Toro Groundsmaster 5900, 5910 (Models 31598, 31599) Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Groundsmaster 5900, 5910 (Models 31598, 31599)

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
Jacking Instructions
Raising the Front of the Machine
Raising the Rear of the Machine
Safety and Instructional Decals

Chapter 2 : Specifications and Maintenance

Specifications
Decimal and Millimeter Equivalents
U.S. to Metric Conversions
Torque Specifications
Identifying the Fastener
Calculating the Torque Values When Using a Drive-Adapter Wrench
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Series)
Other Torque Specifications
Conversion Factors
Shop Supplies
Special Tools

Chapter 3 : Diesel Engine

1 Specifications
Diesel Engine
General Information
Operator’s Manual
Engine Identification
Engine Electronic Control Module (ECM)
Shutting Off the Engine
Fuel-Injection System
Adjustments
Adjusting the Valve Clearance
Service and Repairs
Air Filter System
Exhaust System
Turbocharger
Fuel Tank
Radiator
Alternator
Starter Motor
Valve Cover
Engine Breather System
Thermostat
Water Pump
Front Cover
Oil Pan
Engine
Flywheel Coupling Assembly

Chapter 4 : Hydraulic System

1 Specifications
Hydraulic System
General Information
Checking the Hydraulic Fluid
Releasing Pressure from the Hydraulic System
Towing the Traction Unit
Traction Circuit Component Failure
Hydraulic Hoses
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port)
Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit: Low Speed
Traction Circuit: High Speed
Traction Circuit: Traction Control
Raising the Cutting Deck
Lowering the Cutting Deck
PTO Mow Circuit
Steering Circuit
Engine Cooling Fan Circuit
Special Tools
Hydraulic Pressure Testing Kit
15 GPM Hydraulic Tester (Pressure and Flow)
40 GPM Hydraulic Tester (Pressure and Flow)
Hydraulic Hose Kit
High Flow Hydraulic Filter Kit
O-Ring Kit
Hydraulic Test Fitting Kit
Measuring Container
Rear Wheel Hub Puller
Troubleshooting
General Hydraulic System Problems
Traction Problems
PTO Problems
Steering Circuit Problems
Lift, Lower Problem
Testing the Hydraulic System
Determining which Hydraulic Tests to Perform
Testing the Traction Circuit Charge Pressure (Using Pressure Gauge)
Testing the Traction Circuit Relief Pressure (Using Pressure Gauge)
Testing the Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge)
Testing the Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
Testing the Counterbalance Pressure (Using Pressure Gauge)
Testing the Piston (Traction) Pump Flow (Using Tester with Pressure Gauge and 40 GPM Flow Meter)
Testing the Cutting Deck Circuit Pressure (Using Pressure Gauge)
Testing the Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauge and 40 GPM Flow Meter)
Testing the Cutting Deck Motor for Case Drain Leakage (Using Tester with Pressure Gauge and 40 GPM Flow Meter)
Testing the Lift, Lower Circuit Relief Pressure (Using Pressure Gauge)
Testing the Steering Circuit Relief Pressure (Using Pressure Gauge)
Testing the Steering Cylinder for Internal Leakage
Testing the Gear Pump (P3) (PTO, Steering, Cooling Fan, Lift, Lower, and Traction Charge Circuits) Flow (Using Tester with Pressure Gauges and Flow Meter)
Adjustments
Adjusting the Pressure Valve
Service and Repairs
General Precautions for Removing and Installing the Hydraulic System Components
Checking the Hydraulic Lines and Hoses
Flushing the Hydraulic System
Charging the Hydraulic System
Filtering the Closed-Loop Traction Circuit
Hydraulic Reservoir
Gear Pump
Servicing the Gear Pump
Traction Circuit
Piston (Traction) Pump
Servicing the Piston (Traction) Pump (Rexroth)
Servicing the Piston (Traction) Pump (Sauer-Danfoss)
Front Wheel Motors
Servicing the Front Wheel Motor
Rear Wheel Motors
Servicing the Rear Wheel Motor
Traction Control Manifold
Servicing the Traction Control Manifold
4-Wheel Drive Control Manifold
Servicing the 4-Wheel Drive Control Manifold
Traction Flush Manifold
PTO Circuit
Cutting Deck Motor
Servicing the Cutting Deck Motor
PTO Control Manifolds
Servicing the PTO Control Manifold
Filter Manifold
Hydraulic Oil Cooler
Cutting Deck Raise, Lower Circuit
Front Deck Lift Cylinder
Servicing the Front Deck Lift Cylinder
Wing Deck Lift Cylinder
Servicing the Wing Deck Lift Cylinder
Lift Control Manifold
Servicing the Lift Control Manifold
Steering and Engine Cooling Fan Circuit
Steering Control Valve
Servicing the Steering Control Valve
Steering Cylinders
Servicing the Steering Cylinder
Engine Cooling Fan Motor
Servicing the Engine Cooling Fan Motor
Steering, Engine Cooling Fan Control Manifold
Servicing the Steering, Engine Cooling Fan Control Manifold
DANFOSS D SERIES GEAR PUMP SEAL KIT SERVICE INSTRUCTION BULLETIN
REXROTH VARIABLE PUMP A10VG REPAIR INSTRUCTIONS
REXROTH VARIABLE PUMP A10VG REPAIR MANUAL
DANFOSS H1 CLOSED CIRCUIT AXIAL PISTON PUMPS Service Repair Manual
DANFOSS H1 CLOSED CIRCUIT AXIAL PISTON PUMPS REPAIR INSTRUCTIONS
EATON REPAIR INFORMATION: MODEL 74318 and 74348 PISTON MOTORS
PARKER TORQMOTORTM SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
EATON PARTS AND REPAIR INFORMATION: 5 SERIES STEERING CONTROL UNITS

