Toro Groundsmaster 5900 Series - GEARS Troubleshooting Approach

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GEARS–TheSystematicApproachtoDening,

DiagnosingandSolvingProblems

GatherInformation

•Informationreportedbythecustomer

•Informationobservedbyyou

•Establishthewhat,whereandwhenoftheissue

EvaluatePotentialCauses

•Considerpossiblecausesoftheproblemtodevelopahypothesis

•Narrowdownthefocusoftheproblem

AssessPerformance

•Ensureyouhaveallthenecessarytoolsfortesting

•Testallpotentialcausesofthefailure

•Reevaluateandcreateanewhypothesisifnecessary

Repair

•Returntheunittoservicebyrepairing,rebuildingorreplacing

SolutionConrmation

•Didtheissuegoaway

•Wastherootcauseoftheissuecorrectlyrepaired

•Arethereanyothernewsymptoms

Troubleshooting:Page3–2

Groundsmaster

5900&5910

16227SLRevB

Main Page

Table of Contents7
Chapter 1: Safety11
Safety Instructions12
Before Operating the Machine12
While Operating the Machine13
Maintenance and Service14
Battery-Disconnect Switch15
Jacking Instructions16
Safety and Instructional Decals18
Chapter 2: Specifications and Maintenance19
Specifications20
Overall Dimensions20
Engine21
Hydraulic System22
Chassis23
Cutting Decks24
Torque Specifications25
Calculating the Torque Values When Using a Drive-Adapter Wrench26
Identifying the Fastener27
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)28
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)29
Other Torque Specifications30
Conversion Factors30
Shop Supplies31
Special Tools33
Chapter 3: Troubleshooting39
GEARS - the Systematic Approach to Defining, Diagnosing and Solving Problems40
Gather Information40
Evaluate Potential Causes40
Assess Performance40
Repair40
Solution Confirmation40
General Hydraulic System Problems41
Traction Circuit Problems42
PTO Problems44
Lift/Lower Circuit Problems45
Steering Circuit Problems46
Starting Problems47
General Run and Transport Problems49
Cutting Deck (PTO) Operating Problems50
Cutting Deck Lift/Lower Problems52
Operator Advisories54
To Start55
To Engage Pto55
To Set Cruise Control55
To Lower Deck56
To Float Deck56
To Set High Range56
To Set Low Range57
For Traction57
Engine57
Fuel Level58
Traction Pedal58
To Raise Deck58
Using the Infocenter Display for Troubleshooting59
Machine Faults61
Engine Faults65
Factors that Can Affect Quality of Cut and Clipping Dispersion67
Chapter 4: Yanmar Diesel Engine67
General Information70
Operator's Manuals70
Yanmar Service and Troubleshooting Manuals70
Stopping the Engine70
Engine Electronic Control Unit (ECU)71
Yanmar Engine73
Diesel Particulate Filter74
General Information77
Service and Repairs79
Air Filter79
Exhaust System81
Fuel System85
Radiator90
Engine93
Pump Adapter Plate (Coupler)99
Chapter 5: Hydraulic System101
General Information103
Operator's Manual103
Relieving Hydraulic System Pressure103
Towing Traction Unit103
Traction Circuit Component Failure105
Hydraulic Hoses106
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal)107
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)109
Hydraulic Schematic112
Hydraulic Flow Diagrams113
Traction Circuit Operation114
Traction Circuit: Low Range Traction Speed (Mow)116
Traction Circuit: High Range Traction Speed (Transport)119
Raise Cutting Deck122
Lower Cutting Deck125
PTO Mow Circuit128
PTO Mow Circuit Cutting Deck Blade Braking131
Steering Circuit133
Testing136
Before Performing Hydraulic Tests136
Precautions for Hydraulic Testing136
Which Hydraulic Tests Are Necessary137
Traction Circuit Charge Pressure Test (Using Pressure Gauge)139
Traction Circuit Relief Pressure Test (Using Pressure Gauge)142
Counterbalance Pressure Test (Using Pressure Gauge)145
Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter)147
Cutting Deck Circuit Pressure Test (Using Pressure Gauge)150
