Toro Reelmaster 5410, 5510, 5610 Service Repair Manual

Table of Content – Reelmaster 5410, 5510, 5610

• Title Page
• Revision History
• Reader Comments
• NOTES:
• Preface
• Product Variations
• Service Procedure Icons
• Table of Contents
• 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)