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Toro Reelmaster 5510 Series, Service Manual

The Toro Reelmaster 5510 Series is a top-of-the-line turf maintenance machine designed for precision cutting and superior performance. Ensure your equipment stays in top shape with the Service Manual, available for free download from manualshive.com. This comprehensive manual will guide you through proper maintenance and troubleshooting procedures.

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Exhaust System

g229844

Figure 31

1.

Gasket

12.

DPF assembly

23.

Nut (16 each)

2.

Exhaust assembly stay

13.

Pressure sensor

24.

Bolt (4 each)

3.

Clip band

14.

Sensor bracket

25.

Pipe joint bolt (2 each)

4.

DPF silencer

15.

DPF gasket (2 each)

26.

Exhaust pressure pipe (DPF inlet)

5.

Bolt (2 each)

16.

Bolt (16 each)

27.

Sensor gasket (4 each)

6.

Engine flywheel housing

17.

DPF lifter

28.

Exhaust pressure pipe (DPF outlet)

7.

DOC temp sensor (inlet)

18.

DPF stiffener (5 each)

29.

Exhaust hose

8.

DOC temp sensor (outlet)

19.

DPF stiffener

30.

Hose clip (2 each)

9.

Flange nut (4 each)

20.

DPF stiffener

31.

Hose

10.

DOC assembly

21.

DPF stiffener/lifter

32.

Bolt (2 each)

11.

Bolt (2 each)

22.

Bolt (2 each)

33.

Hose clip (2 each)

Reelmaster

®

5410/5510/5610 Series

Page 4–15

Yanmar Diesel Engine: Service and Repairs

15216SL Rev C

Summary of Contents for Reelmaster 5510 Series

Page 1: ...SL Rev C Reelmaster 5410 5510 5610 Series Models with InfoCenter Display 2019 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Ri...

Page 2: ...issue A 01 2018 Incorporated 5610 D Model 03679 B 04 2018 Revised bedknife installation procedure and painted aluminum side plate cutting unit information C 03 2019 Updated Chassis chapter Revision Hi...

Page 3: ...encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Mana...

Page 4: ...NOTES NOTES Page 4 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 5: ...ww toro com The Toro Company reserves the right to change the product specifications or this publication without notice DANGER This safety symbol means danger When you see this symbol carefully read t...

Page 6: ...ent reel motors without cross over relief valves 5510 03676 Kubota non Tier4 compliant diesel engine 5510 G 03609 03689 Kubota gasoline engine 5510 D 03607 03687 Yanmar Tier4 compliant engine 2 wheel...

Page 7: ...component orientation that may not be obvious Critical Torque This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard Torque Tables re...

Page 8: ...n 6 6 Hydraulic Schematics 6 17 Hydraulic Flow Diagrams 5410 5410 D 5510 5510 D 5610 6 20 Hydraulic Flow Diagrams 5610 D 6 32 Special Tools 6 44 Troubleshooting 6 50 Testing the Hydraulic System 6 56...

Page 9: ...gine Wire Harness Drawing 5410 D 5510 D Models 03672 and 03687 with Yanmar Diesel Engine A 16 Engine Wire Harness Diagram 5410 D 5510 D Models 03672 and 03687 with Yanmar Diesel Engine A 17 Engine Wir...

Page 10: ...Preface Page 10 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 11: ...2 Before Operating the Machine 1 2 While Operating the Machine 1 3 Maintenance and Service 1 4 Jacking Instructions 1 6 Raising the Front of the Machine 1 6 Raising the Rear of the Machine 1 7 Safety...

Page 12: ...ine Review and understand the contents of the Operator s Manuals and Operator s Training DVD before starting and operating the machine Become familiar with the controls and know how to stop the machin...

Page 13: ...ine release the parking brake and keep foot off the traction pedal Ensure that the machine does not move Note If machine movement is evident the traction pedal linkage is adjusted incorrectly therefor...

Page 14: ...ment keep your hands feet clothing and other parts of the body away from the cutting decks and other moving parts Keep bystanders away Do not overspeed the engine by changing the engine governor setti...

Page 15: ...gine coolant filters battery in an environmentally safe manner Follow all local codes and regulations when recycling or disposing of waste At the time of manufacture the machine conformed to the safet...

Page 16: ...of the machine Always block the wheels with chocks Use appropriate jack stands to support the raised machine Do not use the cutting deck or implement as a jacking point Raising the Front of the Machi...

Page 17: ...of the machine off the ground 3 Position the jack stands under the frame to support the machine Figure 3 Safety and Instructional Decals Numerous safety and instruction decals are affixed to the tract...

Page 18: ...Safety Safety and Instructional Decals Page 1 8 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 19: ...Locking Feature 2 5 Calculating the Torque Values When Using a Drive Adapter Wrench 2 6 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 7 Standard Torque for Dry Zinc Plated and...

Page 20: ...1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625...

Page 21: ...s Decimals mm Fractions Decimals mm 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 inch 0 001 inch 0 0254 mm Reelmaster 5410 5510 5610 Series Page 2 3 Specif...

Page 22: ...Feet Cubic Meters 0 028 Volume Cubic Inches Cubic Centimeters 16 39 Tons Short Metric Tons 0 908 Pounds Kilograms 0 454 Weight Ounces Avdp Grams 28 349 Pounds Sq In Kilopascal 6 895 Pressure Pounds S...

Page 23: ...he lubricated fasteners to achieve the similar stress as a dry fastener The torque values must be reduced when the fastener is threaded into the aluminum or brass The specific torque value should be d...

Page 24: ...wrench 3 Torque wrench 2 Effective length of torque wrench 4 Effective length of torque wrench drive adapter wrench Using a drive adapter wrench e g crowfoot wrench in any position other than 90 and 2...

Page 25: ...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 1...

Page 26: ...X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note Reduce the torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a l...

Page 27: ...14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Sc...

Page 28: ...installation Most thread locking compounds allow the fastener to be removed with standard tools once cured High strength thread locking compounds may require applying heat to the fastener and the sur...

Page 29: ...nd previously used gaskets or gasket compounds SILICONE SEALANT Designed for a broad variety of sealing and bonding requirements silicone sealants are usually room temperature vulcanizing RTV which fo...

Page 30: ...ts for flow and pressure capacities The tester flow measurement maximum is 57 LPM 15 GPM This tester includes the following Inlet Hose This hose connects the system circuit to the inlet side of the hy...

Page 31: ...ge rated at 20 to 150 LPM 4 to 40 GPM Note This tester does not include any hydraulic hoses or fittings refer to Hydraulic Hose Kit Toro Part No TOR6007 and Hydraulic Test Fitting Kit Tor Part No TOR4...

Page 32: ...11 16 16 TOR4079 18 8 ORFS 13 16 16 TOR4079 19 CAP 2 each 10 ORFS 1 14 TOR4079 20 6 ORFS 11 16 16 to 8 SAE ORB 3 4 16 TOR4079 8 8 ORFS 13 16 16 to 8 SAE ORB 3 4 16 TOR4079 9 UNION 1 each 10 ORFS 1 14...

Page 33: ...t page 2 13 Note The replacement filter element is Toro Part No TOR6012 The filter element canister tightening torque is 34 N m 25 ft lb Remote Starter Switch After flushing the hydraulic system or re...

Page 34: ...s current is not allowed through the meter This excess current can damage the circuits that are not designed to carry it Battery Terminal Protector Toro Part No 107 0392 Use this aerosol spray on the...

Page 35: ...ting off the Engine Reelmaster 5610 3 5 Adjustments 3 6 Adjusting the Throttle Control 3 6 Service and Repairs 3 8 Air Cleaner Assembly 3 8 Exhaust System 3 11 Fuel System 3 14 Radiator Assembly 3 17...

Page 36: ...fer to the Traction Unit Operator s Manual for additional fuel information Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle DNOPD Fuel Tank Capacity 53 L 14 US gallons Governor...

Page 37: ...Displacement 1 498 cm3 91 4 in3 Firing Order 1 gear case end 3 4 flywheel end 2 Fuel Diesel or Biodiesel up to B20 Fuel with Low or Ultra Low Sulfur Content Fuel Injection Pump Bosch MD Type Mini Fuel...

Page 38: ...2 L 5 5 US qt with Filter Cooling System Capacity including reserve tank 9 5 L 10 US qt Starter 12 VDC 1 2 KW Alternator Regulator 12 VDC 40 A Dry Weight approximate 114 kg 251 lb Kubota Diesel Engin...

Page 39: ...maintenance and maintenance intervals for the Kubota diesel engine that powers your Reelmaster machine The Kubota Operator s Manual includes information specific to the engine used in your Reelmaster...

Page 40: ...4 Throttle cable clamp g229070 Figure 10 1 Speed control lever 2 High speed screw 3 Cable swivel position Proper throttle operation is dependent upon proper adjustment of throttle control Ensure that...

Page 41: ...eed control lever should be contacting the high speed screw when the throttle control lever is in the FAST position 3 If necessary throttle control can be adjusted by loosening cable clamp screw and r...

Page 42: ...ounting band 8 Air cleaner inlet hose 14 Bolt 2 each 3 Hex nut 9 Hose clamp 4 each 15 Air cleaner mount bracket 4 Shoulder bolt 10 Air cleaner hose 16 Flange head screw 3 each 5 Spring 11 Flange nut 7...

Page 43: ...cleaner assembly Figure 12 Removing the Air Cleaner Assembly 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the key switch Raise and suppor...

Page 44: ...pter and indicator to housing Install adapter so that grooves in adapter hex and adapter filter element are installed toward service indicator Figure 13 Torque the indicator to 1 4 to 1 6 N m 12 to 15...

Page 45: ...uffler 7 Lock washer 14 Bolt 2 each Note Reelmaster 5010 series machines with a Kubota diesel engine have very similar exhaust systems Reelmaster 5410 and 5510 machines use the same exhaust system Fig...

Page 46: ...gure 15 Discard exhaust gasket if it is removed Installing the Exhaust System Note Ensure that all exhaust system flanges and sealing surfaces are free of debris or damage that may prevent a tight sea...

Page 47: ...p to secure exhaust header to muffler inlet Finally tighten fasteners that secure muffler outlet to brackets g229076 Figure 16 1 Right frame rail 2 Screw 2 each 3 Muffler guard D Adjust muffler guard...

Page 48: ...diesel fuel is flammable use caution when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running when engine is hot or when machine is in an enc...

Page 49: ...witch to the RUN position for 10 to 15 seconds which allows the fuel pump to prime the fuel system Do not use the engine starter motor to crank the engine in order to prime the fuel system Removing th...

Page 50: ...que the fuel sender cap to 20 to 22 N m 175 to 200 in lb B Also to prevent damage to fuel sender during assembly ensure that the fuel sender does not turn as the sender cap is tightened 2 Correctly co...

Page 51: ...h 22 Upper radiator hose 37 Draincock 8 Foam seal 2 each 23 Lower radiator hose 38 Radiator cap 9 Flange nut 4 each 24 Fan shroud 39 Foam seal 10 Flange nut 22 each 25 Hydraulic hose 2 each 40 Spacer...

Page 52: ...g units stop engine engage parking brake and remove key from the key switch 2 Unlatch screen at rear of machine Lift screen from hinges and remove screen from machine 3 Raise and support hood CAUTION...

Page 53: ...me Replace damaged foam seals Installing the Radiator Assembly 1 Remove plugs placed in radiator and hose openings during the removal procedure 2 Carefully position radiator assembly to the radiator f...

Page 54: ...Assembly continued 13 After running engine for a short time stop engine and Ensure radiator is full Add coolant if necessary Kubota Diesel Engine Service and Repairs Page 3 20 Reelmaster 5410 5510 56...

Page 55: ...fan 15 Snubbing washer 4 each 25 Lock washer 2 each 6 Fan spacer 16 Flange nut 4 each 26 Muffler tailpipe bracket 7 Pulley 17 Front engine mount bracket 2 each 27 Lock washer 2 each 8 Temperature sen...

Page 56: ...hildren and pets 4 Drain coolant from radiator refer to Radiator Assembly page 3 17 5 Remove air cleaner assembly from machine refer to Air Cleaner Assembly page 3 8 6 Remove exhaust system from machi...

Page 57: ...during engine installation 10 Label all engine wire harness leads for assembly purposes Disconnect wire harness connectors from the following components A The 2 engine wire harness connectors from th...

Page 58: ...CAUTION One person should operate lift or hoist while another person guides the engine out of the machine IMPORTANT Ensure to not damage the engine fuel hoses hydraulic lines electrical harness radiat...

Page 59: ...operate lift or hoist while another other person guides the engine into the machine IMPORTANT Ensure to not damage the engine fuel hoses hydraulic lines electrical harness radiator battery or other pa...

Page 60: ...tle cable to engine and driveshaft brackets As clamps are tightened ensure that the cable is not bent which could cause cable binding E Adjust throttle control refer to Adjusting the Throttle Control...

Page 61: ...ontrol Unit ECU 4 6 Yanmar Engine 4 7 Diesel Particulate Filter DPF 4 7 Shutting Off the Engine Reelmaster 5610 D 4 11 Service and Repairs 4 12 Air Cleaner System 4 12 Exhaust System 4 15 Radiator 4 1...

Page 62: ...465 x 3 543 inches Total Displacement 1 642 cm3 100 2 in3 Firing Order 1 flywheel end 3 fan end 2 Direction of Rotation Counterclockwise viewed from flywheel Fuel Diesel or Biodiesel up to B7 Fuel wi...

Page 63: ...ty Refer to the Traction Unit Operator s Manual Oil Pump Gear Driven Trochoid Type Crankcase Oil Capacity 5 2 L 5 5 US qt with Filter Cooling System Capacity including reserve tank 6 6 L 7 US qt Start...

Page 64: ...3 38 inches Stroke 90 mm 3 54 inches Total displacement 1568 cm3 95 68 in3 Firing order 1 closest to the flywheel end 3 2 Direction of rotation Counterclockwise viewed from the flywheel Fuel Diesel or...

Page 65: ...case oil capacity 4 7 L 4 9 US qt Oil pump Yanmar trochoid pump Coolant capacity 9 5 L 10 US qt Alternator Regulator 12 VDC 55 A Engine weight dry 200 kg 441 lb Reelmaster 5410 5510 5610 Series Page 4...

Page 66: ...ar Model 3TNV88C DTR Tier 4F compliant engine The engine that powers certain Reelmaster 5610 machines is a Yanmar Model 3TNV86CT Tier 4F compliant engine The Yanmar Engine Service Manual and Troublesh...

Page 67: ...er 5610 D also includes a turbocharger The engine ECU combined with numerous engine sensors monitor and control the engine operation for optimum performance During the operation of the engine if condi...

Page 68: ...ion Visit www toro com to download the traction unit Operator s Manual with the correct DPF regeneration instructions for the machine Types of regeneration that are performed automatically while the m...

Page 69: ...a critical level Can only be initiated when prompted by the engine ECU For software 119 7798T and up the machine mow function PTO will be disabled at first notification Manually initiate a recovery re...

Page 70: ...egeneration processes The lighter ash is discharged through the exhaust system while the heavier ash collects in the soot filter When enough ash accumulates in the soot filter the engine ECU will gene...

Page 71: ...allowing the engine to run at low idle speed for 5 minutes before shutting off the engine This allows the turbocharger and internal engine components to cool down Failure to allow this cool down perio...

Page 72: ...outlet hose 8 Flange head screw 2 each 14 Spring 3 Hose clamp 2 each 9 Air cleaner stand 15 Bolt 4 Hose clamp 10 Bolt 2 each 16 Adapter 5 Air cleaner assembly 11 Yanmar engine 17 Service indicator 6 F...

Page 73: ...ervals of the air cleaner 1 Park the machine on a level surface lower the cutting decks shut off the engine set the parking brake and remove the key from the key switch 2 Unlatch the hood and raise it...

Page 74: ...lling the adapter and service indicator to the housing Figure 30 Install the adapter so that the grooves in the adapter hex and adapter filter element are installed toward service indicator Torque the...

Page 75: ...6 each 27 Sensor gasket 4 each 6 Engine flywheel housing 17 DPF lifter 28 Exhaust pressure pipe DPF outlet 7 DOC temp sensor inlet 18 DPF stiffener 5 each 29 Exhaust hose 8 DOC temp sensor outlet 19 D...

Page 76: ...the soot filter requires special equipment and should only be done by a company familiar with the reconditioning process An alarm timer in the engine ECU must be reset when the soot filter is recondit...

Page 77: ...is or damage that may prevent a tight seal 1 Ensure to install new gaskets in place of all gaskets that were removed Do not use any type of gasket sealant on gasket or flange surfaces 2 Assemble all e...

