Toro 5910, 5900 User Manual

Part No. 08159SL

Service Manual

Groundsmaster

Preface

The purposeof this publication is to provide theservice technician with information for troubleshooting, testing, and repair of major systems and components on the Groundsmaster 5900 and 5910.

REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for yourmachine into Chapter 2 of this service manual. Additional copies of the Operator’s Manual and Parts Catalog are available on the internet at www.Toro.com.

TheToroCompanyreserves the right to changeproduct specifications or this publication without notice.

5900 & 5910

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: ANOTE willgive generalinformation aboutthe

correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give importantinstructionswhichmust befollowedto prevent damage to systems or components on the machine.

E The Toro Company -- 2009

This page is intentionally blank.

Groundsmaster 5900/5910

Chapter 1 -- Safety

General Safety Instructions 1 -- 2..................

Jacking Instructions 1 -- 5.........................

Safety and Instruction Decals 1 -- 6................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Diesel Engine

General Information 3 -- 2........................

Engine Specifications 3 -- 4.......................

Engine Fastener Torque Specifications 3 -- 5........

Adjustments 3 -- 7...............................

Service and Repairs 3 -- 8........................

Chapter 4 -- Hydraulic System

Specifications 4 -- 2..............................

General Information 4 -- 3........................

Hydraulic Schematic 4 -- 11.......................

Hydraulic Flow Diagrams 4 -- 12...................

Special Tools 4 -- 30.............................

Troubleshooting 4 -- 33...........................

Testing 4 - - 38...................................

Adjustments 4 -- 60..............................

Service and Repairs 4 -- 61.......................

SAUERDANFOSSDSERIESGEARPUMPSEALKIT

SERVICE INSTRUCTION BULLETIN

REXROTH VARIABLE PUMP A10VG REPAIR IN-

STRUCTIONS

REXROTHVARIABLEPUMPA10VG REPAIRMANU-

EATON REPAIR INFORMATION: MODEL 74318 and

74348 PISTON MOTORS

PARKER TORQMOTOR

(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

EATON PARTS AND REPAIR INFORMATION: 5

SERIES STEERING CONTROL UNITS

SERVICE PROCEDURE

Chapter 5 -- Electrical System

General Information 5 -- 2........................

Electrical Drawings 5 -- 3.........................

Special Tools 5 -- 4..............................

Troubleshooting 5 -- 6............................

Info Center Display 5 -- 11........................

Electrical System Quick Checks 5 -- 28.............

Adjustments 5 -- 30..............................

Component Testing 5 -- 32........................

Service and Repairs 5 -- 63.......................

Chapter 6 -- Axles, Planetaries and Brakes

Specifications 6 -- 2..............................

General Information 6 -- 3........................

Service and Repairs 6 -- 4........................

Chapter 7 -- Chassis

General Information 7 -- 1........................

Service and Repairs 7 -- 2........................

Chapter 8 -- Cutting Decks

Specifications 8 -- 2..............................

Troubleshooting 8 -- 3............................

General Information 8 -- 4........................

Service and Repairs 8 -- 6........................

SafetyProduct Records

Diesel

Hydraulic

Electrical

Axles, Planetaries

and Maintenance

Engine

System

and Brakes

Groundsmaster 5900/5910

Cutting Decks Chassis

This page is intentionally blank.

Groundsmaster 5900/5910

Table Of Contents (Continued)

Chapter 9 -- Operator Cab

General Information 9 -- 2........................

Service and Repairs 9 -- 3........................

ICE COMPRESSOR SERVICE MANUAL

Chapter 10 -- Foldout Drawings

Hydraulic Schematic 10 -- 3.......................

Electrical Schematics 10 -- 4......................

Wire Harness Drawings 10 -- 10..................

Cab

OperatorFoldout

Drawings

Groundsmaster 5900/5910

This page is intentionally blank.

Groundsmaster 5900/5910

Chapter 1

Table of Contents

GENERAL SAFETY INSTRUCTIONS 2............

Before Operating 2............................

While Operating 3.............................

Maintenance and Service 4....................

JACKING INSTRUCTIONS 5.....................

Jacking the Front End 5........................

Jacking the Rear End 5........................

SAFETY AND INSTRUCTION DECALS 6..........

Safety

Groundsmaster 5900/5910 Page 1 -- 1 Safety

General Safety Instructions

TheGroundsmaster 5900 and 5910 are testedand certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.Improperuseormaintenance of themachinecan resultininjuryordeath. Toreduce the potentialforinjury or death, comply with the following safety instructions.

Before Operating

WARNING

To reduce the potential for injury or death, comply with the following safety instructions.

1. Review and understand the contents of the Operator’s Manual and Operator’s DVD before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. Additionalcopies ofthe Operator’s Manual are available on the internet at www.Toro.com.

2. Keep all shields, safetydevicesanddecals in place. Ifashield,safetydeviceordecalisdefective,illegibleor damaged, repair or replace it before operating the machine.Alsotightenany loose nuts,boltsorscrewstoensure machine is in safe operating condition.

3. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and PTO switch is OFF (disengaged).

4. Since diesel fuel is flammable, handle it carefully: A. Use an approved fuel container. B. Donotremove fueltankcapwhile engineishotor

running. C. Do not smoke while handling fuel. D. Fillfueltankoutdoorsandonly towithinaninchof

the top of the tank, not the filler neck.Do notoverfill fuel tank.

E. Wipe up any spilled fuel.

Groundsmaster 5900/5910Page 1 -- 2Safety

While Operating

1. Sit onthe seatwhen starting and operating the machine.

2. Before starting the engine: A. Engage the parking brake. B. Makesurethetractionpedalis intheneutralposi-

tion and the PTO switch is OFF (disengaged). C. Afterengineisstarted, releaseparkingbrakeand

keepfootofftractionpedal.Machinemustnot move. Ifmovementisevident,the traction pedal isadjusted incorrectly;therefore,shutengineoffandadjusttraction system until machinedoesnotmove when traction pedal is released.

3. Do not run engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

4. Do not touch engine, radiator or exhaust system

whileengineis runningorsoonafteritis stopped.These areas could be hot enough to cause burns.

5. Before getting off the seat: A. Ensure that traction pedal is in the neutral posi-

tion. B. Apply parking brake. C. Lower the cutting decks fully to the ground. This

relieves pressure from the lift circuit and eliminates the risk of the cutting decks accidentallylowering to the ground.

D. Disengage cutting decks and wait for cutting blades to stop completely.

E. Allow engineto run at low idle speed for at least five (5)minutes after full load operation to allow the turbocharger to cool.

F. Stopengineandremovekeyfromswitch.Waitfor all machine movement to stop.

6. Do not park machine on slopes unless wheels are

chocked or blocked.

Safety

Groundsmaster 5900/5910 Page 1 -- 3 Safety

Maintenance and Service

1. Before servicing or making machine adjustments, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

2. Make sure machine isinsafeoperating condition by keeping all nuts, bolts and screws tight.

3. Shut engine off before checking or adding oil to the engine crankcase.

4. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt.Clean protective screen on machine frequently.

5. Never store the machine or fuel container inside wherethereisanopenflame,suchasnearawaterheater or furnace.

6. Do not overspeed the engineby changing governor setting.Toassuresafetyandaccuracy,checkmaximum engine speed.

7. Disconnect batteries before servicing the machine. Disconnect negative battery cables first and positive cables last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the batteries. Reconnect positive battery cables first and negative cables last.

8. Battery acid is poisonous and can cause burns. Avoidcontact with skin,eyesand clothing. Protect your face, eyes and clothing when working with a battery.

9. Battery gases canexplode. Keep cigarettes,sparks and flames away from the battery.

10.When changing attachments, tires or performing otherservicethatrequiresthemachine toberaised,use correct jacks, hoists and supports.Make suremachine is parked on a solid level surface such as a concrete floor. Prior to raising the machine, remove any attachmentsthatmayinterferewiththe safeandproperraising ofthemachine.Always chockorblockwheels.Uses uitable jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machinemay move or fall,which mayresultinpersonal injury (see Jacking Instructions in this chapter).

11.Make sureallhydrauliclineconnectorsare tight,and all hydraulic hoses and lines are in good condition before applying pressure to the system.

12.Keepbodyandhandsawayfrompinholeleaksinhydrauliclinesthatejecthighpressurehydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin mustbesurgicallyremovedwithinafewhoursby a doctor familiar with this form of injury or gangrene may result.

13.Before disconnectingorperforming any work onthe hydraulic system, all pressure in system must be relieved by stopping engine and lowering the cutting decks to the ground.

14.Make sure all engine fuel system connectors and components are correctly installed, and all fuel hoses are in good condition before starting engine.

15.Keep bodyandhandsawayfrom leaksinenginefuel injectionlines.Usecardboard or papertofindhighpressurefuelleaksiftheymayexist.Leakingfuelunderpressure can penetrate skin and cause injury.

16.If enginemustberunningtoperformmaintenance or an adjustment, keep hands, feet, clothing and other parts of the body away from cutting decks and other moving parts. Keep bystanders away.

17.At the time ofmanufacture, the machine conformed tothesafetystandardsfor riding mowers. Toassureoptimumperformanceandcontinued safety certificationof the machine, use genuine Toro replacement parts and accessories.Replacementpartsandaccessoriesmade by other manufacturers mayresultin non-conformance with the safety standards, and the warranty may be voided.

18.When welding on machine, disconnect all battery cables to preventdamageto machine electronicequipment. Disconnect negative battery cable first and positive cable last. Disconnect and remove engine electronic control module (ECM) from engine before welding on the machine. Also, attach welder ground cable no more than two (2) feet (0.61 meters) from the welding location.

19.If major repairsareeverneededor assistance is desired, contact an Authorized Toro Distributor.

Groundsmaster 5900/5910Page 1 -- 4Safety

Jacking Instructions

CAUTION

When changing attachments, tires or performingotherservice thatrequiresthemachine tobe raised,usecorrect jacks,hoistsandsupportsto raise and support the machine. Make sure machineisparkedonasolid levelsurfacesuch asa concretefloor.Prior to raising machine, remove anyattachmentsthatmay interfere with thesafe and proper raising of the machine. Always chock or block wheels. Use appropriate jack stands to support the raised machine. Ifthemachine is not properly supportedby jack stands, the machine may moveor fall, which may result in personal injury.

Jacking the Front End (Fig. 1)

1. Chock both rear tires to prevent the machine from moving.

2. Position jack securely under the frame, just to the inside ofthe fronttire. Makesure thatjack does not contact hydraulic lift cylinder.

3. Position appropriate jackstands under theframeas close to the front wheel as possible to support the machine.

Jacking the Rear End (Fig. 2)

Figure 1

1. Frame jacking point 2. Front tire

Figure 2

1. Rear axle jacking point 2. Rear tire

Safety

1. Applyparkingbrakeandchockbothfronttires toprevent the machine from moving.

2. Place jack securely under the center of rear axle. Jack rear of machine off the ground.

3. Use appropriate jack stands under the rear axle to support the machine.

Groundsmaster 5900/5910 Page 1 -- 5 Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.

Groundsmaster 5900/5910Page 1 -- 6Safety

Product Records and Maintenance

Table of Contents

Chapter 2

PRODUCT RECORDS 1.........................

MAINTENANCE 1...............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

TORQUE SPECIFICATIONS 3....................

Fastener Identification 3.......................

Product Records

Insert Operator’s Manuals and Parts Catalogs for your Groundsmaster at the end of this chapter. Additionally, if any optional equipment or accessories have been installedto your machine, inserttheInstallationInstructions, Operator’s Manuals andPartsCatalogs for those options at the end of this chapter.

Maintenance

Maintenanceproceduresand recommended serviceintervalsforyourGroundsmasterarecoveredintheOperator’s Manuals. Refer to this publication when performing regular equipment maintenance.

Standard Torque for Dry, Zinc Plated, and

Steel Fasteners (Inch Series) 4...............

Standard Torque for Dry, Zinc Plated, and

Steel Fasteners (Metric) 5....................

Other Torque Specifications 6..................

Conversion Factors 6..........................

Product Records

and Maintenance

Groundsmaster 5900/5910 Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375

Groundsmaster 5900/5910Page 2 -- 2Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the followingtables.Forcriticalapplications,asdetermined byToro, eithertherecommendedtorqueora torque that is unique to theapplicationis clearly identifiedandspecified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shallapply to all fastenerswhich donot have a specific requirement identified inthis Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener, presenceof a prevailingtorque feature (e.g. Nylock nut), hardness of the surface underneath thefastener’sheadorsimilarconditionwhichaffectsthe installation.

Fastener Identification

Asnotedin thefollowingtables,torque valuesshouldbe reduced by 25% for lubricated fasteners to achieve the similar stress as a dry fastener. Torquevalues may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based onthe aluminum or brass material strength, fastener size, length of thread engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measurethetorquerequiredtotightenthefastener until the lines match up.

Product Records

and Maintenance

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 1

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

Groundsmaster 5900/5910 Page 2 -- 3 Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

# 6 -- 32 UNC

# 6 -- 40 UNF

# 8 -- 32 UNC

# 8 -- 36 UNF

#10--24UNC

#10--32UNF

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373

3/8 -- 16 UNC 16 + 2 16 + 2 22+ 3 30 + 3 41 + 4 43 + 5 58 + 7

Grade 1, 5 &

8withThin

Height Nuts

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 56

18 + 2 30 + 5 339 + 56

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

15 + 2 169 + 23 23 + 3 262 + 34

17 + 2 192 + 23 25 + 3 282 + 34

29 + 3 328 + 34 41 + 5 463 + 56

31 + 4 350 + 45 43 + 5 486 + 56

42 + 5 475 + 56 60 + 6 678 + 68

48 + 5 542 + 56 68 + 7 768 + 79

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 -- 24 UNF 17 + 2 18 +2 24 +3 35 + 4 47 + 5 50 + 6 68 + 8

7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 +7 95 +9

7/16 -- 20 UNF 29 +3 29 + 3 39 + 4 55 + 6 75 + 8 77 +8 104 + 11

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 +11 105 + 11 142 + 15

1/2 -- 20 UNF 32 + 4 53 +7 72 +9 85 + 9 115 + 12 120 + 12 163 + 16

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 +10 95 + 15 129 + 20 170 + 18 230 + 24 240 +24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 +37 375 + 38 508 + 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 +43 569 + 58

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89

NOTE: Reduce torque values listed inthe tableabove by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite.

NOTE: The nominal torque values listed above for Grade 5 and8 fasteners arebased on 75%of the minimumproofload specified in SAE J429. The toleranceis approximately +

10% of the nominal torquevalue. Thin

height nuts include jam nuts. NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specifictorque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Groundsmaster 5900/5910Page 2 -- 4Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Class 8.8 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm

M6 X 1.0 96 + 10 in--lb 1085 + 113 N- -cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93+ 10 ft--lb 126 + 14 N--m

M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m

NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specifictorque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAEJ1199.Thetoleranceis approximately+ nominal torque value.

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

10%ofthe

Product Records

and Maintenance

Groundsmaster 5900/5910 Page 2 -- 5 Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5in--lb

Threads per Inch Type A Type B

Recommended Torque**

65 + 10 ft--lb 88 + 14 N--m

80 + 10 ft--lb 108 + 14 N--m

Baseline Torque

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

Conversion Factors

in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

No. 8 15 18 30 + 5in--lb No. 10 12 16 38 + 7in--lb No. 12 11 14 85 + 15 in--lb

*Holesize,materialstrength,materialthicknessandfinish must be considered when determining specific torquevalues.All torquevaluesarebasedon non--lubricated fasteners.

Groundsmaster 5900/5910Page 2 -- 6Product Records and Maintenance

Table of Contents

GENERAL INFORMATION 2.....................

Operator’s Manual 2..........................

Engine Identification 2.........................

Engine Electronic Control Module (ECM) 2.......

Stopping the Engine 3.........................

Fuel Injection System 3........................

ENGINE SPECIFICATIONS 4....................

ENGINE FASTENER TORQUE SPECIFICATIONS 5

ADJUSTMENTS 7..............................

Valve Clearance 7............................

SERVICE AND REPAIRS 8......................

Air Filter System 8............................

Exhaust System 10...........................

Turbocharger 12..............................

Fuel System 14...............................

Check Fuel Lines and Connections 14..........

