Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- NOTES:
- Preface
- Table of Contents
- Chapter 1 : Safety
- Chapter 2 : Specifications and Maintenance
- Specifications
- Torque Specifications
- Identifying the Fastener
- Fasteners with a Locking Feature
- Calculating the Torque Values When Using a Drive-Adapter Wrench
- Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
- Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
- Other Torque Specifications
- Conversion Factors
- Shop Supplies
- Special Tools
- Chapter 3 : Kubota Diesel Engine
- Chapter 4 : Yanmar Diesel Engine
- Chapter 5 : Kubota Gasoline Engine
- Chapter 6 : Hydraulic System
- 1 Specifications
- General Information
- Checking the Hydraulic Fluid
- Pushing or Towing the Traction Unit
- Releasing Pressure from the Hydraulic System
- Traction Circuit Component Failure
- Hydraulic Hoses
- Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting)
- Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port)
- Hydraulic Schematics
- Hydraulic Flow Diagrams (5410/5410-D/5510/5510-D/5610)
- Hydraulic Flow Diagrams (5610-D)
- Special Tools
- Troubleshooting
- Testing the Hydraulic System
- Traction Circuit Relief Valve (R3) and (R4) Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Traction Circuit Charge Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Gear Pump (P3) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Front Wheel Motor Efficiency Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Relief Valve (R1) and (R2) Pressure Test (Cutting (Mow) Circuit) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Gear Pump (P1) and (P2) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Cutting Reel Motor Efficiency Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Cutting Reel Motor Cross-Over Relief Pressure Test (5510/5510-G/5510-D/5610)
- Lift Relief Valve (SVRV) Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Gear Pump (P4) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Lift Cylinder Internal Leakage Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Steering Relief Valve (R10) Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Steering Cylinder Internal Leakage Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610)
- Testing the Traction Circuit–Charge Pressure (5610-D)
- Testing the Traction Circuit–Wheel Motor Efficiency (5610-D)
- Testing the Traction Circuit–Piston Pump/Hydrostat Flow and Relief Pressure (5610-D)
- Testing the Mow Circuit–Circuit Pressure (5610-D)
- Testing the Mow Circuit–Reel Motor Efficiency/Case Drain (5610-D)
- Testing the Mow Circuit–Reel Motor Cross−Over Relief Pressure (5610-D)
- Testing the Mow Circuit–Relief Valve (RV1) and (RV2) Pressure (5610-D)
- Testing the Mow Circuit–Gear Pump (P1) and (P2) Flow (5610-D)
- Testing the Steering Circuit–Steering Control Valve, Relief Valve (R10) Pressure, and Steering Cylinder (5610-D)
- Testing the Steering Circuit–Gear Pump (P3) Flow (5610-D)
- Testing the lift Circuit–Relief Valve (SVRV) Pressure (5610-D)
- Testing the Lift Circuit–Lift Cylinder Internal Leakage (5610-D)
- Testing the Lift Circuit–Gear Pump (P4) Flow (5610-D)
- Service and Repairs
- General Precautions for Removing and Installing the Hydraulic System Components
- Checking the Hydraulic Lines and Hoses
- Priming the Hydraulic Pumps
- Flushing the Hydraulic System
- Filtering the Closed-Loop Traction Circuit
- Charging the Hydraulic System
- Hydraulic Tank
- Piston (Traction) Pump Control Assembly
- Hydraulic Pump Driveshaft
