Form No. 15216SL Rev E Reelmaster® 5410/5510/5610 Series (Models with InfoCenter Display) © 2021—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date – 03/2015 Initial 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. D 05/2020 Updated wheel motor and brake service procedures, Cutting Unit, Universal Groomer and Electrical Drawings chapters. E 06/2021 Updated Engine and Hydraulic chapters.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
NOTES: NOTES: Page 4 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components of Reelmaster 5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610, and 5610-D. Equipment model numbers covered in this manual include 03606, 03607, 03608, 03609, 03672, 03673, 03675, 03676, 03677, 03678, 03679, 03687, and 03689.
g230519 Figure 1 Product Variations Machine Name Model Numbers Engine 5410 03675 Kubota non-Tier4 compliant diesel engine 5410-G 03608 Kubota gasoline engine Traction Drive 03673 5410-D 03606 03672 Yanmar Tier4 compliant engine 5510 03676 Kubota non-Tier4 compliant diesel engine 5510-G 03609 Kubota gasoline engine 2-wheel drive 03689 5510-D 03607 03687 5610 03677 03678 5610-D Preface 03679 Yanmar Tier4 compliant engine Turbocharged Kubota non-Tier4 compliant diesel engine Turboc
Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–6 Safety and Instructional Decals .
Adjustments ............................................................................................... 10–4 Service and Repairs ................................................................................... 10–6 Chapter 11: Universal Groomer (Optional) .................................................... 11–1 General Information ................................................................................... 11–2 Troubleshooting ..................................................................
Eaton Delta Motors Parts and Repair Manual Parker Torqmotor Service Procedure (TC, TB, TE, TJ, TF, TG, TH, and TL Series) Danfoss Steering Unit Type OSPM Service Manual Preface Page 10 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Supervisor’s Responsibilities ............................................................................................................. 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ..........
Safety Instructions The Reelmaster machines meets or exceeds safety standard specifications when weights are installed according to information in the Operator’s Manual. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
While Operating the Machine • Sit on the seat when starting and operating the machine. • Anytime you park the machine (short or long term), lower the cutting decks to the ground. IMPORTANT When you lower the cutting deck to the ground, the pressure from the hydraulic lift circuit releases and prevents the cutting deck from accidentally lowering. • If you park the machine on a slope, block or chock the wheels.
Maintenance and Service • Before servicing or making any adjustments to the machine, lower the cutting • • • • • • • • • • • • • • • • Safety: Safety Instructions decks, set the parking brake, shut off the engine, and remove the key from the key switch. Ensure that the machine is in safe operating condition by keeping all the nuts, bolts, and screws tight. Do not store the machine or a fuel container inside where there is an open flame, such as near a water heater or furnace.
Maintenance and Service (continued) battery cable and then the positive cable. Disconnect the engine wire harness from the Toro Electronic Controller (TEC), disconnect and remove the engine ECU, and disconnect the terminal connector from the alternator, attach the welder ground cable not more than 610 mm (2 ft) from the welding location. • Ensure to dispose of potentially harmful waste (e.g., fuel, oil, engine coolant, filters, battery) in an environmentally safe manner.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to raise and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Raising the Rear of the Machine g186591 Figure 3 1. Rear wheel 2. Rear axle pivot bracket 3. Jack stand location 1. Set the parking brake and block the 2 front wheels with chocks to prevent the machine from moving. 2. Position the jack securely at the center of the rear axle under the axle pivot bracket. Lift the rear of the machine off the ground. 3. Position the jack stands under the frame to support the machine (Figure 3).
Safety: Safety and Instructional Decals Page 1–8 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Decimal and Millimeter Equivalents ................................................................................................... 2–2 U.S. to Metric Conversions ................................................................................................................
Specifications Insert a copy of the Operator’s Manuals and Parts Catalogs for your machine at the end of this chapter. Additionally, if any optional equipment or accessories are installed to your machine, insert the Installation Instructions, Operator’s Manuals, and Parts Catalogs for those options at the end of this chapter. The maintenance procedures and recommended service intervals for your machine are covered in the Operator’s Manuals.
Decimal and Millimeter Equivalents (continued) Fractions 31/64 1/2 Decimals mm 0.484375 12.303 0.5000 12.700 Fractions 63/64 1 1 mm = 0.03937 inch Reelmaster® 5410/5510/5610 Series 15216SL Rev E Decimals mm 0.984375 25.003 1.000 25.400 0.001 inch = 0.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.914 Feet Meters 0.305 Feet Centimeters 30.48 Inches Meters 0.025 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.093 Square Inches Square Centimeters 6.452 Acre Hectare 0.405 Cubic Yards Cubic Meters 0.765 Cubic Feet Cubic Meters 0.028 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These torque specifications for the installation and tightening of the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Fasteners with a Locking Feature (continued) found on externally threaded fasteners such as screws, or on internally threaded fasteners such as nuts. Locking features are designed to create friction, so even after slight loosening, the friction continues to resist further loosening. Keep in mind, a fastener with a locking feature usually means there will be friction during assembly as well.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 ± 6 in-lb 644 ± 68 N∙cm 78 ± 8 in-lb 881 ± 90 N∙cm M6 X 1.0 96 ± 10 in-lb 1085 ± 113 N∙cm 133 ± 14 in-lb 1503 ± 158 N∙cm M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N∙m 28 ± 3 ft-lb 38 ± 4 N∙m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ± 10 ft-lb 18 ± 3 ft-lb 1/2 - 13 UNC 75 ± 15 ft-lb 50 ± 10 ft-lb Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess 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.
Chapter 3 Kubota Diesel Engine Table of Contents Specifications ....................................................................................................................................... 3–2 Kubota Diesel Engine ........................................................................................................................ 3–2 General Information ..............................................................................................................................
Specifications Kubota Diesel Engine Reelmaster 5410 and 5510 g237075 Figure 7 1. Fuel injection pump 3. Alternator 5. Starter motor 2. Engine cooling fan 4. Engine oil filter 6. Flywheel Item Description Make/Designation Kubota V1505-E3B, 4-stroke, Liquid Cooled, OHV Diesel 4 Number of Cylinders Bore x Stroke 78 mm x 78.4 mm (3.07 x 3.09 inches) Total Displacement 1,498 cm3 (91.
Kubota Diesel Engine (continued) Item Description Alternator/Regulator 12 VDC 40 A Dry Weight (approximate) 110 kg (242 lb) Reelmaster 5610 g237074 Figure 8 1. Turbocharger 4. Engine oil filter 7. 2. Engine cooling fan 5. Starter motor 3. Alternator 6. Fuel injection pump Item Flywheel Description Make/Designation Kubota V1505-T-E3B, 4-stroke, Liquid Cooled, OHV, Turbocharged Diesel 4 Number of Cylinders Bore x Stroke 78 mm x 78.4 mm (3.07 x 3.
Kubota Diesel Engine (continued) Item Description Crankcase-Oil Capacity 5.2 L (5.5 US qt) with Filter Cooling System Capacity (including reserve tank) 9.5 L (10 US qt) Starter 12 VDC 1.
General Information This chapter gives information about specifications, assembly and repair of the Kubota V1505-E3B and V1505-T-E3B diesel engine used in certain Reelmaster 5410, 5510, and 5610 machines. Most repairs and adjustments require tools which are commonly available in many service shops. The use of some specialized test equipment is explained in the engine service manual included at the end of this chapter.
Adjustments Adjusting the Throttle Control g229062 Figure 9 1. Throttle cable swivel 3. Cable stop 2. Swivel locknut 4. Throttle cable clamp 5. Throttle cable 3. Cable swivel position g229070 Figure 10 1. 2. Speed control lever High speed screw Proper throttle operation is dependent upon proper adjustment of throttle control. Ensure that the throttle control is operating properly.
Adjusting the Throttle Control (continued) Note: The throttle cable swivel should be positioned in the lowest hole in the speed control lever. 1. Move throttle control lever on control console to FAST position. 2. Check position of the engine speed control lever on fuel injection pump. The speed control lever should be contacting the high speed screw when the throttle control lever is in the FAST position. 3.