Drain and Clean Fuel Tank 14.................

Fuel Tank Removal 15.......................

Fuel Tank Installation 15......................

Chapter 3

Diesel Engine

Radiator 16..................................

Alternator 18.................................

Starter Motor 20..............................

Valve Cover 22...............................

Engine Breather System 24....................

Thermostat 26................................

Water Pump 28...............................

Front Cover 30...............................

Oil Pan 34...................................

Engine 36....................................

Engine Removal 36..........................

Engine Installation 38........................

Flywheel Coupling Assembly 40................

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 1 Diesel Engine

General Information

This Chapter gives information about specifications of the Cummins B3.3 diesel engine used in the Groundsmaster 5900 and 5910. Additionally, some engine repairproceduresaredescribedinthismanual.Described adjustments and repairs require tools which are commonly available in many service shops.

Some service and repair parts for the engine in your Groundsmaster are supplied through your Authorized Toro Distributor. Bepreparedto provide your distributor with the Toro model andserial number ofyourmachine to obtain parts.

Operator’s Manual

The Operator’s Manualprovides informationregarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine.Refertothe Operator’s Manualfor additional information when servicing the machine.

Engine Identification

Detailedinformationonengine troubleshooting, testing, disassembly and reassembly is identified in the Cummins Service Manual that is available from Cummins. The use of some specialized tools and test equipment is explained in the CumminsServiceManual.However, the specialized natureof some engine repairs maydictate that the work be done at an engine repair facility.

The engine dataplate located near the startermotor includes the engine serial number and control parts list number. The fuel injection dataplate is located on the fuel injection pump. The ECM dataplate is on the electroniccontrolmoduleattachedtotheflywheelend of the engine. These engine identification tags will assist in identifying the correct partsand serviceinformation for the Cummins engine in your Groundsmaster.

Engine Electronic Control Module (ECM)

TheCumminsenginethat isusedintheGroundsmaster 5900 and 5910 uses an electronic control module (ECM) for engine management and also to communicatewiththeTECcontrollersandtheoperator Info Center on the machine. All engine ECM electrical connectors should be plugged intothecontrollerbefore themachineignitionswitch ismovedfromtheOFF position to either the ON or START position. If the engine ECM is to be disconnected for any reason, make sure thattheignitionswitch isintheOFFposition with thekey removed before disconnecting the ECM. Also, to preventpossiblemoduledamagewhenweldingon the machine,disconnectandremovetheengineECM from the engine before welding.

Groundsmaster 5900/5910Page 3 -- 2Diesel Engine

Stopping the Engine

IMPORTANT: Before stopping the engine after mowing or full load operation, allow the engine to runatlowidlespeedfor five (5) minutes.Thiswillallow the turbocharger and internal engine components to adequately cool down.Failuretoallow this cooldown period may lead to premature turbocharger and engine failure.

Fuel Injection System

The engine fuelinjection system operatesat high pressures during engine operation. Do not loosen any fuel system components, fittings or hoses while the engine is running.

Keepbodyandhandsawayfromleaksinenginefuel injection lines.Use cardboard or paper to find high pressure fuel leaks if they may exist. Leaking fuel under pressure can penetrate skin and cause injury.

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 3 Diesel Engine

Engine Specifications

Item Description

Make / Designation Cummins, 4--Cycle, 4 Cylinder,

Bore 3.74 in (95.0 mm)

Stroke 4.53 in (115 mm)

Total Displacement 201 in3(3300 cc)

Firing Order 1 (Closest to Engine Pulley) -- 2 -- 4 -- 3

Direction of Rotation Clockwise (Viewed from EnginePulley)

Compression Ratio 17:1

ValveClearance

Intake 0.014” (0.35 mm) Exhaust 0.020” (0.50 mm)

Fuel Diesel or Biodiesel (up to B20) with Low/Ultra Low Sulfur Content

Fuel TankCapacity 35 U.S. gallons (132 liters)

Fuel Injection Pump Zexel Rotary Type VE Pump

Injection Nozzle Closed Nozzle, Hole Type

Liquid Cooled, Turbocharged, Diesel Engine

Governor Electronic

Low Idle (no load) 1350 RPM

High Idle (no load) 2750 RPM

Oil Pump Geroter Type

Engine Oil API CH--4 or CI--4 (see Operator’s Manual for Viscosity)

Crankcase Oil Capacity 8.5 U.S.quarts (8.0 liters) with Filter

Starter 12 VDC, 2.2 kW

Alternator/Regulator 12 VDC, 120 AMP

Coolant Capacity

GM 5900 (without cab) 13.5 U.S. quarts (12.8 liters) GM 5910 (with cab) 18 U.S. quarts (17 liters)

Engine Dry Weight 606 U.S. pounds (275 kg)

Groundsmaster 5900/5910Page 3 -- 4Diesel Engine

Engine Fastener Torque Specifications

Item Description

Alternator Adjusting Cap Screw 23 ft--lb (31 N--m)

Alternator Mounting Bracket Cap Screw (2 used) 23 ft--lb (31 N--m)

Alternator Mounting Cap Screw 49 ft--lb (66N--m)

Crankshaft Pulley Bolt 274 ft--lb (372 N--m)

Exhaust Manifold Flange Head Screw (8 used) 33 ft--lb (45 N--m)

Front Cover Flange Head Screw (16 used) 14 ft--lb (19 N--m)

Oil Drain Plug 38 ft--lb (51 N--m)

Oil Pan Flange Head Screw (24 used) 24 to 38 ft--lb (32 to 51 N--m)

Oil Suction Tube Flange Head Screw (2 used) 14 ft--lb (19 N--m)

Starter Mounting Flange Head Screw (2 used) 32 ft--lb (43 N--m)

Thermostat Housing Flange Head Screw (2 used) 14 ft--lb (19 N--m)

Turbocharger Mounting Nut (4 used) 22 ft--lb (30 N--m)

Turbocharger Oil Drain Line Cap Screw (2 used) 18 ft--lb (24 N--m)

Turbocharger Oil Supply Line Banjo Bolt 18 ft--lb (24 N--m)

ValveAdjustment Nut (rocker arm) 29to36ft--lb(39to49N--m)

ValveCover Nut (3 used) 80 in--lb (9 N--m)

Water Pump Pulley Flange Head Screw (4 used) 23 ft--lb (31 N--m)

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 5 Diesel Engine

This page is intentionally blank.

Groundsmaster 5900/5910Page 3 -- 6Diesel Engine

Adjustments

Valve Clearance

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood.

3. Remove valve cover from engine (see Valve Cover RemovalintheServiceandRepairssectionofthischapter).

4. Position engine crankshaft so cylinder #1 is at top deadcenter(TDC)attheendofthecompression stroke:

A. While watching the movement of the cylinder #4 intakevalve,rotate enginecrankshaftinnormal rotation direction (clockwise). When the cylinder #4 intakevalve starts to open,cylinder#1is approaching TDC at the end of the compression stroke.

B. Continue rotating the crankshaft in the normal rotation direction (clockwise) until the cutout in the tone wheel attached to the back of the crankshaft pulleyalignswith“1.4TOP”castinenginefrontcover (Fig. 1).

5. Inthiscrankshaftposition,adjustvalve clearance for intakevalvesforcylinders#1and#3andexhaustvalves for cylinders #1 and #2 (Fig. 2 and 3).

8. Installvalvecovertoengine(seeValveCoverInstallationintheServiceandRepairssectionofthis chapter).

9. Lower and secure hood.

Figure 1

1. Crankshaft pulley

2. Tone wheel cutout

3. TDC indicator

Diesel

Engine

A. Loosenthelock nutontherocker armadjustment screw.

B. Insert correct feeler gauge between the valve stem and the rocker arm. Intake valve clearance specification is 0.014” (0.35 mm). Exhaust valve clearance specification is 0.020” (0.50 mm).

C. Adjust screw until aslightdragisfeltonthefeeler gauge.

D. Hold adjustment screw in position and tighten lock nut to secure valve clearance adjustment. Torque lock nut from29 to 36 ft--lb (39 to 49 N--m).

E. After tightening lock nut, re--check valve clearance.

6. Rotate crankshaft in the normal rotation direction (clockwise) one complete revolution. The tone wheel cutout should again be aligned with “1.4 TOP”.

7. Inthiscrankshaftposition,adjustvalve clearance for intakevalvesforcylinders#2and#4andexhaustvalves for cylinders #3 and #4. Follow procedureunder step5 above.

1. Lock nut

2. Adjustment screw

1. #1 intake

2. #1 exhaust

3. #2 intake

4. #2 exhaust

Figure 2

Figure 3

3. Rocker arm

4. Valve clearance

5. #3 intake

6. #3 exhaust

7. #4 intake

8. #4 exhaust

Groundsmaster 5900/5910 Page 3 -- 7 Diesel Engine

Service and Repairs

Air Filter System

12 to 15 in--lb

(1.4 to 1.6 N--m)

45 to 55 in--lb

(5.1 to 6.2 N--m)

45 to 55 in--lb

(5.1 to 6.2 N--m)

50 to 70 in--lb

(5.7 to 7.9 N--m)

50 to 70 in--lb

(5.7 to 7.9 N--m)

RIGHT

FRONT

1. Clamp

2. Air hose

3. Flange head screw (6 used)

4. Air cleaner mount

5. Flange nut (8 used)

6. Air cleaner mounting band (2 used)

7. Air cleaner assembly

8. Adapter

9. Service indicator

Figure 4

10. Worm clamp

11. Intake tube

12. U--bolt

13. Cap screw

14. Mount plate

15. Tube clamp

16. Flat washer

17. Flange nut (3 used)

18. Carriage screw (4 used)

19. Hose clamp (8 used)

20. Tube

21. Air intake tube (4 used)

22. Tube

23. Radiator assembly

24. Airbox

25. Spacer plate (as needed)

26. Carriage screw (2 used)

Groundsmaster 5900/5910Page 3 -- 8Diesel Engine

Removal (Fig. 4)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Remove air cleaner components as needed using Figure 4 as a guide.

4. Inspect all tubes andclampsfor evidence of wearor damage. Replace components as needed.

NOTE: If charge air cooler in radiator assembly needs to be serviced (Fig. 5), refer to Radiator Removal and Installation in this section.

Installation (Fig. 4) IMPORTANT: Any leaks in the air filter system will

causeseriousenginedamage.Makesurethatallair cleaner components are in good condition and are properly secured during installation.

1. Radiator

2. LH cooler bracket

3. Charge air cooler

Figure 5

4. Pin clip (8 used)

5. Pin (8 used)

6. RH cooler bracket

Diesel

Engine

1. Assemble air cleaner system using Figure 4 as a guide.

A. Verify that tabs in air cleaner mounting bands mesh fully with slots in air cleaner body.

B. Position hose clamps (item 1)so thatthere is no interference with hood foam when hood is closed.

C. Torque hose clamps (items 1 and 10)from 45 to 55 in--lb (5.1 to 6.2 N--m).

D. Torquehoseclamps(item 19)from50to70 in--lb (5.7 to 7.9 N--m).

E. Make sure that air cleaner vacuator valve is pointed down after assembly (Fig. 6).

F. If service indicator (item 8) and adapter (item 9) wereremovedfromaircleanerhousing,applythread sealant toadapter threads before installing adapter and indicator to housing. Install adapter so that groovesinadapterhexand adapterfilterelementare installed toward service indicator(Fig.7). Torque indicator from 12 to 15 in--lb (1.4 to 1.6 N--m).

1. Air cleaner housing

2. Safety filter

3. Filter element

VACUATOR

VALVE

DIRECTION

Figure 6

4. Cover

5. Vacuator valve

2. Apply chalk onairboxlip, lower hoodandcheckthat hood makes a continuoussealaround airbox (item 24). If necessary, use shim(s) (item 25) to adjustlocation of

airbox for proper sealing with hood.

3. Lower and secure hood.

Figure 7

1. Adapter

2. Service indicator

3. Adapter filter element

4. Adapter grooves

Groundsmaster 5900/5910 Page 3 -- 9 Diesel Engine

Exhaust System

50 to 70 in--lb

(5.7 to 7.9 N--m)

RIGHT

FRONT

1. Exhaust clamp

2. Exhaust tube

3. Muffler clamp (2 used)

Figure 8

4. Muffler

5. Tailpipe

6. Flange head screw (4 used)

7. Heat shield

Groundsmaster 5900/5910Page 3 -- 10Diesel Engine

Removal (Fig. 8)

CAUTION

B. Position new manifold gasket and exhaust manifoldtocylinderheadand secure witheight(8)flange head screws. Tighten the screws in the sequence shown in Figure 10. Torque screws 33 ft--lb (45

N--m).

The engine and exhaust system may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system.

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to exhaust system.

3. Remove sidepanel from right side offrame to allow easier access to exhaust system components.

4. Removemufflerand/orexhausttubefromtheengine as necessary using Figure 8 as a guide.

5. If necessary, remove exhaust manifold from engine (Fig. 9):

A. Remove turbocharger from exhaust manifold (see Turbocharger Removal in this section).

B. Support exhaust manifold to prevent it from falling.

C. Secure turbocharger to exhaust manifold (see Turbocharger Installation in this section).

3. Install muffler and/orexhaust tube to the engineusing Figure 8 as a guide. Torque exhaustclamp (item1) from 50 to 70 in--lb (5.7 to 7.9 N--m).

4. After exhaust system assembly, check that tailpipe is approximately parallel to the ground. Loosen clamp and adjust tailpipe if necessary.

5. Install and secure side panel to right side of frame.

6. Lower and secure hood.

Antiseize lubricant

Diesel

Engine

C. Removeeight(8)flangehead screwsthatsecure exhaustmanifoldtocylinderhead.Removemanifold from engine.

D. Remove and discard manifold gasket. Clean mating surfaces of cylinder head and manifold.

6. Ifexhaustopeningsaretobeleftopenfor any length oftime,coveropeningstopreventanymaterialfromfalling into openings.

Installation (Fig. 8) NOTE: Makesure all exhaust systemsealingsurfaces

are free of debris or damage that may prevent a tight seal.

1. Removeallcoversandplugsthatwereplacedduring removal to prevent contamination entry.

2. Installexhaustmanifoldtoengineifremoved(Fig.9):

A. Apply antiseize lubricant to threads of flange head screws used to secure exhaust manifold.

33 ft--lb

(45 N--m)

1. Exhaust manifold

2. Manifold gasket

Figure 9

Figure 10

3. Engine

4. Flange screw (8 used)

Groundsmaster 5900/5910 Page 3 -- 11 Diesel Engine

Turbocharger

22 ft--lb

(30 N--m)

18 ft--lb

(24 N--m)

33 ft--lb

(45 N--m)

18 ft--lb

(24 N--m)

FRONT

RIGHT

18 ft--lb

(24 N--m)

1. Turbocharger assembly

2. Flange nut (4 used)

3. Banjo bolt

4. Sealing washer

5. Oil supply tube

6. Exhaust manifold

7. Banjo bolt

Figure 11

8. Sealing washer

9. Coupling

10. O--ring

11. Exhaust manifold gasket

12. Gasket

13. Flange head screw(2 used)

14. Flange head screw(8 used)

15. Oil drain tube

16. Flange head screw(2 used)

17. Gasket

18. Turbocharger gasket

Groundsmaster 5900/5910Page 3 -- 12Diesel Engine

Removal (Fig. 11)

CAUTION

9. Carefully lift turbocharger from exhaust manifold.

10.Cover engine, air cleaner and turbocharger openings to prevent any material from falling into openings. Also, plug openings in oil supply and drain lines.

The engine and exhaust system may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the turbocharger.

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Thoroughly clean turbochargerareatoprevent contaminants from entering engine.

4. Loosen clamps that secure exhaust tube to turbocharger outletand muffler inlet. Remove exhaust tube.

5. Loosen clamps that secure air intake tube to turbocharger inlet and air cleaner outlet. Remove air intake tube.

6. Remove two (2) cap screws that secure oil drainline to turbocharger. Separateoil drainline fromturbocharger.

7. Remove banjo bolt that secures oil supply line to turbocharger. Separate oil supply line from turbocharger.

8. Removefour(4)nuts thatsecureturbochargertoexhaust manifold.

Installation (Fig. 11) NOTE: Makesuremufflerflangeand exhaust manifold

sealing surfaces are free ofdebris or damage that may prevent a tight seal.