Page 78: ...4 O ring 2 each 23 Radiator and oil cooler assembly 32 Reservoir hose 6 Flange head screw 14 each 15 Straight hydraulic fitting 2 each 24 Hose clamp 3 each 33 Radiator frame 7 Foam seal 2 each 16 O ri...

Page 79: ...radiator draincock turn clockwise and allow the coolant to drain from radiator IMPORTANT Follow all local codes and regulations when recycling or disposing engine coolant 5 Remove the air cleaner inle...

Page 80: ...an shroud and radiator frame Replace any foam seals that are damaged Installing the Radiator g189544 Figure 34 1 Radiator 3 Hydraulic tube 2 Straight hydraulic fitting 2 each 4 Hydraulic tube 1 If the...

Page 81: ...the air cleaner inlet hose refer to Air Cleaner System page 4 12 11 Ensure that the radiator draincock is closed 12 To allow air to escape during radiator filling remove the pipe plug item 31 in Figu...

Page 82: ...g 2 each 4 Fuel supply hose 12 Clamp 2 each 20 Bolt 28 Flange head screw 3 each 5 Flange head screw 2 each 13 Draincock 21 Sender cover 29 Carriage screw 2 each 6 Fuel pump 14 Hose clamp 22 Cable stra...

Page 83: ...r fuel system maintenance e g draining the fuel water separator replacing the fuel filter or a fuel hose To prime the fuel system ensure that the fuel tank has fuel in it Then turn the key switch to t...

Page 84: ...n the hose clamps and carefully disconnect the fuel supply and return items 17 and 2 in Figure 35 hoses from the fittings on the top of the fuel sender 9 Cover or plug the fuel hoses or fitting openin...

Page 85: ...ender cap is tightened 3 Connect the fuel supply and return items 17 and 2 in Figure 35 hoses to the fittings on the top of the fuel sender Secure the fuel hoses with the hose clamps 4 Secure the wire...

Page 86: ...nut 10 each 3 Bolt 4 each 9 Flange nut 10 each 15 Flange head screw 8 each 4 Right rear engine mount 10 Yanmar engine 16 Right front engine mount 5 Left rear engine mount 11 Driveshaft assembly 17 Li...

Page 87: ...hylene glycol antifreeze is poisonous Keep the coolant away from children and pets Keep the coolant in a labelled container Discard the coolant in accordance with local hazardous waste ordinances g189...

Page 88: ...t contamination Position the disconnected hoses away from the engine 8 Remove the hydraulic pump driveshaft refer to Hydraulic Pump Driveshaft page 6 159 g212729 Figure 39 1 Cord grip locknut 3 Cord g...

Page 89: ...ground cable at the engine block Figure 40 E The engine wire harness connectors from the main power glow start and EGR relays Figure 41 F The engine wire harness connector from the fuel pump G The 2 e...

Page 90: ...he engine with lift or hoist to prevent the engine from shifting or moving CAUTION Use 1 person to operate the lift or hoist while the other person guides the engine into the machine IMPORTANT When in...

Page 91: ...gine Connect the hoses to the engine A Use the labels that you attached during removal to correctly connect the fuel supply and return hoses to the fuel filter on the engine Figure 38 Secure the fuel...

Page 92: ...orrect quantity of fluid if necessary refer to the Operator s Manual 16 Prime the fuel system refer to Priming the Fuel System page 4 23 17 Start the engine and operate the hydraulic controls to prope...

Page 93: ...Engine 5 4 Engine Electronic Control Unit ECU 5 4 Service and Repairs 5 6 Air Cleaner Assembly 5 6 Exhaust System 5 9 Fuel System 5 11 Fuel Evaporative Control System 5 14 Radiator and Oil Cooler Ass...

Page 94: ...case end 3 4 flywheel end 2 Direction of Rotation Counterclockwise viewed from flywheel Fuel Unleaded regular grade gasoline 87 octane minimum Fuel Injection type Electronic fuel injection Fuel Pump...

Page 95: ...gine continued Item Description Starter 12 VDC 1 0 KW Alternator Regulator 12 VDC 40 A Dry Weight approximate 119 kg 262 lb Reelmaster 5410 5510 5610 Series Page 5 3 Kubota Gasoline Engine Specificati...

Page 96: ...ine Engine The engine used on your Reelmaster is a Kubota WG Series gasoline engine Engine features include an electronic control unit ECU that controls a common rail fuel injection system with direct...

Page 97: ...oubleshooting IMPORTANT Do not plug or unplug the engine ECU for a period of 30 seconds after the machine key switch is turned OFF The ECU may remain energized even though the key switch is OFF If the...

Page 98: ...er 2 each 4 Shoulder bolt 13 Vent 22 Flange head screw 2 each 5 Spring 14 Hose clamp 2 each 23 Locknut 4 each 6 Service indicator 15 Air cleaner hose 24 Hose to EVAP control valve 7 Adapter 16 Air cle...

Page 99: ...d condition and are properly secured during assembly 1 Assemble air cleaner system Figure 43 g229321 Figure 44 1 Air cleaner assembly 3 Adapter 2 Indicator 4 Evacuator valve A If service indicator ite...

Page 100: ...tinued C Torque the hose clamps to the values identified in Figure 43 2 After air cleaner has been properly installed lower and secure hood Kubota Gasoline Engine Service and Repairs Page 5 8 Reelmast...

Page 101: ...d 31 Exhaust mount 6 Bolt 2 each 19 Nut 4 each 32 Flange head screw 4 each 7 Flat washer 2 each 20 Exhaust manifold gasket 33 Exhaust support bracket 8 Flange nut 2 each 21 Oxygen sensor 34 Bolt 2 eac...

Page 102: ...the engine as necessary Discard all removed gaskets items 13 17 and or 20 in Figure 45 Installing the Exhaust System Note Ensure that all exhaust system flanges and sealing surfaces are free of debris...

Page 103: ...sher head screw 5 Clamp 2 each 15 Fuel fitting 25 Fuel hose 2 each 35 Fuel pump gasket 6 Fuel tank 16 Hose clamp 3 each 26 Fuel hose 36 Vent 7 Pump cover 17 Strap 27 Straight fitting 37 Hose clamp 2 e...

Page 104: ...nk out with clean solvent Ensure that the tank is free of all contaminates and debris Priming the Fuel System The fuel system needs to be primed before starting the engine for the first time after run...

Page 105: ...1 Install fuel tank to frame Figure 46 Secure fuel hoses with cable ties as noted during fuel tank removal If fuel pump assembly was removed from fuel tank ensure that fuel fitting on pump is orientat...

Page 106: ...evaporative emissions from the fuel tank and engine A carbon canister that is mounted to the left side of the frame near the rear of the machine is used to collect these evaporative emissions Fuel va...

Page 107: ...an safety approved container and keep the cap in place Use gasoline for the engine only not for any other purpose 3 Inspect carbon cannister and attached hoses for damage or obvious leaks A damaged or...

Page 108: ...tion for assembly purposes Figure 50 identifies control valve hose locations Installing the Fuel Evaporative Control System 1 Install all removed EVAP components Figure 48 Figure 49 and Figure 50 Ensu...

Page 109: ...crew 4 each 29 Draincock 8 Flange nut 10 each 19 Draw latch 30 Radiator cap 9 Hose clamp 4 each 20 Washer head screw 6 each 31 Reservoir cap 10 Radiator and oil cooler assembly 21 Foam seal 2 each 32...

Page 110: ...TANT Follow all local codes and regulations when recycling or disposing engine coolant 5 Remove air cleaner inlet hose from inlet in top of radiator frame refer to Air Cleaner Assembly page 3 8 6 Disc...

Page 111: ...oil cooler to radiator frame with removed flange head screws 4 Position fan shroud to radiator oil cooler and secure with removed flange head screws Ensure that at least 6 4 mm 0 250 inch clearance e...

Page 112: ...e Radiator and Oil Cooler Assembly continued 17 Install and secure screen item 23 in Figure 51 to rear of machine Kubota Gasoline Engine Service and Repairs Page 5 20 Reelmaster 5410 5510 5610 Series...

Page 113: ...her 27 Bolt 4 each 6 Exhaust manifold 17 Tailpipe bracket 28 Spacer 4 each 7 Flange nut 4 each 18 Flange head screw 2 each 29 Snubbing washer 4 each 8 Exhaust manifold gasket 19 Oxygen sensor 30 Flang...

Page 114: ...y or store it in a properly labeled container away from children and pets 6 Drain coolant from radiator refer to Radiator and Oil Cooler Assembly page 5 17 7 Remove air cleaner from machine refer to A...

Page 115: ...and wire harness connection at the engine block left side near the engine ECU Figure 54 D Remove harness retainer from forward engine mount bracket on left side of machine Figure 54 g229350 Figure 55...

Page 116: ...42 ft lb 4 Connect lift or hoist to the engine lift brackets CAUTION One person should operate hoist or lift while a second person guides the engine out of the machine IMPORTANT Ensure to not damage t...

Page 117: ...ystem to machine refer to Exhaust System page 3 11 Exhaust tube should have 9 5 mm 3 8 inch clearance with guard in all directions after assembly 13 Add engine coolant to radiator 14 Check engine hydr...

Page 118: ...Kubota Gasoline Engine Service and Repairs Page 5 26 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 119: ...ster Kit Pressure and Flow 6 44 40 GPM Hydraulic Tester Pressure and Flow 6 45 Hydraulic Hose Kit 6 45 O Ring Kit 6 45 Hydraulic Test Fitting Kit 6 46 High Flow Hydraulic Filter Kit 6 47 Spindle Plug...

Page 120: ...ircuit Relief Valve SVRV Pressure 5610 D 6 136 Testing the Lift Circuit Lift Cylinder Internal Leakage 5610 D 6 139 Testing the Lift Circuit Gear Pump P4 Flow 5610 D 6 142 Service and Repairs 6 145 Ge...

Page 121: ...oss LPV Closed Circuit Axial Piston Pump Service 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...

Page 122: ...relief pressure Rear mow circuit R1 Front mow circuit R2 17 500 kPa 2 500 psi 24 100 kPa 3 500 psi Cutting reel motor RM 5410 5410 G 5410 D Displacement per revolution Gear motor 12 cm 0 73 in Cutting...

Page 123: ...volution Parker Hannifin 310 cm 18 9 in Mow circuit relief pressure Rear mow circuit RV1 Front mow circuit RV2 17 500 kPa 2 500 psi 24 100 kPa 3 500 psi Cutting reel motor Displacement per revolution...

Page 124: ...Figure 56 1 Cap with dipstick 2 Hydraulic tank The hydraulic system on your machine is designed to operate on anti wear hydraulic fluid The reservoir holds approximately 34 1 L 9 US gallons of hydraul...

Page 125: ...at a speed below 4 8 km h 3mph and for a very short distance If you must move the machine a considerable distance more than a few feet transport it on a truck or trailer The piston traction pump is e...

Page 126: ...both the forward and reverse direction Releasing the Hydraulic Pressure from the Lift Circuit 1 Turn the key switch to the ON do not start the engine and fully lower the cutting units to the ground 2...

Page 127: ...omponent damage After you have installed the Toro high flow hydraulic fluid filter in the traction circuit raise and support the machine with all the drive wheels off the ground Then operate the tract...

Page 128: ...fitting with the other wrench refer to Installing the Hydraulic Hose and Tube O Ring Face Seal Fitting page 6 11 Note If the hose has an elbow at 1 end tighten the swivel nut on the elbow end before...

Page 129: ...alue within the specified range of torque values refer to the Hose Tube Installation Torque Table page 6 12 This procedure to tighten the swivel nut requires a drive adapter wrench e g crowfoot wrench...

Page 130: ...ads per inch Installation Torque 4 9 16 18 25 to 29 N m 18 to 22 ft lb 6 11 16 16 37 to 44 N m 27 to 33 ft lb 8 13 16 16 51 to 63 N m 37 to 47 ft lb 10 1 14 82 to 100 N m 60 to 74 ft lb 12 1 3 16 12 1...

Page 131: ...values refer to the Fitting Installation Torque Table page 6 13 Note It may be necessary to use a drive adapter wrench e g crowfoot wrench to install a hydraulic fitting refer to Calculating the Torq...

Page 132: ...160 N m 96 to 118 ft lb 16 1 5 16 12 274 to 336 N m 202 to 248 ft lb 165 to 202 N m 121 to 149 ft lb 20 1 5 8 12 335 to 410 N m 247 to 303 ft lb 202 to 248 N m 149 to 183 ft lb Flat From Finger Tight...

Page 133: ...kwise 7 Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the fitting to the recommended torque value within the specified range of torque values refer to the...

Page 134: ...ht Table Size FFFT 4 1 4 inch nominal hose or tubing 1 00 0 25 6 3 8 inch 1 50 0 25 8 1 2 inch 1 50 0 25 10 5 8 inch 1 50 0 25 12 3 4 inch 1 50 0 25 16 1 inch 1 50 0 25 Hydraulic System General Inform...

Page 135: ...Hydraulic Schematics g230012 Figure 63 Reelmaster 5410 5510 5610 Series Page 6 17 Hydraulic System Hydraulic Schematics 15216SL Rev C...

Page 136: ...g230013 Figure 64 Hydraulic System Hydraulic Schematics Page 6 18 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 137: ...g213698 Figure 65 Reelmaster 5410 5510 5610 Series Page 6 19 Hydraulic System Hydraulic Schematics 15216SL Rev C...

Page 138: ...a constant supply of charge fluid to the closed loop traction circuit This charge fluid provides lubrication for traction circuit components and also replenishes traction circuit fluid that is lost d...

Page 139: ...Reverse Direction continued g230011 Figure 66 Reelmaster 5410 5510 5610 Series Page 6 21 Hydraulic System Hydraulic Flow Diagrams 5410 5410 D 5510 5510 D 5610 15216SL Rev C...

Page 140: ...to maximize traction To reduce tire scuffing when turning traction system pressure is equalized in the AWD control manifold with an orifice and a bi directional relief valve Check valves in the AWD c...

Page 141: ...sition cutting units in the raised position flow from pump sections P1 and P2 is directed out the mow manifold port T and returns to the hydraulic reservoir by passing the reel motors Mow When solenoi...

Page 142: ...either valve MR1 or MR2 is set to the backlap position the valve reverses the direction of hydraulic flow through the rear or front reel motors allowing the backlap operation Hydraulic System Hydraul...

Page 143: ...Backlap continued g230014 Figure 68 Reelmaster 5410 5510 5610 Series Page 6 25 Hydraulic System Hydraulic Flow Diagrams 5410 5410 D 5510 5510 D 5610 15216SL Rev C...

Page 144: ...se position of the front outside cutting units During conditions of not raising or lowering the cutting units joystick in the neutral center position all 4 lift manifold solenoid valves SV1 SV2 SV3 an...

Page 145: ...Raise the Cutting Units continued g230015 Figure 69 Reelmaster 5410 5510 5610 Series Page 6 27 Hydraulic System Hydraulic Flow Diagrams 5410 5410 D 5510 5510 D 5610 15216SL Rev C...

Page 146: ...nifold C1 C4 C5 and C23 control the lowering speed by providing a restriction for the return flow from the lift cylinders Because cutting unit weight assists in extending the lift cylinders when lower...

Page 147: ...Lower the Cutting Units continued g230016 Figure 70 Reelmaster 5410 5510 5610 Series Page 6 29 Hydraulic System Hydraulic Flow Diagrams 5410 5410 D 5510 5510 D 5610 15216SL Rev C...

Page 148: ...nsures that the fluid flow to the steering cylinder is proportional to the amount of turning on the steering wheel Fluid leaving the steering cylinder flows back through the steering control spool val...

Page 149: ...Right Turn continued g230017 Figure 71 Reelmaster 5410 5510 5610 Series Page 6 31 Hydraulic System Hydraulic Flow Diagrams 5410 5410 D 5510 5510 D 5610 15216SL Rev C...

Page 150: ...ction speed When the traction pedal is pressed a small amount a small swash plate rotation results in low pump output and lower traction speed When the traction pedal is pressed fully the pump swash p...

Page 151: ...a 3 625 psi by the reverse traction relief valve R4 located in the traction pump The fluid flowing from the wheel motors returns to the traction pump and is continuously pumped through the closed loop...

Page 152: ...Reverse Direction continued g213692 Figure 72 Hydraulic System Hydraulic Flow Diagrams 5610 D Page 6 34 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 153: ...efined by the InfoCenter reel speed setting provides the input for the TEC to output the appropriate amount of current to the proportional valve coils Flow through the proportional valves SP1 and SP2...

Page 154: ...en either manual direction valve MV1 or MV2 is set to the backlap R position the valve reverses the direction of hydraulic flow through the rear or front reel motors allowing the backlap operation Hyd...

Page 155: ...Backlap continued g213701 Figure 73 Reelmaster 5410 5510 5610 Series Page 6 37 Hydraulic System Hydraulic Flow Diagrams 5610 D 15216SL Rev C...

