Toro Reelmaster 5410, 5510, 5610 Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Reelmaster 5410, 5510, 5610

Title Page
Revision History
Reader Comments
NOTES:
Preface
Product Variations
Service Procedure Icons

Chapter 1 : Safety

Safety Instructions
Supervisor’s Responsibilities
Before Operating the Machine
While Operating the Machine
Maintenance and Service
Jacking Instructions
Raising the Front of the Machine
Raising the Rear of the Machine
Safety and Instructional Decals

Chapter 2 : Specifications and Maintenance

Specifications
Decimal and Millimeter Equivalents
U.S. to Metric Conversions
Torque Specifications
Identifying the Fastener
Fasteners with a Locking Feature
Calculating the Torque Values When Using a Drive-Adapter Wrench
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
Shop Supplies
Special Tools

Chapter 3 : Kubota Diesel Engine

1 Specifications
Kubota Diesel Engine
General Information
Operator’s Manuals
Kubota Workshop Manual
Shutting off the Engine (Reelmaster 5610)
Adjustments
Adjusting the Throttle Control
Service and Repairs
Air Cleaner Assembly
Exhaust System
Fuel System
Radiator Assembly
Engine
Kubota Workshop Manual, Diesel Engine, 05-E3B Series

Chapter 4 : Yanmar Diesel Engine

1 Specifications
Yanmar Diesel Engine
General Information
Traction Unit Operator’s Manual
Yanmar Engine Service and Troubleshooting Manuals
Engine Electronic Control Unit (ECU)
Yanmar Engine
Diesel Particulate Filter (DPF)
Shutting Off the Engine (Reelmaster 5610-D)
Service and Repairs
Air Cleaner System
Exhaust System
Radiator
Fuel System
Engine
Yanmar TNV (Tier 4) Series Service Repair Manual
Yanmar TNV (Tier 4) Series Troubleshooting Manual

Chapter 5 : Kubota Gasoline Engine

1 Specifications
Kubota Gasoline Engine
General Information
Traction Unit Operator’s Manual
Kubota Workshop and Diagnosis Manuals
Kubota Gasoline Engine
Engine Electronic Control Unit (ECU)
Service and Repairs
Air Cleaner Assembly
Exhaust System
Fuel System
Fuel Evaporative Control System
Radiator and Oil Cooler Assembly
Engine
Kubota Workshop Manual, WG1605-G-E3
Kubota Diagnosis Manual, ECM System, WG1605-G-E3