1. Install newgaskets if original gasket wasdamaged.

2. Removeallcoversandplugsthatwereplacedtoprevent contamination entry.

3. Position turbocharger to exhaust manifold and secure with four (4) nuts. Torque nuts 22 ft--lb (30 N--m).

4. Positionoildrainlinetoturbochargerandsecurewith two (2) cap screws. Torque screws 18 ft--lb (24 N--m).

5. Pour clean engine oil into oil supply line port to ensure turbocharger lubrication on start--up.

6. Position oil supply line to turbocharger and secure with banjo bolt. Torque banjo bolt 18 ft--lb (24 N--m).

7. Fit air intake tube to turbochargerinletandaircleaner outlet. Secure intake tube with clamps.

8. Fit exhaust tube to turbocharger outlet and muffler inlet. Secure exhaust tube with clamps.

9. Lower and secure hood.

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 13 Diesel Engine

Fuel Tank

RIGHT

FRONT

1. Fitting cover

2. Screw (3 used)

3. Fuel supply standpipe

4. Fuel return standpipe

5. Bushing (2 used)

6. Elbow fitting

7. Bushing

8. Fuel tank

9. Fuel hose (2 used)

10. Flange nut (2 used)

11. Tank hold down

12. Flange head screw(2 used)

13. Clamp (2 used)

14. Cap

15. Plug (4 used)

DANGER

Becausedieselfuelishighly flammable,usecaution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosedarea. Always fill fueltank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep cap in place. Use diesel fuelas an engine fuel only; not for any other purpose.

Figure 12

16. Gasket

17. Fuel sender

18. Lock washer (5 used)

19. Screw (5 used)

20. Fuel hose

21. Worm clamp (3 used)

22. Fuel hose

Check Fuel Lines and Connections

Checkfuellinesand connections periodically asrecommendedintheOperator’s Manual. Check lines for deterioration,damage, leaks or loose connections.Replace hoses, clamps and connections as necessary.

Drain and Clean Fuel Tank

Drain and clean the fuel tank periodically as recommendedintheOperator’sManual.Also,drain and clean the fuel tank if the fuel system becomes contaminated or if themachineis to bestoredfor an extendedperiod.

To clean fuel tank, flush tank out with clean diesel fuel. Make sure tank is free of contaminates and debris.

Groundsmaster 5900/5910Page 3 -- 14Diesel Engine

Fuel Tank Removal (Fig. 12)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Chock rear wheels and jack up front of machine. Support machine on jack stands. Remove front, left wheel to allow fuel tank removal.

3. Useafueltransferpumptoremovefuelfromthefuel tank and into a suitable container.

4. Removethree(3) socketheadscrews thatsecurefitting cover (item 1) to fuel tank. Remove fitting cover.

5. Disconnect power (blue/red) and ground (black) wires from the fuel sender on the fuel tank (Fig. 13).

5. Using labels placed during tank removal, correctly connect fuel hoses to thefuel supply standpipe, the return standpipe andthevent elbow fitting.Secure hoses with hose clamps.

6. Connect electrical wiring to the fuel sender. A. Connect blue/red wireto the centerterminal and

black wire to any of the screws that secure the fuel sender to the fuel tank.

B. Apply skin--over grease (ToroPartNo.505--165) to the wire terminal connections.

7. Position fitting cover to fuel tank and secure with

three (3) socket head screws.

6. Labelfuelhosestoassure properassembly.Disconnect fuel hosesfrom the fuelsupply standpipe (item 3), the return standpipe (item 4) and the vent elbow fitting (item 6) in top of tank (Fig. 13).

7. Route fuel lines from under clamps (item 13) that route fuel lines from standpipes. If necessary, remove plugs and clamps from top of tank.

8. Remove two (2) flange head screws and lock nuts that secure tankhold down (item11) to frame.Remove tank hold down.

9. Slide fuel tank from left side of machine to remove tank.

10.If necessary, remove standpipes, elbow bushings and fuel sender from fuel tank.

Fuel Tank Installation (Fig. 12)

1. If removed, install standpipes, elbow bushings and fuel sender into fuel tank.

2. Install fuel tank from left side of machine.

WARNING

Failure to maintain proper torque couldresultin failureorlossof wheel andmayresultin personal injury.

8. Install front, left wheel assembly.

9. Lower machine to ground. Torque wheel lug nuts in

a crossing pattern from70 to 90 ft--lb (95 to 122N--m).

10.Fill fuel tank.

Diesel

Engine

3. Position tank hold down (item 11) to fuel tank and machine frame. Secure hold down with two (2) flange head screws and lock nuts.

1. Sender power wire

2. Sender ground wire

3. Fuel sender

Figure 13

4. Fuel supply hose

5. Return fuel hose

6. Vent hose

4. Route fuel supplyand return hosesunder clamps in top of tank.

Groundsmaster 5900/5910 Page 3 -- 15 Diesel Engine

Radiator

Thread Sealant

RIGHT

FRONT

50 to 70 in--lb

(5.7 to 7.9 N--m)

28 30

26 2

4 5

50 to 70 in--lb

(5.7 to 7.9 N--m)

1. Radiator assembly

2. Flange nut (4 used)

3. Support plate (2 used)

4. Flange nut (4 used)

5. Rubber pad (4 used)

6. Hose clamp (3 used)

7. Upper radiator hose

8. Overflow hose

9. Hose clamp

10. Worm clamp (5 used)

11. Barb fitting

12. Drain cock fitting

13. Fan shroud

14. Air intake tube (4 used)

15. Hose clamp (8 used)

16. Tube

17. Coolant reservoir

18. Grommet (2 used)

19. Lock nut (2 used)

20. Hose

21. Cap screw (4 used)

22. Hose

23. Radiator cap

24. Support rod

25. Flat washer (10 used)

26. Flange nut (4 used)

27. Hose sleeve

Removal (Fig. 14)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise andsupport hoodto allow access to radiator.

Figure 14

28. Cap screw (2 used)

29. Tube

30. Washer (4 used)

31. Flange nut (14 used)

32. Clamp (2 used)

33. Carriage screw (14 used)

34. Lower radiator hose

35. Fan motor bracket

36. Fitting

37. Coolant level sensor

38. Cap screw (2 used)

39. Reservoir cap

40. Flat washer (2 used)

3. Rotate clamps that secure oil cooler to radiator frame. Tilt oil cooler toward rear of machine.

4. Loosenhoseclampsanddisconnect airintaketubes (item14) from the charge air cooler.

5. Disconnectwireharnessconnectorfromcoolantlevel sensor on right side of radiator.

Groundsmaster 5900/5910Page 3 -- 16Diesel Engine

CAUTION

6. Connect air intake tubes (item14) to the charge air

cooler and secure with hose clamps. Torque clamps from 50 to 70 in--lb (5.7 to 7.9 N--m).

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Ethylene--glycol antifreeze is poisonous. Dispose of coolantproperly, orstore it in aproperly labeled container away from children and pets.

6. Drain radiatorinto a suitable container using the radiator drain. The radiator drain is located near the hydraulic 4WD manifold (Fig. 15).

7. Loosenhoseclampsand disconnect upper and lower coolant hoses (item 6) from the radiator.

8. Loosen hose clampthat secures coolant drainhose tofitting(item 36)onbottomofradiator.Removecoolant drain hose assembly from radiator.

9. Disconnectreservoirhose(item22)fromtheradiator vent tube.

10.Detach radiator from the fan shroud and support by removingtwo(2) carriagescrews(item33),flatwashers and flange nuts.

7. Connect wire harness connector to coolant level

sensor on right side of radiator.

8. Install coolant drain hose assemblytoradiatorfitting

and secure with hose clamp.

9. Connectreservoirhose(item22)totheradiator vent

tube and secure with hose clamp.

10.Make sure radiator drain is closed. Fill radiatorwith

coolant.

11.Secure oil cooler to radiator frame.

12.Run engine and check for any coolant leaks.

13.Lower and secure hood.

Diesel

Engine

11.Tilt radiator and charge air cooler assembly toward rearof machine and carefully lift assembly fromthe machine.

12.Plug all radiator and hoseopenings to prevent contamination.

13.Inspect rubber pads (item 5) at bottom of radiator. Replace pads if worn or damaged.

14.Disassemble radiator and charge air cooler assembly as needed using Figure 16 as a guide.

Installation (Fig. 14)

1. Assemble radiator and charge air cooler assembly as needed using Figure 14 as a guide. Apply thread sealant to coolant level sensor if it was removed.

2. Remove plugs from radiator and hoses placed during the removal procedure.

3. Carefully lower radiator and charge air cooler assembly into the machine.

4. Attach radiator to the fan shroud and support with two (2) carriage screws, flat washers and flange nuts.

1. Radiator hose

2. Radiator drain

Figure 15

3. Air intake tube

5. Connect upper and lower coolant hoses (item 6) to the radiator. Secure hoses with hose clamps.

1. Radiator

2. LH cooler bracket

3. Charge air cooler

Figure 16

4. Pin clip (8 used)

5. Pin (8 used)

6. RH cooler bracket

Groundsmaster 5900/5910 Page 3 -- 17 Diesel Engine

Alternator

FRONT

23 ft--lb

(31 N--m)

RIGHT

49 ft--lb

(66 N--m)

1. Alternator

2. Front cover

3. Belt

4. Bevel washer (2 used)

5. Flange head screw

Figure 17

6. Flat washer

7. Hex nut

8. Flange head screw (2 used)

9. Alternator bracket

10. Cap screw

11. Water pump

12. Adjusting bracket

13. Alternator bracket

Groundsmaster 5900/5910Page 3 -- 18Diesel Engine

Removal (Fig. 17)

Installation (Fig. 17)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Remove battery accesspanel. Disconnect negative battery cable first and then positive battery cable (see Battery Removal in the Service and Repairs section of Chapter 5 -- Electrical System).

4. Loosen flange head screw (item 5) that secures alternator to adjusting bracket. Rotate alternator toward enginetoloosendrivebelt.Removebeltfromalternator pulley.

5. Inspect drive belt for glazing or damage. Replace belt if necessary.

6. For assemblypurposes, labelall wires that connect toalternator.Disconnect wiresfromalternatorterminals and position wires away from alternator.

7. Support alternator to prevent it from shifting or falling.

1. Position alternator to engine brackets.

2. Secure alternator to mounting brackets and adjust-

ingbracketwithremovedfastenersandwashers.Donot fully tighten fasteners.

3. Place drivebelt on alternator pulley. Rotate alterna-

tor away from engine to properly tension drive belt.

4. Tighten screws to secure alternator. Torque cap

screw at mounting bracket (item 10) to 49 ft--lb (66 N--m). Torque flange head screw at adjusting bracket (item 5) to 23 ft--lb (31 N--m).

5. Using labels placed during alternator removal, cor-

rectly connect all wires to alternator terminals.

6. Connectpositivebatterycable topositivebatteryter-

minal.Then,connectnegativebatterycable tonegative battery terminal (see Battery Installation in the Service and Repairs section of Chapter 5 -- Electrical System). Install battery access panel.

7. Lower and secure hood.

Diesel

Engine

8. Remove flange head screw andflat washer thatsecure alternator to adjusting bracket (item 12). Remove cap screw, two (2) bevel washers and hex nut that secure alternator to mounting brackets (items 9 and 13).

9. Carefully remove alternator from engine and machine.

Groundsmaster 5900/5910 Page 3 -- 19 Diesel Engine

Starter Motor

32 ft--lb

(43 N--m)

FRONT

RIGHT

Figure 18

1. Engine 2. Starter motor 3. Flange head screw (2 used)

Groundsmaster 5900/5910Page 3 -- 20Diesel Engine

Removal (Fig. 18)

Installation (Fig. 18)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Remove battery accesspanel. Disconnect negative battery cable first and then positive battery cable (see Battery Removal in the Service and Repairs section of Chapter 5 -- Electrical System).

4. Label all wires that connect to starter for assembly purposes. Disconnect wiresfrom starter terminals.and position away from starter (Fig. 19).

A. Removenutand lockwasherthatsecurecableto starter stud. Remove cable from starter stud.

B. Loosen screw used to secure harness blue wire to starter solenoid. Unplug wire from starter.

5. Support starter to prevent it from shifting or falling.

6. Remove two (2) flange head screws that secure starter to engine.

1. Position starter to engine housing.

2. Secure starter to engine with two (2) flange head

screws. Torque screws 32 ft--lb (43 N--m).

3. Using labels placed during removal, correctly con-

nect and secure removed wires to starter terminals.

4. Connectpositivebatterycable topositivebatteryter-

minal.Then,connectnegativebatterycable tonegative battery terminal (see Battery Installation in the Service and Repairs section of Chapter 5 -- Electrical System). Install battery access panel.

5. Lower and secure hood.

Diesel

Engine

7. Carefully remove starter from engine and machine.

1. Starter stud

2. Starter solenoid

Figure 19

3. Screw

Groundsmaster 5900/5910 Page 3 -- 21 Diesel Engine

V alve Cover

80 in--lb (9 N--m)

3 4

FRONT

RIGHT

1. Engine

2. Valve cover

3. Lock nut (3 used)

Figure 20

4. Flat washer (3 used)

5. Isolation washer (3 used)

6. Oil fill cap

7. Valve cover gasket

Groundsmaster 5900/5910Page 3 -- 22Diesel Engine

Removal (Fig. 20)

Installation (Fig. 20)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Thoroughly clean valve cover and cylinder head to prevent contaminant entry into engine.

4. Remove crankcase breather tube from valve cover (see Engine Breather Removal in this section).

5. Removethree(3)locknuts, flatwashersandisolator washers.

6. Remove valve cover from cylinder head. Remove and discard valve cover gasket.

1. Position new gasket and valve cover to cylinder

head.

2. Secure valve cover to cylinder head with three (3)

isolatorwashers,flatwashersandlocknuts.Torquelock nuts 80 in--lb (9 N--m).

3. Connectcrankcasebreathertubetovalve cover and

secure with hose clamp (see Engine Breather Installation in this section).

4. Check engine oil level and add oil if necessary.

5. Lower and secure hood.

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 23 Diesel Engine

Engine Breather System

FRONT

RIGHT

1. Hose

2. Hose clamp

3. Spacer

4. Breather mount plate

5. Cap screw (2 used)

6. Breather

Figure 21

7. Breather outlet hose

8. Latch plate

9. Hose clamp

10. Breather inlet hose

11. Hose clamp

12. Hose clamp

13. Breather hose

14. Hose barb

15. Hose

16. Check valve

17. Worm clamp

Groundsmaster 5900/5910Page 3 -- 24Diesel Engine

Removal (Fig. 21)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Clean breather components before removal to prevent contaminant entry into breather system.

4. Remove breather components as necessary using Figure 21 as a guide.

Installation (Fig. 21)

1. Install removed breather components using Figure 21 as a guide. If removed, make sure that check valve (item 16) is installed with black side toward the engine oil pan (Fig. 22).

2. Lower and secure hood.

FROM BREATHER

TOWARD ENGINE

Figure 22

1. Base (gray) 2. Cover (black)

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 25 Diesel Engine

Thermostat

1. Water pump

2. Seal

14 ft--lb (19 N--m)

Figure 23

3. Thermostat

4. Gasket

5. Thermostat housing

6. Flange head screw (2 used)

Removal (Fig. 23)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Ethylene--glycol antifreeze is poisonous. Dispose of coolantproperly, orstore it in aproperly labeled container away from children and pets.

3. Draincoolantfrom radiatorandengine (seeRadiator Removal in this section).

4. Remove upper coolant hose from thermostat housing.

5. Removetwo(2)flangeheadscrewsthatsecurethermostat housing to water pump. Remove thermostat housing.

6. Removethermostatand sealfromwater pumphousing.

7. Clean gasket surfaces of pump and thermostat housing.

8. Inspect thermostat sealing areas in pump housing. Thoroughly clean sealing surfaces if any corrosion or debris buildup is evident.

Thermostat Testing

1. Remove the thermostat (see Water Pump, Hose, Pipe and Thermostat Removal and Installation).

2. Suspendthethermostat andathermometerinacontainerofwater(Fig. 24). Foraccuratetestresults,donot allowthethermostator thermometer to contact the container.