Service and Repairs Air Cleaner Assembly g229071 Figure 11 Reelmaster 5410/5510 1. Air cleaner assembly 7. Adapter 13. Air cleaner bracket 2. Air cleaner mounting band 8. Air cleaner inlet hose 14. Bolt (2 each) 3. Hex nut 4. Shoulder bolt Hose clamp (4 each) 15. Air cleaner mount bracket 10. Air cleaner hose 16. Flange-head screw (3 each) 5. 6. Spring 11. Flange nut (7 each) Service indicator 12. Flange-head screw (2 each) Kubota Diesel Engine: Service and Repairs 9.
g229072 Figure 12 Reelmaster 5610 1. Air cleaner assembly 7. Adapter 13. Air cleaner bracket 2. Mounting band 8. Inlet hose 14. Bolt 3. Hex nut 9. Hose clamp 15. Mount bracket 4. Shoulder bolt 10. Air cleaner hose 16. Hose clamp 5. Spring 11. Flange nut 6. Service indicator 12. Flange-head screw Note: Reelmaster 5010 series machines with a Kubota diesel engine have very similar air cleaner assemblies.
Installing the Air Cleaner Assembly (continued) 1. Assemble air cleaner system (Figure 11 or Figure 12). g229073 Figure 13 1. Air cleaner assembly 3. Adapter 2. Service indicator 4. Evacuator valve A. If service indicator and adapter were removed from air cleaner housing, apply thread sealant to adapter threads before installing adapter and indicator to housing. Install adapter so that grooves in adapter hex and adapter filter element are installed toward service indicator (Figure 13).
Exhaust System g229074 Figure 14 Reelmaster 5410/5510 1. Exhaust gasket 2. Lock washer (4 each) 3. Flange nut (4 each) 8. Bolt 15. Rubber hanger 9. Isolator plate 16. Spacer (2 each) 10. Hex nut (2 each) 17. Exhaust header 4. Bolt (4 each) 11. Clamp 18. Support bracket 5. Carriage screw (4 each) 12. Flange nut (2 each) 19. Tail pipe bracket 6. Flange nut (4 each) 13. Flat washer (2 each) 20. Muffler 7. Lock washer 14.
Removing the Exhaust System (continued) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch. Raise and support hood. 2. Raise and support hood to gain access to exhaust system. Allow engine and exhaust system to cool before doing any disassembly of exhaust system components. g229075 Figure 15 Reelmaster 5610 1. Exhaust header 5. Muffler 2. Flange nut (4 each) 6. Carriage screw (4 each) 9. Tailpipe bracket 10.
Installing the Exhaust System (continued) fasteners, secure muffler to support bracket first and then tighten nuts that secure exhaust header to engine exhaust manifold. Once these connections are secure, tighten clamp 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 (item 3 in Figure 16) so that there is 9.
Fuel System g229077 Figure 17 1. Fuel tank 8. Hose clamp 15. Bolt 2. Fuel tank cap 9. Fuel return hose 16. Flat washer 3. Screw (7 each) 10. Clamp (2 each) 17. Bumper 4. Strap 11. Flange-head screw (2 each) 18. Fuel sender cap 5. Sender cover 12. Flange nut (3 each) 19. Fuel sender 6. Hose clamp 13. Draincock 20. Gasket 7. Fuel supply hose 14. Hose clamp DANGER Because diesel fuel is flammable, use caution when storing or handling it.
Checking the Fuel Lines and Connections Check fuel lines and connections periodically as recommended in the Traction Unit Operator’s Manual. Check lines for deterioration, damage, leakage or loose connections. Replace fuel hoses, clamps and connections as necessary. Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recommended in the Traction Unit Operator’s Manual.
Removing the Fuel Tank (continued) g229063 Figure 18 1. Fuel sender 2. Fuel supply fitting 3. Fuel return fitting IMPORTANT If fuel sender is removed from fuel tank, note orientation of fittings for assembly purposes (Figure 18). Installing the Fuel Tank 1. Install fuel tank to frame (Figure 17). Secure fuel hoses with cable ties as noted during fuel tank removal. A.
Radiator Assembly g229064 Figure 19 Reelmaster 5410 and 5510 1. Coolant reservoir 16. Bolt (2 each) 31. Locknut 2. Hose clamp (3 each) 17. Washer (4 each) 32. Bolt (4 each) 3. Overflow hose 18. Radiator assembly 33. Rear screen 4. Foam seal (2 each) 19. Radiator frame 34. Intake screen 5. 6. Oil cooler Flat washer (8 each) 20. 21. Reservoir bracket Reservoir bracket 35. 36. Overflow hose Oil cooler bracket 7. Hose clamp (4 each) 22. Upper radiator hose 37. Draincock 8.
g229065 Figure 20 Reelmaster 5610 1. Radiator 3. Radiator frame 5. Flange-head screw 2. Fan shroud 4. Flange-head screw 6. Flange nut Note: Two radiator assemblies are used on Reelmaster 5010 series machines with a Kubota diesel engine. Reelmaster 5410 and 5510 machines use the same radiator (Figure 19). Reelmaster 5610 machines use a slightly different radiator (Figure 20). All of these models use a similar procedure for radiator removal and installation. Removing the Radiator Assembly 1.
Removing the Radiator Assembly (continued) radiator. Ensure that the drain container is large enough to hold cooling system contents; refer to Specifications (page 3–2). IMPORTANT Follow all local codes and regulations when recycling or disposing engine coolant. 5. Disconnect radiator hoses (upper and lower) from the radiator. 6. Remove air cleaner inlet hose from air intake on fan shroud; refer to Air Cleaner Assembly (page 3–8). 7. Loosen hose clamp and remove overflow hose from radiator fill opening. 8.
Installing the Radiator Assembly (continued) 13. After running engine for a short time, stop engine and Ensure radiator is full. Add coolant if necessary.
Engine g229066 Figure 21 Reelmaster 5410 and 5510 1. Engine assembly 11. Flange nut (2 each) 21. Muffler bracket 2. V-belt 12. Bolt (6 each) 22. Bolt 3. Bolt (4 each) 13. Bolt (4 each) 23. Lock washer 4. Flat washer (4 each) 14. Spacer (4 each) 24. Bolt (2 each) 5. Cooling 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.
Note: The engine removal and installation procedure is similar for all models with a Kubota diesel engine. Removing the Engine 1. Park machine on a level surface, lower cutting units, stop engine and remove key from the key switch. Chock wheels to keep the machine from moving. Open hood. 2. If engine is to be disassembled, drain oil from engine. 3. Disconnect negative (-) and then positive (+) battery cables from the battery.
Removing the Engine (continued) A. Loosen clamps and remove upper and lower radiator hoses from the engine. B. Loosen hose clamps and disconnect fuel supply and return hoses. Slide return hose from R-clamp on bracket attached to flywheel plate. C. Plug disconnected hoses and engine openings to prevent leakage and contamination. Position disconnected hoses away from engine. 9. Disconnect hydraulic pump driveshaft from engine; refer to Hydraulic Pump Driveshaft (page 6–159).
Removing the Engine (continued) B. Connect a hoist or chain fall at the center of the short section of chain. Apply enough tension on the short chain so that the engine will be supported. C. Remove fasteners that secure the engine (with mount brackets) to the engine mounts. CAUTION One person should operate lift or hoist while another person guides the engine out of the machine.
Installing the Engine 1. Locate machine on a level surface with cutting units lowered and key removed from the key switch. Chock wheels to keep the machine from moving. 2. Ensure that the all parts removed from the engine during maintenance or rebuilding are installed to the engine. 3. If engine mount brackets were removed from the engine, secure brackets to engine with lock washers and bolts. Torque the bolts to 47 to 56 N∙m (34 to 42 ft-lb). 4. Install engine to machine. A.
Installing the Engine (continued) g229068 Figure 24 1. Fuel return hose 2. Fuel supply hose 3. Fuel/water filter A. Connect fuel supply and fuel return hoses to engine fittings (Figure 24). Ensure that return hose is routed through R-clamp on bracket attached to flywheel plate. Secure hoses with hose clamps. B. Connect upper and lower radiator hoses to the engine. Secure hoses with hose clamps. 8. Connect throttle cable to injector pump (Figure 22): A.