Page 156: ...al raise position of the front outside cutting units During the conditions of not raising or lowering the cutting units joystick in the neutral center position all 4 lift manifold solenoid valves SV1...

Page 157: ...Raise the Cutting Units continued g213699 Figure 74 Reelmaster 5410 5510 5610 Series Page 6 39 Hydraulic System Hydraulic Flow Diagrams 5610 D 15216SL Rev C...

Page 158: ...t control manifold CV1 CV4 CV5 and CV23 control the lowering speed by providing a restriction for the return flow from the lift cylinders Because cutting unit weight assists in extending the lift cyli...

Page 159: ...Lower the Cutting Units continued g213700 Figure 75 Reelmaster 5410 5510 5610 Series Page 6 41 Hydraulic System Hydraulic Flow Diagrams 5610 D 15216SL Rev C...

Page 160: ...ted through the rotary meter V1 and out through the L port The pressure retracts the steering cylinder piston for a left turn The rotary meter ensures that the fluid flow to the steering cylinder is p...

Page 161: ...Right Turn continued g213705 Figure 76 Reelmaster 5410 5510 5610 Series Page 6 43 Hydraulic System Hydraulic Flow Diagrams 5610 D 15216SL Rev C...

Page 162: ...lic circuits and components for flow and pressure capacities as recommended in Testing the Hydraulic System page 6 56 This tester includes the following Inlet Hose This hose connects the system circui...

Page 163: ...the operating circuit with a gauge rated at 20 to 150 L minute 4 to 40 gallons minute Note This tester does not include the hoses refer to Hydraulic Hose Kit page 6 45 Hydraulic Hose Kit Toro Part No...

Page 164: ...6 ORFS 11 16 16 TOR4079 18 8 ORFS 13 16 16 TOR4079 19 Cap 2 each 10 ORFS 1 14 TOR4079 20 6 ORFS 11 16 16 to 8 SAE ORB 3 4 16 TOR4079 8 8 ORFS 13 16 16 to 8 SAE ORB 3 4 16 TOR4079 9 Union 1 each 10 OR...

Page 165: ...cuit components or after you replace a failed traction circuit component e g piston pump or wheel motor This filter removes contamination from the hydraulic fluid in the traction circuit thereby preve...

Page 166: ...ency of a hydraulic motor while the hydraulic system pressurizes the motor The table gives the gallons per minute gpm conversion for the measured milliliter or ounce motor case drain leakage GPM mL 15...

Page 167: ...rcuit protection A remote stater switch can also be constructed using the Toro switch 106 2027 a length of 14 gauge wire a 20 A in line fuse 2 alligator clips and necessary connectors Connecting the w...

Page 168: ...e more noticeable after initial filling of hydraulic tank The hydraulic fluid level in the hydraulic tank is low The hydraulic system has a wrong type of fluid One of the pump suction lines has an air...

Page 169: ...irection only The traction control linkage is incorrectly adjusted disconnected binding or damaged The check relief valve in the piston traction pump is not seating or is damaged Note The check relief...

Page 170: ...e charge pressure is low The check valves in the piston traction pump are damaged The valve plate s in the piston traction pump is worn or damaged The wheel motor is worn or damaged Note If 1 traction...

Page 171: ...urposes The mow backlap lever for the rear cutting units MR1 MV1 is not rotated fully An electrical problem exists that prevents MSV1 SP1 solenoid coil on the mow control manifold from being energized...

Page 172: ...damaged None of the cutting units will raise or lower Note The operator must be in the seat or the parking brake engaged and mow speed limiter must be in mow speed position in order to lower the cutt...

Page 173: ...affected cutting reel is damaged The flow control orifice in the lift control manifold for the affected cutting reel is plugged stuck or damaged The check valve in the lift control manifold CV1 CV4 CV...

Page 174: ...essure Do not use your hands to search for leaks use a piece of paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If h...

Page 175: ...raulic fluid level in the hydraulic tank and ensure that the tank has the correct fluid level 10 When you use a hydraulic tester pressure and flow open the tester load valve fully before you start the...

Page 176: ...es have been completed check the hydraulic fluid level in the hydraulic tank to ensure that the hydraulic fluid level is correct Hydraulic System Testing the Hydraulic System Page 6 58 Reelmaster 5410...

Page 177: ...traction circuit relief pressures are correct Test Procedure 1 Drive machine to an open area Park machine on a level surface with the cutting units lowered and disengaged Ensure that the engine is shu...

Page 178: ...l drive machine 1 Right wheel motor 3 Forward test port 2 Left wheel motor 4 Reverse test port g230034 Figure 82 2 wheel drive machine 1 Forward test port 2 Reverse test port 3 Clean traction circuit...

Page 179: ...lts Note Forward R3 and reverse R4 relief valves are identical Relief valves can be switched in piston traction pump to help in identifying a damaged relief valve g230035 Figure 83 1 Piston traction p...

Page 180: ...ectly Test Procedure 1 Park machine on a level surface with the cutting units lowered and disengaged Ensure that the engine is shut off Apply the parking brake 2 Read all Warning Cautions and precauti...

Page 181: ...6 Figure 85 1 Piston traction pump 3 Hydraulic tube 2 Oil filter filter adapter 4 Test port g230037 Figure 86 1 Piston traction pump 3 O ring 5 Spring 2 Plug 4 Shim kit 6 Charge relief poppet 4 Clean...

Page 182: ...arge pressure from step 8 with pressure from step 9 A If charge pressure is good under no load step 8 but drops below specification when under traction load step 9 the piston traction pump should be s...

Page 183: ...charge circuit and steering circuit have adequate hydraulic flow Test Procedure 1 Park machine on a level surface with the cutting units lowered and disengaged Ensure that the engine is shut off Appl...

Page 184: ...MPORTANT Ensure that the fluid flow indicator arrow on the flow meter is showing that the fluid will flow from the hydraulic tube through the tester and into the piston traction pump 5 Install tester...

Page 185: ...valve shut off the engine and record test results 13 If flow is less than 20 L minute 4 gallons minute or a pressure of 5 500 kPa 800 psi cannot be obtained consider that a gear pump problem exists Ch...

Page 186: ...el motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affec...

Page 187: ...System page 6 8 4 Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing 5 Chock front wheels to prevent wheel rotation Note I...

Page 188: ...or both of the motors may be damaged Individual front wheel motor testing is necessary 13 To test individual front wheel motors A Remove front wheel from wheel motor that is not being tested Remove wh...

Page 189: ...ANT Traction circuit flow for your Reelmaster is approximately 114 L minute 30 gallons minute Use 150 L minute 40 gallons minute hydraulic Tester AT40002 pressure and flow for this test refer to Speci...

Page 190: ...mp 3 Hydraulic hose forward 5 Hydraulic hose reverse 2 Right elbow fitting 4 Left elbow fitting 6 Clean junction of hydraulic hose and right side fitting on bottom of traction pump Figure 92 Disconnec...

Page 191: ...h a phototac that the engine speed is still 3 000 rpm Note If engine speed is not 3 000 rpm during this test pump flow will be different than listed GPM LPM 12 Observe flow gauge Flow indication shoul...

Page 192: ...e The front cutting unit circuit is protected by relief valve R2 The rear cutting unit circuit is protected by relief valve R1 refer to Hydraulic Flow Diagrams 5410 5410 D 5510 5510 D 5610 page 6 20 T...

Page 193: ...the backlap levers are positioned in the MOW position g230041 Figure 94 1 Cutting reel motor 2 Motor inlet hose 3 Motor outlet hose 6 Clean junction of hydraulic inlet hose and reel motor fitting on...

Page 194: ...0 to 3 600 psi for relief valve R2 13 Open the tester flow control valve disengage cutting units and shut off the engine 14 If pressure is incorrect remove solenoid valve on mow manifold and clean or...

Page 195: ...h fluid can by pass to cause the reels to stall in heavy cutting conditions Continued operation with a worn inefficient pump can generate excessive heat and cause damage to seals and other components...

Page 196: ...PORTANT Ensure that the fluid flow indicator arrow on the flow gauge is showing that the fluid will flow from the gear pump through the tester and into the hose 5 Install tester with pressure gauge an...

Page 197: ...pproximately 31 L minute 8 2 gallons minute at 13 800 kPa 2 000 psi 10 Open the tester flow control valve and shut off the engine Record test results 11 If flow is less than 20 4 L minute 5 4 gallons...

Page 198: ...tor to stall under heavy cutting conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect...

Page 199: ...fitting 4 For reel motor to be tested clean junction of the motor case drain hose small diameter hose where it connects to traction unit bulkhead not at the motor Figure 98 Disconnect the case drain...

Page 200: ...e end from container Then move the reel engage switch to OFF open the tester flow control valve and shut off the engine 11 Identify amount of fluid collected in the graduated measuring container Recor...

Page 201: ...damaged motor will typically run slower produce fewer clippings and may cause clip marks a choppy appearance on the turf IMPORTANT Do not perform the cutting reel motor cross over relief pressure test...

Page 202: ...ors are connected in series To isolate a damaged motor all motors in the circuit may have to be tested by starting with the up stream motor closest to the pump first g230044 Figure 100 1 Cutting reel...

Page 203: ...e a pressure differential between the gauges on the inlet and outlet side of the motor Note this pressure difference which should be Pressure differential between the 2 gauges should be approximately...

Page 204: ...rcuit relief pressure is correct Test Procedure 1 Park machine on a level surface with the cutting units lowered and reel engage switch OFF Ensure that the engine is shut off Apply the parking brake 2...

Page 205: ...o test port can be obtained from below the front of the machine Connect a 35 000 kPa 5 000 psi pressure gauge to test port 5 After installing pressure gauge to manifold test port start engine and run...

Page 206: ...gine Record test results 10 If measured pressure is incorrect remove solenoid relief valve SVRV on lift control manifold and clean or replace valve refer to Servicing the Lift Control Manifold page 6...

Page 207: ...ing unit lift circuit has adequate hydraulic flow Test Procedure 1 Park machine on a level surface with the cutting units lowered and reel engage switch OFF Ensure that the engine is shut off Apply th...

Page 208: ...ump P4 through the tester and into the disconnected hose 5 Install tester with pressure gauges and flow meter in series between gear pump fitting and disconnected hose Ensure that the flow control val...

Page 209: ...9 5 L minute 2 5 gallons minute or a pressure of 6 900 kPa 1 000 psi cannot be obtained consider that a pump problem exists Check for restriction in pump intake line If intake is not restricted remov...

Page 210: ...ift cylinder binding extra weight on the cutting units and or binding of lift components Ensure that the these items are checked before proceeding with lift cylinder internal leakage test Test Procedu...

Page 211: ...the supported lift arm Disconnect the hydraulic hose from the lift cylinder rod end fitting Figure 106 IMPORTANT When capping lift cylinder fitting and hydraulic hose end use a steel cap and plug to...

Page 212: ...and lift cylinder rod movement is less than 31 7 mm 1 250 inches consider that the lift cylinder is in good condition A cylinder in good usable condition will show minimal movement B Rod movement in e...

Page 213: ...ut off the engine and check for any hydraulic leakage 11 If necessary repeat steps 3 through 9 for other lift cylinders 12 After lift cylinder testing is completed check hydraulic fluid level in hydra...

Page 214: ...ng circuit relief pressure is correct Test Procedure 1 Park machine on a level surface with the cutting units lowered and reel engage switch OFF Ensure that the engine is shut off Apply the parking br...

Page 215: ...000 psi pressure gauge to the tee fitting 6 After installing pressure gauge start engine and run at idle speed Check for any hydraulic leakage from test connections and correct before proceeding with...

Page 216: ...uld also be suspected of wear damage or inefficiency refer to Gear Pump P3 Flow Test Using Tester with Flow Meter and Pressure Gauge 5410 5410 G 5410 D 5510 5510 G 5510 D 5610 page 6 65 Note If the fl...

Page 217: ...t on the vehicle and or binding of rear axle steering components Ensure that the these items are checked before proceeding with steering cylinder internal leakage test Test Procedure 1 Ensure that the...

Page 218: ...cylinder 8 With the engine shut off continue turning the steering wheel for a right turn clockwise with the steering cylinder fully extended Observe the open fitting on the steering cylinder as the wh...

Page 219: ...an from working on a hot machine applicable to tests when possible any test that requires an open un pluged capped line case drain tests would not apply and oil should be warmed before disconnecting t...

Page 220: ...ircuit test port 5 Hydraulic tube 3 Hydraulic tube 6 Connect a pressure gauge to the charge circuit test port Figure 114 g217039 Figure 115 1 Traction circuit test port 2 Wheel motor left front 7 Conn...

Page 221: ...1 500 psi is reached on the traction circuit pressure gauge 13 Record the reading on the charge circuit pressure gauge under load The charge pressure under load should not drop more than 20 when compa...

Page 222: ...Testing the Traction Circuit Wheel Motor Efficiency 5610 D g216153 Figure 116 Hydraulic System Testing the Hydraulic System Page 6 104 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 223: ...flow bypasses the rear wheel motors Start by testing the front wheel motors combined then test the front wheel or rear wheel motors individually as necessary Special Equipment Required Pressure gauge...

Page 224: ...w indicator arrow on the flow meter is showing that the fluid will flow from the pump through the tester and into the disconnected hydraulic hose 3 Install a tester with pressure gauge and flow meter...

Page 225: ...the hydraulic tubes to the frame B Clean and disconnect hydraulic lines from the front wheel motor that is not being tested Cap the disconnected hydraulic lines and plug the ports of the disconnected...

Page 226: ...h the pressure gauge and flow meter in series between the disconnected hydraulic hose and the rear wheel motor Ensure that the tester flow control valve is fully open IMPORTANT Before lifting the mach...

Page 227: ...of wheel motor leakage in the 3 different wheel positions will provide the most accurate test results 9 Leakage for a rear wheel motor should be less than 4 5 L minute 1 2 gallons minute 10 If specifi...

Page 228: ...he unit to stall under heavy load conditions Continued operation can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance S...

Page 229: ...so that all the wheels are off the ground refer to Jacking Instructions page 1 6 g217939 Figure 121 1 Traction pump 2 Hydraulic hose forward 3 Right elbow fitting 6 Clean the junction of the hydraulic...

Page 230: ...he traction relief valve operation as follows A Return the traction pedal to the NEUTRAL position B Fully close the flow meter flow control valve C Slowly set the traction pedal to full forward positi...

Page 231: ...ecommended to check the cutting unit circuit performance The results from this test will help determine which component s are the cause of cutting unit performance issues Special Equipment Required Pr...

Page 232: ...and install a pressure gauge with hydraulic hose to the test fitting CAUTION Keep away from the cutting units during test to prevent personal injury from the cutting reel blades 6 Sit in the operator...

Page 233: ...met consider the following A The relief valve RV1 or RV2 is damaged refer to Testing the Mow Circuit Relief Valve RV1 and RV2 Pressure 5610 D page 6 123 B The gear pump P1 P2 is damaged refer to Testi...

Page 234: ...nder load of more than 9 of total motor flow indicates the gears and wear plates in the motor have worn A worn motor may bypass the hydraulic fluid to its case drain causing the motor to be less effic...

Page 235: ...rking brake CAUTION Before opening the hydraulic system operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid refer to Releasing Pressure...

Page 236: ...Keep away from the cutting units during the test to prevent personal injury from the rotating reel blades Do not stand in front of the machine Note This test requires 2 people one in the seat and one...

Page 237: ...n testing more than one cutting unit motor check and adjust the hydraulic fluid level in the tank after testing each motor 19 When testing is complete start the engine check for hydraulic fluid leaks...

Page 238: ...ll run slower produce fewer clippings and may cause a different appearance on the turf Note Before testing the cutting reel motor cross over relief pressure ensure that the reel motor is in good condi...

Page 239: ...on Note The cutting reel motors are connected in series If a damaged reel motor is not obvious based on quality of cut issues you may have to test all motors in the circuit If testing all cutting reel...

Page 240: ...ng on both the inlet and outlet side pressure gauges 11 Disengage the cutting units and shut off the engine 12 Calculate the pressure differential between the 2 gauges If the pressure differential is...

Page 241: ...ugh pressure to open properly functioning relief valves Note The front cutting reel circuit is supplied by pump P2 and protected by a relief valve RV2 in the mow control manifold The rear cutting reel...

Page 242: ...oid injury from the pressurized hydraulic fluid refer to Releasing Pressure from the Hydraulic System page 6 8 2 Read all Warning Cautions and precautions listed at the beginning of this section g2179...

Page 243: ...Use the InfoCenter display to set reel speed control to the full speed setting Ensure that the mow backlap lever on the mow control manifold is in the MOW position 7 Ensure that the hydraulic fluid i...

Page 244: ...or replace the valve refer to Servicing the Mow Control Manifold Assembly page 6 191 14 If you are not able to obtain relief pressure check for a restriction in the pump intake line and or check the g...