Groundsmaster 5900/5910Page 3 -- 26Diesel Engine

3. Slowly heat the waterandstir water to allowuniform watertemperature.Noteandrecord the temperaturefor the following:

A. The thermostat should start to open at 180

C).

(82

B. The thermostat should be fully open (0.315” (8

mm) lift) at 203

F(95oC).

4. If the thermostat fails to open,only partiallyopensor sticks, it should be replaced.

Installation (Fig. 23)

1. Installseal andthermostatintowaterpumphousing.

2. Position thermostat gasket and housing to water pump housing. Secure thermostat housingwith two (2) flange head screws. Torque screws 14 ft--lb (19 N--m).

3. Installuppercoolanthoseto thermostathousingand secure with hose clamp.

4. Fill cooling system with coolant.

5. Run engine and check for any coolant leaks.

6. Lower and secure hood.

Figure 24

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 27 Diesel Engine

Water Pump

FRONT

RIGHT

23 ft--lb

(31 N--m)

14 ft--lb

(19 N--m)

13 10

1. Flange head screw (4 used)

2. Water pump pulley

3. Belt

4. Flange head screw

5. Flange head screw (2 used)

Figure 25

6. O--ring

7. Gasket

8. Thermostat housing

9. Flange head screw (3 used)

10. Water pump

11. Thermostat

12. Front cover

13. Seal

14. Gasket

Groundsmaster 5900/5910Page 3 -- 28Diesel Engine

Removal (Fig. 25)

Installation (Fig. 25)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Ethylene--glycol antifreeze is poisonous. Dispose of coolantproperly, orstore it in aproperly labeled container away from children and pets.

3. Draincoolantfrom radiatorandengine (seeRadiator Removal in this section).

4. Disconnect wire harness connector from temperature sensor on water pump housing (Fig. 26).

5. Remove upper andlower radiator hoses from water pump.

1. Make sure that gasket surfaces on engine, water

pump and thermostat housing are thoroughly cleaned.

2. PositionnewO--ringandgaskettowaterpumphous-

ing.

3. Secure water pump to engine with four (4) cap

screws.

4. Ifpulleywas removedfromwaterpumpshaft,secure

pulley with four (4) cap screws. Torque cap screws 23 ft--lb (31 N--m).

5. If thermostatwas removedfrom waterpump, install

thermostat to water pump (see Thermostat Installation in this section).

6. Install upper and lower radiator hoses to water

pump. Secure hoses with hose clamps.

7. On Groundsmaster 5910 machines: A. Install and secure cab heater hoses to water

pump. B. Install and adjust A/C compressor drive belt.

Diesel

Engine

6. On Groundsmaster 5910 machines: A. Remove cab heater hoses from water pump. B. Remove A/C compressor drive belt.

7. Remove alternator and drive belt from engine (see

Alternator Removal in this section).

8. Removefour(4)capscrewsthatsecurewaterpump

to engine.

9. Carefully remove water pump from engine.

10.Remove and discard O--ring and gasket from be-

tween water pump and engine.

11.If necessary, remove thermostat from water pump

(see Thermostat Removal in this section). Make sure that gasket surfaces on water pump and thermostat housing are thoroughly cleaned.

12.If necessary, remove pulley from water pump. A. Removefour(4)capscrewsthatsecurepulleyto

pump shaft.

8. Connect wire harness connector to temperature sensor on water pump (Fig. 26).

9. Install alternator and drive belt toengine (seeAlternator Installation in this section). Adjust drive belt.

10.Fill cooling system with coolant.

11.Run engine and check for any coolant leaks.

12.Lower and secure hood.

Figure 26

1. Water pump 2. Temperature sensor

B. Pull pulley from pump shaft.

Groundsmaster 5900/5910 Page 3 -- 29 Diesel Engine

Front Cover

FRONT

RIGHT

49 ft--lb

(66 N--m)

23 ft--lb

(31 N--m)

1. Belt

2. Front cover

3. Water pump pulley

4. Bevel washer (2 used)

5. Flange head screw

6. Flat washer

7. Hex nut

274 ft--lb

(372 N--m)

Figure 27

8. Flange head screw (2 used)

9. Alternator bracket

10. Water pump assembly

11. Crankshaft pulley with tone wheel

12. Adjusting bracket

13. Alternator bracket

24 ft--lb

(32 N--m)

14. Cap screw

15. Alternator

16. Flange head screw

17. Oil pan

18. Mounting plate

19. Cap screw

Groundsmaster 5900/5910Page 3 -- 30Diesel Engine

Removal (Fig. 27)

1. Park machine on a level surface, lower cutting

decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Loosen screws that secure alternator to mounting

brackets and rotate alternator toward engine to loosen drive belt. Remove belt frommachine.

4. On Groundsmaster 5910 machines, remove A/C

compressor drive belt.

5. Removeelectricalcomponents fromfrontcover(Fig.

28): A. Remove screws that secure electrical harness

clamps to front cover. B. Removescrewsthat securecrankshaftandcam-

shaft position sensors to front cover. C. Carefullypulltwo(2)sensorsfromfront cover.In-

spect O--rings onsensors andreplace if necessary. D. Position wire harness and sensors away from

front cover.

6. Remove five (5) flange head screws that secure oil

pantofrontcover (see Oil Pan Removal in this section).

1. Crankshaft sensor

2. Camshaft sensor

3. Tone wheel

Figure 28

4. Harness clamp

5. Crankshaft pulley

Diesel

Engine

7. Remove lock nutandthrustwasher that securerear

axlepivotshaft to frame. Slide pivot shaft towardrearof machine toallow clearance for engine pulley bolt to be removed (see Rear Axle Removal in the Service and Repairs section of Chapter 6-- Axles, Planetaries and Brakes).

8. Remove crankshaft pulley (Fig. 28):

IMPORTANT: When removing crankshaft pulley, take care to not damage tone wheelthat is secured to back of pulley.

A. Useappropriateholding tool topreventthepulley and engine crankshaft from rotating.

B. Loosen and remove cap screw and mounting plate that secure pulley to crankshaft.

C. Slide pulley fromcrankshaft.Locate and retrieve woodruff key from crankshaft.

IMPORTANT: Three (3) different lengths of flange head screws are used to secure the front cover. To assist with assembly, note location of screws as they are removed.

14 ft--lb

(19 N--m)

Figure 29

1. Front cover

2. Flange head screw

3. Flange head screw

4. Oil seal

5. Alternator bracket

6. Flange head screw

9. Removesixteen(16) flangeheadscrewsthatsecure frontcovertoengine(Fig.29).R otate alternator bracket away from front cover.

10.Carefully remove front cover from engine.

11.Removesealfromfrontcovertakingcaretonotdamage seal bore in cover.

12.Thoroughly clean all removed components. Make surethat all sealant is removedfromfrontcoversealing surfaces.

13.Inspectcrankshaftsurfaceinoilsealareaforanyevidenceof wear or damage.Repairorreplacecrankshaft if necessary.

Groundsmaster 5900/5910 Page 3 -- 31 Diesel Engine

Installation (Fig. 27)

1. Make sure that mounting surfaces on engine, front cover and oil pan are thoroughly cleaned.

9. Secure electrical components to front cover (Fig.

28): A. Positionwireharness and sensors to front cover.

2. Fill 50% of theseallip space with grease.UseCummins seal installer tool #3164900 (or equivalent) to install new oil seal into front cover.

3. ApplyCumminssealant#3164067(or equivalent),to the front cover mounting surfaces. Make sure to apply sealant to all engine and oil pan mating surfaces.

4. Carefully install front cover to engine taking care to not damage the oil seal during assembly.

5. Rotate alternator bracket to front cover.

6. Usingnotestakenduringfrontcoverremovaltoidentify correct screw location, securefront cover to engine withsixteen(16)flange head screws. Torquescrews14 ft--lb (19 N--m).

7. Secureoilpantofrontcoverwithfive(5)flangehead screws. Torque screws 14 ft--lb (19 N--m).

8. Install crankshaft pulley:

IMPORTANT: When installing crankshaft pulley, take care to not damage tone wheelthat is secured to back of pulley.

A. Place woodruff key into crankshaft slot. B. Carefully slide pulley onto crankshaft making

suretonotdamageoil sealinfrontcover.Also,make sure to align keyslot in pulley with woodruff key in crankshaft.

B. Apply a light film of clean oil to crankshaft and camshaft position sensorsO-- rings. Carefully install sensors into front cover and secure with screws.

C. Secure electrical harness clamps to front cover.

10.Secure rearaxlepivot shaft to frame(seeRear Axle

Removal in theServiceand Repairs section ofChapter 6-- Axles, Planetaries and Brakes).

A. Slide axle pivot shaft toward front of machine. Make sure that that roll pin on pivot shaft is positioned in frame reliefs.

B. Installthrustwasher and locknutontopivotshaft. C. Tightenlocknut to eliminate any axialmovement

of rear axle.Makesure that axlecanstill pivot freely after lock nut is tightened.

11.Position drivebelttocrankshaft, water pump andal-

ternator pulleys. Tension belt and tighten alternator mountingscrews (see Alternator Installation in thissection).

12.On Groundsmaster 5910 machines, install and ad-

just A/C compressor drive belt.

13.Check engine oil level and adjust if necessary.

14.Start engine and check for any oil leakage.

15.Lower and secure hood.

C. Install mounting plate (item 18) and cap screw (item 19) to pulley and crankshaft.

D. Using an appropriate holding tool to prevent the pulley and engine crankshaft from rotating, torque cap screw 274 ft--lb (372 N--m).

Groundsmaster 5900/5910Page 3 -- 32Diesel Engine

This page is intentionally blank.

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 33 Diesel Engine

Oil Pan

14 ft--lb

(19 N--m)

FRONT

RIGHT

14 ft--lb

(19 N--m)

38 ft--lb

(51 N--m)

1. O--ring

2. Flat washer

3. Flange head screw (2 used)

Figure 30

4. Flange head screw (24 used)

5. Sealing washer

6. Drain plug

7. Oil pan

8. Oil suction tube

24 ft--lb

(32 N--m)

Groundsmaster 5900/5910Page 3 -- 34Diesel Engine

Removal (Fig. 30)

Installation (Fig. 30)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Raise and support hood to allow access to engine.

3. Drain oil from engine.

4. Removetwentyfour (24)flangehead screwsthatsecure oil pan to engine.

5. Carefully,remove oil panfrom engine takingcare to not damage theoil pan or the sealingsurface. Remove oil pan from engine.

6. Ifnecessary,removetwo(2)flangeheadscrewsthat secure oil suction tube to engine. Remove oil s uction tube.

7. Thoroughly clean sealing surfaces of removed components. Inspect parts for cracks or other damage.

1. Ifoilsuctiontubewasremoved,placeO--ringontube and position tube to engine. Secure with two(2) flange head screws. Torque screws 14 ft--lb (19 N--m).

2. Using Cummins sealant #3164067 (or equivalent), apply a 0.039” (1 mm) sealant bead around all oil pan mounting screw holes. Then, apply a 0.118” (3 mm) sealant bead to the oil pan mounting surface.

3. Carefully raise oil pan to cleaned engine mounting surface and secure oil pan to engine with twenty four (24) flange head screws. Torque screws 24 ft--lb (32 N--m).

4. Make sure thatdrainplug (item 6)isinstalled into oil pan. Torque drain plug 38 ft--lb (51 N--m).

5. Add oil to engine to the proper level.

6. Start engine and check for any oil leakage.

7. Lower and secure hood.

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 35 Diesel Engine

Engine

RIGHT

FRONT

1. Engine assembly

2. Traction flush manifold

3. Cap screw (8 used)

4. Cap screw (4 used)

5. Rear engine mount (2 used)

6. Lock washer (4 used per mount)

7. Cap screw (4 used per mount)

8. Engine isolator mount (4 used)

9. Snubbing washer (4 used)

10. Lock nut (4 used)

11. Cap screw (4 used per mount)

Engine Removal (Fig. 31)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parkingbrake andremove key from the ignition switch.

2. Ifengineis tobedisassembled,drainoilfromengine.

3. Remove hood (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chassis).

4. Remove battery accesspanel. Disconnect negative battery cable first and then positive battery cable (see Battery Removal in the Service and Repairs section of Chapter 5 -- Electrical System).

Figure 31

12. Lock washer (4 used per mount)

13. Front LH engine mount

14. Front RH engine mount

15. Flange nut (8 used)

16. 4WD control manifold

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Ethylene--glycol antifreeze is poisonous. Dispose of coolantproperly, orstore it in aproperly labeled container away from children and pets.

5. Drain coolant from the radiator into a suitable con-

tainer (see Radiator Removal in this section). Disconnect coolant hoses from the radiator.

Groundsmaster 5900/5910Page 3 -- 36Diesel Engine

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the exhaust system to cool before working on or near the muffler.

6. Remove exhaustsystem fromengine (seeExhaust System Removal in this section).

7. Remove air cleaner system from engine (see Air Cleaner Removal in this section). Also, remove intake hoses from charge air cooler.

8. Note location of cable ties used to secure electrical wires. Disconnect wires and/or electrical connections from the following electrical components:

A. The alternator (Fig 32). B. The temperature sensor onwater pump housing

(Fig. 33). C. Battery,frameandwireharness groundattheen-

gine block (Fig. 34). D. The engine electronic control module. E. The electric starter motor. F. The air intake heater. G. The air conditioning compressor (Groundsmas-

ter 5910 machines) (Fig. 35).

9. Disconnect fuel hose from water separator outlet (Fig. 36). Cap fuel hose and water separator outlet to prevent contamination.

Figure 32

1. Alternator

2. Cable

3. Harness connector

Figure 33

1. Water pump 2. Temperature sensor

Diesel

Engine

IMPORTANT: Support hydraulic pump assembly to prevent it from falling and being damaged.

10.Remove hydraulic pumpassemblyfromengine(see Pump Assembly Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System).

11.On Groundsmaster 5910 machines,removeairconditioning compressor from brackets (seeAir Conditioning Compressor Removal in the Service and Repairs

section of Chapter 10 -- Operator Cab). Position compressor away from engine taking care to not damage compressor or hoses. Support c ompressor to make sure it will not fall during engine removal.

12.Make surethatallcable ties securing the wiringhar-

1. Positive battery cable

2. Negative battery cable

3. Cap screw

4. Cap screw

5. Internal lock washer

Figure 34

6. Internal lock washer

7. Flange nut

8. Negative battery cable

9. Positive battery cable

ness,fuellinesandhydraulichosesto theengineareremoved.

Groundsmaster 5900/5910 Page 3 -- 37 Diesel Engine

CAUTION

Makesurethat hoist orliftusedto remove engine can properly support engine. Engine weighs approximately 606 pounds (275 kg).

13.Connect suitable hoistor lift to the front and rearlift tabs on engine.

14.Remove lock nuts, snubbing washers and cap screwssecuringtheenginebracketstotheengineisolator mounts.

CAUTION

One person should operatelift or hoist whilethe other person guides the engine out of the machine.

IMPORTANT: Make sure to not damage the engine, fuel lines, hydraulic lines,electrical harness or othermachinecomponents while removing theengine.

15.Carefully raise engine from the machine.

Figure 35

1. AC compressor 2. Connector

16.If necessary, remove engine mount brackets from the engine.

17.If necessary,remove engineisolatormounts(item8) from frame. Note that one of the fasteners for the RH frontmotormountalsosecurestheframegroundcable.

18.Coverorplugallengineopenings topreventcontaminants from entering engine.

Engine Installation (Fig. 31)

1. If removed, install engine mount brackets to engine and isolator mounts to frame.

2. Make sure that all parts removed from the engine during maintenance or rebuildingarecorrectly installed to the engine.

3. Remove all covers and plugsfrom engineopenings that were placed during engine removal.

CAUTION

Figure 36

1. Water separator

2. Outlet

4. Connect suitable hoist or lift to the front and rear lift

tabs on engine.

3. Fuel hose

CAUTION

One person should operatelift or hoist whilethe otherpersonguides theengineinto themachine.

IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness orother parts while installing the engine.

5. Slowly lower engine into the machine.

6. Align engine mount brackets to the engine isolator

mountsandsecurewith cap screws, snubbing washers and lock nuts.

Make sure that hoist orlift used to install engine can properly support engine. Engine weighs approximately 606 pounds (275 kg).