Cutting Deck Circuit Relief Pressure Test (Using Tester with Pressure Gauge and 40 GPM Flow Meter)153
Cutting Deck Motor Case Drain Leakage Test (Using Tester with Pressure Gauge & 40 GPM Flow Meter)156
Lift/Lower Circuit Relief Pressure Test (Using Pressure Gauge)160
Steering Circuit Relief Pressure Test (Using Pressure Gauge)163
Steering Cylinder Internal Leakage Test165
Gear Pump (PTO, Steering, Deck Lift/Lower and Traction Charge Circuits) Flow Test (Using Tester with Pressure Gauges and Flow Meter)167
Adjustments172
Adjust Manifold Relief Valves172
Service and Repairs173
General Precautions for Removing and Installing Hydraulic System Components173
Check Hydraulic Lines and Hoses175
Priming Hydraulic Pumps176
Flush Hydraulic System177
Charge Hydraulic System179
Filtering Closed−Loop Traction Circuit181
Hydraulic Reservoir183
Gear Pump186
Gear Pump Service188
Traction Circuit193
Piston (Traction) Pump193
Piston (Traction) Pump Service198
Front Wheel Motors200
Rear Wheel Motors205
Wheel Motor Service207
Traction Control Manifold209
Traction Control Manifold Service212
Brake Release Manifold214
Brake Release Manifold Service216
Cutting Deck Circuit217
Cutting Deck Motor218
Cutting Deck Motor Service220
Cutting Deck Control Manifolds225
Cutting Deck Control Manifold Service228
Steering and Cutting Deck Lift Circuits230
Steering Control Valve (for Machines Serial Number below 403450000)231
Steering Control Valve (for Machines Serial Number above 403450001)234
Steering Control Valve Service (for Machines Serial Number below 40345000)237
Steering Control Valve Service (for Machines Serial Number above 403450001)238
Steering Cylinders239
Steering Cylinder Service241
Front Cutting Deck Lift Cylinders243
Front Cutting Deck Lift Cylinder Service245
Wing Cutting Deck Lift Cylinders248
Wing Cutting Deck Lift Cylinder Service250
Steering/Deck Lift Control Manifold252
Steering/Deck Lift Control Manifold Service255
Cartridge Valve Service258
Chapter 6: Electrical System263
General Information265
Operator's Manual265
Operator Cab Components265
Toro Electronic Controllers (TEC)265
Engine Electronic Control Unit (ECU)267
Yanmar Engine Electrical Components267
Battery−Disconnect Switch268
Electrical System Operation269
12 Volt System269
Can−Bus Communications270
Electrical Drawings270
Infocenter Display271
Operator Information Screen272
Main Menu275
Service276
Hours277
Traction Pedal278
Fan Override280
Fan Demo281
Regeneration282
Diagnostics Screens284
Electrical System Quick Checks304
Adjustments308
Cutting Deck Position Switch Adjustment308
Component Testing315
Fusible Link Harness316
Mega Fuses318
Fuses319
Battery−Disconnect Switch323
Toro Electronic Controllers (Tecs)325
Key Switch330
PTO Switch332
Cutting Deck Raise/Lower Switches334
Throttle Switch336
High/Low Range Traction Speed Switch338
Cruise Control Switch340
Headlight Switch342
Turn Signal Switch344
Hazard Switch346
Parking Brake Switch348
Horn Button350
Contactors351
Seat Switch353
Windshield Wiper/Washer Switch (Groundsmaster 5910)354
Air Conditioning Switch (Groundsmaster 5910)356
Fan Speed Switch (Groundsmaster 5910)357
Work Light and Beacon Switches (Groundsmaster 5910 − Optional)359
Relays with Four (4) Terminals361
Relays with Five (5) Terminals364
Air Filter Service Indicator370
Fuel Sender371
Fuel Pump373
Hydraulic Oil Temperature Sender375
Can−Bus Terminator Resistor377
Resistor Assemblies378
Diode Assemblies380
Audible Alarm384
Traction Pedal Position Sensor385
Piston (Traction) Pump Control Solenoid Coils386
Cutting Deck Position Switches388
24 Volt Alternator392
24 Volt Voltage Divider394
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit)396
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit)398
Service and Repairs400
Batteries400
Hydraulic Solenoid Valve Coils408