Page 245: ...der load of more than 15 indicates the gears and wear plates in the pump have worn A worn pump may bypass the hydraulic fluid that reduces the pump efficiency After sometime sufficient fluid loss caus...

Page 246: ...the junction of gear pump fitting and the hydraulic outlet hose and then disconnect the hose from the pump fitting Pump section P1 for the rear cutting units Pump section P2 for the front cutting uni...

Page 247: ...trol valve until you get 10 340 kPa 1 500 psi B Record the tester pressure and flow readings under load 12 Press the engine speed switch to low speed 1 175 to 1 225 rpm position and shut off engine 13...

Page 248: ...c steering cylinder extra weight on the vehicle and or binding of the rear axle steering components Ensure that these conditions are checked and functioning properly before proceeding with any steerin...

Page 249: ...d precautions listed at the beginning of this section D Clean the fitting and hose end disconnect the hydraulic hose from the fitting on the rod end of the steering cylinder E Use an elbow or a tee fi...

Page 250: ...ification is not met repair or replace the steering control valve refer to Servicing the Steering Control Valve page 6 226 7 After you complete the testing shut off the engine and then release hydraul...

Page 251: ...rn pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system Special Equipment Required Flow meter with pressure gauge that has at least a 16 L minute...

Page 252: ...rrow on the flow meter is showing that the fluid will flow from the hydraulic tube through the tester and into the traction pump 5 Install a tester with the pressure gauge and flow meter in place of t...

Page 253: ...ings under load 12 Press the engine speed to low speed 1 175 to 1 225 rpm position and shut off the engine 13 The under load test flow reading step 11B should not drop more than 15 when compared to th...

Page 254: ...mal operating temperature by operating the machine for at least 10 minutes 2 Park the machine on a level surface with the reel engage switch off lower the cutting units shut off the engine mow speed l...

Page 255: ...n extended period may damage system components 7 Ensure that the reel engage switch is OFF and then pull the joystick lever rearward to pressurize the lift circuit While holding lever in the RAISE rea...

Page 256: ...he testing shut off the engine and disconnect the pressure gauge from the lift control manifold test port 13 Start the engine check for hydraulic fluid leaks repair any leaks as necessary and fill the...

Page 257: ...eing tested is damaged The lift cylinders must be tested individually Note The raise lower circuit operation can be affected by the lift cylinder binding extra weight on the cutting reel and or bindin...

Page 258: ...nect the hydraulic hose from the lift cylinder barrel end fitting Figure 139 IMPORTANT When capping the lift cylinder fitting and hydraulic hose end use a steel cap and plug to ensure that there is no...

Page 259: ...draulic hose to the lift cylinder fitting 13 Carefully remove the jack from under the lift arm Start the engine and operate the lift cylinders through several up and down cycles Shut off the engine an...

Page 260: ...eat and cause damage to the seals and other components in the hydraulic system Special Equipment Required Flow meter with pressure gauge that has at least a 16 L minute 5 gallons minute capacity Note...

Page 261: ...that the fluid will flow from the pump P4 through the tester and to the lift control manifold 5 Connect the tester inlet to the pump fitting and connect the tester outlet to the disconnected hydraulic...

Page 262: ...to the no load test flow reading step 8A A difference in flow of more than 15 or the inability to achieve specified pressure may indicate A A restriction in the pump inlet line B The gear pump P4 is...

Page 263: ...essure and avoid injury from the pressurized hydraulic fluid refer to Releasing Pressure from the Hydraulic System page 6 8 5 The hydraulic fluid may be hot Be careful when you loosen and remove the h...

Page 264: ...e hydraulic tank and add correct quantity of fluid if necessary Checking the Hydraulic Lines and Hoses WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Ensure that a...

Page 265: ...gure 142 It is not necessary to remove this blue wire from the solenoid terminal for hydraulic pump priming 3 Connect the remote starter switch electrical leads to the starter motor solenoid B termina...

Page 266: ...the tank Consider removing and cleaning the reservoir if necessary 4 Clean the area around the mounting areas of the hydraulic fluid filters Remove and replace the hydraulic fluid filters 5 Inspect a...

Page 267: ...mination assume normal operation and follow the recommended maintenance intervals Filtering the Closed Loop Traction Circuit Filtering a closed loop hydraulic system after a major component failure e...

Page 268: ...hose connections are properly tightened IMPORTANT Using other hydraulic fluids could damage the hydraulic system Use the hydraulic fluids that are specified in the Operator s Manual 5 After you instal...

Page 269: ...a filter that is not bi directional unwanted material from the filter will again enter the traction circuit 9 With the engine running at high idle speed alternately move the traction pedal from forwa...

Page 270: ...hine 8 Ensure that the traction pedal is in the NEUTRAL position Start the engine and run it at low idle speed Note The hydraulic pumps must pick up the hydraulic fluid and fill the hydraulic system I...

Page 271: ...Shut off the engine and lower the machine to the ground 17 If the traction pump was replaced or rebuilt operate the traction circuit so that all the wheels rotate slowly for 10 minutes 18 Operate the...

Page 272: ...0 hydraulic fitting 19 O ring 4 Tank strainer 12 O ring 20 Clamp 2 each 5 Clamp 2 each 13 Recess bumper 21 Washer head screw 2 each 6 Hydraulic hose 14 Flat washer 22 Screen filter 7 Gear pump 15 Bolt...

Page 273: ...If the hydraulic fittings were removed from the hydraulic tank lubricate and install new O rings to the fittings To properly align and install the fittings into the tank openings use the marks that yo...

Page 274: ...n cable bracket 24 Bolt 7 Flat washer 16 Flange head screw 2 each 25 Carriage screw 8 Flat washer 17 Traction control cable 9 Bolt 18 Flange nut Disassembling the Piston Traction Pump Control Assembly...

Page 275: ...e switch through entire traction pump control arm movement g213708 Figure 146 1 Pump lever 4 Cable jam nut 2 each 2 Cable rod end 5 Traction neutral switch 3 Traction control cable 1 Install the compo...

Page 276: ...of the neutral switch and the traction pump lever Figure 147 refer to the Traction Neutral Switch page 7 46 for additional neutral switch information 3 After the traction pump control assembly has be...

Page 277: ...each 2 Flange nut 4 each 7 Flange head screw 8 each 12 Piston traction pump 3 Driveshaft assembly 8 Flange nut 6 each 13 Guard hoop 4 Flywheel adapter plate 9 Bolt 2 each 5 Back up ring 10 Heat shield...

Page 278: ...the driveshaft guard hoop to the machine frame and remove the guard hoop 4 On machines with a Yanmar diesel engine remove the 2 flange head screws item 11 in Figure 148 and 2 flange nuts that secure t...

Page 279: ...secure the installed bearing F Place second bearing into the yoke bore and onto the cross shaft Press the bearing into the yoke and secure with the snap ring G Repeat the procedure for the other yoke...

Page 280: ...criss cross pattern 6 Slide the driveshaft yoke on the pump input shaft so that the yoke is flush with end of the input shaft Secure the driveshaft yoke to the pump input shaft with the 2 bolts and 2...

Page 281: ...mp support bracket 9 Gear pump assembly 25 Flange nut 6 each 41 Carriage screw 2 each 10 O ring 26 O ring 2 each 42 Locknut 2 each 11 Flange head screw 2 each 27 90 hydraulic fitting 43 Straight fitti...

Page 282: ...amination 8 Remove the hydraulic pump driveshaft refer to Removing the Hydraulic Pump Driveshaft page 6 160 9 Disconnect the traction control cable and neutral switch on the piston pump control assemb...

Page 283: ...cessary remove the 2 locknuts item 42 in Figure 151 that secure the pump support bracket to the gear pump and remove the bracket and 2 flat washers from the gear pump 15 If necessary remove the hydrau...

Page 284: ...components while installing the pump assembly 4 Carefully lower the pump assembly into the machine frame Align the piston pump input shaft to the pump driveshaft and slide the pump assembly to the ma...

Page 285: ...ns slowly until air is out of system refer to Charging the Hydraulic System page 6 151 14 Check the traction drive for neutral and traction neutral switch operation Adjust if necessary Reelmaster 5410...

Page 286: ...ring 42 O ring 7 O ring 19 Plug 2 each 31 Bearing 43 Bypass valve 8 End cap 20 O ring 2 each 32 Neutral return arm 44 Seal kit 9 End cap gasket 21 Traction pump housing 33 Neutral return pivot 45 Coup...

Page 287: ...raction pump failure occurs refer to Traction Circuit Component Failure page 6 9 for information regarding the importance of removing contamination from the traction circuit Reelmaster 5410 5510 5610...

Page 288: ...l 8 each 19 Stud bolt 2 each 4 Driveshaft 12 Back up ring 8 each 20 Nut 2 each 5 Body P1 section 13 Square section seal 8 each 21 Bolt 2 each 6 Flange 3 each 14 Drive gear 22 Rear cover 7 Splined conn...

Page 289: ...es Figure 155 IMPORTANT Use caution when clamping the gear pump in a vise to avoid distorting any pump components 3 Secure the front cover of the pump in a vise with the driveshaft pointing down 4 Loo...

Page 290: ...4 Gear shaft 3 Inspect the drive gears and idler gears for the following Figure 156 A Gear shafts should be free of scoring rough surfaces and excessive wear at the bushing points and sealing areas B...

Page 291: ...sections starting at the front cover end Apply grease or petroleum jelly to new section seals to hold them in position during the gear pump assembly 3 After the pump has been assembled tighten the bo...

Page 292: ...ving the Front Wheel Motor CAUTION Before opening the hydraulic system operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid refer to Rele...

Page 293: ...heel motor mark the fitting orientation for assembly purposes Remove the fittings from the wheel motor and discard the O rings from the fittings Installing the Front Wheel Motor IMPORTANT Because of t...

Page 294: ...rum and front wheel to the machine refer to Servicing the Brakes page 8 10 8 Ensure to torque the locknut item 10 in Figure 157 to 407 to 542 N m 300 to 400 ft lb 9 Operate the machine functions slowl...

Page 295: ...Note The front wheel motors of your Reelmaster machine are Eaton Delta motors of the same basic design with minor differences The right side motor has a reverse timed manifold to allow correct rotati...

Page 296: ...el motor fails refer to the Traction Circuit Component Failure page 6 9 for information regarding the importance of removing contamination from the traction circuit Hydraulic System Service and Repair...

Page 297: ...ing the Rear Wheel Motor CAUTION Before opening the hydraulic system operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid refer to Releas...

Page 298: ...he locknut and wheel hub from the motor shaft Discard the locknut D Locate and retrieve the woodruff key item 7 in Figure 159 from the wheel motor shaft 8 Clean the hydraulic hose ends and fittings on...

Page 299: ...the wheel motor Use the labels that you attached during the removal process to correctly connect the hydraulic hoses to the wheel motor fittings refer to Installing the Hydraulic Hose and Tube O Ring...

Page 300: ...for hydraulic fluid leaks repair any leaks as necessary and fill the hydraulic tank with the correct quantity of new hydraulic fluid before returning the machine to service Hydraulic System Service an...

Page 301: ...18 Manifold Note The rear wheel motors used on machines with the CrossTrax AWD are the Parker Torqmotor motors of the same basic design with minor differences The right side motor has a reverse timed...

Page 302: ...TANT If a wheel motor fails refer to the Traction Circuit Component Failure page 6 9 for information regarding the importance of removing contamination from the traction circuit Hydraulic System Servi...

Page 303: ...king brake and remove the key from the key switch CAUTION Before opening the hydraulic system operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydrau...

Page 304: ...ydraulic fluid position the O rings to the fittings and install the fittings into the manifold refer to Installing the Hydraulic Fittings SAE Straight Thread O Ring Fitting into the Component Port pag...

Page 305: ...he bi directional relief valve item 11 in Figure 162 Note The CrossTrax AWD control manifold uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is designed t...

Page 306: ...Mow control manifold 11 Hydraulic hose 18 O ring 2 each 5 O ring 4 each 12 O ring 19 Flange head screw 3 each 6 Hydraulic fitting 4 each 13 Hydraulic fitting 20 Hydraulic tube 7 O ring 4 each 14 O ri...

Page 307: ...the bracket and remove the mow control manifold from the machine 10 If necessary remove the hydraulic fittings from the manifold Discard the O rings that were removed Installing the Mow Control Manifo...

Page 308: ...ld Assembly continued 9 Operate the machine functions slowly until air is out of system refer to Charging the Hydraulic System page 6 151 Hydraulic System Service and Repairs Page 6 190 Reelmaster 541...

Page 309: ...l valve SP1 14 Relief valve RV2 5 Spring pin 2 each per spool 10 Solenoid coil 2 each Note The ports on the mow control manifold are marked for easy identification of the components Example P1 is the...

Page 310: ...c fluid refer to Releasing Pressure from the Hydraulic System page 6 8 g216664 Figure 165 1 4 zero leak plug 4 6 zero leak plug 7 Dowel pin 2 each 2 Mow control manifold 5 Backlap switch 2 each 8 Ball...

Page 311: ...nstalling the plugs torque the plugs to the values identified in Figure 164 and Figure 165 Servicing the Mow Backlap Spool IMPORTANT Before removing the mow backlap spool from the mow manifold remove...

Page 312: ...to the spool Apply a light coating of grease to the O ring C Carefully raise the mow backlap spool until the upper retaining ring groove on the spool is exposed on the top of the manifold Install the...

Page 313: ...to Testing the Hydraulic Solenoid Valve Coils page 7 96 Removing the Lift Control Manifold 1 Park the machine on a level surface lower the cutting units shut off the engine set the parking brake and r...

Page 314: ...d 8 Remove the 2 flange head screws that secure the manifold to the machine frame 9 Remove the lift control manifold from the machine g217168 Figure 168 1 Straight fitting 2 each 3 Orifice 0 046 2 eac...

Page 315: ...ange head screws but do not fully tighten 3 Remove the caps and plugs from the hydraulic lines and fittings 4 Lubricate and install new O ring s on the manifold fittings Correctly connect the hydrauli...

Page 316: ...mp P4 connection port and SV2 is the location for solenoid valve SV2 refer to the Hydraulic Schematic in Appendix A page A 1 to identify the function of the hydraulic lines and cartridge valves at eac...

Page 317: ...manifold Figure 170 The lift control manifold uses 3 different orifice sizes If the fittings are removed from the manifold and an orifice is in the manifold port ensure that you remove the orifice and...

Page 318: ...cartridge valve with a deep well socket wrench Note the correct location of the O rings sealing rings and back up rings 4 Remove and discard the seal kit 5 Visually examine the port in the manifold f...

Page 319: ...istortion of the stem tube can cause binding and malfunction When installing the cartridge valve into the control manifold ensure that the deep well socket fully engages the valve base C Turn the cart...

Page 320: ...Sauer Danfoss cutting reel motors are used on Reelmaster 5410 5410 G 5410 D machines with serial numbers below 313999999 Casappa cutting reel motors are used on Reelmaster 5410 5410 G 5410 D machines...

Page 321: ...l Motor page 9 17 7 If the hydraulic fittings are to be removed from the motor mark the fitting orientation for assembly purposes Remove the fittings from the motor and discard the O rings from the fi...

Page 322: ...ess to correctly connect the hydraulic hoses to the motor fittings Tighten the hose connections refer to Installing the Hydraulic Hose and Tube O Ring Face Seal Fitting page 6 11 5 Check the hydraulic...

Page 323: ...r 5 Drive gear 12 Pressure seal 19 Dowel pin 6 Idler gear 13 Dust seal 20 Rear cover RM 5510 5610 series 7 Socket head screw 4 each 14 Shaft seal 21 Relief cartridge RM 5510 5610 series Note Casappa c...

Page 324: ...670 Figure 174 1 Marker line 2 Use a marker to make a diagonal line across the front flange body and rear cover for assembly purposes Figure 174 IMPORTANT When you clamp the motor in a vise clamp the...

Page 325: ...gaskets and pressure seals from the wear plates 11 Turn the front flange over with the seal side up IMPORTANT Ensure that you do not damage the front flange counterbore when removing the seals from th...

Page 326: ...rs if you find any sharp gear face edge 4 Inspect the wear plates for the following A Bearing areas must not have excessive wear or scoring B Face of the wear plates that are in contact with the gears...

Page 327: ...clean hydraulic fluid Install the idler gear shaft into the remaining position in the front wear plate Apply a light coating of clean hydraulic fluid to the gear faces 10 Install the rear wear plate...

Page 328: ...lmaster 5510 and 5610 series reel motor install the cross over relief valves into the rear flange if they were removed torque the relief valves to 25 N m 18 ft lb 20 Remove the motor from the vise 21...