7. Connectfuelhosetowaterseparatoroutlet(Fig. 36).

8. Install hydraulic pump assembly to engine (see

Pump Assembly Installationinthe Service andRepairs section of Chapter 4 -- Hydraulic Systems).

Groundsmaster 5900/5910Page 3 -- 38Diesel Engine

9. OnGroundsmaster5910machines,installairconditioning compressor to brackets (see Air Conditioning CompressorInstallationin theServiceandRepairssectionofChapter 10 -- OperatorCab).Makesure thatdrive belt is properly tensioned.

10.Using notes taken during engine removal, connect wiresand/orelectricalconnections tothefollowingelectrical components:

A. The alternator (Fig 32). B. The temperature sensor onwater pump housing

(Fig. 33). C. Battery,frameandwireharness groundattheen-

gine block (Fig. 34).

IMPORTANT: When connecting wire harness to engine electronic control module, make sure thatharnessconnectortabisalignedwithcorresponding slot in control module.

12.Installexhaustsystem tomachine(seeExhaustSystem Installation in this section).

13.Connect coolanthosestotheradiator.Makesureradiator drain isshut. Fill radiator and reservoir with coolant.

14.Check positionofelectricalharnesses,fuel linesand hydraulic hoses forproperclearance with rotating,high temperature and moving components.

15.Connect positive battery cable first and then negativebatterycable(seeBatteryInstallationin the Service and Repairs section of Chapter 5 -- Electrical System). Secure batteries to machinewith straps.Install access panel.

16.Check and adjust engine oil as needed.

17.Check and adjust hydraulic oil as needed.

18.Bleed fuel system.

Diesel

Engine

D. The engine electronic control module. E. The electric starter motor. F. The air intake heater. G. The air conditioning compressor (Groundsmas-

ter 5910 machines) (Fig. 35).

11.Install aircleanerassembly to the engineandintake hoses tocharge aircooler (see Air Cleaner Installation in this section). Make sure to torque hose clamps that secure intake system hosesfrom 45 to 55in--lb (5.1to

6.2 N--m).

19.Run engine and check for any leaks.

20.Operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System in the Service and Repairs section of Chapter 4 -- Hydraulic System).

21.Install hoodtomachine (see HoodInstallation in the Service and Repairs section of Chapter 7 -- Chassis).

Groundsmaster 5900/5910 Page 3 -- 39 Diesel Engine

Flywheel Coupling Assembly

Permatex

Threadlocker

29 to 33 ft--lb

(40to44N--m)

RIGHT

FRONT

1. Cap screw (12 used)

2. Washer (12 used)

3. Coupling housing

Figure 37

4. Cap screw (8 used)

5. Washer (8 used)

6. Flywheel coupling

7. Engine assembly

Groundsmaster 5900/5910Page 3 -- 40Diesel Engine

Disassembly (Fig. 37)

1. If engine is in machine, hydraulic pump assembly needs to be removed from engine before coupling can be serviced (see Pump Assembly in Chapter 4 -- Hydraulic Systems).

2. Remove coupling housing and flywheel coupling from engine using Figure 37 as a guide.

Assembly (Fig. 37)

1. Position flywheelcoupling to engineflywheel. Make sure that coupling hub is away from engine flywheel (Fig. 38).

2. Apply Permatex Blue Gel medium strength threadlocker (or equivalent)tothreads of cap screws(item 4). Secure coupling to engine flywheel with eight (8) cap screws and washers.Torque cap screws from29 to 33 ft--lb (40 to 44 N--m).

3. Positioncouplinghousing toengine.Securehousing withtwelve(12)capscrewsandwashersusingacrossingpatterntighteningprocedure.Torquescrewsfrom29 to 33 ft--lb (40 to 44 N--m).

4. If engine is in machine, install hydraulic pump assembly (see Pump Assembly in Chapter 4 -- Hydraulic Systems).

Hydraulic

Pump Side

1. Flywheel housing

2. Engine flywheel

3. Flywheel coupling

Figure 38

4. Coupling hub

5. Cap screw (8 used)

Engine Side

Diesel

Engine

Groundsmaster 5900/5910 Page 3 -- 41 Diesel Engine

This page is intentionally blank.

Groundsmaster 5900/5910Page 3 -- 42Diesel Engine

Table of Contents

Chapter 4

Hydraulic System

SPECIFICATIONS 2.............................

GENERAL INFORMATION 3.....................

Traction Unit Operator’s Manual 3...............

Check Hydraulic Fluid 3.......................

Relieving Hydraulic System Pressure 3..........

Towing Traction Unit 4.........................

Traction Circuit Component Failure 5............

Hydraulic Hoses 6............................

Hydraulic Hose and Tube Installation (O--Ring Face

Seal Fitting) 7...............................

Hydraulic Fitting Installation (SAE Straight Thread

O--Ring Fitting into Component Port) 8.........

HYDRAULIC SCHEMATIC 11....................

HYDRAULIC FLOW DIAGRAMS 12...............

Traction Circuit: Low Speed 12..................

Traction Circuit: High Speed 14.................

Traction Circuit: Traction Control 16.............

Raise Cutting Deck 18.........................

Lower Cutting Deck 20........................

PTO Mow Circuit 22...........................

PTO Mow Circuit Cutting Deck Blade Braking 24..

Steering Circuit 26............................

Engine Cooling Fan Circuit 28..................

SPECIAL TOOLS 30............................

TROUBLESHOOTING 33........................

TESTING 38...................................

Traction Circuit Charge Pressure Test 40.........

Traction Circuit Relief Pressure Test 42..........

Rear Traction Circuit (RV) Relief Pressure Test 44.

Traction Circuit Reducing Valve (PR)

Pressure Test 46............................

Counterbalance Pressure Test 48...............

Cutting Deck Circuit Pressure Test 50............

Lift/Lower Circuit Relief Pressure Test 52.........

Steering Circuit Relief Pressure Test 54..........

Steering Cylinder Internal Leakage Test 56.......

Gear Pump (P3) Flow Test 58..................

ADJUSTMENTS 60.............................

Adjustable Pressure Valve 60...................

SERVICE AND REPAIRS 61.....................

General Precautions for Removing and

Installing Hydraulic System Components 61....

Check Hydraulic Lines and Hoses 61............

Flush Hydraulic System 62.....................

Charge Hydraulic System 64...................

Hydraulic Reservoir 66........................

Gear Pump 68................................

Gear Pump Service 70.........................

Traction Circuit 72.............................

Piston (Traction) Pump 74......................

Piston (Traction) Pump Service 76..............

Front Wheel Motors 78........................

Front Wheel Motor Service 80

Wheel Motors 82.........................

Rear Rear Wheel

Traction Control Manifold 86....................

Traction Control Manifold Service 88.............

4WD Control Manifold 90......................

4WD Control Manifold Service 92...............

Traction Flush Manifold 94.....................

PTO Circuit 96................................

Cutting Deck Motor 98.........................

Cutting Deck Motor Service 100.................

PTO Control Manifolds 104.....................

PTO Control Manifold Service 108...............

Filter Manifold 110............................

Hydraulic Oil Cooler 112.......................

Cutting Deck Raise/Lower Circuit 114............

Front Deck Lift Cylinder 116....................

Front Deck Lift Cylinder Service 118.............

Wing Deck Lift Cylinder 120....................

Wing Deck Lift Cylinder Service 122.............

Lift Control Manifold 124.......................

Lift Control Manifold Service 126................

Steering and Engine Cooling Fan Circuit 128.....

Steering Control Valve 130.....................

Steering Control Valve Service 132..............

Steering Cylinders 134.........................

Steering Cylinder Service 136..................

Engine Cooling Fan Motor 138..................

Engine Cooling Fan Motor Service 140...........

Steering/Engine Cooling Fan Control Manifold 142 Steering/Engine Cooling Fan Control Manifold

Service 144.................................

SAUER DANFOSS D SERIES GEARPUMPSEALKIT

SERVICE INSTRUCTION BULLETIN

REXROTH VARIABLE PUMP A10VG REPAIR IN-

STRUCTIONS

REXROTH VARIABLE PUMP A10VGREPAIRMANU-

EATON REPAIR INFORMATION: MODEL 74318 and

74348 PISTON MOTORS

PARKER TORQMOTOR

(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

EATON PARTS AND REPAIR INFORMATION: 5

SERIES STEERING CONTROL UNITS

Motor Service 84...................

..................

SERVICE PROCEDURE

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 1

Specifications

Item Description

Piston (Traction) Pump Rexroth Bosch, Variable Displacement Piston Pump

Maximum Pump Displacement (per revolution) 3.84 Cubic Inches (63 cc)

Traction Relief Pressure

Forward 4330 PSI (299 bar) Reverse 5330 PSI (368 bar)

Charge Circuit Relief Pressure 330 PSI (22.8 bar)

Front Wheel Motors Eaton Fixed Displacement Piston Motor

Displacement (per revolution) 1.80 Cubic Inches (29.5 cc)

Rear Wheel Motors Parker Orbital Rotor Motor, TG Series

Displacement (per revolution) 14.5Cubic Inches (238 cc)

Gear Pump Sauer--Danfoss 3 Section Gear Pump, D Series

Section P1 Displacement (per revolution) 1.94 Cubic Inches (31.8 cc) Section P2 Displacement (per revolution) 1.94 Cubic Inches (31.8 cc) Section P3 Displacement (per revolution) 1.25 Cubic Inches (20.5 cc)

Cutting Deck Motors Casappa Gear Motor

Displacement (per revolution) 1.61 Cubic Inches (26.4 cc) Relief Pressure (front andleft decks) 3000 PSI (207 bar) Relief Pressure (right deck) 2000 PSI (138 bar)

Steering Valve Eaton Steering Unit, Series 5

Steering Circuit Relief Pressure 2100 PSI (145 bar)

Lift/Lower Circuit Relief Pressure 1350 PSI (93 bar)

Engine Cooling Fan Motor Casappa Gear Motor

Displacement (per revolution) 1.03 Cubic Inches (16.9 cc)

Hydraulic Filters (2 used) Spin--on Cartridge Type

Hydraulic Reservoir Capacity 19 U.S. Gallons (71.9 Liters)

Hydraulic Reservoir In--line Suction Strainer 100 Mesh (in Reservoir)

Hydraulic Oil See Operator’s Manual

40 PSI (2.8 bar) Bypass in Filter Manifold

Filter Manifold Includes Filter Restriction Indicator

Groundsmaster 5900/5910Hydraulic System Page 4 -- 2

General Information

Traction Unit Operator’s Manual

The Traction Unit Operator’s Manual providesinformation regarding the operation,general maintenance and maintenance intervals for your Groundsmaster machine.Referto thatpublicationforadditional information when servicing the machine.

Check Hydraulic Fluid

The hydraulic system on your Groundsmaster is designed to operate onanti--wear hydraulic fluid.Thereservoir holds approximately 19 gallons (71.9 liters) of hydraulic fluid. Check level of hydraulic fluid daily. See Operator’s Manual for fluid level checking procedure and hydraulic oil recommendations.

Relieving Hydraulic System Pressure

Beforedisconnectingorperforming any work on the hydraulic system, all pressure in the hydraulic system mustbe relieved.Parkmachineonalevelsurface,lower cuttingdecksfully,disengagePTO,stop engine and engage parking brake.

Systempressurein mowcircuitisrelievedwhen the cutting decks are disengaged. To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions.

Figure 1

1. Hydraulic oil cap 2. Tank cover

Torelievehydraulicpressureinliftcircuit,makesurethat engine is not runningandhave operator seat occupied. Turn ignition switch toRUN, depress deck lift switches to the deck lower positionand then release switch. Return ignition switch to the OFF position.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 3

Towing Traction Unit

IMPORTANT: If towing limits are exceeded, severe damage to the piston (traction) pump may occur.

If it becomes necessary to tow or push the machine, move machine in a forward direction at a speed below 2mph(3.2kph),andforaveryshortdistance.Ifthemachine needs to be moved more than 1/4 mile (0.4 km), machine should be transported on a trailer. The piston (traction) pumpis equippedwith two(2) bypass valves that must be opened for towing or pushing (Fig. 2).

IMPORTANT: If the machine must be pushed or towed in a reverse direction, the check valve in the 4WDcontrolmanifold mustbebypassed.Tobypass thischeck valve, connect a hydraulic hose between the traction pump reverse pressure test port (MA) and the 4WD control manifoldtestport(G2) (Fig. 3). Toro part numbers 95--8843 (hydraulic hose), 95--0985 (coupler fitting) (2 required) and 340--77 (hydraulic fitting) (2 required) are needed for this connection.

If towing the machine is necessary, use the following procedure:

1. Forward bypass valve

2. Reverse bypass valve

Figure 2

3. Reverse test port (MA)

1. Locate bypassvalves onthe tractionpump (Fig.2).

2. Open both bypass valves in traction pump: A. Loosen the jam nut on bypass valve stem. B. Thread bypass valve stem in six (6) turns. C. Tighten the jam nut.

3. Tow or push machine in a forward direction as re-

quired.Make suretonotexceedspeedordistancelisted above.

IMPORTANT: Using the tow option bypasses the high pressure relief valves. Catastrophic component damage can occur if hydraulic traction circuit empties or overheats.

4. After moving machine, close both bypass valves: A. Loosen the jam nut on bypass valve stem. B. Threadbypassvalvestemallthewayout.Donot

exceed 8 ft--lb (11 N--m) torque to close bypass valve.

Figure 3

1. 4WD manifold reverse test port (G2)

2. Traction pump reverse test port (MA)

3. Hydraulic hose

C. Tighten jam nut to secure bypass valve.

Groundsmaster 5900/5910Hydraulic System Page 4 -- 4

Traction Circuit Component Failure

The traction circuit on Groundsmaster 5900 and 5910 machines is aclosed loop systemthatincludes the piston (traction) pump andfour (4) wheel motors.Ifa component in the traction circuit should fail, debris and contamination from the failed component will circulate throughout the traction circuit. This contamination can damageothercomponentsin the circuitsoitmustberemoved to prevent additional component failure.

If acomponent failure occurs in the traction circuit,it is recommended that the entire traction circuit be disassembled,drainedandthoroughlycleanedtoensure that all contamination is removed fromthe circuit.If any debrisremainsinthetractioncircuitandthe machine isoperated, the debris can cause additional component failure.

An alternative method of removing traction circuit contamination would be to temporarily install a high pressurehydraulicoilfilter(seeSpecialTools)intothecircuit. Thefiltershouldbeusedwhenconnectinghydraulictest gaugesinordertotesttractioncircuitcomponentsorafter replacing a failed traction circuit component (e.g. traction(piston)pumporwheelmotor).Thefilterwillensure that contaminates are removed from the closed loopandthus,donotcauseadditionalcomponentdamage.

Oncethefilter hasbeenplacedin thecircuit,operatethe tractioncircuittoallow oilflowthroughthecircuit. Thefilter will remove contamination from the traction circuit during circuit operation.The filter canbe removed from the machine after contamination has been removed from the traction circuit.

IMPORTANT: When operatingthetractionsystem with the highpressure filter installed, make sure that flow is always directed through the filter before entering a replaced component (e.g. do notpress the traction pedal in the reverse direction if the filter is placed for forward direction flow). If flow is reversed, debris from the filter will re--enter the traction circuit.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 5

Hydraulic Hoses

Hydraulichoses are subject to extreme conditions such aspressuredifferentialsduringoperationandexposure to weather, sun, chemicals, very warm storage conditionsormishandling duringoperationandmaintenance. These conditions can causehosedamage and deterioration. Some hoses are more susceptible to these conditions than others. Inspect all machine hydraulic hoses frequently for signs of deterioration or damage:

WARNING

Beforedisconnectingorperforminganyworkon hydraulic system, relieve all pressure in system (seeRelievingHydraulicSystemPressureinthis section).

Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose.

Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings.

When replacing a hydraulichose,be sure that thehose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint (layline) on thehose.Usetwowrenches;holdthehosestraightwith one wrench andtightenthe hose swivelnutonto the fitting with the other wrench ( See Hydraulic Hose and Tube Installation in this section). If the hose has an elbowatoneend, tightentheswivelnuton thatendbefore tightening the nut on the straight end of the hose.

For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

Keepbodyandhandsaway frompinholeleaksor nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar withthistype ofinjury.Gangrenemayresultfrom such an injury.

