Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- NOTES
- Preface
- Table of Contents
- Chapter 1 : Safety
- Chapter 2 : Specifications and Maintenance
- Chapter 3 : Troubleshooting
- GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems
- 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
- 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
- Chapter 5 : Hydraulic System
- General Information
- Hydraulic Schematic
- Hydraulic Flow Diagrams
- 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
- 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
- Chapter 6 : Electrical System
- General Information
- Electrical System Operation
- InfoCenter Display
- Adjustments
- 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
- Chapter 7 : Chassis
- General Information
- 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
- Chapter 9 : Operator Cab
- 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
EngineInstallation(continued)
10.Installthe24Voltalternator/airconditioningcompressordrivebelt(see24
VoltAlternator/AirConditioningCompressorDriveBelt(page6–147)).
11.Connectthesupplyandreturnfuelhosestothefuelpump(Figure26).
Securetheclampsupportingthefuelhosestothefuelpumpmountingscrew.
12.Connectwiresand/orelectricalconnectionstotheengineassemblyatthe
followinglocations:
A.Four(4)connectionsatYanmarengineharness
B.Oilpressureswitch
C.Glowplugs
D.Electricstarter
E.Alternator
F.DieselParticulateFilter(DPF)
13.Installcoolerframeassemblytomachineframe.Tightenrearcoolerframe
mountingfastenersrst,followedbyfrontfasteners.
14.Installthebattery−disconnectswitchbracketandconnectwiresand/or
electricalconnectionstothecoolerframeassemblyatthefollowinglocations:
A.Radiatorfans(2)
B.Airlterserviceindicator
C.Oilcoolerfans(2)
D.Windshieldwasherreservoirpump(GM5910only)
15.Installairintakehose.Tightenhoseclampsfrom10to11N·m(90to100
in−lb).
16.Installupperandlowercoolanthoses.Tightenhoseclampsfrom3to5N·m
(30to45in−lb).Closeradiatordrainandllradiatorandreservoirwith
coolant(seemachineOperator’sManual).
17.Replaceallcableties,clampsandclipsremovedduringdisassemblyand
secureelectricalharness.Checkpositionofelectricalharnesses,fuellines
andhydraulichosesforproperclearancewithrotating,hightemperatureand
movingcomponents.
18.Installhood(seeHoodandLowerShrouds(page7–47)).
19.Checkandadjustengineoilasneeded.
20.Checkandadjusthydraulicoilasneeded.
21.Turnthebatter−disconnectswitchtotheONposition.
22.Runengineandcheckforanyleaks.
23.Operatehydrauliccontrolstoproperlyllhydraulicsystem(seeCharge
HydraulicSystem(page5–79)).
24.Installhoodtomachine(seeHoodandLowerShrouds(page7–47)).
YanmarDieselEngine:ServiceandRepairs
Page4–30
Groundsmaster
®
5900&5910
16227SLRevE