Toro Reelmaster 5210, 5410, 5510, 5610 Series Service Repair Manual

Table of Content – Reelmaster 5210, 5410, 5510, 5610 Series

Title Page
Revision History
Reader Comments
Preface
1 – Safety
Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Maintenance
Equivalents and Conversions
Torque Specifications
3 – Kubota Diesel Engine
General Information
Traction Unit Operator’s Manual
Stopping the Engine (Reelmaster 5610)
Specifications: Reelmaster 5210
Specifications: Reelmaster 5410 and 5510
Specifications: Reelmaster 5610
Adjustments
Adjust Throttle Control
Service and Repairs
Fuel System
Air Cleaner
Exhaust System
Radiator
Engine
Kubota 05 E2B Series Workshop Manual (S.N below 280000000)
Kubota 05-E3B Series Workshop Manual (S.N 280000001 and up)
4 – Hydraulic System
Specifications
General Information
Traction Unit Operator’s Manual
Check Hydraulic Fluid
Towing Traction Unit
Hydraulic Hoses
Hydraulic Fitting Installation
Relieving Hydraulic System Pressure
Traction Circuit Component Failure
Hydraulic Schematics
Hydraulic Flow Diagrams
Traction Circuit
Mow Circuit
Lift Circuit – Raise Cutting Units
Lift Circuit – Lower Cutting Units
Steering Circuit
Special Tools
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
Mow Circuit Problems
Lift Circuit Problems
Steering Circuit Problems
Testing
Before Performing Hydraulic Tests
Precautions for Hydraulic Testing
Which Hydraulic Tests Are Necessary?
Traction Circuit Relief Valve (R3) and (R4) Pressure Test
Traction Circuit Charge Pressure Test
Gear Pump (P3) Flow Test
Front Wheel Motor Efficiency Test
Piston (Traction) Pump Flow Test
Relief Valve (R1) and (R2) Pressure Test
Gear Pump (P1) and (P2) Flow Test
Reel Drive Motor Efficiency Test
Reel Drive Motor Cross–Over Relief Pressure Test
Lift Relief Valve (SVRV) Pressure Test
Gear Pump (P4) Flow Test
Lift Cylinder Internal Leakage Test
Steering Relief Valve (R10) Pressure Test
Steering Cylinder Internal Leakage Test
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Flush Hydraulic System
Filtering Closed-Loop Traction Circuit
Hydraulic System Start–up
Hydraulic Reservoir
Hydraulic Pump Drive Shaft
Hydraulic Pump Assembly
Piston (Traction) Pump Service
Gear Pump Service
Front Wheel Motor
Wheel Motor Service (Parker)
Front Wheel Motor Service (Eaton)
Mow Control Manifold
Mow Control Manifold Service
Lift Control Manifold
Lift Control Manifold Service
CrossTrax AWD (Optional Kit) Manifold
CrossTrax AWD (Optional Kit) Manifold Service
Cutting Reel Motor
Cutting Reel Motor Service (Bosch and Sauer-Danfoss)
Cutting Reel Motor Service (Casappa)
Lift Cylinder
Lift Cylinder Service
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Oil Cooler
Danfoss LPV Pump Repair Manual
Danfoss LPV Pump Service Repair Manual
Parker Torqmotor Service Procedure
Eaton Delta Motor Service Procedure
Danfoss OSPM Steering Unit Service Repair Manual
5 – Electrical System
General Information
Electrical Diagrams
Special Tools
Troubleshooting
Diagnostic Light
Diagnostic Display
Electronic Control Module Logic Chart
Starting Problems
General Run and Transport Problems
Cutting Unit Operating Problems
TurfDefender Leak Detector (Optional)
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test
Check Operation of Interlock Switches
Adjustments
Traction Neutral Switch
Parking Brake Switch
Up Limit Switch
Component Testing
Ignition Switch
Indicator Lights
Hour Meter
Temperature Gauge
PTO Switch
Traction Neutral Switch
Seat Switch
Headlight Switch