Groundsmaster 5900/5910Hydraulic System Page 4 -- 6

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)

1. Makesurethreadsandsealingsurfacesofthehose/ tube and the fittingarefree of burrs,nicks,scratches or any foreign material.

2. Asapreventativemeasureagainstleakage,itisrecommended that the face seal O--ring be replaced any time the connection isopened.Make sure theO--ring is installedandproperlyseatedinthefittinggroove.Lightly lubricate the O--ring with clean hydraulic oil.

3. Place the hose/tube against the fitting body so that theflatfaceofthehose/tube sleevefullycontactstheO-ring in the fitting.

4. Thread the swivelnut onto thefittingby hand. While holding the hose/tube with a wrench, use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 6. This tightening process will require the use of an offset wrench ( e.g. crowfoot wrench). Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench. Tightening torque when usingatorquewrenchwithanoffsetwrenchwillbelower than the listed installation torque (see Using a Torque Wrench with anOffsetWrench in theTorque Specificationssectionof Chapter 2 -- Product Records andMaintenance).

C. Useasecondwrenchto tightenthenuttothe correct FlatsFrom WrenchResistance (F.F.W.R.). The markingsonthenutandfittingbodywillverifythatthe connection has been properly tightened.

Size F.F.W.R.

4 (1/4 in. nominal hose or tubing) 1/2to 3/4 6 (3/8 in.) 1/2 to 3/4 8 (1/2 in.) 1/2 to 3/4 10 (5/8 in.) 1/2 to 3/4 12 (3/4 in.) 1/3 to 1/2 16 (1 in.) 1/3 to1/2

Swivel Nut

Tube or Hose

O--ring

Fitting Body

Figure 4

System

Hydraulic

5. If a torque wrench isnot available or if space at the swivelnutpreventsuseof a torque wrench,analternate method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 2).

Mark Nut

and Fitting

Body

Final

Position

A. Usingawrench, tightentheswivelnutontothefittinguntillightwrenchresistanceisreached (approxi-

Extend Line

mately 30 in--lb). B. Mark the swivel nut and fitting body. Hold the

hose/tube with a wrench to prevent it from turning.

AT WRENCH RESISTANCE

Figure 5

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18to22ft--lb(25to29N--m) 6 11/16 -- 16 27to33ft--lb(37to44N--m)

8 13/16 -- 16 37to47ft--lb(51to63N--m) 10 1--14 60 to 74 ft--lb (82 to 100 N--m) 12 13/16--12 85 to 105 ft--lb (116 to 142 N--m)

Initial Position

AFTER TIGHTENING

16 17/16--12 110 to 136 ft--lb (150 to 184 N--m) 20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m)

Figure 6

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 7

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Non--Adjustable Fitting (Fig. 7)

1. Make sureall threads andsealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asapreventativemeasureagainstleakage,itisrecommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwithnolubricantapplied.

IMPORTANT: Before installing fitting into port, determine port material.If fitting is to be installed into an aluminum port, installation torque is reduced.

4. Install the fitting into the port. Then, use a torque wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 8.

NOTE: Useof an offsetwrench(e.g. crowfoot wrench) will affect torquewrench calibration dueto the effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be less than the recommendedinstallation torque. See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product RecordsandMaintenance todeterminenecessaryconversion information.

5. If atorque wrench is not available,or if space at the portpreventsuse ofatorquewrench,analternatemethod ofassembly is the Flats From Finger Tight (F.F.F.T.) method.

A. Install thefitting into the port and tighten it down full length until finger tight.

B. If port material is steel, tighten the fitting to the listed F.F.F.T. If portmaterialis aluminum, tightenfitting to 60% of listed F.F.F.T.

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

Fitting

O--ring

0.25

Figure 7

Fitting

Dash Size

Fitting Port Side

Thread Size

Installation Torque Into

Steel Port

Installation Torque Into

Aluminum Port

4 7/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m) 5 1/2 -- 20 18to22ft--lb(25to29N--m) 11to15ft--lb(15to20N--m) 6 9/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)

8 3/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--m) 10 7/8 -- 14 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m) 12 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m) 14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m) 16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 20 15/8--12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)

Figure 8

Groundsmaster 5900/5910Hydraulic System Page 4 -- 8

Adjustable Fitting (Fig. 9)

1. Make sureall threads andsealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asapreventativemeasureagainstleakage,itisrecommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwithnolubricantapplied.

4. Turnback the lock nutasfar as possible. Makesure the back up washerisnotloose and is pushedupasfar as possible (Step 1 in Figure 10).

IMPORTANT: Before installing fitting into port, determine port material.If fitting is to be installed into an aluminum port, installation torque is reduced.

Lock Nut

Back--up Washer

O--ring

Figure 9

5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2).

6. Toputthefittinginthedesired position, unscrew itby the required amount, but no more than one full turn (Step 3).

7. Hold thefitting in the desired positionwith awrench and use atorquewrench to tightenthefitting to therecommended installation torque shown in Figure 8. This tightening process will require the use of an offset wrench (e.g. crowfoot wrench). Useofanoffsetwrench will affect torquewrench calibration dueto the effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be lower thanthe listed installation torque (seeUsing a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product Records and Maintenance).

8. If atorque wrench is not available,or if space at the portpreventsuse ofatorquewrench,analternatemethod ofassembly is the Flats From Finger Tight (F.F.F.T.) method. Hold the fitting in the desired position with a wrench and, ifport material issteel, tighten the locknut withasecondwrenchto thelistedF.F.F.T (Step4).Ifport material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Step 3Step 1

Step 2 Step 4

Figure 10

System

Hydraulic

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 9

This page is intentionally blank.

Groundsmaster 5900/5910Hydraulic System Page 4 -- 10

Hydraulic Schematic

The hydraulic schematic for Groundsmaster 5900 and 5910machinesis locatedinChapter10 -- Foldout Drawings.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 11

Hydraulic Flow Diagrams

REAR

WHEEL

MOTORS

FOR

FRONT

WHEEL

MOTORS

CHG

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

Traction Circuit: Low Speed (Forward Shown)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 12

Traction Circuit: Low Speed

A variable displacement, bi--directional piston pump is directly coupled to the engine flywheel to provide hydraulic flow for the traction circuit. The piston pump swash plate movement is controlled by an electronic proportionalservoassembly. Pushingthetractionpedal rotates a potentiometer that sends a signal to the machineTEC--5002 controller. Thecontroller inturnsends acorresponding PWM (Pulse Width Modulation) output signal to the hydrostat electronic control to rotate the pumpswashplateaccordinglyto controlthepump’soutput.Theoilfrom thehydrostatisdirected tothefrontand rear wheel motors through the traction, 4WD and traction flush control manifolds.

Operating pressure on the high pressure side of the closed loop traction circuitisdetermined by theamount of load developed at the fixed displacement wheel motors. As the load increases, circuit pressure can increaseto relief valve settings:4330 PSI(299bar)inthe forward direction and 5330 PSI (368 bar) in reverse. If pressureexceedsthereliefsetting,oilflowsthrough the relief valve to the low pressure side of the closed loop traction circuit.

Traction circuit pressure (forward and reverse) can be measured at test ports located on the hydrostat.

The traction circuit provides operation in either low speed (four wheel assist) or high speed (two wheel drive).

The traction pump and wheel motors use a small amount of hydraulic fluidforinternal lubrication. Fluidis designed to leak across the pump and motor partsand into the component case drain. This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced. The charge circuit is designed to replace this traction circuit leakage.

Thegearpumpsection(P3)thatsuppliesoiltothesteering, lift and coolingfan circuits, also providescharge oil for thetraction circuit. The gear pump is driven directly off the traction pump. It provides a constant supply of charge oil tothe traction circuitto make upfor oil thatis lost to internal leakage in the traction pump and wheel motors. Charge pump flow is directed through the charge oil filter before entering the hydrostat.This filter has a bypass valve that allows charge oil flow to the closed traction loop if the filter becomes plugged.

The charge pressure is limitedto 330 PSI(22.8 bar)by a relief valvelocated in thehydrostat. Charge pressure canbemeasured atthechargepressuretestport(G)on the hydrostat.

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 13

Forward Direction

Withthelowspeedrangeselectedandthetractionpedalpushed in the forward direction, oil from the hydrostat port MB passes through the traction control valve (see TractionCircuit: TractionControlin thissection).Oilflow fromtractioncontrolvalve portM1drivesthefrontwheel motors in the forward direction and then returns to the hydrostat. Oil flowfrom traction control valve port M2 is routed to the P1 port of the 4WD controlvalve where it is directedto the PD1 cartridge and out of the manifold to drive the rear wheel motors in the forward direction. Oil returning from the rear motors re--enters the 4WD control valve at the M2 port. Flow passes through the PD2 cartridge, through the CV check valve, out valve port P2 and back to the hydrostat.

To keep the traction circuit oil properly cooled, a flush valveisincorporatedintothe tractioncircuit.Wheninthe forward direction, theflush valve spoolisshifted by forward pressure and allows a small amount of hydraulic fluidtobleedoffforcoolingofthe closedlooptraction circuit.Thechargesystemreplenishesoilthatisbledfrom the traction circuit due to the flushing valve operation.

When going down a hill, the tractor becomes an over-running load that drivesthewheelmotors. In this condition, the rear wheel motors could lock up as the oil pumped from the motors increases pressure as it returns to thehydrostat. To prevent wheel lock up, an adjustable relief valve (RV) in the 4WD control valve reduces rear motor pressure created in down hill, dynamic braking conditions.

Reverse Direction

The traction circuitoperates essentially the same inreverselowspeedasitdoesintheforwarddirection.However, the flow through the circuit is reversed. Oil flow fromthe hydrostat port MA isdirectedtothefront wheel motorsandto4WD control valve port P2. Oil to the front wheel motors drives them in the reverse direction and thenreturnstothehydrostatthroughthe traction control valve.Oilflowtothe4WDcontrolvalveflowsthroughthe PR pressure reducing valve which limits the down streampressuretothe rear wheelmotorsto650PSI(45 bar) so the rear wheels will not scuff the turf. This reduced pressure flow passes throughthe PD2cartridge andoutport M2totherear wheelmotors.Returnoil from the rear motors re--enters the 4WD controlvalveat port M1, flows throughthe PD1 cartridge,exits the manifold at port P1 andreturns to the hydrostatthrough the traction control manifold.

When in the r everse direction, the flush valve spool remains in the unshifted position to prevent any traction circuit fluid loss.

System

Hydraulic

REAR

WHEEL

MOTORS

FOR

FRONT

WHEEL

MOTORS

CHG

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

Traction Circuit: High Speed (Forward Shown)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 14

Traction Circuit: High Speed

Traction circuit pressure (forward and reverse) can be measured at test ports located on the hydrostat.

The traction circuit provides operation in either low speed (four wheel assist) or high speed (two wheel drive).

Forward Direction

With the Hi--Lo speed switchin the highrange position, solenoid valve (S) in the 4WD control manifold is energized. The solenoid valve spool shifts to direct charge pressure that shifts the PD1 and PD2 control valve spools. The shifted PD1 valve prevents hydraulic flow from the hydrostat to the rear wheel motors. With flow blockedtotherearwheel motors, all hydrostatflowisdirectedto the front wheel motors to allowahigher, transport speed in the forward direction.

Without flow to therear wheelmotors, therotating rear wheels drive the rear wheel motors so they act like a pump. Inlet oil totherear wheel motorsisprovided by a check valve that allows charge oil into the rear wheel motor circuit. Oil leaving the rear wheel motors enters the4WDcontrolmanifoldatportM2and isdirectedback to the rear wheelmotorsthrough the PD1cartridgeand manifold port M1. To allow for rear wheel loop cooling whenin forward Transport operation, a small amountof oilexitsthroughtheshiftedPD2cartridgeandreturnsto the charge circuit.

Reverse Direction

With the Hi--Lo speed switchin the highrange position, solenoid valve (S) in the 4WD control manifold is energized. The solenoid valve spool shifts to direct charge pressure that shifts the PD1 and PD2 control valve spools. Oil flow from the hydrostat port MA enters the 4WD control manifold at port P2, flows through the PR pressure reducing valve and is stopped at the shifted PD2 valve. With flow blockedto the rear wheel motors, allhydrostatflow is directed to thefrontwheelmotorsto allow a higher, transportspeed in thereverse direction.

Without flow to therear wheelmotors, therotating rear wheels drive the rear wheel motors so they act like a pump. Inlet oil totherear wheel motorsisprovided by a checkvalveatthe4WD control manifold CHportthatallows charge oil into the rear wheel motor circuit. This charge oil is routed through the shifted PD2 cartridge and out manifold port M2to the rearwheel motors. Return flow from the rear wheel motors enters the 4WD controlmanifoldatport M1,throughtheshiftedPD1 cartridge and and is then directed back to the rear wheel motors as they turn in the reverse direction.

System

Hydraulic

The charge pressure is limitedto 330 PSI(22.8 bar)by a relief valvelocated in thehydrostat. Charge pressure canbemeasuredat thechargepressuretestport on the hydrostat.

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 15

REAR

WHEEL

MOTORS

FOR

CHG

FRONT

WHEEL

MOTORS

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

Traction Circuit: Traction Control (Traction Assist Switch Depressed in Low Speed)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 16

Traction Circuit: Traction Control

A flow divider is incorporated into the traction circuit to provide a proportioned flow to the front and rear wheel motorsforatruefour--wheeldrivesystem.WhentheHi-Lo speed switch is in the Low position and the traction pedal is pressed for the forward direction, the operator canengagethetractionflowdividerwhenlowtractionsituations could leadto wheel spin.The engaged flowdividersplitstractionpump flow equally between the front andrearwheelmotorstoreducethechancethatexcessive flow goes to a spinning wheel.

TheTEC--5001 controllerdoesnotallowTractionAssist to be activated while the tractor is in the high speed range in either forward or reverse. The controller also preventsTractionAssistinthereversedirectionwhen in low speed range.

To further enhance traction control, the lift/lower circuit is equipped with a counterbalancesystem.Counterbalanceisachievedby applying a constant pressure to the base end of the lift cylinders to lift the cutting decks slightly. This action causes some of the cutting deck weight to be transferred to the traction unit to improve traction. An adjustable counterbalance valve (LC) located in the deck lift control manifold controls the amount of counterbalance pressure in the lift circuit.

Traction Assist Switch in OFF Position

Inlowspeed range with the TractionAssistswitchinthe OFF position, solenoid valve (S) in the traction control manifold is de--energized allowing the PD cartridge spooltobeintheneutralposition.Withthetractionpedal in the forwarddirection, hydraulic oilfrom the hydrostat port MB enters the traction control manifold at port P, flows through the FD cartridge and enters the PD cartridge.FlowatthePDcartridgesplitsintotwocircuitsdepending on downstreampressure.The flow leavingthe PDcartridgesplits between the M1 manifold port for the frontwheelmotorsand the M2 manifold port for the rear wheel motors.

Traction Assist Switch in ON Position

Inlowspeedrangewiththetractionpedalintheforward direction and themomentary Traction Assist switchdepressed and heldinthe ON position, solenoidvalve (S) in the traction control manifold is energized allowing charge pressure to shift the PD cartridge spool. The shifted PD cartridge blocks oil flow from the hydrostat, therebyforcinghydrostat oilflowthroughtheFD proportional flow control valve. The flow from the hydrostat is split approximately equally between the front and rear wheelmotorsas longastheTractionAssistswitchisdepressed.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 17

REAR

WHEEL

MOTORS

FOR

FRONT

WHEEL

MOTORS

CHG

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

(Deck Lift Control Manifold Solenoids S1 and S5 Energized)

Raise Cutting Deck (Center Deck Switch Pressed To Raise)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 18

Raise Cutting Deck

Athreesectiongearpumpiscoupledtothe piston (traction) pump. The gear pump section (P3) farthest from thepistonpumpsupplieshydraulicflowtotheliftcontrol manifold, the steering/cooling fan control manifold and the traction charge circuit. Hydraulic flow from pump section (P3) is splitbetween the lift/lower circuit andthe steering/coolingfan/chargecircuitbya proportionalflow dividerlocatedin theliftcontrolmanifold.Thisflowdivider splitspump flowapproximately 25%for thelift/lower circuit(4GPM/15.1 LPM)and75%for thesteering/cooling fan/charge circuit (10 GPM/37.9 LPM).