Chapter 4 Yanmar Diesel Engine Table of Contents Specifications ....................................................................................................................................... 4–2 Yanmar Diesel Engine........................................................................................................................ 4–2 General Information ..............................................................................................................................
Specifications Yanmar Diesel Engine Reelmaster 5410-D and 5510-D g236519 Figure 25 1. Flywheel 4. Fuel filter 7. Engine cooling fan 10. Engine oil cooler 2. Diesel-particulate filter (DPF) 5. Starter motor 8. Supply pump 11. Common rail 3. Engine ECU 6. Alternator 9. Engine oil filter Item Description Make/Designation Yanmar Model 3TNV88C-DTR: 4-Cycle, 3 Cylinder, Water Cooled, Tier 4 Diesel Engine 3 Number of Cylinders Bore x Stroke 88 x 90 mm (3.465 x 3.
Yanmar Diesel Engine (continued) Item Description Engine Oil API CJ-4 or higher; refer to the Traction Unit Operator’s Manual for additional engine oil information Engine Oil Viscosity 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) Starter 12 VDC 1.
Yanmar Diesel Engine (continued) Reelmaster 5610-D g236518 Figure 26 1. Flywheel 4. Engine cooling fan 7. Diesel-particulate filter (DPF) 10. Engine oil filter 2. Starter motor 5. Alternator 8. Fuel filter 11. Engine oil cooler 3. Engine ECU 6. Turbocharger 9. Supply pump 12. Common rail Item Description Make/Designation Yanmar 3TNV86CT: 4-cycle, 3 cylinder common-rail water cooled diesel with EGR, turbocharged, and diesel-particulate filter (DPF). EPA Tier 4 Final compliant.
Yanmar Diesel Engine (continued) Item Description Crankcase-oil capacity 4.7 L (4.9 US qt) Yanmar trochoid pump Oil pump Coolant capacity 9.
General Information This chapter gives information about specifications and repair of the Yanmar diesel engine used on certain Reelmaster 5410-D, 5510-D, and 5610-D machines. The general maintenance procedures are described in the Operator’s Manual. Detailed information on engine troubleshooting, testing, disassembly, and assembly is identified in the Yanmar Engine Service Manual and Troubleshooting Manual. Additionally, some engine repair procedures are described in this manual.
Engine Electronic Control Unit (ECU) (continued) The engine electrical components (e.g., ECU, fuel injectors, EGR, and exhaust DPF) are identified and matched in the engine ECU program. If the engine electrical components are replaced, the Yanmar electronic tool must be used to update the ECU program which will ensure correct engine operation. If the engine ECU identifies that an engine problem exists, the engine speed may be reduced or the engine may shut off.
Regeneration The engine ECU monitors the exhaust pressure before and after the soot filter in the DPF to determine if soot is accumulating. If soot is accumulating during normal engine operation, the pressure differential will increase. The increase in pressure will signal the engine to begin a process called Regeneration.
Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. May be caused by prolonged operation at low engine speed, low engine load, or the use of incorrect fuel or engine oil. Manually initiate a parked regeneration as soon as possible.
Soot Accumulation If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addition to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Shutting Off the Engine (Reelmaster 5610-D) IMPORTANT After mowing or full load operation on machines with a turbo-charged engine, cool the turbo-charger by 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 period may lead to premature turbocharger and engine failure.
Service and Repairs Air Cleaner System g188092 Figure 28 Reelmaster 5610-D 1. Clamp 7. Air cleaner bracket 13. Air cleaner mounting band 2. Air cleaner outlet hose 8. Flange-head screw (2 each) 14. Spring 3. Hose clamp (2 each) 9. Air cleaner stand 15. Bolt 4. Hose clamp Bolt (2 each) 16. Adapter 10. 5. Air cleaner assembly 11. Yanmar engine 17. Service indicator 6. Flange nut (4 each) 12. Nut 18.
g229843 Figure 29 1. Hose clamp 7. Air cleaner stand 13. Shoulder bolt 2. Adapter 8. Bolt (2 each) 14. Hose clamp (2 each) 3. Service indicator 9. Flange-head screw (2 each) 15. Air cleaner hose 4. Air cleaner assembly 10. Hex nut 16. Hose clamp 5. Flange nut (4 each) 11. Air cleaner mounting band 17. Air cleaner inlet hose 6. Air cleaner bracket 12.
Installing the Air Cleaner System IMPORTANT Leaks in the air filter system will allow dirt to enter into the engine and can cause serious engine damage. Ensure that all the air cleaner components are in good condition and are properly secured during installation. 1. Assemble the air cleaner system as shown in Figure 28 or Figure 29. A.
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.
g211750 Figure 32 Reelmaster 5610-D 9. Tailpipe bracket 1. Muffler clamp 5. Washer-head screw (2 each) 2. Exhaust tube 6. Tailpipe guard 10. Flange nut (2 each) 3. Flange-head screw (2 each) 7. Flange-head screw (2 each) 11. Diesel-particulate filter assembly (DPF includes DOC) 4. Exhaust clamp 8. Tailpipe bracket 12. Engine The exhaust system used in Reelmaster requires a diesel exhaust particulate filter (DPF).
Removing the Exhaust System (continued) 2. Block the wheels with chocks to prevent the machine from moving. 3. Unlatch the hood and raise it. Allow engine and exhaust system to cool before doing any disassembly of exhaust system components. 4. Remove the exhaust system components as shown in Figure 31 and Figure 32. Discard all gaskets that were removed (items 1 and 15 in Figure 31).
Radiator g188098 Figure 33 1. Screen 10. Washer-head screw (6 each) 19. Hose clamp (4 each) 28. Reservoir bracket 2. Pop rivet (2 each) 11. Mounting bracket (2 each) 20. Lower radiator hose 29. Button-head screw (5 each) 3. Detent ball pin 12. Foam seal (2 each) 21. Upper radiator hose 30. Reservoir cap 4. Draw latch 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.
Removing the Radiator 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. Remove the screen (item 1 in Figure 33) from the machine. 3. Unlatch the hood and raise it. DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. WARNING Ethylene-glycol antifreeze is poisonous.
Removing the Radiator (continued) Carefully position the coolant reservoir and reservoir bracket away from the fan shroud. 13. On the left side of the machine, remove the 2 button-head screws (item 29 in Figure 33) and 2 flange nuts that secure the fan shroud to the radiator frame. 14. Remove the 14 flange-head screws (item 6 in Figure 33) that secure the fan shroud to the radiator, and radiator to the radiator frame. Position the fan shroud away from the radiator. 15.
Installing the Radiator (continued) 4. Position the coolant reservoir and reservoir bracket to the fan shroud. Secure the reservoir bracket to the fan shroud and radiator frame with the 2 button-head screws (item 29 in Figure 33) and 2 flange nuts. 5. On the left side of the machine, secure the fan shroud to the radiator frame with the 2 button-head screws (item 29 in Figure 33) and 2 flange nuts. 6.
Fuel System g188096 Figure 35 1. Hose clamp (2 each) Fuel tank cap 17. Fuel supply hose 25. 2. Fuel return hose 10. 9. Fuel tank 18. Recess bumper 26. Fuel/water separator 3. Hose clamp (6 each) 11. Washer-head screw (2 each) 19. Flat washer 27. 90° elbow fitting (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.
DANGER Diesel fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle diesel fuel. • Do not smoke while filling the fuel tank. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Removing the Fuel Tank (continued) IMPORTANT To prevent damage to the fuel hoses, numerous cable ties are used to secure the hoses to the machine components. Record the location of all cable ties that are removed from the machine during the fuel tank removal so that they can be properly replaced during the tank installation. 8. Loosen 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.
Installing the Fuel Tank 1. Install the fuel tank to the frame (Figure 35). Secure the fuel hoses with the cable ties as recorded during the fuel tank removal. g188097 Figure 36 1. Fuel sender 2. Fuel supply fitting 3. Fuel return fitting 2. If the fuel sender was removed from the fuel tank, ensure that the fuel fittings on the sender are orientated at 90° from right side of the tank as shown in Figure 36.
