piston (Traction) Pump Control Solenoid Coils
Cutting Deck Position Switches
24 Volt Cooling Fans
24 Volt Alternator
24 Volt Voltage Divider
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit)
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit)
Service and Repairs
Batteries
Hydraulic Solenoid Valve Coils
24 Volt Alternator, Air Conditioning Compressor Drive Belt
24 Volt Alternator

Chapter 7 : Chassis

General Information
Operator’s Manual
Service and Repairs
Wheels
Steering Column (For machines serial number below 403450000)
Steering Column (For machines serial number above 403450001)
Rear Axle
Rear Axle Service
Front Deck Lift Arms
Wing Deck Lift Arms
Wing Deck Lift Arm Joint Yoke
Wing Deck Impact Arm Assembly
Console Arm
Traction Pedal
Operator Seat
Operator Seat Service
Operator Seat Suspension
Hood and Lower Shrouds

Chapter 8 : Cutting Decks

General Information
Operator’s Manual
Blade Stopping Time
Service and Repairs
Front Cutting Deck
Front Cutting Deck Winglets
Wing Cutting Decks
Drive Belt Idler Assemblies
Blade Spindles
Blade Spindle Service
Castor Forks and Wheels
Deck Skids and Front Deck Roller ( and )

Chapter 9 : Operator Cab

General Information
Operator’s Manual
Electrical Components, Schematics and Wire Harness Drawings
Air Conditioning System
Cab Heater System
Air Conditioning System Performance
Service and Repairs
General Precautions for Removing and Installing Air Conditioning System Components
Air Conditioning Compressor
Roof Assembly
Heating and Air Conditioning Components
A, C Condenser Fan Assembly
A, C Condenser Assembly
Mixing Box Assembly
Heater and A, C Evaporator Cores
Blower Fan
Windshield Wiper Assembly
Sanden SD Compressor Service Guide
Appendix A: Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic
Electrical Schematic (machine serial numbers below 316000200)
Electrical Schematic (machine serial numbers below 316000200)
Electrical Schematic (machine serial numbers 316000201 to 399999999)
Electrical Schematic (machine serial numbers 316000201 to 399999999)
Electrical Schematic (machine serial numbers 400000000 to 403450000)
Electrical Schematic (machine serial numbers 400000000 to 403450000)
Electrical Schematic (machine serial numbers 403450001 to 405600000)
Electrical Schematic (machine serial numbers 403450001 to 405600000)
Electrical Schematic (machine serial numbers 405600001 to 408000000)
Electrical Schematic (machine serial numbers 405600001 to 408000000)
Electrical Schematic (machine serial numbers above 408000000)
Electrical Schematic (machine serial numbers above 408000000)
Operator Platform Wire Harness Drawing (machine serial numbers below 316000200)
Operator Platform Wire Harness Diagram (machine serial numbers below 316000200)
Operator Platform Wire Harness Diagram (machine serial numbers below 316000200)
Operator Platform Wire Harness Drawing (machine serial numbers 316000201 to 316999999)
Operator Platform Wire Harness Diagram (machine serial numbers 316000201 to 316999999)
Operator Platform Wire Harness Diagram (machine serial numbers 316000201 to 316999999)
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000)
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000)
Operator Platform Wire Harness Diagram (machine serial numbers 400000000 to 403450000)
Operator Platform Wire Harness Diagram (machine serial numbers 403450001 to 405600000)
Operator Platform Wire Harness Diagram (machine serial numbers 403450001 to 405600000)
Operator Platform Wire Harness Diagram (machine serial numbers 403450001 to 405600000)
Operator Platform Wire Harness Drawing (machine serial numbers 405600001 to 408000000)
Operator Platform Wire Harness Diagram (machine serial numbers 405600001 to 408000000)
Operator Platform Wire Harness Drawing (machine serial numbers above 408000000)
Operator Platform Wire Harness Diagram (machine serial numbers above 408000000)
Rear Wire Harness Drawing (machine serial numbers below 316000200)
Rear Wire Harness Diagram (machine serial numbers below 316000200)
Rear Wire Harness Drawing (machine serial numbers 316000201 to 403450000)
Rear Wire Harness Drawing (machine serial numbers 316000201 to 403450000)
Rear Wire Harness Drawing (machine serial numbers 403450001 to 405600000)
Rear Wire Harness Drawing (machine serial numbers 403450001 to 405600000)
Rear Wire Harness Drawing (machine serial numbers 405600001 to 408000000)
Rear Wire Harness Diagram (machine serial numbers 405600001 to 408000000)
Rear Wire Harness Drawing (machine serial numbers above 408000000)
Rear Wire Harness Diagram (machine serial numbers above 408000000)
Engine Wire Harness Drawing (machine serial numbers 316000001 to 316999999)
Engine Wire Harness Drawing (machine serial numbers 316000001 to 316999999)
Engine Wire Harness Drawing (machine serial numbers 400000000 to 403450000)
Engine Wire Harness Drawing (machine serial numbers 400000000 to 403450000)
Engine Wire Harness Drawing (machine serial numbers above 403450001)
Engine Wire Harness Drawing (machine serial numbers above 403450001)
Engine DPF Wire Harness Drawing (machine serial numbers above 408000000)
NO TITLE
Cab Power Supply Wire Harness (Machine serial numbers below 316000200)
Cab Headliner Wire Harness Drawing (Machine serial numbers below 308000000)
Cab Headliner Wire Harness Diagram (Machine serial numbers below 308000000)
Cab Headliner Wire Harness Drawing (Machine serial numbers above 308000000)
Cab Headliner Wire Harness Diagram (Machine serial numbers above 308000000)
Wire Harness Diagram − Two−Post ROPS Extension
Wire Harness Diagram − Two−Post ROPS Extension