An adjustable counterbalancevalve (LC)in the liftcontrolmanifoldmaintainsbackpressureonthedeckliftcylinders to allow some of the cutting deck weight to be transferred to thetraction unit toimprove traction. A reliefvalve(RV)locatedintheliftcontrolmanifold limitslift/ lower circuit pressure to 1350 PSI (93 bar).

Each of the cutting decks (center, right and left) can be raised independently with the use of threeswitches on the armrest console ( Fig. 11). Pressing the rear of a switch provides aninputfor the TEC--5001 controller to raise a cutting deck. The controller provides electrical outputs to solenoids in the lift control manifold to allow appropriate valve shift to cause a deck to raise.

When the cutting decks are in a stationary position, all solenoids in the lift control manifold are de--energized. In this position,the flow fromthe gear pumpthat is proportioned for the lift/lower circuit is by--passed through the solenoid valve S1, the counterbalance logic cartridge LC and returns to the hydraulic reservoir.

NOTE: The operator must be in the operator seat to raise a cutting deck.

Center Cutting Deck Raise

To raise the center cutting deck, the rear of the center console switch is depressed.Theswitch signal is aninput to theTEC--5001 controller whichprovides an electrical output to solenoid valves S1 and S5 in the lift control manifold. The energizedsolenoidvalves shift to allowapassagefor circuit oilflowtothebarrel end ofthe centerdeckliftcylinder.ShiftedS1preventsoil flowfrom returning directly to the reservoir. Shifted S5 allows an oil path to thebarrelend of theliftcylinder to extend the liftcylinderandraisethecentercuttingdeck.Oilfromthe extending cylinder returns to the hydraulic reservoir.

When the deck switch is released, the lift/lower control solenoids are de--energized and the center deckliftcylinders and center cutting deck are held in position.

Right Cutting Deck Raise

To raise the right wing deck, the rear of the right console switchispushed asaninputto theTEC--5001 controller. The controller provides an electrical output to solenoid valves S1 and S7 in the lift control manifold. The energizedsolenoid valves shifttoallowa passage for circuit oil flow to the rod end of the right deck lift cylinder. ShiftedS1preventsoilflowfromreturningdirectlytothe reservoir. Shifted S7 allows an oil path through the check valve at S9 (de--energized), the check valve at OR2andtothebarrelendoftheliftcylindertoextendthe lift cylinder andraise the rightcutting deck. Oilfrom the extending cylinder is directed through S9 (de--energized) and returns to the hydraulic reservoir.

When the deck switch is released, the lift/lower control solenoids are de--energized and the lift cylinder and right cutting deck are held in position.

Left Cutting Deck Raise

To raise the left wing deck, the rear of the left console switchispushed asaninputto theTEC--5001 controller. The controller provides an electrical output to solenoid valves S1 and S2 in the lift control manifold. The energizedsolenoid valves shifttoallowa passage for circuit oil flow to the barrel end of the left deck lift cylinder. ShiftedS1preventsoilflowfromreturningdirectlytothe reservoir. Shifted S2 allows an oil path through the check valve at S4 (de--energized), the check valve at OR1andtothebarrelendoftheliftcylindertoextendthe lift cylinder and raise the left cutting deck. Oil from the extending cylinder is directed through S3 (de--energized) and returns to the hydraulic reservoir.

When the deck switch is released, the lift/lower control solenoids are de--energized and the liftcylinderandleft cutting deck are held in position.

Figure 11

1. Right deck switch

2. Center deck switch

3. Left deck switch

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 19

REAR

WHEEL

MOTORS

FOR

CHG

FRONT

WHEEL

MOTORS

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

(Deck Lift Control Manifold Solenoids S1, S8 and S9 Energized)

Lower Cutting Deck (Right Wing Deck Switch Pressed To Lower)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 20

Lower Cutting Deck

Athreesectiongearpumpiscoupledtothe piston (traction) pump. The gear pump section (P3) farthest from thepistonpumpsupplieshydraulicflowtotheliftcontrol manifold, the steering/cooling fan control manifold and the traction charge circuit. Hydraulic flow from pump section (P3) is splitbetween the lift/lower circuit andthe steering/coolingfan/chargecircuitbya proportionalflow dividerlocatedin theliftcontrolmanifold.Thisflowdivider splitspump flowapproximately 25%for thelift/lower circuit and 75% for the steering/cooling fan/charge circuit.

Each of the cutting decks (center, right and left) can be loweredindependentlywiththeuseofthree(3)switches on the armrestconsole(Fig. 11).Pressing the frontofa switch provides aninputfor the TEC--5001 controller to lower a cutting deck. The controller provides electrical outputs to solenoids in the lift control manifold to allow appropriate valve shift to cause a deck to lower.

NOTE: Theoperatormustbe in the operator seat inorder to lower a cutting deck.

Center Cutting Deck Lower

To lower the center cutting deck, the front ofthe center console switch is depressed.Theswitch signal is aninput to theTEC--5001 controller whichprovides an electrical output to solenoid valve S6 in the lift control manifold. Energizedsolenoid valve S6 shifts to allow a passage for oilflow from therod end ofthe center deck lift cylinders. The weight of the cutting deck causesthe center deck lift cylinders toretract and lower the center cutting deck.

When the deck switch is released, the lift/lower control solenoid is de--energized andthe lift cylinders andcenter cutting deck are held in position.

Right Cutting Deck Lower

Tolowertherightwingdeck,thefrontoftherightconsole switchispushed asaninputto theTEC--5001 controller. The controller provides an electrical output to solenoid valvesS1,S8andS9intheliftcontrolmanifold.Theenergized solenoid valves shift to allow a passage forcircuit oil flow to the rod end of the right deck lift cylinder. ShiftedS1preventsoilflowfromreturningdirectlytothe reservoir.Shifted S8allows an oil path to the shaft end ofthe lift cylinder to retracttheliftcylinder and lower the right cutting deck. Oil from the retracting cylinder flows throughorificeOR2to control the drop speed of the cutting deck.Flow is then directed through the shiftedS9, counterbalance v alve (LC) andreturns tothe hydraulic reservoir.

When the deck switch is released, the lift/lower control solenoids are de--energized and the lift cylinder and right cutting deck are held in position.

Left Cutting Deck Lower

To lower the left wing deck, the front of theleft console switchispushed asaninputto theTEC--5001 controller. The controller provides an electrical output to solenoid valvesS1,S3andS4intheliftcontrolmanifold.Theenergized solenoid valves shift to allow a passage forcircuit oil flow to the rod end of the left deck lift cylinder. ShiftedS1preventsoilflowfromreturningdirectlytothe reservoir.Shifted S3allows an oil path to the shaft end ofthe lift cylinder to retracttheliftcylinder and lower the left cutting deck. Oil from the retracting cylinder flows throughorificeOR1to control the drop speed of the cutting deck.Flow is then directed through the shiftedS3, counterbalance v alve (LC) andreturns tothe hydraulic reservoir.

When the deck switch is released, the lift/lower control solenoids are de--energized and the liftcylinderandleft cutting deck are held in position.

Cutting Deck Float

Cutting deck float allowsthefully lowered cuttingdecks to follow ground surface contours. Lift control manifold solenoid valves S4(left deck), S6 (centerdeck) and S9 (rightdeck) are energized w hen thedecksarefully lowered.These energizedsolenoidsprovideanoilpassage toandfromtheliftcylinderstoallowcylinderandcutting deck movement while mowing. Counterbalance pressure will affect deck float operation.

System

Hydraulic

NOTE: If a deckis already fullylowered when the igni-

tionswitch is moved from OFF toRUN,thedeckwill not be in float until thedeck lift/lowerswitch is momentarily pressed to lower.

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 21

REAR

WHEEL

MOTORS

FOR

CHG

FRONT

WHEEL

MOTORS

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

PTO Mow Circuit (All Deck Motors Rotating)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 22

PTO Mow Circuit

Athreesectiongearpumpiscoupledtothe piston (traction) pump. Hydraulic flow for the PTO mow circuit is suppliedbytwo(2) sections of the gear pump. The gear pump section (P1) closest to the piston pump supplies hydraulic flow inseries to theright and leftdecks, while the next gear pump section (P2) supplies the center deck.Eachofthethree(3)cuttingdecksiscontrolledby a hydraulic control manifold equipped with a solenoid control valve (S), logic cartridges (LC1) and (LC2), a brake relief cartridge(RV2) and a circuit relief cartridge (RV1).

PTO Not Engaged

WhenthePTOswitchisOFForifthedeckisraisedw ith thePTOswitchON,thePTOmanifoldsolenoidvalve(S) is not energizedand the solenoidspool is in theneutral position. The solenoid valve spool in neutral allows a small amount ofhydraulic flow toreturn to tankthrough a manifold sensing line which causes a pressure increase that shiftslogic cartridge LC1. The pumpflow is routed through shifted LC1 and out manifold port P2. Logic cartridge LC2 remainsin the unshifted positionto prevent any return flowfromthedeck motor to keepthe motor from rotating.

Return flow from the front and right deck control manifolds is routed through the oil cooler, oil filter and then to the gear pump input. Return flow from the left deck control manifold provides supply for the right deck.

PTO Circuit Relief

Maximum mow circuitpressure is limited for eachdeck by a relief valve(RV1)in the hydraulic controlmanifold. Thecenterandleft deckreliefvalvesareset at3000PSI (207bar)andtherightdeckreliefvalveissetat2000PSI (138 bar).

Relief valve (RV1) and logic cartridge (LC1) work together as a two stage relief. Whenincreased circuitresistance is met or if a cutting blade should strike an object, the pressureincrease is feltatthe relief valve.If the pressure should exceed therelief valve setting, the reliefvalvewillopen, creatingasmallamount ofhydraulicflow to return to tank throughamanifoldsensingline. This flow causes a pressure increase that shifts logic cartridgeLC1anddivertscircuitflowawayfromthedeck motor to manifold port P2 (Fig. 12). When circuit pressurelowers,reliefvalve(RV1)closeswhichreturnslogic cartridge LC1 back to its neutral position allowing flow to return to the deck motor.

PUMP FLOW

System

Hydraulic

PTO Engaged

When the PTO switch is turned ON and the decks are lowered, the PTO control manifoldsolenoid valve (S)is energizedbythe TEC--5002controller.Theshifted solenoid valve spool prevents any sense line flow through the spool which causes the logic cartridge LC1 to be in its neutral position. Gear pump flow entering the manifold is routed out manifold port M1 and to the cutting deck motor.The return flow fromthedeck motor re--enters manifold port M2. Theshifted solenoidvalve spool allows a small amountofhydraulicflow to return totank through a manifold sensing line which causes a pressure increase that shifts logic cartridge LC2. Hydraulic flowisrouted through shifted LC2, out manifold port P2, through the oilcoolerand filter andthen is routed tothe gear pump input. The deckmotorcontinuestorotateas long as solenoid valve (S) is energized.

Deckmotorcasedrainleakagereturnsdirectlytothehydraulic reservoir.

Figure 12

RETURN

SOLENOID S ENERGIZED DECK MOTOR STALLED RV1 SHIFTED LC1 SHIFTED

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 23

PTO Mow Circuit Cutting Deck Blade Braking

WhentheoperatorturnsthePTOswitchOFForifadeck is raised with thePTOswitchON,PTOcontrolmanifold solenoid valve (S) is de--energized causing logic cartridge(LC1)toshift(refertoinformationinPTOMowCircuit in this section). This shifted cartridge allows oil return out manifold port P2. At the same time, solenoid valve (S) in its neutral position prevents any sense line flow through thespool which causes the logiccartridge LC2 to shift to its neutral position blocking return flow fromthedeckmotorand slowing thecuttingblades(Fig.

13). Theinertiaoftherotatingcuttingblades,however,effec-

tively turns the deck motor into a pump causing an increaseinpressure as the flow from themotor comesup againsttheclosedlogiccartridge(LC2).Whenthispressure builds to approximately 600 PSI (41 bar), relief valve (RV2) opens which allows a small amount of hydraulic flow to return totankthroughamanifoldsensing line(Fig. 14). This flowcausesapressure increase that shifts logic cartridge LC2 to once again allow oil flow from the motor (Fig. 15). When return pressure drops below 600 PSI (41 bar), relief valve (RV2) reseats and causesLC2 to close again blockingreturnflowfromthe deckmotortofurtherslowthe cuttingblades.Thisaction of the brakerelief valve openingand the logic cartridge shifting occurs several timesin avery shorttime frame as the blades finally come to a stop. Once the blades havestopped,logic cartridge LC2remainsintheneutral position to keep the deck motor from rotating.

PUMP FLOW

RETURN

Figure 13

PUMP FLOW

RETURN

Figure 14

Figure 15

PUMP FLOW

RETURN

Groundsmaster 5900/5910Hydraulic System Page 4 -- 24

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System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 25

REAR

WHEEL

MOTORS

FOR

CHG

FRONT

WHEEL

MOTORS

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

Steering Circuit (Left Turn Shown)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 26

Steering Circuit

Athreesectiongearpumpiscoupledtothe piston (traction) pump. The gear pump section (P3) farthest from the piston pumpsupplies hydraulic flowto the steering/ coolingfancontrolmanifold,theliftcontrolmanifoldand the traction charge circuit. Hydraulic flow from pump section (P3) is split between the steering/cooling fan/ charge circuit and the lift/lower circuit by a proportional flow divider locatedin the liftcontrol manifold. Thisflow divider splits pump flow approximately 75% for the steering/cooling fan/charge circuit (10.5 GPM/39.7 LPM) and 25% for the lift/lower circuit (3.5 GPM/13.2 LPM).

The steering/cooling fan control manifold controls the operationof the steering control valveandthegearmotorthatdrivesthe engine cooling fan. Priority valve (PV) inthemanifoldcontrolstheoilflowtothesteeringcontrol valve which is a closedcenter,load sensing valve.The steering control valve sensestheoil flow that isneeded for steering and the priority valve (PV) will supply the correct amount. Oil not used by steering is provided to thecoolingfanmotor.

With the steering wheel in the neutral, at rest position andthe engine running, hydraulicoilfromtheliftcontrol manifold flow divider enters the steering/cooling fan control manifold port P, flows through the priority valve (PV) and to the steering control valve where it dead heads at the spool. Oil is also sent to both ends of the (PV)spool.Ononeendofthespool,oil is directed to the steering relief valve (RV) and also is directed through the OR orifice andoutthe LS manifoldportto the steeringcontrolvalve.This flow providessteeringloadsense pressureand is directed through asmallpassageinthe steeringcontrolvalvespoolandsleevebeforereturning to the charge circuit. While this load sense pressure is returning to the charge circuit, the priority valve (PV) spool shifts to direct pump flow tothe engine fan motor circuit. Without steering input, no oil is flowing through the steering control valve.

Left Turn

When a left turn is made with the engine running, the turningofthesteeringwheelpositionsthespoolvalveso that the load sense flow is blocked off. Without load sense flow, pressures on the ends of manifold priority valve(PV)starttoequalizecausing(PV)to movetoward its neutral position which allows the needed oil to the steeringcontrolvalve.Oilis routed outmanifoldportCF,

into steering valve port P, through the steering control spool,isdrawnthroughtherotarymetersectionandout theLporttothesteering cylinders. The rotary meter ensures thatthe oil flow to the cylinders is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinders flows backthrough steeringvalve R port, the spool valve, out the T port and is then used for traction circuit charge oil.

The steering wheel and steering control valve return to the neutral position when turning is completed.

Right Turn

When a right turn is made with the engine running,the turningofthesteeringwheelpositionsthespoolvalveso that the load sense flow is blocked off. Without load sense flow, pressures on the ends of manifold priority valve(PV)starttoequalizecausing(PV)to movetoward its neutral position which allows the needed oil to the steeringcontrolvalve.Oilis routed outmanifoldportCF, into steering valve port P, through the steering control spool,isdrawnthroughtherotarymetersectionandout theRporttothe steering cylinders. Therotarymeterensures thatthe oil flow to the cylinders is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinders flows back through the steering valve L port, the spool valve, out the T port and is then used for traction circuit charge oil.

The steering wheel and steering control valve return to the neutral position when turning is completed.