- Hydraulic Pump Assembly
- Servicing the Piston (Traction) Pump
- Servicing the Gear Pump
- Front Wheel Motors
- Servicing the Front Wheel Motor
- Rear Wheel Motors (Machine with CrossTrax AWD)
- Servicing the Rear Wheel Motor (Machine with CrossTrax AWD)
- CrossTrax™ AWD Control Manifold Assembly
- Servicing the CrossTrax AWD Control Manifold Assembly
- Mow Control Manifold Assembly
- Servicing the Mow Control Manifold Assembly
- Lift Control Manifold
- Servicing the Lift Control Manifold
- Servicing a Control Manifold Cartridge Valve
- Cutting Reel Motor
- Servicing the Cutting Reel Motor (Casappa)
- Servicing the Cutting Reel Motor (Sauer-Danfoss)
- Lift Cylinder
- Servicing the Lift Cylinder
- Steering Control Valve
- Servicing the Steering Control Valve
- Steering Cylinder
- Servicing the Steering Cylinder
- Oil Cooler (5410/5510/5610)
- Radiator and Oil Cooler Assembly (5410-G/5410-D/5510-G/5510-D/5610-D)
- Chapter 7 : Electrical System
- General Information
- Special Tools
- InfoCenter Display
- Troubleshooting
- Electrical System Quick Checks
- Adjustments
- Testing the Electrical Components
- Fusible Link Harness (Machines with Kubota or Yanmar Diesel Engine)
- System Fuses
- Engine Fuses (Gasoline Engine)
- Toro Electronic Controller (TEC)
- Key Switch
- Reel Engage Switch
- Engine Speed Switch (If Equipped)
- Lower/Raise Joystick Switches
- Headlight Switch
- Seat Switch
- Cutting Unit Down Limit Switch
- Traction Neutral Switch
- Parking Brake Switch
- Mow/Transport Switch
- Backlap Switches
- Oil Pressure Switch (Machine with Kubota Engine)
- Relays with 4 Terminals
- Relays with 5 Terminals (Diesel Engine)
- Engine Relays with 5 Terminals (Gasoline Engine)
- Hydraulic Solenoid Valve Coils
- Temperature Sender (Machine with Kubota Diesel Engine)
- Engine Run Solenoid (Machine with Kubota Diesel Engine)
- Fuel Sender (Diesel Engine)
- Fuel Sender (Gasoline Engine)
- Fuel Pump (Machine with Yanmar Diesel Engine)
- Fuel Pump (Machine with Kubota Diesel Engine)
- Fuel Pump (Machine with Kubota Gasoline Engine)
- CAN-bus Terminator Resistor
- Resistor Assembly (Machine with Yanmar Diesel or Kubota Gasoline Engine)
- Diode Assemblies (Diesel Engine)
- Service and Repairs
- Chapter 8 : Chassis
- Chapter 9 : Cutting Unit
- 1 Specifications
- General Information
- Special Tools
- Aftercut Appearance
- Adjustments
- Service and Repairs
- Hydraulic Reel Motor
- Backlapping
- Bedbar Assembly
- Bedknife Replacement and Grinding
- Servicing the Bedbar Adjuster
- Reel Assembly (cutting units with painted side plates)
- Reel Assembly Service (cutting units with painted side plates)
- Reel Assembly (cutting units with aluminum side plates)
- Reel Assembly Service (cutting units with aluminum side plates)
- Preparing the Reel for Grinding
- Front Roller
- Rear Roller
- Servicing the Roller
- Rear Roller Brush – Optional (cutting units with painted side plates)
- Rear Roller Brush – Optional (cutting units with aluminum side plates)
- Chapter 10 : Belt Driven Groomer (Optional)
- Chapter 11 : Universal Groomer (Optional)
- Appendix A: Foldout Drawings
- Electrical Drawing Designations
- Hydraulic Schematic-5410/5410-D
- Hydraulic Schematic-5510/5510-D/5610
- Hydraulic Schematic-5610-D
- Electrical Schematic-5410/5510/5610 (Models with Kubota Diesel Engine) (Serial Numbers Below 403430000)
- Electrical Schematic-5410/5510/5610 (Models with Kubota Diesel Engine) (Serial Numbers Above 403430000)
- Electrical Schematic-5410-D/5510-D/5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Below 403430000)