Chapter 6 : Hydraulic System

1 Specifications
Hydraulic System
General Information
Checking the Hydraulic Fluid
Pushing or Towing the Traction Unit
Releasing Pressure from the Hydraulic System
Traction Circuit Component Failure
Hydraulic Hoses
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port)
Hydraulic Schematics
Hydraulic Flow Diagrams (5410, 5410-D, 5510, 5510-D, 5610)
Traction Circuit (5410, 5410-D, 5510, 5510-D, 5610)
Mow Circuit (5410, 5410-D, 5510, 5510-D, 5610)
Lift Circuit (5410, 5410-D, 5510, 5510-D, 5610)
Steering Circuit (5410, 5410-D, 5510, 5510-D, 5610)
Hydraulic Flow Diagrams (5610-D)
Traction Circuit (5610-D)
Mow Circuit (5610-D)
Lift Circuit (5610-D)
Steering Circuit (5610-D)
Special Tools
Hydraulic Pressure Testing Kit
15 GPM Hydraulic Tester Kit (Pressure and Flow)
40 GPM Hydraulic Tester (Pressure and Flow)
Hydraulic Hose Kit
O-Ring Kit
Hydraulic Test Fitting Kit
High Flow Hydraulic Filter Kit
Spindle Plug
Wheel Hub Puller
Measuring Container
Remote Starter Switch
Troubleshooting
Testing the Hydraulic System
Traction Circuit Relief Valve (R3) and (R4) Pressure Test (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Traction Circuit Charge Pressure Test (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Gear Pump (P3) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Front Wheel Motor Efficiency Test (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Relief Valve (R1) and (R2) Pressure Test (Cutting (Mow) Circuit) (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Gear Pump (P1) and (P2) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Cutting Reel Motor Efficiency Test (Using Tester with Flow Meter and Pressure Gauge) (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Cutting Reel Motor Cross-Over Relief Pressure Test (5510, 5510-G, 5510-D, 5610)
Lift Relief Valve (SVRV) Pressure Test (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Gear Pump (P4) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Lift Cylinder Internal Leakage Test (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Steering Relief Valve (R10) Pressure Test (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Steering Cylinder Internal Leakage Test (5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610)
Testing the Traction Circuit–Charge Pressure (5610-D)
Testing the Traction Circuit–Wheel Motor Efficiency (5610-D)
Testing the Traction Circuit–Piston Pump, Hydrostat Flow and Relief Pressure (5610-D)
Testing the Mow Circuit–Circuit Pressure (5610-D)
Testing the Mow Circuit–Reel Motor Efficiency, Case Drain (5610-D)
Testing the Mow Circuit–Reel Motor Cross−Over Relief Pressure (5610-D)
Testing the Mow Circuit–Relief Valve (RV1) and (RV2) Pressure (5610-D)
Testing the Mow Circuit–Gear Pump (P1) and (P2) Flow (5610-D)
Testing the Steering Circuit–Steering Control Valve, Relief Valve (R10) Pressure, and Steering Cylinder (5610-D)
Testing the Steering Circuit–Gear Pump (P3) Flow (5610-D)
Testing the lift Circuit–Relief Valve (SVRV) Pressure (5610-D)
Testing the Lift Circuit–Lift Cylinder Internal Leakage (5610-D)
Testing the Lift Circuit–Gear Pump (P4) Flow (5610-D)
Service and Repairs
General Precautions for Removing and Installing the Hydraulic System Components
Checking the Hydraulic Lines and Hoses
Priming the Hydraulic Pumps
Flushing the Hydraulic System
Filtering the Closed-Loop Traction Circuit
Charging the Hydraulic System
Hydraulic Tank
Piston (Traction) Pump Control Assembly
Hydraulic Pump Driveshaft
Hydraulic Pump Assembly
Servicing the Piston (Traction) Pump
Servicing the Gear Pump
Front Wheel Motors
Servicing the Front Wheel Motor
Rear Wheel Motors (Machine with CrossTrax AWD)
Servicing the Rear Wheel Motor (Machine with CrossTrax AWD)
CrossTrax™ AWD Control Manifold Assembly
Servicing the CrossTrax AWD Control Manifold Assembly
Mow Control Manifold Assembly
Servicing the Mow Control Manifold Assembly
Lift Control Manifold
Servicing the Lift Control Manifold
Servicing a Control Manifold Cartridge Valve
Cutting Reel Motor
Servicing the Cutting Reel Motor (Casappa)
Servicing the Cutting Reel Motor (Sauer-Danfoss)
Lift Cylinder
Servicing the Lift Cylinder
Steering Control Valve
Servicing the Steering Control Valve
Steering Cylinder
Servicing the Steering Cylinder
Oil Cooler (5410, 5510, 5610)
Radiator and Oil Cooler Assembly (5410-G, 5410-D, 5510-G, 5510-D, 5610-D)
Danfoss LPV Closed Circuit Axial Piston Pump Service Repair Manual
Eaton Delta Motors Parts and Repair Manual
Parker Torqmotor Service Procedure (TC, TB, TE, TJ, TF, TG, TH, and TL Series)
Danfoss Steering Unit Type OSPM Service Repair Manual

Chapter 7 : Electrical System

General Information
Electrical Schematic and Wire Harness Drawings, Diagrams
Toro Electronic Controller (TEC)
CAN-bus Communications
Yanmar Engine Electronic Control Unit (ECU)
Yanmar Engine Electrical Components
Kubota Gasoline Engine Electronic Control Unit (ECU)
Kubota Gasoline Engine Electrical Components
Special Tools
Multimeter
Terminal Protector
Battery Hydrometer
Dielectric Gel
InfoCenter Display
Splash Screen
Main Information Screen
Operator Advisory Screen
Main Menu Screen
Faults Screen
Service Screen
Diagnostics Screen
Settings Screen
About Screen
Troubleshooting
Operator Advisories
Using the InfoCenter Display for Troubleshooting
Machine Faults
Engine Faults
General Run and Transport Problems
Electrical System Quick Checks
Testing the Battery (Open Circuit Test)
Testing the Charging System
Testing the Glow Plug System (Machines with Kubota Diesel Engine)
Checking the Operation of the Interlock Switches
Adjustments
Traction Neutral Switch
Parking Brake Switch
Cutting Unit Down Limit Switch
Mow, Transport Switch
Testing the Electrical Components
Fusible Link Harness (Machines with Kubota or Yanmar Diesel Engine)
System Fuses
Engine Fuses (Gasoline Engine)
Toro Electronic Controller (TEC)
Key Switch
Reel Engage Switch
Engine Speed Switch (If Equipped)
Lower, Raise Joystick Switches
Headlight Switch
Seat Switch
Cutting Unit Down Limit Switch
Traction Neutral Switch
Parking Brake Switch
Mow, Transport Switch
Backlap Switches
Oil Pressure Switch (Machine with Kubota Engine)
Relays with 4 Terminals
Relays with 5 Terminals (Diesel Engine)
Engine Relays with 5 Terminals (Gasoline Engine)
Hydraulic Solenoid Valve Coils
Temperature Sender (Machine with Kubota Diesel Engine)
Engine Run Solenoid (Machine with Kubota Diesel Engine)
Fuel Sender (Diesel Engine)
Fuel Sender (Gasoline Engine)
Fuel Pump (Machine with Yanmar Diesel Engine)
Fuel Pump (Machine with Kubota Diesel Engine)
Fuel Pump (Machine with Kubota Gasoline Engine)
CAN-bus Terminator Resistor
Resistor Assembly (Machine with Yanmar Diesel or Kubota Gasoline Engine)
Diode Assemblies (Diesel Engine)
Service and Repairs
Hydraulic Solenoid Valve Coils
Backlap Switches
Battery Storage
Battery Care
Servicing the Battery