Chapter 5 : Electrical System

General Information
Toro Electronic Controllers (TEC)
Cummins Engine Electronic Control Module (ECM)
CAN-Bus Communications
Electrical Drawings
Special Tools
Multimeter
Dielectric Gel
Battery Terminal Protector
Battery Hydrometer
Troubleshooting
Starting Problems
General Run and Transport Problems
Cutting Deck (PTO) Operating Problems
Cutting Deck Lift, Lower Problems
InfoCenter Display
Operator Information
Operator Advisories
Engine Faults
Diagnostics
Administration Settings
Administration Service
Administration About
Electrical System Quick Checks
Testing the Battery (Open Circuit Test)
Testing the Charging System
Checking the Operation of the Interlock Switches
Testing the Component
Key Switch
Fuses
Maxi Fuses
Mega Fuses
Cab Fuses (Groundsmaster 5910 Machine Only)
PTO Switch
Cutting Deck Lift Switches
Traction Assist Switch
Cruise Control Switch
Throttle Control Switch
Increment, Decrement Switch
High-Low Speed Switch
Headlight Switch
Turn Signal Switch
Windshield Wiper, Washer Switch (Groundsmaster 5910 Machine Only)
Air Conditioning Switch (Groundsmaster 5910 Machine Only)
Intake Air Heater Contactor
Seat Switch
Parking Brake Switch
Service Brake Switches
Main Power, Controller, Start, and Cab (Groundsmaster 5910 Machine Only) Relays
Air Conditioning Relay (Groundsmaster 5910 Machine Only)
Toro Electronic Controller (TEC)
Hydraulic Valve Solenoid Coils
Fuel Sender
Hydraulic Fluid Temperature Sender
Diode Assembly
Audible Alarm
Traction Pedal Potentiometer
Air Filter Sensor (Machines with Serial Number Above 313000300)
Up Limit Switches
Adjustments
Calibrating the Traction Pedal
Traction Pedal Teach
Service and Repairs
Battery Storage
Battery Care
Servicing the Battery
Hydraulic Valve Solenoid Coil

Chapter 6 : Axles, Planetaries, and Brakes

1 Specifications
Axles, Planetaries, and Brakes
General Information
Adjustments
Planetary Drive Assembly Endplay (OPH-2 series planetary drives)
Service and Repairs
Wheels
Brake Assembly
Servicing the Brake
Planetary Drive Assembly
Servicing the OPH-2 Series Planetary Drive
Servicing the VA02 Series Planetary Drive
Rear Axle
Servicing the Rear Axle