Page 329: ...pin 4 each 13 Drive gear 2 Front flange 6 Body 10 Rear cover 14 Tab washer 3 Back up ring 2 each 7 Idler gear 11 Bolt 4 each 4 Pressure seal 2 each 8 O ring 2 each 12 Rear bearing block Note Internal...

Page 330: ...r in a vise with the shaft end down Use of a vise with soft jaws is recommended 4 Loosen bolts that secure rear cover 5 Remove motor from vise and remove bolts 6 Remove front flange from the body then...

Page 331: ...tor Be careful to not damage the machined grooves IMPORTANT Ensure to not damage the front flange counterbore when removing the shaft seal 9 Position front flange with seal side up Remove tab washer a...

Page 332: ...n contact with gears should be free of wear roughness or scoring 4 Inspect front flange and rear cover for damage or wear Assembling the Cutting Reel Motor Note When assembling the motor check the mar...

Page 333: ...cover onto the assembly using marker line for proper location Firm hand pressure should be sufficient to engage the dowel pins 10 Position the motor with rear cover downwards Carefully slide the fron...

Page 334: ...ies lift cylinders Figure 182 shows the lift cylinder for the left front 4 cutting unit Removing the Lift Cylinder 1 Park the machine on a level surface lower the cutting units shut off the engine set...

Page 335: ...that secure the lift cylinder to the cylinder pin 9 Remove the lift cylinder from the cylinder pin and frame 10 If the hydraulic fittings are to be removed from the lift cylinder mark the fitting ori...

Page 336: ...ons refer to Installing the Hydraulic Hose and Tube O Ring Face Seal Fitting page 6 11 8 If the lift cylinder for outside front cutting units 4 or 5 was removed secure the R clamp to the lift cylinder...

Page 337: ...s are longer with more stroke than the other lift cylinders which are identical Service procedures for all lift cylinders used on Reelmaster 5010 machines are the same Disassembling the Lift Cylinder...

Page 338: ...efully slide the head off the shaft Note Do not scratch or damage the piston 6 Remove the wear ring BP seal and O ring from the piston Note Do not scratch or damage the head 7 Remove the O ring back u...

Page 339: ...barrel in a vise by clamping on the clevis end of the barrel IMPORTANT When installing the head into the barrel pay careful attention to the retaining ring slot in the barrel to ensure that the piston...

Page 340: ...t 7 Steering control valve 12 Column brace 3 Flat washer 8 O ring 4 each 13 Socket head screw 4 each 4 Steering wheel 9 Straight hydraulic fitting 4 each 14 Steering column assembly 5 Socket head scre...

Page 341: ...185 Remove the shroud from the machine to get access to the steering control valve 3 Locate and retrieve the 2 rubber bushings and spacers 4 Slide the rubber bellows up from the bottom of the steerin...

Page 342: ...secure the steering column to the machine 13 Remove the steering column and steering control valve assembly from the machine 14 Loosen and remove the 4 socket head screws that secure the steering con...

Page 343: ...you attached during valve removal to connect the hydraulic lines to the fittings on the steering control valve Tighten the connections refer to Installing the Hydraulic Hose and Tube O Ring Face Seal...

Page 344: ...ve 23 Spool 6 Inner gearwheel 15 Dust seal ring 24 Spring set 7 Distributor plate 16 Housing 25 Thrust washer 8 O ring 17 Check ball 26 Shaft seal 9 Cardan shaft 18 Ball stop Note For the steering con...

Page 345: ...nut 19 Grease fitting 6 Hydraulic hose 13 Cotter pin 20 Bolt 7 90 grease fitting 14 Washer Removing the Steering Cylinder 1 Park the machine on a level surface lower the cutting units shut off the en...

Page 346: ...e ball joint is to be removed from the cylinder shaft fully retract the cylinder shaft and measure the ball joints center to center length for easy installation of the ball joint into the cylinder sha...

Page 347: ...r fittings Correctly connect the hydraulic hoses to the steering cylinder refer to Installing the Hydraulic Hose and Tube O Ring Face Seal Fitting page 6 11 10 Check the hydraulic fluid level in the h...

Page 348: ...ports and clean the outer surface of the cylinder IMPORTANT When you clamp the steering cylinder in a vise clamp the barrel clevis only to prevent damage Do not close the vise on the barrel 2 Mount th...

Page 349: ...g the Steering Cylinder CAUTION Use eye protection such as goggles when using compressed air 1 Wash all the cylinder components in clean solvent and dry them with compressed air 2 Inspect the internal...

Page 350: ...that the piston and head seals do not lodge in the slot 6 Put a light coating of clean hydraulic fluid on all internal parts Carefully slide the piston shaft and head assembly into the barrel Note Do...

Page 351: ...Washer 4 each 19 Oil cooler bracket 4 Pop rivet 2 each 12 Flange nut 4 each 20 Radiator frame 5 Oil cooler 13 Bolt 4 each 21 Radiator assembly 6 Hydraulic hose 2 each 14 Flat washer 8 each 22 Foam se...

Page 352: ...gine set the parking brake and remove the key from the key switch 2 Unlatch and open the rear screen 3 Label all hydraulic connections for assembly purposes Clean hydraulic connections before you loos...

Page 353: ...rings onto fittings Install fittings into cooler openings using marks made during the removal process to properly orientate fittings Tighten fittings refer to Installing the Hydraulic Fittings SAE Str...

Page 354: ...atch 13 Foam seal 2 each 22 Draincock 31 Pipe plug 5 Foam seal 2 each 14 O ring 2 each 23 Radiator and oil cooler assembly 32 Reservoir hose 6 Flange head screw 14 each 15 Straight hydraulic fitting 2...

Page 355: ...ulic oil cooler is combined with the radiator For 5410 D 5510 D 5610 D machines refer to Radiator page 4 18 and for 5410 G 5510 G machines refer to Radiator and Oil Cooler Assembly page 5 17 for infor...

Page 356: ...Hydraulic System Service and Repairs Page 6 238 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 357: ...ng 7 26 Operator Advisories 7 26 Using the InfoCenter Display for Troubleshooting 7 28 Machine Faults 7 32 Engine Faults 7 35 General Run and Transport Problems 7 39 Electrical System Quick Checks 7 4...

Page 358: ...lenoid Machine with Kubota Diesel Engine 7 100 Fuel Sender Diesel Engine 7 102 Fuel Sender Gasoline Engine 7 105 Fuel Pump Machine with Yanmar Diesel Engine 7 108 Fuel Pump Machine with Kubota Diesel...

Page 359: ...control the appropriate machine functions outputs based on the inputs Communication between the TEC InfoCenter display and engine ECU if equipped is provided by a CAN bus system The status of inputs t...

Page 360: ...hese resistors is included in the wire harness near the InfoCenter display and the second is either inside the engine ECU or included in the engine wire harness The CAN bus link controls each of the c...

Page 361: ...key switch is moved from the OFF position to either the ON RUN or START position If the engine ECU is to be disconnected for any reason ensure that the key switch is in the OFF position with the key r...

Page 362: ...ice tool to confirm the real time engine running status and to offer timely technical services Contact your Toro distributor for assistance in Kubota gasoline engine troubleshooting Electrical System...

Page 363: ...ures that the excess current is not allowed through the meter This excess current can damage the circuits that are not designed to carry it Terminal Protector Toro Part No 107 0392 Use this aerosol sp...

Page 364: ...the connector into the component unplug the connector apply the gel to both surfaces again and connect the harness connector to the component again The connectors must be fully packed with gel for eff...

Page 365: ...s inputs for the adjustable machine settings Figure 198 The power for the InfoCenter is available when the main power relay is energized key switch in the RUN or START position A CAN bus system involv...

Page 366: ...g213684 Figure 198 Electrical System InfoCenter Display Page 7 10 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 367: ...turned to the RUN or START position the fault indicator illuminates for a few seconds to verify indicator operation and the InfoCenter splash screen appears Figure 199 and Figure 200 The splash scree...

Page 368: ...0 seconds The main information screen is the default screen as it will be displayed during normal machine operation The main information screen provides the following information to the operator Engin...

Page 369: ...s not pressed within 6 seconds Operator Advisory Screen g187150 Figure 203 1 Fault indicator 3 Advisory description 2 Advisory qualifier 4 Advisory number code If the Toro Electronic Controller TEC in...

Page 370: ...atisfied any additional qualifiers that remain to be satisfied will appear in the operator advisory screen individually Note If a machine fault occurs during machine operation the InfoCenter fault ind...

Page 371: ...ing menu screens Faults Service Diagnostics Settings About Press the down button as indicated by the at the bottom of the screen to highlight the desired menu screen then press the left right button a...

Page 372: ...d by a number code and when the fault occurred The faults that might occur on the machine are listed in the Machine Faults page 7 32 If a machine fault occurs during operation the InfoCenter fault ind...

Page 373: ...cleared faults will be removed from the InfoCenter list but will be retained in the TEC memory Contact your Toro Distributor to view faults stored in the TEC memory Engine Faults g187359 Figure 208 1...

Page 374: ...key switch has been in the ON position Engine Run identifies the number of hours that the engine has been running PTO On identifies the number of hours that the machine has been operated with the cutt...

Page 375: ...left right button as indicated by the at the bottom of the screen and then pressing the down button as indicated by the Yes or at the bottom of the screen Additional information can be found in the Y...

Page 376: ...oid SV2 Solenoid SV3 Solenoid SVRV Lower identifies the machine requirements necessary to allow the TEC to lower the cutting units Inputs Qualifiers Outputs Joystick Lower Low Range Solenoid SV1 Seat...

Page 377: ...units Inputs Qualifiers Outputs Front Backlap Neutral Front MSV1 Rear Backlap Parking Brake Rear MSV2 Reel Engage Switch Cutting Units Down Engine Running Settings Screen g187358 Figure 211 1 Settings...

Page 378: ...in in view for 5 seconds Language Use the left right button as indicated by the at the bottom of the screen to select from numerous language options Allow the desired selection to remain in view for 5...

Page 379: ...ote To change the machine PIN access the protected menu items by entering the current PIN The InfoCenter display screen should indicate PIN in the upper right hand corner after the current PIN number...

Page 380: ...ory 176 Reel Speed Changed will appear on the InfoCenter display to confirm that the change has been recorded F Reel RPM Initially the front reel speed is set by the TEC based on the values entered fo...

Page 381: ...in the Settings Screen page 7 21 the InfoCenter software is displayed and the CAN bus status will be visible Press the down button to scroll through the screen items as indicated by the at the bottom...

Page 382: ...ory will be displayed on the InfoCenter display refer to Operator Advisory Screen page 7 13 Advisory numbers descriptions and reason for advisories are listed in the Advisories Table page 7 26 Some ad...

Page 383: ...177 Reel Speed Changed Out of Range Check the reel settings blade count mow speed and HOC using the InfoCenter Settings screen 178 Low fuel Fuel level in the fuel tank is low 179 Ash cleaning warning...

Page 384: ...o testing each component individually Lift The components necessary to raise the cutting units Lower The components necessary to lower the cutting units PTO The components necessary to engage the cutt...

Page 385: ...e left right button as indicated by the at the bottom of the screen g189683 Figure 216 1 Input items 3 Down button 2 Left right button 4 Menu back button 5 Manually operate each input item listed Figu...

Page 386: ...listed Figure 217 The qualifier condition on the InfoCenter display should alternate and as the qualifiers condition is changed If and do not alternate during qualifier operation the qualifier compone...

Page 387: ...should be ON If the outputs remain OFF the Toro Electronic Controller TEC or TEC software may be damaged and require reloading or replacement Contact your Toro Distributor for assistance 10 If the out...

Page 388: ...the OFF position Leave the switch in the OFF position for 30 seconds and then start the machine During this system reboot process the machine controllers often can reset the electrical components to...

Page 389: ...ed in the TEC so they cannot be viewed using the InfoCenter Faults Screen Machine Fault Table Fault Code Fault Description Service Suggestions 1 Excessive engine coolant temperature above 105 C caused...

Page 390: ...t relay is excessive Check the start relay and circuit wiring 27 TEC output current to fuel pump is excessive Check the fuel pump and circuit wiring 37 TEC output current to energize glow relay is exc...

Page 391: ...gure 218 2 If a Stop fault is displayed on the InfoCenter the operator should cease operation of the machine and the engine as quickly and as safely as possible to reduce damage to the engine 3 If a C...

Page 392: ...s damaged The engine cranks but does not start Note After 30 seconds of engine cranking the Toro Electronic Controller TEC output to the engine starter motor will de energize even if the key switch is...

Page 393: ...ne cranks but should not when the traction pedal is pressed The traction neutral switch is out of adjustment The traction neutral switch or circuit wiring is damaged The engine starts but stops when t...

Page 394: ...ent The traction neutral switch or circuit wiring is damaged The seat switch or circuit wiring is damaged The parking brake switch or circuit wiring is damaged The joystick switch or circuit wiring is...

Page 395: ...peration but it is able to start again Note Excessive coolant temperature will cause the cutting units to be disengaged and can cause the engine to shutdown If the excessive engine coolant temperature...

Page 396: ...ables are loose or corroded The fusible link connecting the engine starter motor is damaged machine with diesel engine The alternator is damaged The battery is damaged Cutting Unit Operating Problems...

Page 397: ...maged A hydraulic problem in the cutting unit circuit exists refer to Troubleshooting page 6 50 The TEC is damaged The cutting units run but should not when lowered with joystick and the reel engage s...

Page 398: ...tion High engine coolant temperature has disabled cutting unit operation The front or rear backlap switch or circuit wiring is damaged The cutting unit down limit switch or circuit wiring is damaged A...

Page 399: ...cuit wiring is damaged The lift control manifold SV2 solenoid coil or circuit wiring is damaged A hydraulic problem in the cutting unit lift lower circuit exists refer to Troubleshooting page 6 50 The...

Page 400: ...ging system is functioning It tells you if the charging system has an output but not its capacity Note The InfoCenter display can be used to identify battery voltage during the operation of the machin...

Page 401: ...er glow plug 27 A total on Reelmaster 5210 and 36 A total on models with 4 cylinder engine If low current reading is observed 1 or more glow plugs is damaged Checking the Operation of the Interlock Sw...

Page 402: ...he traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the NEUTRAL position The switch mounts to a pump plate on the traction pump Figure 219 The sens...

Page 403: ...ap between the head of the neutral switch and the pump lever should be 2 4 to 2 5 mm 0 094 to 0 100 inch Figure 220 4 If gap is incorrect loosen the jam nuts that secure the neutral switch to the pump...

Page 404: ...parking brake switch is attached to the bottom of the brake pedal Figure 221 When the parking brake is not set the parking brake detent is positioned near the target end of the parking brake switch so...

Page 405: ...o 0 100 inch Figure 222 3 If gap is incorrect loosen the jam nuts that secure the switch to the brake pedal Position the switch with jam nuts to allow correct gap between the switch and the detent tab...

Page 406: ...rmally open proximity switch that closes when the front outside cutting units are in the turn around position The down limit switch is attached to a frame bracket inside the front right lift arm pivot...

Page 407: ...arm 2 Bracket 3 Down limit switch 2 The distance between the down limit switch and the sensing plate on lift arm should be 2 4 to 2 5 mm 0 094 to 0 100 inch Figure 224 3 If distance is incorrect loose...

Page 408: ...h mounts to a bracket on the footrest platform Figure 225 The sensing plate for the mow transport switch is the mow speed limiter Adjusting the Mow Transport Switch IMPORTANT To prevent the mow transp...

Page 409: ...switch and the mow speed limiter Tighten the jam nuts to secure the adjustment Torque the jam nuts to 18 4 to 22 4 N m 162 to 198 in lb After the jam nuts are tightened ensure that clearance between...

Page 410: ...hooting Manual IMPORTANT When testing the electrical components for continuity with a multimeter ohms setting ensure that you disconnect the power to the circuit Fusible Link Harness Machines with Kub...

Page 411: ...the continuity exists between each terminal pin in the connector P1 and connector J1 at the starter Figure 228 4 If any of the fusible links are open replace the fusible link harness Note Do not repla...

Page 412: ...fuse block there are 2 additional fuses included in the engine wire harness These fuses plug into the in line fuse holders near the starter motor Figure 230 The fuses have the following functions 2 A...

Page 413: ...nstalled in the fuse block use a multimeter to check that 12 VDC exists at both of the terminal test points on the fuse If 12 VDC exists at 1 of the fuse test points but not at the other the fuse is d...

Page 414: ...g the Fuses continued 5 After you complete the fuse testing install the control arm access cover Electrical System Testing the Electrical Components Page 7 58 Reelmaster 5410 5510 5610 Series 15216SL...

Page 415: ...ses in the power center a 60 A maxi fuse is included in the engine wire harness to protect the charging circuit This maxi fuse resides in an in line fuse holder near the engine starter motor Figure 23...