Chapter 8 : Chassis

1 Specifications
Chassis
General Information
Special Tools
Wheel Hub Puller
Service and Repairs
Wheels
Steering Column
Servicing the Brakes
Rear Wheel Bearings (Machines with 2-Wheel Drive)
Rear Axle Motor Housings
Rear Axle
Control Arm
Operator Seat
Mechanical Seat Suspension
Front Lift Arms
Rear Lift Arms
Hood

Chapter 9 : Cutting Unit

1 Specifications
Cutting Unit Specifications
General Information
Special Tools
Aftercut Appearance
Adjustments
Characteristics
Adjusting the Reel Bearing (cutting units with painted side plates)
Leveling the Rear Roller
Service and Repairs
Hydraulic Reel Motor
Backlapping
Bedbar Assembly
Bedknife Replacement and Grinding
Servicing the Bedbar Adjuster
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 the Reel for Grinding
Front Roller
Rear Roller
Servicing the Roller
Rear Roller Brush – Optional (cutting units with painted side plates)
Rear Roller Brush – Optional (cutting units with aluminum side plates)

Chapter 10 : Belt Driven Groomer (Optional)

General Information
Grooming Performance
Groomer Reel Mechanical Problems
Adjustments
Adjusting the Height, Depth of the Groomer
Service and Repairs
Replacing the Groomer Drive Belt
Groomer Plate Assembly
Groomer Reel
Servicing the Groomer Reel
Groomer Pivot Hub
Height Adjuster Assembly
Servicing the Grooming Brush (Optional)

Chapter 11 : Universal Groomer (Optional)

General Information
Factors Affecting Grooming
Troubleshooting
Groomer Reel Mechanical Problems
Service and Repairs
Gear Box Assembly
Idler Assembly
Groomer Reel
Servicing the Groomer Reel
Height Adjuster Assembly
Servicing the Grooming Brush (Optional)
Appendix A: Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic-5410, 5410-D
Hydraulic Schematic-5510, 5510-D, 5610
Hydraulic Schematic-5610-D
Electrical Schematic-5410, 5510, 5610 (Models with Kubota Diesel Engine) (Serial Numbers Below 403430000)
Electrical Schematic-5410, 5510, 5610 (Models with Kubota Diesel Engine) (Serial Numbers Above 403430000)
Electrical Schematic-5410-D, 5510-D, 5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Below 403430000)
Electrical Schematic-5410-D, 5510-D, 5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Above 403430000)
NO TITLE
Electrical Schematic-5410-G, 5510-G (Models with Kubota Gasoline Engine)
Wire Harness Drawing-Main (Serial Number Below 403430000)
Wire Harness Drawing-Main (Serial Number Below 403430000)
Wire Harness Drawing-Main (Serial Numbers 403430001 to 405680000)
Wire Harness Drawing-Main (Serial Numbers 403430001 to 405680000)
Wire Harness Drawing-Main (Serial Numbers Above 405680001)
Wire Harness Drawing-Main (Serial Numbers Above 405680001)
Wire Harness Drawing-Seat
Wire Harness Drawing-Seat
Engine Wire Harness Drawing-5410, 5510, 5610 (Models with Kubota Diesel Engine)
Engine Wire Harness Diagram-5410, 5510, 5610 (Models with Kubota Diesel Engine)
Engine Wire Harness Drawing-5410-D, 5510-D (Models 03672 and 03687 with Yanmar Diesel Engine)
Engine Wire Harness Diagram-5410-D, 5510-D (Models 03672 and 03687 with Yanmar Diesel Engine)
Engine Wire Harness Drawing-5410-D, 5510-D, 5610-D (Models 03606, 03607, and 03679)
Engine Wire Harness Diagram-5410-D, 5510-D, 5610-D (Models 03606, 03607, and 03679)
Engine Wire Harness Drawing-5410-G, 5510-G (Models with Kubota Gasoline Engine)
Engine Wire Harness Diagram-5410-G, 5510-G (Models with Kubota Gasoline Engine)