- Electrical Schematic-5410-D/5510-D/5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Above 403430000)
- NO TITLE
- Electrical Schematic-5410-G/5510-G (Models with Kubota Gasoline Engine)
- Wire Harness Drawing-Main (Serial Number Below 403430000)
- Wire Harness Drawing-Main (Serial Number Below 403430000)
- Wire Harness Drawing-Main (Serial Numbers 403430001 to 405680000)
- Wire Harness Drawing-Main (Serial Numbers 403430001 to 405680000)
- Wire Harness Drawing-Main (Serial Numbers Above 405680001)
- Wire Harness Drawing-Main (Serial Numbers Above 405680001)
- Wire Harness Drawing-Seat
- Wire Harness Drawing-Seat
- Engine Wire Harness Drawing-5410/5510/5610 (Models with Kubota Diesel Engine)
- Engine Wire Harness Diagram-5410/5510/5610 (Models with Kubota Diesel Engine)
- Engine Wire Harness Drawing-5410-D/5510-D (Models 03672 and 03687 with Yanmar Diesel Engine)
- Engine Wire Harness Diagram-5410-D/5510-D (Models 03672 and 03687 with Yanmar Diesel Engine)
- Engine Wire Harness Drawing-5410-D/5510-D/5610-D (Models 03606, 03607, and 03679)
- Engine Wire Harness Diagram-5410-D/5510-D/5610-D (Models 03606, 03607, and 03679)
- Engine Wire Harness Drawing-5410-G/5510-G (Models with Kubota Gasoline Engine)
- Engine Wire Harness Diagram-5410-G/5510-G (Models with Kubota Gasoline Engine)
UsingMachineFaults(continued)
MachineFaultTable(continued)
FaultCode
FaultDescription
ServiceSuggestions
9Enginealternatorchargingistoo
low
Checkthealternatordrivebelt
Checktheenginealternatorand
circuitwiring
10Enginehasnotbeenseenon
theCAN-busfor10seconds
(machineswithYanmardieselor
Kubotagasolineengine)
CheckCAN-busconnectionto
engineECU
Verifybatterypowerexistsatengine
ECU
CheckCAN-busterminatorresistors
12
InfoCenterhasnotbeenseenon
theCAN-busfor1second
CheckCAN-busconnectionto
InfoCenterDisplay
Verifybatterypowerexistsat
InfoCenterDisplay
CheckCAN-busterminatorresistors
13Keyswitchisdamaged
Checktheswitchandcircuitwiring
15Enginespeedswitchisdamaged
(machineswithYanmardieselor
Kubotagasolineengine)
Checkthecontrolarmenginespeed
switchandcircuitwiring
19Enginecoolanttemperature
sensorcircuithasopenorshort
Checktheenginecoolantsensor
andcircuitwiring
24Joystickraiseandlowerswitches
closedatsametime
Checkthejoystickswitchesand
circuitwiring
26
TECoutputcurrenttoenergize
startrelayisexcessive
Checkthestartrelayandcircuit
wiring
27
TECoutputcurrenttofuelpump
isexcessive
Checkthefuelpumpandcircuit
wiring
37
TECoutputcurrenttoenergize
glowrelayisexcessive
Checktheglowrelayandcircuit
wiring
53
TECoutputcurrentforhydraulic
solenoidcoilSV1isexcessive
Checktheliftcontrolmanifold
solenoidcoilSV1andcircuitwiring
54
TECoutputcurrentforhydraulic
solenoidcoilSV2isexcessive
Checktheliftcontrolmanifold
solenoidcoilSV2andcircuitwiring
55
TECoutputcurrentforhydraulic
solenoidcoilSV3isexcessive
Checktheliftcontrolmanifold
solenoidcoilSV3andcircuitwiring
56
TECoutputcurrentforhydraulic
solenoidcoilSVRVisexcessive
Checktheliftcontrolmanifold
solenoidcoilSVRVandcircuit
wiring
57
TECoutputcurrentforhydraulic
solenoidcoilMSV1isexcessive
Checkthemowcontrolmanifold
solenoidcoilMSV1andcircuitwiring
58
TECoutputcurrentforhydraulic
solenoidcoilMSV2isexcessive
Checkthemowcontrolmanifold
solenoidcoilMSV2andcircuitwiring
68Alternatornotcharging
Checktheenginealternatorand
circuitwiring
69Lowengineoilpressure
Checktheengineoilpressure
switchandcircuitwiring
ElectricalSystem:Troubleshooting
Page7–34
Reelmaster
®
5410/5510/5610Series
15216SLRevE