Chapter 7 : Chassis

General Information
Service and Repairs
Steering Tower
Wing Deck Rear Impact Arm Assembly
Lift Arm Joint Yoke
Front Deck Lift Arms
Wing Deck Lift Arms
Console Arm
Traction Pedal
Operator Seat
Servicing the Operator Seat
Operator Seat Suspension (Machine with Serial Number Below 315000200)
Operator Seat Suspension (Machine with Serial Number Above 315000200)
Hood

Chapter 8 : Cutting Decks

1 Specifications
Cutting Decks
General Information
Operator’s Manual
Castor Wheel Tire Pressure
Blade Stopping Time
Troubleshooting
Factors that can Affect Quality of Cut
Service and Repairs
Front Cutting Deck
Wing Cutting Deck
Idler Assembly
Front Deck Winglets
Blade Spindle
Servicing the Blade Spindle
Castor Forks and Wheels
Deck Skids and Rollers

Chapter 9 : Operator Cab

General Information
Operator’s Manual
Electrical Components and Schematic
Air Conditioning System
Cab Heater System
Air Conditioning System Performance
Service and Repairs
General Precautions for Removing and Installing the Air Conditioning System Components
Air Conditioning Compressor
Servicing the Air Conditioning Compressor
Roof Assembly
Air Conditioning Condenser Assembly
Heater and Evaporator Assembly
ICE COMPRESSOR Service Repair Manual
Appendix A: Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic (Serial Number Below 313000300)
Hydraulic Schematic (Serial Number Above 313000300)
Electrical Schematic Sheet 1 of 5 (Serial Number Below 313000300)
Electrical Schematic Sheet 2 of 5 (Serial Number Below 313000300)
Electrical Schematic Sheet 3 of 5 (Serial Number Below 313000300)
Electrical Schematic Sheet 4 of 5 (Serial Number Below 313000300)
Electrical Schematic Sheet 5 of 5 (Serial Number Below 313000300)
Electrical Schematic Sheet 1 of 5 Serial Number From 313000301 to 313999999)
Electrical Schematic Sheet 2 of 5 (Serial Number From 313000301 to 313999999)
Electrical Schematic Sheet 3 of 5 (Serial Number From 313000301 to 313999999)
Electrical Schematic Sheet 4 of 5 (Serial Number From 313000301 to 313999999)
Electrical Schematic Sheet 5 of 5 (Serial Number From 313000301 to 313999999)
Electrical Schematic Sheet 1 of 5 (Serial Number Above 314000000)
Electrical Schematic Sheet 2 of 5 (Serial Number Above 314000000)
Electrical Schematic Sheet 3 of 5 (Serial Number Above 314000000)
Electrical Schematic Sheet 4 of 5 (Serial Number Above 314000000)
Electrical Schematic Sheet 5 of 5 (Serial Number Above 314000000)
Electrical Schematic Operator Cab (Serial Number Below 313000300)
Electrical Schematic Operator Cab (Serial Number From 313000301 to 313999999)
Electrical Schematic Operator Cab (Serial Number Above 314000000)
Platform Wire Harness Drawing (Serial Number Below 310000000)
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number Below 310000000)
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number Below 310000000)
Platform Wire Harness Drawing (Serial Number From 310000001 to 313000300)
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number From 310000001 to 313000300)
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number From 310000001 to 313000300)
Platform Wire Harness Drawing (Serial Number From 313000301 to 313999999)
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number From 313000301 to 313999999)
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number From 313000301 to 313999999)
Platform Wire Harness Drawing (Serial Number Above 314000000)
Platform Wire Harness Diagram Sheet 1 of 2 (Serial Number Above 314000000)
Platform Wire Harness Diagram Sheet 2 of 2 (Serial Number Above 314000000)
Rear Wire Harness Drawing (Serial Number Below 313000300)
Rear Wire Harness Diagram (Serial Number Below 313000300)
Rear Wire Harness Drawing (Serial Number From 313000301 to 313999999)
Rear Wire Harness Diagram (Serial Number From 313000301 to 313999999)
Rear Wire Harness Drawing (Serial Number Above 314000000)
Rear Wire Harness Diagram (Serial Number Above 314000000)
Cab Wire Harness Drawing (Serial Number Below 314999999)
Cab Wire Harness Diagram (Serial Number Below 314999999)
Cab Wire Harness Drawing (Serial Number Above 315000000)
Cab Wire Harness Diagram (Serial Number Above 315000000)