Engine g189543 Figure 37 Reelmaster 5610-D 1. Bolt (14 each) 7. Spacer (4 each) 13. Bolt (2 each) 2. Lock washer (14 each) 8. Snubbing washer (4 each) 14. Flange nut (10 each) 3. Bolt (4 each) 9. 4. Right rear engine mount 5. 6. Flange nut (10 each) 15. Flange-head screw (8 each) 10. Yanmar engine 16. Right front engine mount Left rear engine mount 11. Driveshaft assembly 17. Lift tab Left front engine mount 12.
Removing the Engine 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. 3. Disconnect both the battery cables at the battery. Disconnect the negative battery cable and then the positive battery cable; refer to Servicing the Battery (page 7–125). DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns.
Removing the Engine (continued) B. For assembly purposes, label the fuel hoses. Disconnect the fuel supply and return hoses from the fuel filter on the engine (Figure 38). C. Cover or plug the fuel hoses and fuel filter fittings openings to prevent 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 grip 2. Negative battery cable 4.
Removing the Engine (continued) IMPORTANT To prevent damage to the electrical wire harness, numerous cable ties are used to secure the wire harness to the machine components. Record the location of all cable ties that are removed from the machine during the engine removal so that they can be properly replaced during the engine installation. 9. For assembly purposes, note the location of the cable ties used to secure the wire harness to the machine.
Removing the Engine (continued) 12. Carefully raise the engine from the machine moving it toward the front of the machine and away from the radiator assembly. 13. If necessary, remove the engine mount brackets from the engine. Installing the Engine IMPORTANT Ensure that all parts are removed from the engine during maintenance or overhaul are correctly installed on the engine. 1. If the engine mount brackets were removed from the engine, secure the brackets to the engine with the lock washers and bolts.
Installing the Engine (continued) C. The engine wire harness power cable to the battery clamp through the cord grip and tighten the cord grip (Figure 39). Note: Make sure that the engine and frame ground surfaces are free from corrosion, oil and paint. D. The negative battery cable, engine wire harness ground cable and frame to engine ground cable at the engine block (Figure 40). E. Torque the engine ground bolt to 46 to 57 N·m (34 to 42 ft-lb) and apply a coat of terminal protector. F.
Installing the Engine (continued) 10. Install the exhaust system to the machine; refer to Installing the Exhaust System (page 4–17). Ensure that the exhaust tube has 9.5 mm (0.375 inch) clearance with tailpipe guard in all directions after assembly. 11. Ensure that the radiator draincock is closed and fill the radiator and reservoir with coolant. 12. Connect both the battery cables to the battery.
Chapter 5 Kubota Gasoline Engine Table of Contents Specifications ....................................................................................................................................... 5–2 Kubota Gasoline Engine .................................................................................................................... 5–2 General Information ..............................................................................................................................
Specifications Kubota Gasoline Engine Reelmaster 5410-G and 5510-G g237076 Figure 42 1. Engine cooling fan 4. Flywheel 7. 2. 3. Intake manifold Engine ECU 5. 6. Starter motor Engine oil filter Item Alternator Description Make/Designation Kubota Model WG1605-G-E3: 4-Cycle OHV, 4 Cylinder, Water Cooled, Gasoline Engine 4 Number of Cylinders Bore x Stroke 79 mm x 78.4 mm (3.11 x 3.09 inches) Total Displacement 1,573 cm3 (93.
Kubota Gasoline Engine (continued) Item Description Starter 12 VDC 1.
General Information This chapter gives information about specifications, troubleshooting, testing and repair of the Kubota gasoline engine used in Reelmaster 5410-G and 5510-G machines. Most repairs and adjustments require tools which are commonly available in many service shops. The use of some specialized test equipment is explained in the engine service manual included at the end of this chapter.
Engine Electronic Control Unit (ECU) (continued) If the engine ECU identifies that an engine problem exists, the engine speed may be reduced or the engine might stop running. The Kubota Diagnosis Manual and Kubota Gasoline service tool should be used to provide assistance in identifying the cause of the problem and the repairs that are necessary. Contact your Toro distributor for assistance in Kubota gasoline engine troubleshooting.
Service and Repairs Air Cleaner Assembly g229320 Figure 43 1. Air cleaner assembly 10. Hose clamp 19. Engine assembly 2. 3. Air cleaner mounting band 11. Hose clamp (4 each) 20. Flange-head screw (2 each) Hex nut 12. Air cleaner hose 21. Spacer (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.
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 support hood. 2. Remove air cleaner components as necessary (Figure 43). 3. Refer to Traction Unit Operator’s Manual for air cleaner service and maintenance procedures. Installing the Air Cleaner Assembly IMPORTANT Any leaks in the air filter system will allow dirt into engine and will cause serious engine damage.
Installing the Air Cleaner Assembly (continued) C. Torque the hose clamps to the values identified in Figure 43. 2. After air cleaner has been properly installed, lower and secure hood.
Exhaust System g229322 Figure 45 1. Heat shield (2 each) 14. Catalytic muffler 27. Flange-head screw (2 each) 2. Flange-head screw (8 each) 15. Flange-head screw (4 each) 28. Tailpipe bracket 3. Heat shield 16. Flange nut (4 each) 29. Flange nut (3 each) 4. Shield strap (2 each) 17. Manifold outlet gasket 30. Carriage screw 3 each) 5. Screw (4 each) 18. Exhaust manifold 31. Exhaust mount 6. Bolt (2 each) 19. Nut (4 each) 32. Flange-head screw (4 each) 7.
To meet gasoline engine emission requirements, the Kubota gasoline engine used on your Reelmaster has a catalytic muffler. In addition to providing sound damping and spark arresting, the muffler also includes a three way catalyst to treat the exhaust gases which are created from the combustion process. The 3-way catalyst consists of a honeycomb core coated with a mixture of precious metals. The hot exhaust gases flow through the catalyst where oxidation and reduction reactions take place.
Fuel System g229323 Figure 46 1. Fuel cap 11. Recess bumper 21. Breather 31. Hose clamp (2 each) 2. Screw (7 each) 12. Draincock 22. Fuel hose 32. Hose clamp 3. Washer-head screw (2 each) 13. Fuel pump assembly 23. Fuel hose 33. Washer-head screw 4. Flange nut (3 each) 14. Fuel fitting 24. Vacuum control valve 34. Washer-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.
DANGER Because gasoline is highly 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 enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting the engine. Store fuel in a clean, safety-approved container and keep container cap in place. Use gasoline for the engine only; not for any other purpose.
Removing the Fuel Tank (continued) 4. Loosen hose clamps that secure fuel supply hose (item 8 in Figure 46) and vent hose to tank fittings. Carefully disconnect fuel supply hose and vent hose from tank fittings. 5. Remove fuel tank from machine (Figure 46). If fuel pump assembly is to be removed from fuel tank, note orientation of fuel pump fitting for assembly purposes (Figure 47). Installing the Fuel Tank g229324 Figure 47 1. Fuel pump assembly 2. Fuel supply fitting 3. Parallel 1.
Fuel Evaporative Control System g229325 Figure 48 1. Hose clamp (2 each) 17. Fuel hose Carbon canister 9. 2. Canister bracket 10. Hose clamp 18. Tee fitting 3. Fuel hose (to fuel tank vent) 11. Fuel hose 19. Fuel hose 4. Fuel hose (canister to control valve) 12. Straight fitting 20. Fuel hose 5. Hose 13. Fuel hose 21. Hose clamp (2 each) 6. Hose clamp 14. Tee fitting 22. Vent (engine air intake) 7. Breather 15. Fuel hose (to PCV valve) 8. Vacuum control valve 16.
Removing the Fuel Evaporative Control System 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the key switch. 2. Raise and support hood. DANGER Gasoline 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 or in an enclosed area. Always fill fuel tank outside and wipe up any spilled fuel before starting the engine.