Page 416: ...1 Ensure that the key switch is in the OFF position and key is removed from key switch 2 Raise and support hood to access engine fuses Remove engine power center cover if necessary Locate fuse s to b...

Page 417: ...rious switches inputs and then direct power output to allow certain machine functions The controller is located behind the control arm access cover next to the fuse block Figure 234 Use the InfoCenter...

Page 418: ...utputs is provided through 3 connectors PWR 2 PWR 3 and PWR 4 each protected with a 7 5 A fuse A 50 pin wire harness connector attaches to the controller The connector pins are identified in Figure 23...

Page 419: ...y cables from the battery disconnect the wire harness connector from the TEC and engine ECU if equipped and disconnect the terminal connector from the alternator This will prevent damage to the electr...

Page 420: ...it wiring are functioning correctly no further key switch testing is necessary 4 If the input testing determines that the key switch and circuit wiring are not functioning correctly proceed with the f...

Page 421: ...oblem still exists check the wire harness refer to the Electrical Schematic and Wire Harness Drawings Diagrams in Appendix A page A 1 10 After you complete the testing connect the main wire harness co...

Page 422: ...a level surface lower the cutting units set the parking brake and shut off the engine 2 Before you disconnect the reel engage switch for testing ensure that you test the switch and its circuit wiring...

Page 423: ...2 1 5 4 Note The reel engage switch terminals 1 and 4 are not used on Reelmaster 5010 machines 8 Replace the reel engage switch if testing determines that the switch is damaged 9 If the reel engage sw...

Page 424: ...r to Using the InfoCenter Display for Troubleshooting page 7 28 3 If the InfoCenter verifies that the engine speed switch and circuit wiring are functioning correctly no further switch testing is nece...

Page 425: ...itch is damaged 9 If the engine speed switch testing is correct and a circuit problem still exists check the wire harness refer to the Electrical Schematic and Wire Harness Drawings Diagrams in Append...

Page 426: ...disengage the cutting units Figure 244 The switches are identical A normally open contact in the switch closes when the joystick is positioned to either lower or raise the cutting units Each switch h...

Page 427: ...ctrical connectors from the raise and lower switches on the joystick assembly 7 Connect a multimeter ohms setting across the switch connector terminals to check the continuity of the switches as follo...

Page 428: ...connector from the headlight switch g223017 Figure 246 4 The headlight switch terminals are identified in Figure 246 and the circuitry of the switch is shown in the Circuit Logic Table page 7 72 With...

Page 429: ...atic and Wire Harness Drawings Diagrams in Appendix A page A 1 7 After you complete the testing connect the wire harness connector to the headlight switch 8 Secure the left control arm cover to the ma...

Page 430: ...en the operator raises out of the seat an operator advisory will be displayed on the InfoCenter The seat switch and its electrical connector are located directly under the operator seat Figure 248 Tes...

Page 431: ...a multimeter ohms setting across the seat switch harness connector terminals to check the continuity of the seat switch A With no pressure on the seat ensure that there is no continuity between the h...

Page 432: ...with the InfoCenter display refer to Using the InfoCenter Display for Troubleshooting page 7 28 3 If the InfoCenter verifies that the down limit switch and circuit wiring are functioning correctly no...

Page 433: ...ire is closed to the ground the pink wire has system voltage present and the switch LED did not function replace the down limit switch Adjust the switch after installation refer to Adjusting the Cutti...

Page 434: ...electrical input with the InfoCenter display refer to Using the InfoCenter Display for Troubleshooting page 7 28 3 If the input testing verifies that the neutral switch and circuit wiring are function...

Page 435: ...th a multimeter that the main wire harness connector terminal for pink wire has system voltage 12 VDC present E Turn the key switch to the OFF position F If the black wire is closed to the ground the...

Page 436: ...ake is set causing the switch to open The Toro Electronic Controller TEC monitors the operation of the parking brake switch Testing the Parking Brake Switch 1 Park the machine on a level surface lower...

Page 437: ...multimeter ohms setting check that the main wire harness connector terminal for black wire is closed continuity to the ground D Turn the key switch to the RUN position do not start the engine and che...

Page 438: ...switch and circuit wiring are functioning correctly no further mow transport switch testing is necessary 4 If the input testing determines that the mow transport switch and circuit wiring are not func...

Page 439: ...did not function replace the mow transport switch Adjust the switch after installation refer to Adjusting the Mow Transport Switch page 7 52 8 If the mow transport switch testing is correct and a cir...

Page 440: ...ring as TEC input with the InfoCenter display refer to Using the InfoCenter Display for Troubleshooting page 7 28 3 If the InfoCenter verifies that the backlap switch and circuit wiring are functionin...

Page 441: ...rrect and a circuit problem still exists check the wire harness refer to the Electrical Schematic and Wire Harness Drawings Diagrams in Appendix A page A 1 13 After you complete the testing connect th...

Page 442: ...Advisory 169 Testing the Oil Pressure Switch 1 Park the machine on a level surface set the parking brake lower the cutting units and shut off the engine Remove the key from the key switch 2 Raise and...

Page 443: ...ng low engine oil as the cause of engine shutdown check for damaged wire in the oil pressure switch circuit 6 After testing is completed connect the wire harness connector to the oil pressure switch L...

Page 444: ...relay is energized by the TEC The glow relay is energized by the engine ECU on machines with a Yanmar diesel engine The main power and glow relay are attached to a frame bracket under the hood next t...

Page 445: ...257 7 Connect the multimeter ohms setting leads to the relay terminals 30 and 87 Then ground terminal 85 and apply 12 VDC to terminal 86 The relay should make and break the continuity between the term...

Page 446: ...r circuit wiring is damaged Testing the Relays with 5 Terminals 1 Park the machine on a level surface lower the cutting units shut off the engine set the parking brake and remove the key from the key...

Page 447: ...apply 12 VDC to the terminal 85 The relay should make and break continuity between the terminals 30 and 87A as 12 VDC is set and removed from the terminal 85 10 After testing disconnect the voltage an...

Page 448: ...gine fault code may be displayed on the InfoCenter Display if the power relay fuel pump relay or circuit wiring is damaged Testing the Engine Relays with 5 Terminals 1 Park machine on a level surface...

Page 449: ...terminals 30 and 87 as 12 VDC is removed from terminal 85 5 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 Replace relay if testing determines that it is damaged 6 Install re...

Page 450: ...continued 9 Secure relay to machine and connect machine wire harness connector to relay 10 Install hood saddle Lower and secure hood Electrical System Testing the Electrical Components Page 7 94 Reel...

Page 451: ...cifications Table page 7 97 Testing of the coils can be done with the coil installed on the hydraulic valve Note The 2 solenoid valve coils on the mow control manifold MSV1 and MSV2 are identical The...

Page 452: ...ft control manifold remove the operator floor plate Figure 265 3 Identify the coil by measuring the height and diameter of the coil 4 Disconnect the wire harness connector from the hydraulic solenoid...

Page 453: ...il refer to Hydraulic Solenoid Valve Coils page 7 120 7 If the solenoid coil testing is correct and a circuit problem still exists check the main wire harness refer to the Electrical Schematic and Wir...

Page 454: ...will be generated to help identify the problem refer to Faults Screen page 7 16 Note Excessive engine coolant temperature a damaged temperature sender or damaged wiring to the temperature sender coul...

Page 455: ...of the sender with a multimeter ohms setting as the temperature increases and record measured resistance values Compare to specifications below Replace sender if specifications are not met Oil Tempera...

Page 456: ...solenoid may be removed from the engine or tested in place 3 If the solenoid is removed from the engine ensure that the solenoid plunger moves freely and is free of dirt unwanted material and corrosi...

Page 457: ...other test lead to the fuel stop solenoid frame ground Figure 269 The resistance of the hold coil should be approximately 15 ohms 6 If either coil resistance is incorrect replace fuel stop solenoid 7...

Page 458: ...Park the machine on a level surface lower the cutting units shut off the engine set the parking brake and remove the key from the key switch 2 Remove the 5 screws that secure the sender cover to the f...

Page 459: ...fuel supply and return hoses from the fittings on the top of the fuel sender g188097 Figure 271 1 Fuel sender 2 Fuel supply fitting 3 Fuel return fitting IMPORTANT Before removing the fuel sender fro...

Page 460: ...he sender with the sender gasket and fuel sender cap Ensure that the fuel fittings on the sender are orientated at 90 from right side of the tank as shown in Figure 271 Also to prevent damage to the f...

Page 461: ...Kubota gasoline engine the fuel sender is a component of the fuel pump assembly which is secured to the top of the fuel tank The resistance of the fuel sender increases as the fuel level in the fuel...

Page 462: ...t the circuit wiring and InfoCenter fuel gauge use a jumper wire to connect the 2 wire harness connector pins and turn key switch to ON RUN InfoCenter fuel gauge should indicate full if circuit wiring...

Page 463: ...mately 2 ohms 7 Replace fuel pump assembly if resistance testing determines that the fuel sender is damaged 8 When testing is complete carefully install gasket and fuel pump assembly to fuel tank 9 En...

Page 464: ...fuel DANGER Diesel fuel is highly flammable Use caution whenever you handle diesel fuel Do not smoke while testing the fuel pump Do not test the fuel pump while the engine is hot Ensure that there is...

Page 465: ...seconds must be approximately 350 ml 11 8 fl oz 7 Replace the fuel pump if output specification is not met IMPORTANT If the fuel pump is replaced ensure that replacement pump is the correct pump for...

Page 466: ...Ensure that there is adequate ventilation when testing Always wipe up any spilled fuel before starting the engine Testing the Fuel Pump Capacity 1 Park machine on a level surface lower cutting units s...

Page 467: ...d cylinder should be approximately 475 ml 16 fl oz after 15 seconds 8 Replace fuel pump if testing determines that it is damaged 9 Install fuel hose to the fuel water separator Ensure to secure fuel h...

Page 468: ...el surface lower the cutting units shut off the engine and set the parking brake Remove the key from the key switch Raise and support the hood CAUTION The fuel supply hose will contain pressurized fue...

Page 469: ...ilter or damaged fuel pump refer to Fuel System page 5 11 6 After testing is completed remove pressure gauge from fuel supply hose Connect fuel supply hose to fuel fitting on engine fuel rail and secu...

Page 470: ...e The insulator wedge in the terminator resistor is blue for identification purposes There is also a center keyway to prevent the terminator resistor from plugging into the wrong wire harness connecto...

Page 471: ...ete the testing ensure that the CAN bus terminator resistor is fully installed into the wire harness connector and secured to the wire harness with cable tie Reelmaster 5410 5510 5610 Series Page 7 11...

Page 472: ...n be identified by its gray color and resistor symbol on the end of the resistor assembly body Figure 281 Testing the Resistor Assembly 1 Park the machine on a level surface set the parking brake lowe...

Page 473: ...replace the resistor assembly 5 After you complete the testing ensure that the resistor is fully installed into the wire harness connector and secured to the wire harness with cable tie Reelmaster 54...

Page 474: ...bly body Figure 282 The 2 diodes plug into the engine wire harness near the Yanmar engine ECU Figure 283 refer to the Engine Wire Harness Drawing Diagram in Appendix A page A 1 A diode assembly D1 is...

Page 475: ...g and the Diode Test Table page 7 119 4 Replace the diode assembly if testing determines that the diode is damaged 5 After you complete the testing ensure that the diode is fully installed into the wi...

Page 476: ...ve Coils g214062 Figure 284 1 Mow control manifold 3 Nut 2 Solenoid coil MSV1 4 Solenoid coil MSV2 g214063 Figure 285 1 Solenoid coil SV3 4 Solenoid coil SV1 7 Solenoid coil SVRV 2 Coil spacer 5 Solen...

Page 477: ...he orientation of the electrical connector on the coil for assembly purposes 4 Remove the nut from the hydraulic valve 5 If equipped SV1 or SV3 on the lift control manifold remove the coil spacer from...

Page 478: ...oubleshooting page 7 28 Removing the Backlap Switches 1 Park the machine on a level surface lower the cutting units shut off the engine set the parking brake and remove the key from the key switch 2 R...

Page 479: ...7 2 Install the backlap switch with new O ring into the manifold port and torque the switch to 27 N m 20 ft lb 3 Connect the harness electrical connector to the backlap switch Use the InfoCenter displ...

Page 480: ...can cause nausea Wear safety goggles and rubber gloves when working with electrolyte Charge the battery in a well ventilated place so that the gasses produced while charging can dissipate Keep open f...

Page 481: ...ed water Note Do not fill the cells above the fill line Servicing the Battery The battery is the heart of the electrical system With the regular and correct service the battery life can be extended Ad...

Page 482: ...riage screw 3 Retainer 6 Negative battery cable The battery on machines with a Yanmar diesel engine or a Kubota gasoline engine is located at the rear of the machine Figure 288 The battery on machines...

Page 483: ...minal protector Toro Part No 107 0392 or petroleum jelly to prevent corrosion 8 Install the battery cover if equipped Close and secure the screen or hood Inspecting Maintaining and Testing the Battery...

Page 484: ...specific gravity is less than 1 225 charge the battery D Charge at the rate and time given in Charging the Battery page 7 129 or until all cells specific gravity is 1 225 or greater with the differenc...

Page 485: ...tery If the test voltage is at or above the minimum return the battery to service 4 After you make the connections apply terminal protector Toro Part No 107 0392 or a light layer of grease on all the...

Page 486: ...60 F before connecting to a charger Charge the battery in a well ventilated place to dissipate the gases produced from the charging These gases are explosive keep open flame and electrical spark away...

Page 487: ...of a battery cell once per hour Note The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for 3 consecutive...

Page 488: ...Electrical System Service and Repairs Page 7 132 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 489: ...irs 8 5 Wheels 8 5 Steering Column 8 7 Servicing the Brakes 8 10 Rear Wheel Bearings Machines with 2 Wheel Drive 8 14 Rear Axle Motor Housings 8 16 Rear Axle 8 19 Control Arm 8 23 Operator Seat 8 26 M...

Page 490: ...m 20 to 26 ft lb Front wheel motor wheel hub locknut torque 407 to 542 N m 300 to 400 ft lb Rear wheel motor wheel hub locknut torque machines with CrossTrax AWD installed 366 to 447 N m 270 to 330 f...

Page 491: ...garding the operation general maintenance and maintenance intervals for your Reelmaster machine Refer to the Operator s Manual for additional information when servicing the machine Reelmaster 5410 551...

Page 492: ...wheel hub puller allows you to safely remove the wheel hub from the wheel motor shaft If the machine is equipped with the optional CrossTrax Kit this wheel hub puller is necessary for removing the rea...

Page 493: ...l 5 Brake assembly left 9 Front wheel 2 Wheel lug nut 5 each per wheel 6 Wheel stud 5 each per hub 10 Locknut 3 Locknut 7 Front wheel hub 11 Rear wheel hub 4 Front wheel motor left 8 Brake drum 12 Rea...

Page 494: ...moved is off the ground Support the machine with appropriate jack stands 5 Remove the 5 wheel lug nuts that attach the wheel to the machine and remove the wheel Installing the Wheel 1 Install the whee...

Page 495: ...nut 7 Steering control valve 12 Column brace 3 Flat washer 8 O ring 4 each 13 Socket head screw 4 each 4 Steering wheel 9 Straight hydraulic fitting 4 each 14 Steering column assembly 5 Socket head sc...

Page 496: ...steners as follows A Remove the cover plate from the platform B Remove the platform shroud from the machine C Locate and retrieve the 2 rubber bushings and 2 spacers 6 Slide the rubber bellows up the...

Page 497: ...g column with the 4 socket head screws item 13 in Figure 291 torque the socket head screws to 9 5 to 13 5 N m 84 to 120 in lb in a criss cross pattern 5 Slide the rubber bellows to the bottom of the s...

Page 498: ...el hub 25 Clevis pin 2 each 8 Bolt 4 each per wheel motor 17 Wheel stud 5 each per hub 26 Right wheel motor 9 Left brake assembly 18 Front wheel shield right front Disassembling the Brake 1 Park the m...

Page 499: ...assembly can be removed from the machine for disassembly refer to step 12 g185919 Figure 295 1 Hold down pin 2 each 6 Brake shoe 2 each 11 Brake actuator 2 Backing plate 7 Shoe spring 12 Brake actuat...

Page 500: ...hoe spring 2 Hold down components 4 Brake actuator Note The shoe spring actuator must be installed at the actuator end of the brake shoes 6 Install the 2 shoe springs items 10 and 7 in Figure 295 to t...

Page 501: ...ay result in personal injury Maintain the proper torque of the wheel lug nuts 14 Torque the wheel hub locknut item 15 in Figure 294 that secures the wheel hub to 407 to 542 N m 300 to 400 ft lb CAUTIO...

