Toro Groundsmaster 5900 User manual

FormNo.3429-577RevA

ContactorKit

Groundsmaster®5900or5910RotaryMower

ModelNo.139-1030

InstallationInstructions

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescriptionQty.Use

1Nopartsrequired–Preparethemachine.

2Nopartsrequired–Disconnectthebattery.

3Nopartsrequired–Removethesidepanels.

4Nopartsrequired–Removethe28-Vsolenoid.

Contactor1

Contactormount1

Cable1

Nut(1/4inch)4

Nut(5/16inch)2

Flangebolt2

Carriagebolt2

Installthecontactor.

Wirecap1

Wirelabel1

Vinylcap1

Nut(M5)1

Cabletie1

RemovetheI-terminalwirefromthe

alternator.

7Moldedcap1Removethediode.

8Fuse(60A)1Installthe60-Afuse.

9Fusedecal(PartNo.139-1031)1Installthedecal.

10Nopartsrequired–Connectthebattery.

11Nopartsrequired–Installthesidepanelsandclosethe

hood.

12Nopartsrequired–Verifythatthe28-Vsystemandcab

power(ifequipped)arefunctioning.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.T oro.com.OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved*3429-577*A

PreparingtheMachine

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Lowerthecuttingunits.

4.Shutofftheengineandremovethekey.

DisconnectingtheBattery

NoPartsRequired

Procedure

1.Openthehood(Figure1).

g251777

Figure1

2.RotatethebatterydisconnectswitchtotheOFF

position,refertotheOperator’sManualforyour

machine.

RemovingtheSidePanels

NoPartsRequired

Procedure

1.Loosenthe2knobsthatsecuretheleftandright

sidepanelstothemachine(Figure2).

g251780

Figure2

Rightsidepanelshown

1.Sidepanel2.Knobs

2.Removethesidepanelsfromthemachine

(Figure2).

Removingthe28-V

Solenoid

NoPartsRequired

Procedure

Note:Yourmachinemayhaveupto3fusesonthe

fusebrackettowardstherearendofthemachine.For

thisprocedure,removethe28-Vsolenoidunderthe

fuseholdershowninFigure3.

g285045

Figure3

1.Openthefuse-holdercover(Figure4).

2.Removethe2ringterminalsfromtheleftpostof

thefuseholder(Figure4).

g282709

Figure4

1.Fusecover4.Nut

2.Ringterminal—28V+FUSE5.Wireconnectors(labeled

COIL+[28VMASTER

CONTACTOR]andCOIL-

[28VMASTERCONTACTOR])

3.Ringterminal—battery

cable

3.Removethewireconnectors(labeledCOIL+[28V

MASTERCONTACTOR]andCOIL-[28VMASTER

CONTACTOR])fromthesolenoid(Figure4).

4.Removetheredinsulatorandringterminal

(labeledSOLENOIDLINEOUT[28VMASTER

CONTACTOR])fromthesolenoid(Figure5).

g282710

Figure5

1.Nut3.Redinsulator

2.Ringterminal—SOLENOID

LINEOUT[28VMASTER

CONTACTOR]

5.Removeanddiscardthejumperstrapand

insulator(Figure6).

g282711

Figure6

1.Nuts3.Bolt

2.Jumperstrapandinsulator4.Solenoid

6.Removetheboltsandnutsthatsecurethe

solenoidtothebracket(Figure6).

7.Removeanddiscardthesolenoidfromthe

bracket(Figure6).

InstallingtheContactor

Partsneededforthisprocedure:

1Contactor

1Contactormount

1Cable

4Nut(1/4inch)

2Nut(5/16inch)

2Flangebolt

2Carriagebolt

Procedure

1.Use2carriageboltsand2nuts(1/4inch)to

securethecontactormounttothebracket

(Figure7).

g282536

Figure7

1.Carriagebolt3.Nut(1/4inch)

2.Contactormount

2.Use2angeboltsand2nuts(1/4inch)tosecure

thecontactortothecontactormount(Figure8).

g282537

Figure8

1.Contactor3.Nut(1/4inch)

2.Flangebolt

3.Useanut(5/16inch)tosecuretheendofthe

cablewiththebootattachedtothecontactor

(Figure9).

g282535

Figure9

1.Nut(5/16inch)3.Nut(5/16inch)

2.Cable

4.Useanut(5/16inch)tosecuretheotherend

ofthecabletotherightpostofthefuseholder

(Figure9).

5.InstallthewireconnectorlabeledCOIL+[28V

MASTERCONTACTOR]totheleftpostatthetopof

thecontactor(Figure10).

g282538

Figure10

1.Ringterminal—28V+FUSE

andringterminal—battery

cable

3.Wireconnector—COIL+

[28VMASTERCONTACTOR]

2.Nut4.Wireconnector—COIL-

[28VMASTERCONTACTOR]

6.InstallthewireconnectorlabeledCOIL-[28V

MASTERCONTACTOR]totherightpostatthetop

ofthecontactor(Figure10).

7.Assembletheringterminallabeled28V+FUSE

ofthemachinewireharnessontotheleftpostof

thefuseholder(Figure10).

8.Assembletheringterminalofthebatterycable

ontotheleftpostofthefuseholderandusethe

previouslyremovednuttosecuretheterminals

tothepost(Figure10).

9.Torquethenutsthatsecuretheconnectorsto

thefuse-holderpoststo14N∙m(10ft-lbs).

10.Installtheredinsulatorandringterminallabeled

SOLENOIDLINEOUT[28VMASTERCONTACTOR]

(Figure11)totheleftpostofthecontactor.

g282534

Figure11

1.Fuse-holdercover2.Ringterminal(SOLENOID

LINEOUT[28VMASTER

CONTACTOR])

11.Torquethenutsthatsecuretheconnectorsto

thecontactorpoststo5to6N∙m(40to50in-lb).