Removing the Fuel Evaporative Control System (continued) g229317 Figure 50 Vacuum control valve connections 1. To tee fitting in PCV system hose 2. To tee fitting and engine air intake vent 3. To middle (purge) canister port B. If hoses are removed from vacuum control valve (item 8 in Figure 48), note hose location for assembly purposes. Figure 50 identifies control valve hose locations. Installing the Fuel Evaporative Control System 1.
Radiator and Oil Cooler Assembly g229318 Figure 51 1. Coolant reservoir 12. Flange-head screw (14 each) 23. Screen 2. Hose clamp (2 each) 13. Reservoir bracket 24. O-ring 3. Button-head screw (5 each) 14. Upper radiator hose 25. O-ring 4. Hydraulic fitting (2 each) 15. Lower radiator hose 26. Detent ball pin 5. Foam seal (2 each) 16. Fan shroud 27. Overflow hose 6. Mounting bracket (2 each) 17. Pop rivet (2 each) 28. Foam seal (4 each) 7. Foam seal (2 each) 18.
Removing the Radiator and Oil Cooler Assembly (continued) CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene-glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly labeled container away from children and pets. 4.
Removing the Radiator and Oil Cooler Assembly (continued) 10. Clean hydraulic tubes at fittings in oil cooler ports (Figure 52). Disconnect hydraulic tubes and put caps or plugs on tubes and fittings to prevent contamination. 11. On right side of machine, remove 2 button-head screws and flange nuts that secure fan shroud to radiator frame. 12. Remove flange-head screws that secure fan shroud to radiator/oil cooler. Position fan shroud away from the radiator. 13.
Installing the Radiator and Oil Cooler Assembly (continued) 17. Install and secure screen (item 23 in Figure 51) to rear of machine.
Engine g229348 Figure 53 1. Gasoline engine assembly 12. Exhaust support bracket 23. Flange-head screw (2 each) 2. Pump driveshaft assembly 13. Bolt 24. Locknut (4 each) 3. Bolt (2 each) 14. Lock washer 25. Engine mount bracket (2 each) 4. Flange nut (2 each) 15. Bolt 26. Engine mount bracket (2 each) 5. Bolt (6 each) 16. Lock washer 27. Bolt (4 each) 6. Exhaust manifold 17. Tailpipe bracket 28. Spacer (4 each) 7. Flange nut (4 each) 18.
Removing the Engine 1. Park machine on a level surface, lower cutting units, stop engine and remove key from the key switch. Chock wheels to keep the machine from moving. 2. Unlatch screen at rear of machine. Lift screen from hinges and remove screen from machine. 3. Disconnect negative (-) and then positive (+) battery cables from battery; refer to Servicing the Battery (page 7–125). 4. If engine is to be disassembled, drain oil from engine. 5. Open and support hood.
Removing the Engine (continued) 10. Disconnect hydraulic pump driveshaft from engine; refer to Hydraulic Pump Driveshaft (page 6–159). Support driveshaft away from engine. IMPORTANT To prevent damage to electrical harness, numerous cable ties are used to secure harness to machine components. Take note of all cable ties that are removed from machine during engine removal so that they can be properly replaced during engine installation. 11.
Removing the Engine (continued) CAUTION One person should operate hoist or lift while a second person guides the engine out of the machine. IMPORTANT Ensure to not damage the engine, fuel hoses, hydraulic lines, electrical harness, radiator, or other parts while removing the engine. 15. Carefully raise engine moving it toward the front of the machine and remove from machine. 16. If necessary, remove engine mount brackets from engine. Installing the Engine 1.
Installing the Engine (continued) 10. Secure engine coolant reservoir and bracket to the fan shroud and radiator frame (Figure 55): A. Position coolant reservoir and bracket to the fan shroud. Secure bracket to fan shroud and radiator frame with 2 button-head screws and flange nuts. B. Connect overflow hose to radiator fill opening and secure with hose clamp. 11. Install air cleaner assembly; refer to Air Cleaner Assembly (page 3–8).
Kubota Gasoline Engine: Service and Repairs Page 5–26 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Chapter 6 Hydraulic System Table of Contents Specifications ....................................................................................................................................... 6–4 Hydraulic System ............................................................................................................................... 6–4 General Information ..............................................................................................................................
Cutting Reel Motor Efficiency Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) ......................................................................... 6–80 Cutting Reel Motor Cross-Over Relief Pressure Test (5510/5510-G/5510-D/5610) .......................... 6–83 Lift Relief Valve (SVRV) Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) .............
Radiator and Oil Cooler Assembly (5410-G/5410-D/5510-G/5510-D/5610-D) ...............................
Specifications Hydraulic System Reelmaster 5410/5410-G/5410-D/5510/5510-G/5510-D/5610 Item Description Piston (traction) pump Closed Circuit Axial Piston Design Maximum pump displacement (per revolution) 35 cm³ (2.14 in³) 4-section, positive displacement gear type pump Gear pump Section P1/P2 displacement (per revolution) (RM 5410/5410-G/5410-D) 8.3 cm³ (0.50 in³) Section P1/P2 displacement (per revolution) (RM 5510/5510-G/5510-D/5610) 10.8 cm³ (0.
Hydraulic System (continued) Reelmaster 5610-D (Model No. 03679) Item Description Piston (traction) pump Sauer-Danfoss, LPV closed circuit axial piston design Maximum pump displacement (per revolution) Gear pump 35 cm³ (2.14 in³) Casappa 4-section, positive displacement gear type pump Section P1 displacement (per revolution) 11.23 cm³ (0.68 in³) Section P2 displacement (per revolution) 11.23 cm³ (0.68 in³) Section P3 displacement (per revolution) 6.6 cm³ (0.
General Information The Operator's Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Operator's Manual for additional information when servicing the machine. Checking the Hydraulic Fluid g213868 Figure 56 1. 2. Cap with dipstick Hydraulic tank The hydraulic system on your machine is designed to operate on anti-wear hydraulic fluid. The reservoir holds approximately 34.
Pushing or Towing the Traction Unit IMPORTANT If towing limits are exceeded, severe damage to the piston (traction) pump may occur. g186201 Figure 57 1. 2. Piston (traction) pump Bypass valve If it becomes necessary to tow or push the machine, tow or push 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.
Releasing Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system. System pressure in the mow circuit is released when the cutting units are disengaged. Releasing the Hydraulic Pressure from the Traction Circuit Note: If you park the machine on an incline or slope, the pressure in the traction circuit does not release. 1. Park the machine on a level surface. 2. Lower the cutting units. 3.
Traction Circuit Component Failure The traction circuit of the Reelsmaster 5010 series machines is a closed loop system that includes the piston (traction) pump and 2 front wheel motors (4 wheel motors on machines equipped with CrossTrax AWD). If a component failure occurs in the traction circuit (e.g., traction (piston) pump or wheel motor), unwanted material and contamination from the damaged component will circulate throughout the traction circuit.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting. Lightly lubricate the O-ring with clean hydraulic fluid. g221221 Figure 58 1. Tube or hose 3. O-ring 2.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (continued) C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (FFWR); refer to the Flats From Wrench Resistance Table (page 6–12). Note: The markings on the nut and body of the fitting show that the connection is correctly tightened.
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) Installing the Non-Adjustable Fittings 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. g221223 Figure 60 1. Fitting 2. O-ring 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing the Non-Adjustable Fittings (continued) Fitting Installation Torque Table (continued) Fitting Dash Size Fitting Port Side Thread Size (inch(es)—threads per inch) Installation Torque Into Steel Port Installation Torque Into Aluminum Port 6 9/16—18 47 to 56 N∙m (34 to 42 ft-lb) 28 to 35 N∙m (20 to 26 ft-lb) 8 3/4—16 79 to 97 N∙m (58 to 72 ft-lb) 48 to 58 N∙m (35 to 43 ft-lb) 10 7/8—14 135 to 164 N∙m (99 to 121 ft-lb) 82 to 100 N∙m (60 to 74 ft-lb) 12 1–1/16—12 182 to 222 N∙m (134
Installing an Adjustable Fitting (continued) 3. Lightly lubricate the O-ring with clean hydraulic fluid. Ensure that the threads of the fitting are clean with no lubricant applied (Figure 61). g221225 Figure 62 4. Turn back the locknut as far as possible. Ensure that the back-up washer is not loose and it is pushed up as far as possible (Step 1 in Figure 62). IMPORTANT Before installing the fitting into the port, determine the material of which the port is made.