Page 502: ...h jack stands 3 Remove the dust cap from the wheel hub 4 Remove the cotter pin retainer jam nut and tab washer Slide the wheel hub from the spindle shaft 5 Pull the seal out of the wheel hub Discard s...

Page 503: ...hub assembly onto the spindle shaft and secure it in place with the tab washer and jam nut Do not fully tighten the nut or install the cotter pin 5 While rotating the wheel hub by hand torque the jam...

Page 504: ...ap 2 each 10 Rear wheel left 17 Motor housing 2 each 24 Motor housing shaft 4 Retaining ring 2 each 11 Wheel lug nut 5 each per wheel 18 Cotter pin 3 each 25 Ball joint 5 Flange bushing 4 each 12 Lock...

Page 505: ...rom the drag link 6 For the machines equipped with CrossTrax AWD remove the 4 bolts item 14 in Figure 298 and 4 lock washers that secure the wheel motor to the motor housing Slide the wheel motor asse...

Page 506: ...ap item 3 in Figure 298 to the top of the motor housing shaft and secure with the flange head screw 6 If the hub and spindle assembly item 2 in Figure 299 was removed 2 wheel drive machines secure the...

Page 507: ...ink 5 Ball joint 14 Left drag link 23 Lock washer 4 each per motor 32 Steering cylinder 6 Thrust washer 2 each 15 Wheel motor left 24 Motor housing 2 each 33 Ball joint 7 Axle bushing 2 each 16 Wheel...

Page 508: ...atch and open the radiator screen assembly B Remove the 3 bolts item 2 in Figure 303 3 lock washers and 3 spacers that secure the CrossTrax AWD control manifold to the frame so that the rear axle pivo...

Page 509: ...rod ball joint and jam nut at the grooved end of the tie rod have left hand threads 1 Loosen the jam nuts and then remove the ball joints from the tie rod 2 Thread new ball joints equally into the tie...

Page 510: ...8 18 5 Install the steering cylinder to the rear axle refer to Installing the Steering Cylinder page 6 228 6 Install the 2 rear wheel assemblies refer to Installing the Wheel page 8 6 7 Check the rear...

Page 511: ...TEC Toro Electronic Controller 19 Spring 30 Cotter pin 9 Fuse block 20 Flat washer 2 each 31 Nylon bushing 2 each 10 Joystick assembly 21 Clevis pin 32 Left control arm cover 11 Screw 22 Flange head s...

Page 512: ...6 Remove the control arm covers from the machine As the left control arm cover item 32 in Figure 304 is removed from the control arm disconnect the wire harness connector from the headlight switch 7...

Page 513: ...at the platform wire harness is routed correctly through the cover openings and the harness foam seal is captured between the control arm covers Figure 306 3 Secure each cover to the control arm with...

Page 514: ...nge nut 13 Seat adjuster w latch 22 Housing cap 5 Screw 14 Flat washer 8 each 23 R clamp 2 each 6 Flange head screw 3 each 15 Socket head screw 4 each 24 Seat adjuster 7 Flat washer 16 Seat switch har...

Page 515: ...1 Park the machine on a level surface lower the cutting units shut off the engine set the parking brake and remove the key from the key switch 2 Disconnect the negative battery cable from the battery...

Page 516: ...he seat and seat base to the seat adjusters 8 Record which set of seat mounting holes are used remove the operator seat and seat base from the seat adjusters Installing the Operator Seat 1 Use the mou...

Page 517: ...seat switch wire harness connector to the platform wire harness Figure 308 5 Connect the negative battery cable to the battery refer to Servicing the Battery page 7 125 Reelmaster 5410 5510 5610 Serie...

Page 518: ...2 each 41 Flat washer 6 Bumper 3 each 18 Extension spring 30 Roller pin 42 Weight indicator assembly 7 Height adjust knob cap 19 Roller 4 each 31 Pivot pin 43 Male snap rivet 2 each 8 Height adjust k...

Page 519: ...head screws item 4 in Figure 311 and 4 flange nuts that secure the seat suspension to the seat frame 6 Remove the seat suspension from the machine g185934 Figure 311 1 Seat adjuster w latch 8 Manual...

Page 520: ...e 2 Position the seat base cover and 4 spacers item 7 in Figure 311 to the seat frame 3 Use the mounting holes that were recorded during removal position the seat suspension to the seat frame and secu...

Page 521: ...lift arm 13 Pivot yoke 3 each 22 Lock washer 2 each 5 Bridge plate 14 Cap 1 each per lift arm 23 Down limit switch 6 Thrust washer 6 each 15 Thrust washer 2 each per yoke 24 Bolt 2 each per chain hoop...

Page 522: ...inder pin that secures the lift cylinder to the lift arm B Pull the cylinder pin from the lift cylinder and lift arm Locate and retrieve the second thrust washer C Pivot the lift cylinder rod end away...

Page 523: ...or damage If necessary remove the roll pin that secures the pivot shaft to the frame and remove the pivot shaft from the frame Discard the roll pin Installing the Front Lift Arms 1 If the lift arm piv...

Page 524: ...g 6 Mount the cutting unit to the lift arm 7 Lubricate the grease fittings on the lift arm pivot yoke and lift cylinder 8 Check operation of lift arm down limit switch and adjust if necessary refer to...

Page 525: ...9 3 lift arm 4 Washer 2 each 12 Chain hoop 2 each 20 Washer head screw 1 each per shaft 5 Shoulder stud 6 each 13 Chain 2 each 21 Pivot shaft 2 each 6 Locknut 6 each 14 Flange nut 2 each per chain hoo...

Page 526: ...ift arm B Pull the cylinder pin from the lift cylinder and lift arm Locate and retrieve the second thrust washer C Pivot the lift cylinder rod end away from the lift arm 4 Remove the lynch pin and thr...

Page 527: ...2 each 5 Right torsion spring 7 Flange head screw 2 each 2 Pivot shaft 2 each 4 Spacer 2 each 6 Spring catch 8 Left torsion spring 6 Remove the torsion springs and components that secure the springs...

Page 528: ...ong leg of spring forward and pointing out from top of the spring On the machines that include a housing to secure the torsion springs shown in Figure 316 the short leg of the torsion springs should b...

Page 529: ...bumper 2 each 12 Hex nut 19 Catch latch 2 each 6 Flange head screw 10 each 13 Spacer 20 Hood saddle 7 Side hood frame tube 2 each 14 Grommet There are some variations in the hoods used on Reelmaster...

Page 530: ...als on the hood Replace the seals that are damaged or missing Note The hood used on Reelmaster 5610 machines powered by a Kubota turbocharged diesel engine has additional shields on the underside of t...

Page 531: ...d Grinding 9 23 Servicing the Bedbar Adjuster 9 27 Reel Assembly cutting units with painted side plates 9 29 Reel Assembly Service cutting units with painted side plates 9 33 Reel Assembly cutting uni...

Page 532: ...th aluminum side plates Cutting units with painted side plates have two double row self aligning ball bearings press fit onto reel shaft with inboard seal for protection Reel bearing adjustment is mai...

Page 533: ...seal package Counterbalance weight A cast iron weight or a groomer and or a powered rear roller brush accessory is mounted opposite to the hydraulic drive motor to balance the cutting unit Cutting uni...

Page 534: ...machine Additionally if optional kits have been installed on the cutting units e g groomer rear roller brush the installation instructions for the kit includes set up and operation information Refer...

Page 535: ...ewdriver type bit is made to fit Toro bedknife attaching screws Use this bit with a torque wrench to secure the bedknife to the bedbar IMPORTANT Important To prevent damage to the bedbar do not use an...

Page 536: ...ng screws from resting on the work surface Spline Insert Tool Toro Part No TOR4112 8 tooth for 5 inch reels Toro Part No TOR4074 9 tooth for 7 inch reels Use the spline insert tool for rotating the cu...

Page 537: ...uring tape for accurately measuring the circumference and outside diameter of the cutting reel and other spherical components Tape calibration is in fixed inch readings no adjustments Reel Bearing Ins...

Page 538: ...el to bedknife clearance 10 packs 30 strips per pack of cutting performance paper are included in this part number Pulley Alignment Tool Toro Part No 114 5446 Use the pulley alignment tool to verify a...

Page 539: ...the bottom side of the bedknife with the digital display facing you as shown 2 Press the Alt Zero button on the angle indicator g223327 Figure 322 1 Bedknife 3 Bedbar 2 Angle Indicator 3 Remove the an...

Page 540: ...speed during machine operation use the InfoCenter display to check the engine speed refer to Chapter 4 Yanmar Diesel Engine page 4 1 for high idle speed specification Reel speed All the cutting reels...

Page 541: ...pping page 9 19 Rear roller adjustment Adjust the rear roller brackets to correct position depending on the height of cut range and aggressiveness of cut that is desired Refer to Rear Roller Adjustmen...

Page 542: ...terbalance spring adjustment Refer to the Traction Unit Operator s Manual for rear lift arm counterbalance spring adjustment procedure Cutting unit accessories A variety of cutting unit accessories ar...

Page 543: ...nt procedures for your Reelmaster machine 1 Adjust the bedknife parallel to the reel 2 Determine the desired height of cut range and install the rear roller mounting shim s accordingly 3 Adjust the he...

Page 544: ...s no contact between the bedknife and the reel 2 Remove the cutting unit components on the LH side plate to get access to the bearing adjuster nut If the cutting unit is equipped with a rear roller br...

Page 545: ...1 Place the assembled cutting unit on a surface plate 2 Ensure that the bedknife is properly adjusted to the cutting reel 3 Check if the rear roller is level to the cutting reel by using a 0 13 mm 0...

Page 546: ...rew 2 each 4 Flat washer 2 each 7 If the rear roller is still not level after adjusting both side plates check to see if the cutting reel is tapered refer to page If the cutting reel is not tapered an...

Page 547: ...ydraulic reel motor 3 Relief vent 2 Bolt 2 each 4 Grease fitting 2 Loosen the 2 bolts item 2 in Figure 327 that secure the hydraulic reel motor to the cutting unit side plate Rotate the motor clockwis...

Page 548: ...location 2 Reel motor location Note Refer to Figure 329 for correct placement of cutting unit reel motors and weights 1 Coat the spline shaft of the reel motor with No 2 multipurpose lithium base gre...

Page 549: ...tors are connected in series rotating one motor causes rotation in other motors Instructions and procedures on backlapping are available in the Traction Unit Operator s Manual and the Toro General Ser...

Page 550: ...key switch 2 Remove the cutting unit from the machine Use the cutting unit kickstand to support the cutting unit refer to page 3 Loosen the locknut item 2 in on the end of each bedbar adjuster assembl...

Page 551: ...acing outward Apply anti seize lubricant to the inside of the flange bushing 3 Apply anti seize lubricant to the bedbar threads and the shoulder area of each bedbar pivot bolt 4 Slide a metal washer a...

Page 552: ...10 until the outside metal washer just rotates Do not over tighten the lock nuts as this can distort the side plates and affect reel to bedknife contact or in the case of cutting units with painted s...

Page 553: ...tion Installing the Bedknife 1 Use a scraper to remove all rust scale and corrosion from the bedbar surface Lightly oil the bedbar surface before installing the bedknife 2 Ensure that the screw thread...

Page 554: ...nife Grinding the Bedknife g207291 Figure 335 1 Top angle 4 Front surface 2 Top surface 5 Front angle 3 Remove burr without dulling sharp corner Bedknife Grinding Specifications Bedknife Lip Height Se...

Page 555: ...nife for impacts When grinding the bedknife be careful to not overheat the bedknife Remove small amounts of material with each pass of the grinder Also clean and dress grinding stone often during the...

Page 556: ...337 The original chamfer should last for the first 40 of the bedknife service life Check and re grind the lead in chamfer as necessary 3 After you complete the bedknife grinding install the bedbar to...

Page 557: ...for early production DPA cutting units Figure 338A used a retaining ring on the end of the bedbar adjuster shaft Current production DPA cutting units Figure 338B include a lock nut on the end of the...

Page 558: ...16 ft lb 2 If flange bushings item 5 were removed apply antiseize lubricant to bore of cutting unit frame Align key on bushing to slot in frame and install bushings into frame Apply antiseize lubrican...

Page 559: ...Note This section provides the procedure for removing and installing the cutting reel assembly cutting reel spline inserts grease seals and bearings from the cutting unit Note Refer to Reel Assembly...

Page 560: ...Removing the Front Roller page 9 43 6 Remove the rear roller refer to Removing the Rear Roller page 9 45 g230064 Figure 340 1 Carrier frame 5 Flat washer 9 LH side plate 2 Shim if equipped 6 Cap scre...

Page 561: ...utting reel see Reel Assembly Service in this section Apply thin coat of grease to outside of grease seals and bearings on cutting reel to ease reel installation Also apply grease to bearing bores and...

Page 562: ...g the Reel Bearing cutting units with painted side plates page 9 13 13 Adjust the cutting unit refer to the Cutting Unit Operator s Manual Note The parallel position of the rear roller to the cutting...

Page 563: ...the reel diameter refer to page 3 Check the threaded inserts in the reel shaft for excessive wear or distortion Replace inserts if damage is evident A The threaded inserts are installed with thread l...

Page 564: ...als onto the reel shaft with the metal side orientated toward the bearing location Final position of the seal should be flush to 1 5 mm 0 060 inch away from the retaining ring on the reel shaft Do not...

Page 565: ...g 18 O ring Note This section provides the procedure for removing and installing the cutting reel assembly cutting reel spline inserts grease seals and bearings from the cutting unit Note Refer to Ree...

Page 566: ...unit from the machine and place on a flat work area 3 If cutting unit is equipped with a counterweight or accessory on LH side plate remove the counter weight or accessory from the cutting unit Remov...

Page 567: ...that secure the LH side plate to the cutting unit frame Remove the LH side plate from the reel shaft and cutting unit frame CAUTION Contact with the reel bedknife or other cutting unit parts can resu...

Page 568: ...frame Tighten the shoulder bolts from 37 to 44 N m 27 to 33 ft lbs 9 Apply Loctite 243 or equivalent to threads of flange head screw that secures frame spacer and carrier frame to LH side plate Instal...

Page 569: ...additional universal groomer information Refer to Rear Roller Brush Optional cutting units with aluminum side plates page 9 57 for additional rear roller brush information 16 If counterweight was remo...

Page 570: ...e 346 1 Reel shaft 2 Plastic plug 2 each 1 If removed install new plastic plugs into cutting reel shaft Plugs should be recessed into reel shaft from 34 8 to 41 4 mm 1 370 to 1 630 inches Figure 346 N...

Page 571: ...ngs fully onto the reel shaft Flocked seals and bearings should bottom on reel shaft shoulder 6 Fill threaded insert splines with high temperature Mobil XHP 222 grease or equivalent Preparing the Reel...

Page 572: ...and the Toro General Service Training Book Reel Mower Basics Toro Part No 09168SL found on the Service Reference Set available from your Authorized Toro Distributor Reel Grinding Specifications Table...

Page 573: ...brackets do the following A Remove the flange nut and carriage screw that secure the bracket to the cutting unit side plate B Remove the height of cut roller bracket from the cutting unit 5 Slide the...

Page 574: ...f cut roller bracket onto the other end of the roller shaft Secure the second bracket to the cutting unit side plate with the carriage screw and flange nut 5 Apply Loctite 243 or equivalent to exposed...

Page 575: ...ws that secure the rear roller bracket and roller shims to the cutting unit side plate B Remove the roller bracket and roller shims from the rear roller and cutting unit 5 Slide the rear roller assemb...

Page 576: ...he other end of roller shaft Secure second roller bracket and shims to cutting unit side plate with two 2 carriage screws and flange nuts Do not fully tighten flange nuts 4 Center the rear roller to t...

Page 577: ...d set of outer seals and bearing from the roller tube by tapping on opposite end of the shaft Remove the shaft from the roller tube 3 Carefully remove the inner seal from both ends of the roller tube...

Page 578: ...and do not bind If there is any binding remove the components and install them again 2 Install a new bearing and the outer seals into one end of the roller tube as follows g195711 Figure 353 1 Roller...

Page 579: ...Ensure that the seals are not damaged as the shaft is installed 4 Install the new bearing and outer seals into the second end of the roller tube as follows A Position a second new bearing to the roll...

Page 580: ...re that all grease is removed from the shaft threads to prevent the loosening of the bearing locknut 5 Clean the threads on both ends of the roller shaft Note If original bearing locknut s are being u...

Page 581: ...Flat washer 2 each 29 Mounting bracket 2 each 6 Excluder seal 2 each 18 Drive belt 30 Brush bearing housing non drive 7 Brush bearing housing drive 19 Bearing 31 O ring 8 Spacer 20 Flange head screw 3...

Page 582: ...emove the roller brush from the brush shaft as follows A Remove the non drive brush bearing housing item 30 from the cutting unit B Slide the excluder seal from the roller brush shaft C Remove the loc...