Steering Relief Operation

Whenthesteeringcylindersreach theendoftheirstroke or if a rear wheelshould encounter an obstruction (e.g. acurb)whilesteering,thepressureinthesteeringcircuit will rise. Relief valve (RV) in the steering/cooling fan control manifold senses this pressure increase. When this pressure builds to approximately 2100 PSI (145 bar), relief valve (RV) opens and allows hydraulic flow toreturntotank.Thisactioncausesflowacrosstherelief valve side orifice of priority valve (PV) which shifts the spool in (PV) to send oil away from the steering circuit tothefan motorcircuit.Reliefvalve(RV)controlstheaction of priority valve(PV)andallows the priority valveto divertonlyenoughoilflow to the steeringcircuittomaintain relief pressure.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 27

REAR

WHEEL

MOTORS

FOR

CHG

FRONT

WHEEL

MOTORS

REV

Flow

Return or Suction

Working Pressure

Low Pressure (Charge)

Engine Cooling Fan Circuit (Forward Direction Shown)

Groundsmaster 5900/5910Hydraulic System Page 4 -- 28

Engine Cooling Fan Circuit

With the steering wheel in the neutral, at rest position andthe engine running, hydraulicoilfromtheliftcontrol manifold flow divider enters the steering/cooling fan control manifold port P, flows through the priority valve (PV) and to the steering control valve where it dead heads at the spool. Oil is also sent to both ends of the (PV)spool.Ononeendofthespool,oil is directed to the steering relief valve (RV) and also is directed through the OR orifice andoutthe LS manifoldportto the steeringcontrolvalve.This flow providessteeringloadsense pressureand is directed through asmallpassageinthe steeringcontrolvalvespoolandsleevebeforereturning to the charge circuit. While this load sense pressure is returning to the charge circuit, the priority valve (PV) spool shifts todirect pump flowto the cooling fanmotor circuit. Without steering input, no oil is flowing through the steering control valvesoallcircuit oil is availablefor thecoolingfanmotor.

Oil flow from the priorityvalve (PV) to the cooling fan is controlled by the proportional relief valve (PRV). The (PRV) adjusts fan circuit pressure and flow based on a PWM (Pulse Width Modulation) signal from the TEC--5002 controller. The controller uses engine coolant and hydraulic oil temperatures to determine the proper PWMsignal for the (PRV) valve. The fan circuit flow determines the speed of the cooling fan.

If the fan motor is stalled for any reason, the priority valve (PRV) has a secondaryfunction as a circuit relief to limit fan motor pressure to 3300 PSI (228 bar).

When the engine is shut off, the over--running inertia load of the fan blades keeps driving the fan motor and turns itinto a pump. The check valve (CV) in the steering/cooling fan control manifold will open to keep the motor circuit full of oil so the fan motor will not cavitate.

Forward Direction Fan Operation

Oil flow from the priority valve (PV) is sent through the de--energized solenoid valve (S), out manifold port M1 and then to rotate the cooling fan motor. Return flow from the motor enters the manifold at port M2, through the de--energized solenoid valve (S), out manifold port CH and is then used for traction circuit charge oil.

Reverse Direction Fan Operation

TheTEC--5002 controller canreverse thecooling fan to clean debris from theradiator,oilcoolerand rear intake screen. If hydraulic oil and/or engine coolant temperaturesincrease to an unsuitable level, the PWM signalto the(PRV)valveissentto slow the cooling fan. The controller then energizes solenoidvalve(S) in the steering/ coolingfancontrol manifoldtoreversecooling fanmotor oil flow so that it runs in the reversedirection. The controller determines the length of time that the fan should be run in reverse before fan rotation is returned to the forward direction.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 29

Special Tools

Order special tools from your Toro Distributor.

Hydraulic Pressure Test Kit

Use to take various pressure readings for diagnostic tests. Quickdisconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges.Use gauges as recommended in Testing section of this chapter.

Toro Part Number: TOR47009

Hydraulic Tester (Pressure and Flow)

Figure 16

This tester requires O--ring Face Seal (ORFS) adapter fittings for use on this machine (see Hydraulic Test Fitting Kit -- TOR4079 in this section).

1. INLET HOSE: Hose connectedfrom the systemcircuit to the inlet side of the hydraulic tester.

2. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow.

3. LOW PRESSURE GAUGE: Low range gauge (0 to 1000 PSI) to provide accuratereading at low pressure.

A protector valve cutsoutwhen pressure is aboutto exceed the normal range for the gauge. The cutout pressure is adjustable.

4. HIGH PRESSURE GAUGE: Highrangegauge (0 to 5000 PSI) whichaccommodatespressures beyond the capacity of the low pressure gauge.

5. FLOW METER: Thismetermeasures actual oilflow in the operating circuit with a gauge rated at 15 GPM.

6. OUTLET HOSE: A hose from the outlet side of the hydraulictesterconnects tothehydraulicsystem circuit.

Figure 17

Toro Part Number: TOR214678

Groundsmaster 5900/5910Hydraulic System Page 4 -- 30

Hydraulic Test Fitting Kit

This kit includes a varietyofO--ring Face Sealfittingsto enable you to connect test gauges into the system.

The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

Toro Part Number: TOR4079

Measuring Container

Use this container for doing hydraulic motor efficiency testing(motorswithcasedrainlines only). Measureefficiency of ahydraulic motor by restricting theoutlet flow from the motor and measuring leakage from the case drainlinewhilethe motor ispressurizedbythehydraulic system.

The table in Figure 20 provides gallons per minute (GPM)conversionformeasuredmilliliterorouncemotor case drain leakage.

TORO TEST FITTING KIT (NO. TOR4079)

Figure 18

System

Hydraulic

Toro Part Number: TOR4077

Figure 19

Figure 20

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 31

Rear Wheel Hub Puller

The rear wheel hub puller allows safe removal of the wheel hub from the rear wheel motor shaft.

Toro Part Number: TOR6100

Figure 21

Groundsmaster 5900/5910Hydraulic System Page 4 -- 32

Troubleshooting

The charts that follow contain information to assist in troubleshooting hydraulic circuit problems. There may possibly be more than one cause for a machine malfunction.

Refer to the Testing section of this Chapter for precautions and specific hydraulic test procedures.

General Hydraulic Problems

Problem Possible Causes

Hydraulic system operates hot. Engine RPM is too low.

Hydraulic reservoir oil level is low. Hydraulic oil is contaminated or the wrong type. Brakes are applied or sticking. Piston pump by--pass valve is open or damaged. Cooling system is not operating properly. Charge pressure is low. Traction circuit pressure is incorrect. Pump(s) or motor(s) are damaged.

System

Hydraulic

Hydraulic oil in reservoir foams. Hydraulic reservoir oil level is low.

Wrong type of oil is in the hydraulic system. Air is leaking in suction line.

Hydraulic oil leak(s). Fitting(s), hose or tube loose or damaged.

Missing or damaged O-ring.

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 33

Traction Problems

Problem Possible Causes

Machine operates in one direction only. System charge check valve and/or system relief valve

is defective. Pilot direction valve in 4WD control manifold is

damaged or sticking. Traction control potentiometer is faulty.

Traction pedal is sluggish. Traction control pedal assembly is stuck or binding.

Charge pressure is low. Piston pump servo control valve is damaged.

Machine travels too far before stopping when the traction pedal is released.

Traction power is lost or unit will not operate in either direction.

Four wheel drive will not engage. An electrical problem exists (see Chapter 5 -- Electrical

Four wheel drive will not disengage. An electrical problem exists (see Chapter 5 -- Electrical

Traction control pedal assembly is binding or out of adjustment.

Piston pump servo control valve is damaged. Traction pedal does not return to neutral.

Hydraulic reservoir oil level is low. Brakes are applied or sticking. Charge pressure is low. Piston pump bypass valve is open or damaged. Traction control potentiometer is damaged or

disconnected.

System). Solenoid valve on 4WD control manifold is faulty. Cartridge valve in 4WD control manifold is damaged or

sticking.

System). Solenoid valve on 4WD control manifold is faulty. Cartridge valve in 4WD control manifold is damaged or

sticking.

Groundsmaster 5900/5910Hydraulic System Page 4 -- 34

PTO Problems

Problem Possible Causes

Cutting decks do not operate. NOTE: Decks have to be fully lowered and traction

speed needs to be in MOW for decks to operate. One cutting deck motor will not operate. An electrical problem exists (see Chapter 5 -- Electrical

All cutting deck motors operate slowly. Engine RPM is low.

An electrical problem exists (see Chapter 5 -- Electrical System).

Gear pump is worn or damaged.

System). Cutting deck problem exists (see Chapter 8 -- Cutting

Decks). System pressure to the affected deck motor is low. Woodruff key on affected deck motor is damaged

(motor rotates but deck belt and blades don’t rotate). Solenoid valve in deck PTOcontrol manifold is faulty. Cartridge valve in deck PTO control manifold is

damaged or sticking. Deck motor or gear pump section is damaged.

Cutting deck problem exists (see Chapter 8 -- Cutting Decks).

System

Hydraulic

Deck motor or gear pump section is damaged.

Cutting deck stops under load. Relief valve in deck PTO control manifold is

by--passing. Cutting deck problem exists (see Chapter 8 -- Cutting

Decks). Deck motor has internal leakage (by--passing oil). Cutting deck gear pump section is inefficient.

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 35

Steering Circuit Problems

Problem Possible Cause

Steering inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are

worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (other hydraulic systems af-

fected as well). Steering relief valve (RV) in steering/cooling fan control valve is

stuck or damaged. Flow divider (FD) in deck lift control valve is faulty. Proportional valve (PV) in steering/cooling fan control valve is

faulty. Steering cylinder leaks internally. Steering control valve is worn or damaged. Gear pump section (P3) is worn or damaged (NOTE: A w orn or

damaged gear pump section (P3) will also affect the traction (charge) and lift circuits).

Groundsmaster 5900/5910Hydraulic System Page 4 -- 36

Lift/Lower Problems

Problem Possible Causes

Cutting deck will not raise. Engine RPM is too low.

Hydraulic oil level in reservoir is low. Lift arm pivots are binding. Lift cylinder is damaged. Relief valve in lift control manifold is stuck. Pilot valve in lift control manifold is damaged or

sticking. Proportional flow divider in lift control manifold is faulty. Gear pump section for lift control manifold is worn or

damaged. Cutting deck raises, but will not stay up. NOTE: Lift cylinders cannot provide an absolutely

perfect seal. The lift arms will eventually lower if left in the raised position during storage.

Side cutting deck drop too fast. Orifice in lift control valve is missing or damaged.

Side cutting deck drop too slow. Orifice in lift control valve is plugged or faulty.

Cutting deck will not lower. Lift arm pivots are binding.

Lift circuit lines or fittings are leaking.

Lift cylinder is damaged.

Check valve in lift control valve is faulty.

Lift arm pivots are binding.

Lift cylinder is damaged.

Counterbalance pressure is excessive.

Lift control valve is worn or damaged.

Pilot valve in lift control manifold is damaged or

sticking.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 37

Testing

The most effectivemethod for isolatingproblems in the hydraulic system is by using hydraulic test equipment suchaspressuregauges and flow meters in the circuits during various operational checks (see the Special Tools section in this Chapter).

Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply,

filter,bindinglinkages, loose fasteners or improper adjustmentsmustbecheckedbeforeassuming that ahydrauliccomponent isthesourceof theproblem.

Precautions for Hydraulic Testing

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved and all rotating machine parts must be stopped. Stop engine; lower or support attachments.

1. Clean machine thoroughly before disconnecting or disassemblinganyhydrauliccomponents.Alwayskeep in mind the need for cleanliness when working on hydraulic equipment. Contaminationwillcause excessive wear of hydraulic components.

CAUTION

Failure to use gauges with recommended pressure (PSI/bar) rating as listed in test procedures couldresultin damagetothegauge andpossible personal injury from leaking hot oil.

CAUTION

All testing should be performed by two (2) people.Oneperson should beintheseat tooperate the machine and the other should read and record test results.

CAUTION

Beforeopeningthehydraulicsystem,operateall hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

2. Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.

3. Theenginemust beingoodoperatingcondition.Use a phototac when performing a hydraulic test. Engine speed can affect the accuracy of the tester readings.

4. Theinletandtheoutlethosesfortesterwithpressure and flow capabilities must be properly connected and not reversed to prevent damage to the hydraulic tester or components.

5. When using hydraulic tester with pressure and flow capabilities, open tester load valve completely before startingtheenginetominimizethepossibilityofdamaging components.

6. Install fittings finger tight and far enough to make sure that they arenotcross--threaded beforetightening them with a wrench.

7. Position tester hoses to prevent rotating machine partsfromcontactinganddamaging the hosesortester.

8. Check oil level in the hydraulic reservoir. After connecting test equipment, make sure tank is full.

WARNING

Keepbodyand handsawayfrom pinholeleaks ornozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within afew hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

9. Check control linkages for improper adjustment, binding or broken parts.

10.After installingtestgauges, run engineat low speed and check for any hydraulic oil leaks.

11.All hydraulic tests should be made with thehydraulic oil at normal operating temperature.

12.Before returning machinetouse,makesurethat hydraulic reservoir has correct fluid level. Also, check for hydraulic leaks aftertestequipment has beenremoved from hydraulic system.

Groundsmaster 5900/5910Hydraulic System Page 4 -- 38

Which Hydraulic Tests Are Necessary?

Before beginning any hydraulictest, identify if theproblem is related to the traction circuit, PTO (mow) circuit, liftcircuitorsteering/engine coolingfancircuit.Oncethe faulty system hasbeenidentified, perform teststhat relate to that circuit.

1. If a traction circuitproblemexists,consider performing one or more of the following tests: Traction Circuit ChargePressure,TractionCircuitReliefPressure,Rear Traction Circuit (RV) Relief Pressure, Traction Circuit Reducing Valve (PR) Pressure and/or Counterbalance Pressure Tests.

2. If aPTO (mow) circuitproblem exists, considerperformingone or more of the followingtests: Cutting Deck Circuit Pressure.

3. If a lift circuit problem exists, consider performing oneor more of the following tests: Lift/LowerCircuit Relief Pressure, Counterbalance Pressure and/or Gear Pump (P3) Flow Tests.

4. If a steering/engine cooling fan circuit problem exists, consider performing one or more of the following tests: Steering Circuit Relief Pressure, Steering Cylinder Internal Leakage and/or Gear Pump (P3) Flow Tests.

System

Hydraulic

Groundsmaster 5900/5910 Hydraulic SystemPage 4 -- 39

Traction Circuit Charge Pressure Test (Using Pressure Gauge)

TO TRACTION CONTROL

VALVE PORT P

TO LEFTDECK CONTROL VALVE

TO DECK LIFT CONTROL VALVE

TO FRONTDECK CONTROL VALVE

FOR

TO FLUSHVALVE

PORT P1

REV

RESERVOIR

TO HYDRAULIC

TO FILTER

MANIFOLD PORT P

PORT CD1

TO FILTER MANIFOLD

Figure 22

The traction circuitcharge pressure testshould be performed to make sure that the traction charge circuit is functioning correctly.

CHG

TO OIL

FILTER

PRESSURE

GAUGE

TO FRONT

WHEEL MOTORS

TO CH PORTS OF

TRACTION CONTROLAND

4WD CONTROLVALVES

Groundsmaster 5900/5910Hydraulic System Page 4 -- 40

Toro 5910, 5900 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

General Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

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

General Information

Operator’s Manual

Engine Identification

Engine Electronic Control Module (ECM)

Stopping the Engine

Fuel Injection System

Engine Specifications

Engine Fastener Torque Specifications

Adjustments

Valve Clearance

Service and Repairs

Air Filter System

Exhaust System

Turbocharger

Fuel Tank

Radiator

Alternator

Starter Motor

Engine Breather System

Thermostat

Water Pump

Front Cover

Oil Pan

Engine

Flywheel Coupling Assembly

Specifications

General Information

Traction Unit Operator’s Manual

Check Hydraulic Fluid

Relieving Hydraulic System Pressure

Towing Traction Unit

Traction Circuit Component Failure

Hydraulic Hoses

Hydraulic Schematic

Hydraulic Flow Diagrams

Special Tools

Hydraulic Pressure Test Kit

Hydraulic Test Fitting Kit

Measuring Container

Rear Wheel Hub Puller

Troubleshooting

General Hydraulic Problems

Traction Problems

PTO Problems

Steering Circuit Problems

Lift/Lower Problems

Testing