Installing an Adjustable Fitting (continued) Flat From Finger Tight 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.
Hydraulic Schematics g230012 Figure 63 Reelmaster® 5410/5510/5610 Series 15216SL Rev E Page 6–17 Hydraulic System: Hydraulic Schematics
g230013 Figure 64 Hydraulic System: Hydraulic Schematics Page 6–18 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
g213698 Figure 65 Reelmaster® 5410/5510/5610 Series 15216SL Rev E Page 6–19 Hydraulic System: Hydraulic Schematics
Hydraulic Flow Diagrams (5410/5410-D/5510/5510-D/5610) Traction Circuit (5410/5410-D/5510/5510-D/5610) The hydraulic traction circuit consists of a variable displacement piston pump (P5) connected in a closed loop, parallel circuit to 2 orbital roller vane wheel motors. The traction pump input shaft is rotated by a driveshaft that is driven from the engine flywheel.
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 E
CrossTrax™AWD (Optional) g230032 Figure 67 On machines equipped with optional CrossTrax AWD, 4 wheel motors are used (Figure 67). Traction pump flow is directed to the front tires and the opposite rear tires 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 control manifold allow the rear wheel motors to over run during tight turns.
Mow Circuit (5410/5410-D/5510/5510-D/5610) A 4-section gear pump is coupled to the piston (traction) pump. Gear pump sections (P1) and (P2) supply hydraulic flow for the mow circuit. These gear pumps take their suction from the hydraulic reservoir. The mow control manifold contains 2 independent control circuits for the front and rear cutting units. Each circuit is supplied by its own pump section.
Backlap During the backlap mode of operation, the reel circuits operate the same as in the mow mode. When 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.
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 E
Lift Circuit (5410/5410-D/5510/5510-D/5610) A 4-section gear pump is coupled to the piston (traction) pump. Gear pump section (P4) supplies hydraulic flow to the lift control manifold and ultimately for the lift cylinders. The gear pump takes its suction from the hydraulic reservoir. Lift circuit pressure is limited to 13,800 kPa (2,000 psi) by a solenoid relief valve (SVRV) located in the lift control manifold. The lift control manifold includes 4 electrically operated solenoid valves.
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 E
Lower the Cutting Units When the joystick is moved to the lower position with the engine running, solenoid valve (SVRV) energizes along with solenoid valves (SV1) and (SV3). Solenoid valve (SV2) is in its normally de-energized position, and directs fluid flow to the piston end of the lift cylinders. Hydraulic pressure against the piston side of the cylinder causes the shafts to extend, and lower the cutting units.
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 E
Steering Circuit (5410/5410-D/5510/5510-D/5610) A 4-section gear pump is coupled to the piston (traction) pump. Gear pump section P3 supplies hydraulic flow to the steering control valve and for the traction charge circuit. The gear pump takes its suction from the hydraulic reservoir. Steering circuit pressure is limited to 6,900 kPa (1,000 psi) by a relief valve (R10) located in the steering control.
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 E
Hydraulic Flow Diagrams (5610-D) Traction Circuit (5610-D) The hydraulic traction circuit consists of a variable displacement piston pump (P5) connected in a closed loop, parallel circuit to 4 orbital roller vane wheel motors. The traction pump input shaft is rotated by a driveshaft that is driven from the engine flywheel. The forward traction circuit pressure can be measured at the test port located in the hydraulic tube that connects the front wheel motors.
Reverse Direction (continued) manifold where the 2 internal check valves allow the hydraulic fluid to bypass the rear wheel motors. Then the fluid flows to the front wheel motors, turning them in the reverse direction. The reverse traction pressure is limited to 25,000 kPa (3,625 psi) by the reverse traction relief valve (R4) located in the traction pump.
Reverse Direction (continued) g213692 Figure 72 Hydraulic System: Hydraulic Flow Diagrams (5610-D) Page 6–34 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Mow Circuit (5610-D) A 4-section gear pump is coupled to the piston (traction) pump. The gear pump sections (P1) and (P2) supply hydraulic flow for the mow circuit. These gear pumps take their suction from the hydraulic reservoir (Figure 73). The mow control manifold contains 2 independent control circuits for the front and rear cutting units. Each circuit is supplied by its own pump section.
Backlap During the backlap mode of operation, the reel circuits operate the same as in the MOW mode. When 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.
Backlap (continued) g213701 Figure 73 Reelmaster® 5410/5510/5610 Series 15216SL Rev E Page 6–37 Hydraulic System: Hydraulic Flow Diagrams (5610-D)
Lift Circuit (5610-D) A 4-section gear pump is coupled to the piston (traction) pump. The gear pump section (P4) supplies hydraulic flow to the lift control manifold and ultimately for the lift cylinders. The gear pump takes its suction from the hydraulic reservoir. The lift control manifold includes 4 electrically operated solenoid valves. The solenoid relief valve (SVRV) located in the lift control manifold limits the lift circuit pressure to 13,800 kPa (2,000 psi).
Raise the Cutting Units (continued) g213699 Figure 74 Reelmaster® 5410/5510/5610 Series 15216SL Rev E Page 6–39 Hydraulic System: Hydraulic Flow Diagrams (5610-D)
Lower the Cutting Units When the joystick is moved to the lower position with the engine running, the solenoid valve (SVRV) energizes along with solenoid valves (SV1) and (SV3). The solenoid valve (SV2) is in its normally de-energized position, and directs fluid flow to the piston end of the lift cylinders. The hydraulic pressure against the piston side of the cylinder causes the shafts to extend, and lower the cutting units.
Lower the Cutting Units (continued) g213700 Figure 75 Reelmaster® 5410/5510/5610 Series 15216SL Rev E Page 6–41 Hydraulic System: Hydraulic Flow Diagrams (5610-D)
Steering Circuit (5610-D) A 4-section gear pump is coupled to the piston (traction) pump. The gear pump section P3 supplies hydraulic flow to the steering control valve and for the traction charge circuit. The steering control valve receives the pump supply first, ensuring pressure and volume is always available for steering control, no matter the charge circuit demand. The gear pump takes its suction from the hydraulic reservoir.
Right Turn (continued) g213705 Figure 76 Reelmaster® 5410/5510/5610 Series 15216SL Rev E Page 6–43 Hydraulic System: Hydraulic Flow Diagrams (5610-D)
Special Tools You can order these special tools from your Toro Distributor. Some tools are also available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
40 GPM Hydraulic Tester (Pressure and Flow) Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities as recommended in Testing the Hydraulic System (page 6–56). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 35,000 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part No. TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the damaged part will remain in the circuit until you remove it.
Measuring Container Toro Part No. TOR4077 Use this container to test hydraulic motor efficiency (motors with case drain lines only). Limit the outlet flow from the motor and measure the leakage from the case drain line to measure the efficiency 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. Hydraulic System: Special Tools GPM mL/15 seconds oz/15 seconds 0.
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g., gear pump, piston pump, or wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Figure 77) can be used for priming the hydraulic pumps. You can get this switch locally. IMPORTANT Important: When using a remote starter switch, it is highly recommended to include a 20 A in-line fuse between the battery and switch connector for circuit protection.
Troubleshooting The following chart contains suggestions that can be used to solve performance issues specific to the hydraulic system. The suggestions are not all-inclusive. There can be more than 1 cause for a machine malfunction. Review the hydraulic schematic found in Appendix A (page A–1) and information on the hydraulic system operation in the Hydraulic Flow Diagrams (5410/5410-D/5510/5510-D/5610) (page 6–20) or Hydraulic Flow Diagrams (5610-D) (page 6–32).
