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.
R
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
Table Of Contents
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-
AL
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
TM
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
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
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)
2
Figure 1
1. Frame jacking point 2. Front tire
2
Figure 2
1. Rear axle jacking point 2. Rear tire
1
Safety
1
2
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: 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: 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
80 + 10 ft--lb 108 + 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.
2
3
1
Figure 1
1. Crankshaft pulley
2. Tone wheel cutout
2
3. TDC indicator
3
1
4
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
8
6
7
1. #1 intake
2. #1 exhaust
3. #2 intake
4. #2 exhaust
Figure 2
5
Figure 3
3. Rocker arm
4. Valve clearance
4
3
5. #3 intake
6. #3 exhaust
7. #4 intake
8. #4 exhaust
2
1
Groundsmaster 5900/5910 Page 3 -- 7 Diesel Engine
Service and Repairs
Air Filter System
5
6
7
8
9
12 to 15 in--lb
(1.4 to 1.6 N--m)
4
3
11
45 to 55 in--lb
(5.1 to 6.2 N--m)
45 to 55 in--lb
(5.1 to 6.2 N--m)
2
1
12
10
24
50 to 70 in--lb
(5.7 to 7.9 N--m)
3
19
23
1
21
20
19
22
17
15
13
14
16
19
25
21
19
18
26
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.
5
6
1. Radiator
2. LH cooler bracket
3. Charge air cooler
4
1
Figure 5
3
2
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
1. Air cleaner housing
2. Safety filter
3. Filter element
2
4
3
5
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
1
4
airbox for proper sealing with hood.
2
3. Lower and secure hood.
3
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)
1
2
3
4
3
RIGHT
FRONT
1. Exhaust clamp
2. Exhaust tube
3. Muffler clamp (2 used)
7
6
5
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
4
1
2
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)
3
1. Exhaust manifold
2. Manifold gasket
4
8
6
Figure 9
1
2
Figure 10
3. Engine
4. Flange screw (8 used)
5
3
7
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)
15
16
17
14
18
13
18 ft--lb
2
4
1
5
6
7
3
(24 N--m)
FRONT
RIGHT
18 ft--lb
(24 N--m)
9
10
8
11
12
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
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