Parking Brake Switch
Up Limit Switch
Joystick Raise and Lower Switches
Mowith Transport Switch
Backlap Switches
Start Relay
Main Power and Glow Relays
Electronic Control Module (ECM)
CAN-bus Termination Resistors (Machine With Serial Number Above 280000000)
Diode Assembly
Fusible Link Harness
Fuses
Hydraulic Solenoid Valve Coil
Temperature Sender
High Temperature Shutdown Switch
Oil Pressure Switch
Fuel Stop Solenoid
Fuel Pump
Service and Repairs
Battery Storage
Battery Care
Battery Service
Control Arm
Hydraulic Solenoid Valve Coil
Backlap Switches
TurfDefender Leak Detector (Optional)
6 – Chassis
Specifications
General Information
Traction Unit Operator’s Manual
Service and Repairs
Wheels
Steering Column
Brake Service
Rear Wheel Bearings (2 Wheel Drive)
Rear Axle
Rear Axle Service
Operator Seat
Mechanical Seat Suspension
Front Lift Arms
Rear Lift Arms
7 – DPA Cutting Units
Specifications
General Information
Cutting Unit Operator’s Manual
Special Tools
Gauge Bar Assembly
Bedknife Screw Tool
Handle Assembly
Plastic Plug
Cutting Unit Kickstand
Spline Insert Tool
Rear Roller Bearing and Seal Installation Tools
Turf Evaluator Tool
Diameter, Circumference Measuring Tape
Reel Bearing Installation Tool (cutting units with painted side plates)
Cutting Reel Shim
Cutting Performance Paper
Pulley Alignment Tool
Bedknife Top Angle Indicator and Mount
Factors That Can Affect Cutting Performance
Set Up and Adjustments
Characteristics
Reel Bearing Adjustment (cutting units with painted side plates)
Leveling Rear Roller
Service and Repairs
Hydraulic Reel Motor
Backlapping
Bedbar Assembly
Bedknife Replacement and Grinding
Bedbar Adjuster Service
Reel Assembly (cutting units with painted side plates)
Reel Assembly Service (cutting units with painted side plates)
Reel Assembly (cutting units with aluminum side plates)
Reel Assembly Service (cutting units with aluminum side plates)
Preparing Reel for Grinding
Front Roller
Rear Roller
Roller Service (greasable bearings with retaining ring)
Roller Service (greasable bearings with bearing nut)
Rear Roller Brush – Optional (cutting units with painted side plates)
Rear Roller Brush – Optional (cutting units with aluminum side plates)
8 – Belt Driven Groomer (Optional)
Grooming Performance
Troubleshooting
Adjustments
Groomer Height, Depth Adjustment
Service and Repairs
Groomer Drive Belt Replacement
Groomer Plate Assembly
Groomer Reel
Groomer Reel Service
Groomer Pivot Hub
Height Adjuster Assembly
9 – Universal Groomer (Optional)
Grooming Performance
Troubleshooting
Groomer Reel Mechanical Problems
Service and Repairs
Gear Box Assembly
Idler Assembly
Groomer Reel
Groomer Reel Service
Grooming Brush (Optional) Service
Height Adjuster Assembly
10 – Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic – 5210, 5410
Hydraulic Schematic – 5510, 5610
Electrical Schematic (Serial Number Below 310000000)
Electrical Schematic (Serial Number Above 310000000)
Glow Plug Circuits
Crank Circuits
Run (Transport) Circuits
Run (Mow) Circuits
Main Wire Harness Drawing (SN Below 310000000)
Main Wire Harness Diagram (SN Below 310000000)
Main Wire Harness Drawing (SN Above 310000000)
Main Wire Harness Diagram (SN Above 310000000)
Seat Wire Harness Drawing (SN Below 310000000)
Seat Wire Harness Diagram (SN Below 310000000)
Seat Wire Harness Drawing (SN Above 310000000)
Seat Wire Harness Diagram (SN Above 310000000)
Engine Wire Harness Drawing
Engine Wire Harness Diagram
Turf Defender Schematic