Traction Circuit Problems Problem Possible Causes The traction response is sluggish. • The piston (traction) pump bypass valve is open or damaged. • The brake is dragging or binding. • The charge pressure is low. • The hydraulic fluid is very cold. • The piston (traction) pump check valve, relief valve, and/or flushing valve is leaking. • The piston (traction) pump or wheel motor(s) is worn or damaged. • The charge relief valve in the piston (traction) pump is not seating or is damaged.
Traction Circuit Problems (continued) Problem Possible Causes The wheel motor does not turn. • The brakes are binding. • The piston (traction) pump bypass valve is open. • The piston (traction) pump or wheel motor is worn or damaged. Note: If 1 traction circuit component has internal wear or damage, it is possible that the other traction components are also damaged. The wheel motor does not hold load in the NEUTRAL position. • The charge pressure is low.
Mow Circuit Problems Problem Possible Causes All the 3 front cutting reel motors do not operate but rear cutting reel motors operate. • The solenoid valve MSV2/SP2 on the mow control manifold is damaged. Note: The solenoid valves MSV1/SP1 and MSV2/SP2 are identical and can be reversed for testing purposes. • The mow/backlap lever for the front cutting units (MR2/MV2) is not rotated fully.
Lift/Lower Circuit Problems Problem Possible Causes • The cutting reel has excessive unwanted elements. One cutting reel raises slowly or not at all. • The lift arm or lift cylinder is binding. • The pilot piston in the lift control manifold is stuck or damaged. • The flow control orifice in lift control manifold for the affected cutting reel is plugged, stuck, or damaged. • The lift cylinder leaks internally. One or more cutting unit raises, but does not stay up.
Lift/Lower Circuit Problems (continued) Problem Possible Causes Neither of the rear cutting units will raise or lower but the front cutting units will raise and lower. • The solenoid valve SV3 on the lift control manifold is damaged. • An electrical problem exists that prevents SV3 solenoid coil on the lift control manifold from being energized (refer to Troubleshooting (page 7–26) or the Electrical Schematic and Wire Harness Drawings/Diagrams in Appendix A (page A–1)).
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 6–44). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Clean the machine fully before you disconnect or disassemble the hydraulic components. Note: Cleanliness is required whenever you work on the hydraulic equipment. Contamination causes too much wear on hydraulic components. 2. When you perform tests on the hydraulic system, wear eye protection. 3.
16. After hydraulic test procedures have been completed, check the hydraulic-fluid level in the hydraulic tank to ensure that the hydraulic-fluid level is correct.
Traction Circuit Relief Valve (R3) and (R4) Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230018 Figure 80 The traction circuit relief pressure test should be performed to ensure that the forward and reverse 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 shut off. Apply the parking brake. 2.
Test Procedure (continued) CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). Note: If machine is equipped with optional CrossTrax AWD, reverse relief pressure test ports are located on CrossTrax hydraulic manifold. g230033 Figure 81 2-wheel drive machine 1. Right wheel motor 3. Forward test port 2. Left wheel motor 4.
Test Procedure (continued) 5. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine under load for approximately 10 minutes. 6. Sit on seat and increase engine speed to high idle speed. 7. Apply brakes and slowly press the traction pedal in the direction to be tested (forward or reverse). While pushing traction pedal down, carefully watch the pressure gauge needle. As the traction relief valve lifts, the gauge needle will momentarily stop.
Traction Circuit Charge Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230019 Figure 84 The traction circuit charge pressure test should be performed to ensure that the traction charge circuit is functioning correctly. 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 precautions listed at the beginning of this section. 3.
Test Procedure (continued) CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). g230036 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.
Test Procedure (continued) 5. Start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 6. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine under load for approximately 10 minutes. 7. Ensure that the traction pedal is in neutral, the steering wheel is stationary and parking brake is engaged. 8.
Gear Pump (P3) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230020 Figure 87 The gear pump (P3) flow test should be performed to ensure that the traction 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. Apply the parking brake. 2.
Test Procedure (continued) CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 3. Raise and prop operator seat to allow access to hydraulic pump assembly. g230038 Figure 88 1. Piston (traction) pump 3. Oil filter/filter adapter 5. Hydraulic tube 2. Piston pump inlet fitting 4. Filter inlet fitting 6. Hydraulic tube 4.
Test Procedure (continued) 9. Increase engine speed to high idle speed (3,000 rpm). Use InfoCenter Display or phototac to verify that engine speed is correct. Note: The gear pump is a positive displacement type. If pump flow is completely restricted or shut off, damage to the pump, tester, or other components could occur. 10. While watching tester pressure gauge, slowly close the tester flow control valve until 5,500 kPa (800 psi) is obtained on gauge. Ensure that the engine speed remains at 3,000 rpm.
Front Wheel Motor Efficiency Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230021 Figure 89 Test Procedure Note: Over a period of time, a wheel motor can wear internally. A worn motor may by-pass fluid causing the motor to be less efficient. Eventually, enough fluid loss will cause the wheel motor to stall under heavy load conditions.
Test Procedure (continued) Note: This test procedure includes steps to test efficiency of both front wheel motors together before testing individual wheel motors. 1. Ensure that the traction pedal is adjusted to the neutral position; refer to the Traction Unit Operator’s Manual. 2. Drive machine to an open area. Park machine on a level surface with the cutting units lowered and disengaged. Ensure that the engine is shut off. 3.
Test Procedure (continued) 7. Install tester with pressure gauge and flow meter in series with the piston pump and the disconnected hose. Ensure that the tester flow control valve is fully open. 8. Start engine and increase engine speed to high idle speed. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine under load for approximately 10 minutes. CAUTION Use extreme caution when performing test.
Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230022 Figure 91 Test Procedure This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. IMPORTANT Traction circuit flow for your Reelmaster is approximately 114 L/minute (30 gallons/minute).
Test Procedure (continued) 2. Ensure that the hydraulic tank is full. 3. Read all Warning, Cautions, and precautions listed at the beginning of this section. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 4. Ensure that the traction pedal is adjusted to the neutral position.
Test Procedure (continued) CAUTION All wheels will be off the ground and rotating during this test. Ensure that the machine is supported so it will not move and accidentally fall to prevent injuring anyone near the machine. 8. Start engine and run at idle speed. Check for any hydraulic leakage from tester and hose connections. Correct any leaks before proceeding. 9. Increase engine speed to high idle speed.
Relief Valve (R1) and (R2) Pressure Test (Cutting (Mow) Circuit) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230023 Figure 93 The relief valve (R1) and (R2) pressure test should be performed to ensure that the cutting unit circuit relief pressures are correct. Note: 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). Test Procedure 1.
Test Procedure (continued) 2. Park machine on a level surface with the cutting units lowered and reel engage switch OFF. Ensure that the engine is shut off and mow/transport lever is in MOW. Apply the parking brake. 3. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Test Procedure (continued) 8. After installing tester, start engine, and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 9. Increase engine speed to high idle speed. CAUTION Keep away from reels during test to prevent personal injury from rotating reel blades. 10. Have a second person occupy seat, press reel engage switch to ON, and then move lower-mow/raise lever forward to engage cutting units.
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) g230024 Figure 95 Over a period of time, the gears, and wear plates in the gear pump can wear. A worn pump will by-pass fluid and make the pump less efficient. Eventually, enough fluid can by-pass to cause the reels to stall in heavy cutting conditions.
Test Procedure (continued) 2. Read all Warning, Cautions, and precautions listed at the beginning of this section. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 3. Raise and prop operator seat to allow access to hydraulic pump. g230042 Figure 96 1. Gear pump 2. Section P1 outlet (rear) 3. Section P2 outlet (front) 4.
Test Procedure (continued) IMPORTANT The gear pump is a positive displacement type. If pump flow is completely restricted or stopped, damage to the pump, tester, or other components could occur. 9. While watching pressure gauges, slowly close the tester flow control valve until 13,800 kPa (2,000 psi) is obtained on gauge. Verify 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.
Cutting Reel Motor Efficiency Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230025 Figure 97 Note: Over a period of time, a reel motor can wear internally. A worn motor may by-pass fluid to its case drain causing the motor to be less efficient. Eventually, enough fluid loss will cause the reel motor to stall under heavy cutting conditions.