12.Closethecoverofthefuse-holder(Figure11)

untilthecoversnapsclosedsecurely.

RemovingtheI-Terminal

WirefromtheAlternator

Partsneededforthisprocedure:

1Wirecap

1Wirelabel

1Vinylcap

1Nut(M5)

1Cabletie

Procedure

1.LocateandremovetheI-terminalwire(green

wire)onthealternator(Figure12).

g283948

Figure12

1.Nut4.Alternatorpost—Remote

senseterminal

2.Ringterminal(I-terminal

wire)

5.Alternatorpost—Iterminal

3.I-terminalwire(greenwire)6.Alternatorpost—R

terminal

2.Cutoffanddiscardtheringterminalfromthe

wire(Figure12).

3.Installthewirecapontheendofthecutgreen

wireandcrimp(Figure13).

g284893

Figure13

1.Vinylcap4.Alternatorpost—Iterminal

2.Wirecap5.Nut(M5)

3.Wirelabel

4.Installthewirelabelontothewire(Figure13).

5.Useacabletietosecurethewiretothewire

harness.

6.Installanut(M5)ushwiththetopofthe

alternatorpost(Figure13).

7.Installavinylcapoverthealternatorpost(Figure

13).

Note:Thenut(M5)helpstosecurethevinyl

capoverthepost.

RemovingtheDiode

Partsneededforthisprocedure:

1Moldedcap

Procedure

Formachineswithaserialnumberof403444961

orbelow:

1.Locatethefuseblockontherightsideofthe

machine(Figure14).

g283947

Figure14

1.Diode3.Fuseblock

2.Fuse-blockcover

2.Accessthefuseblockbypullingthefuseblock

downfromthecover(Figure14).

3.Removethediodefromthefuseblock(Figure

14)anddiscardit.

4.Installthefuseblockintothecover.

Formachineswithaserialnumberof403444962

orabove:

1.Removethemoldeddiodefromtheconnector

labeledP103ontherightsideofthemachine

(Figure15).

g285043

Figure15

1.Diode3.Moldedplug

2.Connector—P103

2.Discardthediode.

3.Installthemoldedplugintotheconnector

(Figure15).

Installingthe60-AFuse

Partsneededforthisprocedure:

1Fuse(60A)

Procedure

Performthisprocedureonlyifyourmachineis

equippedwithacaborcabpowersupply(i.e.,

2-PostROPSExtensionKitorPowerHarnessKit).

Figure16illustratesthefusesasseenfromtherearof

themachine.Forthisprocedure,replacetheexisting

cabpowerfuse(100A)withthe60Afusefromthiskit.

g285820

Figure16

1.24-V-system-powerfuse

(100A)

3.Platform-powerfuse(60

2.Cab-powerfuse(100A)

1.Openthecoverofthecabpowerfuse(Figure

17).

2.Removethenutsfromthepostsofthefuse

holder(Figure17).

g285335

Figure17

1.Ringterminal(yellow)3.Fuse

2.Nut4.Post(fuseholder)

3.Removetheringterminalfortheyellowwireof

themachinewireharnessfromtheleftpostof

thefuseholder(Figure17).

4.Removethefuse(100A)fromthefuseholder

(Figure17)anddiscardit.

5.Installthefuse(60A)tothefuseholder(Figure

17).

6.Assembletheringterminalfortheyellowwireof

themachinewireharnessontotheleftpostof

thefuseholder(Figure17).

7.Assemblethe2nutsontotheleftandrightposts

ofthefuse-holder(Figure17).

8.Torquethenutsto14N∙m(10ft-lbs).

9.Closethecoverofthefuse-holderuntilthecover

snapsclosedsecurely(Figure18).

g285334

Figure18

1.Cover(fuseholder)

InstallingtheDecal

Partsneededforthisprocedure:

1Fusedecal(PartNo.139-1031)

Procedure

1.Removeanydustanddebrisfromtheexisting

fuse-decalsurface;refertoFigure19forthe

decallocation.

g282717

Figure19

1.Contactor2.Decallocation

2.Installthefusedecal(PartNo.139-1031)over

theexistingfusedecal(Figure19).

ConnectingtheBattery

NoPartsRequired

Procedure

RotatethebatterydisconnectswitchtotheON

position;refertotheOperator’sManualforyour

machine.

InstallingtheSidePanels

andClosingtheHood

NoPartsRequired

Procedure

1.Aligntheholesinsidepanelswiththeholes

inthepanelsupportsofthemachine;referto

Figure2in3RemovingtheSidePanels(page

2).

2.Securethesidepanelstothemachinewiththe

2knobsthatyouremovedin3Removingthe

SidePanels(page2).

3.Closethehoodandsecureit.

Verifythe28-VSystemand

Cab-PowerFunction

NoPartsRequired

Procedure

Important:Ensurethatallwiringisroutedaway

fromanyhot,sharp,ormovingpartsonthe

machine.

1.Ensurethatthemachinesoftwareisupdatedto

thelatestversion(i.e.,RevKorhigher).

2.UsetheInfoCentertoconrmthatthe28-V

systemandcabpower(ifequipped)are

charging.

Note:Youcandeterminethatthesesystems

arechargingbytogglingtothevoltageindicators

inthestartupscreen;refertothemachine

SoftwareGuide.

3.Verifythattheradiatorandhydrauliccoolerfans

arefunctioningbyperformingthefollowingsteps

torunthefandemointheInfoCenter:

A.FromtheMainMenuscreen,selectthe

Serviceoption.

B.FromtheServicescreen,selecttheFan

Demooption.

C.FollowtheInfoCenterpromptstoperform

thefandemo.

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