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

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

• Title Page
• Revision History
• Reader Comments
• Notes:
• Preface
• Service Procedure Icons
• Table of Contents
• 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)