Page 583: ...earings with high temperature Mobil XHP 222 grease or equivalent before installation B Press bearing into bearing housing so that bearing contacts shoulder in housing bore C Install grease seals so th...

Page 584: ...ng equally on the inner and outer bearing races Install the bearing so that the bearing seal is closest to the shoulder on the shaft Install snap ring onto shaft to retain bearing B Install new grease...

Page 585: ...and torque fasteners as shown g214810 Figure 362 1 Driven pulley 3 Pulley alignment tool 2 Drive pulley E Check alignment of pulleys with a straight edge placed along the outer face of the driven pul...

Page 586: ...rush is parallel to rear roller with 1 5 mm 0 060 clearance to light contact with rear roller If contact is incorrect brush operation will be adversely affected 6 Install cover There should not be a s...

Page 587: ...tting unit from the cutting reel motor Figure 364 shows components used when the brush drive is on the left side of the cutting unit Note The Installation Instructions for the rear roller brush kit ha...

Page 588: ...aft slide brush onto shaft while rotating brush Secure brush to shaft with two 2 J bolts and lock nuts Make sure that the J bolts are installed with the threaded portion on the outside of the brush Ti...

Page 589: ...then torque flange nut from 37 to 44 N m 27 to 33 ft lb Use a wrench on roller brush shaft flats to prevent shaft from rotating when tightening nut D Check and adjust alignment of drive and driven pul...

Page 590: ...ing reel motor Figure 368 shows components used when the brush drive is on the left side of the cutting unit Note The Installation Instructions for the rear roller brush kit has detailed information r...

Page 591: ...e shaft has left hand threads and can be identified by a groove on the flange If the rear roller brush drive is on right side of cutting unit drive shaft has right hand threads and does not have a gro...

Page 592: ...assembly D When installing drive pulley item 17 make sure that tabs on pulley engage slot in drive shaft E Idler arm item 7 should be free to rotate after assembly to brush plate Make sure that idler...

Page 593: ...b Use a wrench on roller brush shaft flats to prevent shaft from rotating when tightening nut IMPORTANT The roller brush shaft must nor contact the cutting unit side plate Also heavy brush contact on...

Page 594: ...Cutting Unit Service and Repairs Page 9 64 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 595: ...ting the Height Depth of the Groomer 10 4 Service and Repairs 10 6 Replacing the Groomer Drive Belt 10 7 Groomer Plate Assembly 10 9 Groomer Reel 10 15 Servicing the Groomer Reel 10 18 Groomer Pivot H...

Page 596: ...hat factors affecting quality of cut also affect grooming performance Variables That Affect the Use and Performance of the Groomers 1 The growing season and weather conditions 2 General turf condition...

Page 597: ...pulley square key is damaged or missing Replace the missing or damaged square key No rotation of the groomer reel Flange head screw that secures the groomer drive pulley is loose or damaged Tighten th...

Page 598: ...the key from the key switch 2 Ensure that the rollers are clean and the cutting unit is set to the desired height of cut refer to the Cutting Unit Operator s Manual g215685 Figure 373 1 Groomer height...

Page 599: ...tep 4 on the opposite end of the groomer Check the setting on the first side of the groomer The height settings on both the ends of the groomer should be identical Reelmaster 5410 5510 5610 Series Pag...

Page 600: ...before working on the groomer Note The Groomer Kit Installation Instructions provide information regarding the installation set up and operation of the optional groomer on your Reelmaster machine Ref...

Page 601: ...ace the groomer drive belt refer to the Rear Roller Brush Optional cutting units with painted side plates page 9 51 Note When removing the groomer cover the groomer weight does not have to be removed...

Page 602: ...release the idler plate and pulley 4 Install a new drive belt to the drive pulley idler pulley and driven pulley observing correct belt routing Figure 375 Ensure that the groomer drive belt is above...

Page 603: ...eel 13 Locknut 21 Excluder seal 2 each 6 Groomer shim 14 Idler pulley assembly 22 Groomer reel 7 Groomer plate drive 15 Idler plate 23 O ring 8 Pivot hub assembly drive 16 Square key 24 Groomer plate...

Page 604: ...flange head screw item 12 in Figure 376 that retains the drive pulley Pull the drive pulley from the driveshaft Locate and retrieve the square key from the driveshaft Note To prevent the groomer shaft...

Page 605: ...e groomer shaft and cutting unit Remove the groomer shim 3 Remove the groomer plate assembly from the groomer non drive side of the cutting unit as follows A Remove the hydraulic reel motor from the c...

Page 606: ...iron side plates are shown in Figure 378 and Figure 379 Groomer plates used on cutting units with aluminum side plates not shown use a single seal rather than a double seal Assembling the Groomer Plat...

Page 607: ...to the cutting unit g220305 Figure 381 1 Pivot hub non drive side 2 Pivot hub drive side B Apply anti sieze lubricant to the outside diameter of the pivot hub and position the pivot hub to the cutting...

Page 608: ...flange head screw torque the screw to 37 to 44 N m 27 to 33 ft lb Note To prevent the groomer shaft from turning when installing the driven pulley use a wrench on the groomer shaft flats I Apply anti...

Page 609: ...st iron side plates 1 Flange nut 2 each 9 Extension spring 17 Flange nut 2 Socket head screw 4 each 10 Retaining ring 18 Driven pulley 3 Pivot hub assembly non drive 11 Drive pulley 19 Washer as neces...

Page 610: ...the Groomer Plate Assembly page 10 9 3 Carefully pull the groomer reel from the non drive side groomer plate assembly 4 Inspect all the seals bushings and bearings in the groomer plate assemblies for...

Page 611: ...oomer shaft if necessary 7 Check the groomer reel height and mower height of cut settings Adjust as necessary 8 Lubricate the groomer bearings Note After greasing the groomer bearings operate the groo...

Page 612: ...r reel from the cutting unit refer to the Groomer Reel page 10 15 2 Remove the O ring on the non drive end of the groomer shaft 3 Remove the 2 excluder seals from the groomer reel 4 If the groomer ree...

Page 613: ...wrapped around the groomer blade and brush assembly in the correct direction C Loosely wrap the straps around the groomer reel shaft and brushes as shown in Figure 386 The straps should be positioned...

Page 614: ...tes 1 Retaining ring 5 Pivot hub 9 Idler plate 2 Retaining ring 6 Grease seal 10 Groomer driveshaft 3 Ball bearing 7 Extension spring 4 O ring 8 Retaining ring Note The groomer reel drive is located o...

Page 615: ...to be removed from the cutting reel shaft in order to remove the pivot hub Disassembling the Groomer Pivot Hub 1 Remove the pivot hub assembly with the idler plate from the cutting unit refer to the G...

Page 616: ...the shaft Install the retaining ring onto the shaft to retain the bearing B Install the new grease seal into the housing with the lip of the seal toward the outside of the housing Apply grease to the...

Page 617: ...motor Figure 391 shows the components used when the groomer reel drive is on the left side of the cutting unit Disassembling the Height Adjuster Assembly 1 Park the machine on a clean and level surfac...

Page 618: ...Install the shoulder bolt and torque the bolt to 23 to 28 N m 17 to 21 ft lb to secure the ball joint rod 3 Check the groomer reel height and adjust as necessary 4 After the groomer height has been ad...

Page 619: ...continued installed with the threaded portion on the outside of the brush and tighten the locknuts to 2 3 to 2 8 N m 20 to 25 in lb Reelmaster 5410 5510 5610 Series Page 10 25 Belt Driven Groomer Opti...

Page 620: ...Belt Driven Groomer Optional Service and Repairs Page 10 26 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 621: ...ng 11 3 Groomer Reel Mechanical Problems 11 3 Service and Repairs 11 4 Gear Box Assembly 11 6 Idler Assembly 11 11 Groomer Reel 11 13 Servicing the Groomer Reel 11 15 Height Adjuster Assembly 11 17 Se...

Page 622: ...r that factors affecting quality of cut also affect grooming performance Variables that Affect the Use and Performance of the Groomers 1 The growing season and weather conditions 2 General turf condit...

Page 623: ...or groomer set up information The groomer reel blades are bent damaged or missing Repair or replace the blades if necessary The groomer reel shaft is bent or damaged Replace the groomer reel shaft The...

Page 624: ...y 6 Height adjuster assembly 2 each CAUTION Do not work on the groomer with the engine running Always shut off the engine remove the key from the key switch and wait for all machine movement to stop b...

Page 625: ...nstallation set up operation and maintenance of the universal groomer on your machine Refer to these instructions for additional information when servicing the groomer Reelmaster 5410 5510 5610 Series...

Page 626: ...roomer Reel page 11 13 Note If the cutting unit is equipped with an optional powered rear roller brush remove the rear roller brush cover drive belt and drive housing assembly to service the groomer d...

Page 627: ...rain fill plug item 5 in Figure 395 and drain the oil from the gear box 3 Remove the 4 socket head screws item 37 in Figure 395 and separate the gear box cover and housing 4 Remove and discard the cov...

Page 628: ...eal 40 Detent spring 9 Bearing 3 each 25 Bearing 2 each 41 Bushing 2 each 10 Sun gear 26 Output gear 42 Knob 11 Ring gear 27 Locknut 43 O ring 12 Slider gear 28 Retaining ring 2 each 44 Idler gear 2 e...

Page 629: ...rain fill plug to 4 to 5 N m 32 to 42 in lb The gear box oil capacity for reel cutting units is 90 ml 3 fl oz CAUTION Use the 1 3 8 inch flats on the input shaft to prevent the input shaft from rotati...

Page 630: ...ise until it is seated against the reel B Install a new cotter pin and clevis pin and secure the height adjustment rod to the front of the groomer gear box C Tighten the input shaft to 136 to 149 N m...

Page 631: ...brake and remove the key from the key switch 2 Remove the hydraulic reel motor from the cutting unit refer to Removing the Hydraulic Reel Motor page 9 17 3 Remove the groomer reel assembly refer to Re...

Page 632: ...n the shaft to prevent shaft from rotating tighten the flange nut to 37 to 45 N m 27 to 33 ft lb E If the collar was removed from the idler arm install the collar and tighten to 33 to 41 N m 24 to 30...

Page 633: ...cutting unit from the machine refer to the Traction Unit Operator s Manual CAUTION Contact with the reel or other cutting unit parts can result in personal injury Use heavy gloves when handling the g...

Page 634: ...itch 2 Position the groomer reel between the groomer output and stub shafts 3 Secure the groomer reel to the cutting unit with the 4 jam nuts 4 bolts and 4 shaft clamps torque the bolts to 5 to 7 N m...

Page 635: ...the key from the key switch 2 Remove the groomer reel from the cutting unit refer to Groomer Reel page 11 13 3 If the groomer reel is equipped with broomer kit remove the straps and broomer brushes f...

Page 636: ...e full length of the groomer reel Ensure that the brushes are seated in groomer blade slots Figure 400 IMPORTANT The straps must be wrapped around the groomer blade and brush assembly in the correct d...

Page 637: ...and level surface lower the cutting units completely to the ground shut off the engine set the parking brake and remove the key from the key switch 2 Remove the cotter pins and clevis pins that secure...

Page 638: ...the side plate 3 Position front roller between the height adjuster assemblies and secure height adjuster assembly to cutting unit side plate with flange head bolt and flange nut Do not tighten the fl...

Page 639: ...mer Reel page 11 13 The grooming brush element or shaft can be serviced separately Figure 403 To remove the spiral grooming brush from the shaft remove the locknut and J bolt from both ends of the bru...

Page 640: ...Universal Groomer Optional Service and Repairs Page 11 20 Reelmaster 5410 5510 5610 Series 15216SL Rev C...

Page 641: ...13 Engine Wire Harness Drawing 5410 5510 5610 Models with Kubota Diesel Engine A 14 Engine Wire Harness Diagram 5410 5510 5610 Models with Kubota Diesel Engine A 15 Engine Wire Harness Drawing 5410 D...

Page 642: ...ude a line with an alternate color These wires are identified with the wire color and line color with either a or _ separating the color abbreviations listed above e g R BK is a red wire with a black...

Page 643: ...Reelmaster Models 5410 5410 D Drawing 136 7951 Rev A Sheet 1 of 1 15216SL Rev C Page A 3 Hydraulic Schematic 5410 5410 D g229522...

Page 644: ...Page A 4 15216SL Rev C Reelmaster Models 5510 5510 D 5610 Drawing 127 2797 Rev A Sheet 1 of 1 Hydraulic Schematic 5510 5510 D 5610 g229528...

Page 645: ...Reelmaster 5610 D Model 03679 Drawing 133 2949 Rev B Sheet 1 of 1 15216SL Rev C Page A 5 Hydraulic Schematic 5610 D g219149...

Page 646: ...Page A 6 15216SL Rev C Reelmaster 5410 5510 5610 Models with Kubota Diesel Engine Drawing 122 0380 Rev A Sheet 1 of 1 Electrical Schematic 5410 5510 5610 Models with Kubota Diesel Engine g229518...

Page 647: ...Reelmaster 5410 D 5510 D Models with Yanmar Diesel Engine Drawing 120 6345 Rev C Sheet 1 of 1 15216SL Rev C Page A 7 Electrical Schematic 5410 D 5510 D Models with Yanmar Diesel Engine g229521...

Page 648: ...Page A 8 15216SL Rev C Reelmaster 5610 D Model 03679 Drawing 120 6345 Rev C Sheet 1 of 1 Electrical Schematic 5610 D g219146...

Page 649: ...Reelmaster 5410 G 5510 G Models with Kubota Gasoline Engine Drawing 120 6342 Rev B Sheet 1 of 1 15216SL Rev C Page A 9 Electrical Schematic 5410 G 5510 G Models with Kubota Gasoline Engine g229525...

Page 650: ...Page A 10 15216SL Rev C Reelmaster All Models Drawing 120 6356 Rev D Sheet 1 of 2 Wire Harness Drawing Main g219150...

Page 651: ...Reelmaster All Models Drawing 120 6356 Rev D Sheet 2 of 2 15216SL Rev C Page A 11 Wire Harness Drawing Main g219151...

Page 652: ...Page A 12 15216SL Rev C Reelmaster All Models Drawing 115 8081 Rev C Sheet 1 of 2 Wire Harness Drawing Seat g219152...

Page 653: ...Reelmaster All Models Drawing 115 80812 Rev C Sheet 2 of 2 15216SL Rev C Page A 13 Wire Harness Drawing Seat g219153...

Page 654: ...age A 14 15216SL Rev C Reelmaster 5410 5510 5610 Models with Kubota Diesel Engine Drawing 120 6346 Rev C Sheet 1 of 2 Engine Wire Harness Drawing 5410 5510 5610 Models with Kubota Diesel Engine g22952...

Page 655: ...eelmaster 5410 5510 5610 Models with Kubota Diesel Engine Drawing 120 6346 Rev C Sheet 2 of 2 15216SL Rev C Page A 15 Engine Wire Harness Diagram 5410 5510 5610 Models with Kubota Diesel Engine g22951...

Page 656: ...L Rev C Reelmaster 5410 D 5510 D Models 03672 and 03687 with Yanmar Diesel Engine Drawing 122 0231 Rev C Sheet 1 of 2 Engine Wire Harness Drawing 5410 D 5510 D Models 03672 and 03687 with Yanmar Diese...

Page 657: ...D 5510 D Models 03672 and 03687 with Yanmar Diesel Engine Drawing 122 0231 Rev C Sheet 2 of 2 15216SL Rev C Page A 17 Engine Wire Harness Diagram 5410 D 5510 D Models 03672 and 03687 with Yanmar Diese...

Page 658: ...e A 18 15216SL Rev C Reelmaster 5410 D 5510 D 5610 D Models 03606 03607 and 03679 Drawing 122 0893 Rev A Sheet 1 of 2 Engine Wire Harness Drawing 5410 D 5510 D 5610 D Models 03606 03607 and 03679 g219...

Page 659: ...lmaster 5410 D 5510 D 5610 D Models 03606 03607 and 03679 Drawing 122 0893 Rev A Sheet 2 of 2 15216SL Rev C Page A 19 Engine Wire Harness Diagram 5410 D 5510 D 5610 D Models 03606 03607 and 03679 g219...

Page 660: ...ge A 20 15216SL Rev C Reelmaster 5410 G 5510 G Models with Kubota Gasoline Engine Drawing 120 6357 Rev B Sheet 1 of 2 Engine Wire Harness Drawing 5410 G 5510 G Models with Kubota Gasoline Engine g2295...

Page 661: ...elmaster 5410 G 5510 G Models with Kubota Gasoline Engine Drawing 120 6357 Rev B Sheet 2 of 2 15216SL Rev C Page A 21 Engine Wire Harness Diagram 5410 G 5510 G Models with Kubota Gasoline Engine g2295...

Page 662: ......

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