24 Volt Alternator/Air Conditioning Compressor Drive Belt409
24 Volt Alternator411
General Information416
Operator's Manual416
Service and Repairs417
Wheels417
Steering Column (for Machines Serial Number below 403450000)419
Steering Column (for Machines Serial Number above 403450001)422
Rear Axle429
Front Deck Lift Arms431
Wing Deck Lift Arms435
Wing Deck Lift Arm Joint Yoke441
Wing Deck Impact Arm Assembly445
Console Arm449
Traction Pedal451
Operator Seat454
Operator Seat Service456
Operator Seat Suspension458
Chapter 8: Cutting Decks463
General Information464
Operator's Manual464
Blade Stopping Time464
Service and Repairs465
Front Cutting Deck465
Front Cutting Deck Winglets468
Drive Belt Idler Assemblies473
Blade Spindle Service479
General Information488
Operator's Manual488
Electrical Components, Schematics and Wire Harness Drawings488
Air Conditioning System488
Cab Heater System489
Air Conditioning System Performance489
Service and Repairs490
General Precautions for Removing and Installing Air Conditioning System Components490
Air Conditioning Compressor492
Roof Assembly495
Heating and Air Conditioning Components497
A/C Condenser Fan Assembly499
A/C Condenser Assembly502
Mixing Box Assembly505
Blower Fan512
Windshield Wiper Assembly515
Appendix A519
Electrical Drawing Designations520
Hydraulic Schematic521
Electrical Schematic (Machine Serial Numbers below 316000200)522
Electrical Schematic (Machine Serial Numbers below 316000200523
Electrical Schematic (Machine Serial Numbers 316000201 to 399999999)524
Electrical Schematic (Machine Serial Numbers 316000201 to 399999999525
Electrical Schematic (Machine Serial Numbers 400000000 to 403450000)526
Electrical Schematic (Machine Serial Numbers 400000000 to 403450000527
Electrical Schematic (Machine Serial Numbers above 403450001)528
Electrical Schematic (Machine Serial Numbers above 403450001529
Operator Platform Wire Harness Drawing (Machine Serial Numbers below 316000200530
Operator Platform Wire Harness Diagram (Machine Serial Numbers below 316000200531
Operator Platform Wire Harness Diagram (Machine Serial Numbers below 316000200)532
Operator Platform Wire Harness Drawing533
Operator Platform Wire Harness Diagram534
Operator Platform Wire Harness Diagram (Machine Serial Numbers 316000201 to 316999999)535
Operator Platform Wire Harness Diagram536
Operator Platform Wire Harness Diagram537
Operator Platform Wire Harness Diagram538
Operator Platform Wire Harness Diagram (Machine Serial Numbers above 403450001539
Operator Platform Wire Harness Diagram (Machine Serial Numbers above 403450001)540
Operator Platform Wire Harness Diagram (Machine Serial Numbers above 403450001541
Rear Wire Harness Drawing (Machine Serial Numbers below 316000200542
Rear Wire Harness Diagram (Machine Serial Numbers below 316000200543
Rear Wire Harness Drawing (Machine Serial Numbers 316000201 to 403450000544
Rear Wire Harness Drawing (Machine Serial Numbers 316000201 to 403450000)545
Rear Wire Harness Drawing (Machine Serial Numbers above 403450001546
Rear Wire Harness Drawing (Machine Serial Numbers above 403450001)547
Engine Wire Harness Drawing (Machine Serial Numbers 316000001 to 316999999548
Engine Wire Harness Drawing (Machine Serial Numbers 316000001 to 316999999)549
Engine Wire Harness Drawing (Machine Serial Numbers 400000000 to 403450000550
Engine Wire Harness Drawing (Machine Serial Numbers 400000000 to 403450000)551
Engine Wire Harness Drawing (Machine Serial Numbers above 403450001552
Cab Power Supply Wire Harness (Machine Serial Numbers below 316000200554
Cab Headliner Wire Harness Drawing555
Cab Headliner Wire Harness Diagram556
Wire Harness Diagram − Two−Post ROPS Extension557

Toro Groundsmaster 5900 Series - GEARS Troubleshooting Approach

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