Test Procedure 1. Determine which reel motor is malfunctioning. 2. Park machine on a level surface with the cutting units lowered and reel engage switch OFF. Ensure that the engine is shut off and mow/transport lever is in MOW. Apply the parking brake. 3. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Test Procedure (continued) 6. Use the InfoCenter Display to set reel speed control to the full speed position. Ensure that the mow/backlap lever on mow control manifold is in the MOW position. Note: Use a graduated measuring container, special tool TOR4077, to measure case drain leakage (Figure 97). 7. Start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test.
Cutting Reel Motor Cross-Over Relief Pressure Test (5510/5510-G/5510-D/5610) g230026 Figure 99 Note: One way to find a damaged reel motor is to have another person observe the machine while mowing in dense turf. A 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 on Reelmaster 5410 series machines.
Note: Before testing the cutting reel motor cross-over relief pressure, ensure that the reel motor is in good condition by performing the cutting reel motor efficiency test; refer to Cutting Reel Motor Efficiency Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) (page 6–80). Test Procedure 1. Determine which cutting reel motor needs to be tested by observing the machine during mowing. 2.
Test Procedure (continued) 8. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine under load for approximately 10 minutes. Do not engage cutting units. CAUTION Adjacent cutting unit reels will rotate when performing the cross-over relief test. Keep away from cutting units during test to prevent personal injury from rotating reel blades. Do not stand in front of the machine. 9.
Lift Relief Valve (SVRV) Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230027 Figure 101 The lift relief valve (SVRV) pressure test should be performed to ensure that the lift 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 brake. 2. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Test Procedure (continued) CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 3. Gain access to hydraulic lift control manifold from below front of machine. g230045 Figure 102 1. Front axle 2. Lift control manifold 3. Test port (G4) 4. Clean test port (G4) on the bottom of lift control manifold (Figure 102).
Test Procedure (continued) IMPORTANT While performing this test, hold lower-mow/raise lever in the RAISE position only long enough to get a system pressure reading. Holding the lever in raise for an extended period may damage system components. 8. Ensure that the reel engage switch is OFF and then pull lower-mow/raise lever rearward to pressurize lift circuit. While holding lever in the raise (rearward) position, watch pressure gauge carefully.
Gear Pump (P4) Flow Test (Using Tester with Flow Meter and Pressure Gauge) (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230028 Figure 103 The gear pump (P4) flow test should be performed to ensure that the cutting 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 the parking brake. 2.
Test Procedure (continued) CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 3. Raise and prop operator seat to allow access to hydraulic pump. g230046 Figure 104 1. 2. Gear Pump (P4) Hydraulic hose 4. Clean junction of outlet fitting in gear pump (P4) and hydraulic outlet hose (Figure 104). Disconnect hose from pump fitting.
Test Procedure (continued) IMPORTANT The gear pump is a positive displacement type. If pump flow is completely restricted or stopped, damage to the pump, tester, or other components could occur. 10. While carefully watching pressure gauge on hydraulic tester, slowly close the tester flow control valve until 6,900 kPa (1,000 psi) is obtained on gauge. 11. Pump flow will be displayed by flow meter on tester: Flow tester reading to be: A pump in good condition should have a flow of approximately 11.
Lift Cylinder Internal Leakage Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230029 Figure 105 The lift cylinder internal leakage test should be performed if a cutting unit raise and lower problem is identified. This test will determine if a lift cylinder is damaged. Note: Cutting unit raise/lower circuit operation will be affected by lift cylinder binding, extra weight on the cutting units, and/or binding of lift components.
Test Procedure (continued) 3. For the lift cylinder that is to be tested, use a jack to raise the lift arm slightly. This will remove the load from the lift cylinder and relieve lift cylinder hydraulic pressure. Leave the jack under the lift arm to support the lift arm and to prevent the lift arm from lowering. Note: If either of the rear lift cylinders is being tested, both rear lift arms need to be supported. g230047 Figure 106 1. Lift cylinder (#5) 2. Cylinder rod end fitting 3. Hydraulic hose 4.
Test Procedure (continued) g230048 Figure 107 1. Lift cylinder rod 2. Lift cylinder head 3. Tape (initial position) 7. Mark the position of the lift cylinder rod at the lift cylinder head with a piece of tape (Figure 107). g230049 Figure 108 1. Tape (after 2 hours) 2. Cylinder rod movement 8. Leave the machine parked for 2 hours and monitor the lift cylinder. The weight of the cutting unit may cause the lift cylinder to gradually extend.
Test Procedure (continued) 10. Remove jack from under the lift arm. Start engine and operate lift cylinders through several up and down cycles. shut 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 hydraulic reservoir and adjust as necessary.
Steering Relief Valve (R10) Pressure Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230030 Figure 109 The steering relief valve (R10) pressure test should be performed to ensure that the steering 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 brake. 2. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Test Procedure (continued) CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). g230050 Figure 110 1. Steering cylinder 2. Rod end fitting 3. Clean the area around the hydraulic hose and fitting at the rod end of the steering cylinder (Figure 110). 4. Remove hydraulic hose from the fitting on the rod end of the steering cylinder. 5.
Test Procedure (continued) 9. Watch pressure gauge carefully while turning the steering wheel for a left hand turn (counter-clockwise) and holding. 10. System pressure should be approximately 6,900 kPa (1,000 psi) as the steering relief valve lifts. After determining relief pressure, return steering wheel to the neutral position. 11. Shut off engine. Record test results. 12. If specification is not met, repair or replace steering control valve (relief valve in steering control valve is not replaceable).
Steering Cylinder Internal Leakage Test (5410/5410-G/5410-D/5510/5510-G/5510-D/5610) g230031 Figure 111 The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is damaged. Note: Steering circuit operation will be affected by rear tire pressure, steering cylinder binding, extra weight on the vehicle and/or binding of rear axle steering components.
Test Procedure (continued) 3. Read all Warning, Cautions, and precautions listed at the beginning of this section. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 4. Turn the steering wheel for a right turn (clockwise) so the steering cylinder rod is fully extended. g230051 Figure 112 1. Steering cylinder 2. Rod end fitting 5.
Testing the Traction Circuit–Charge Pressure (5610-D) g216152 Figure 113 Test Procedure The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the piston pump/hydrostat. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance. Special Equipment Required: Pressure gauge 1.
Test Procedure (continued) 4. Raise and support the operator seat to get access to the hydraulic pump assembly. 5. Ensure that the traction pedal is in the NEUTRAL position, the steering wheel is stationary and parking brake is set. g217798 Figure 114 1. Traction pump 4. Oil filter/filter adapter 2. Charge circuit 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.
Test Procedure (continued) 9. Block the wheels with chocks to prevent the wheel rotation during testing. 10. Start the engine and press the engine speed switch to full speed (3,005 to 3,055 rpm) position. Use the InfoCenter to check that the engine speed is correct. 11. Record the reading on the charge circuit pressure gauge. The charge pressure (without load) should read from 1,034 to 1,379 kPa (150 to 200 psi). If the charge relief pressure specification is not met, consider the following: A.
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 E
The wheel motor efficiency is the second in a series of tests recommended to determine the traction circuit performance. Hydraulic fluid flow of 5.7 L/minute (1.5 gallons/minute) or more through a single stationary front wheel motor under load indicates an internal leak in the wheel motor. Hydraulic fluid flow of 4.5 L/minute (1.2 gallons/minute) or more through a single stationary rear wheel motor under load indicates an internal leak in the wheel motor. A worn wheel motor is less efficient.
Testing the Front Wheel Motor (continued) 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 from the Hydraulic System (page 6–8). g217797 Figure 117 1. Traction pump 4. Hydraulic hose (forward) 2. Left elbow fitting 5. Right elbow fitting 3. Hydraulic hose (reverse) 2.
Testing the Front Wheel Motor (continued) CAUTION The front wheel motors will try to move the machine forward. Use extreme caution when performing the test. 7. Slowly press the traction pedal in the forward direction until 6,900 kPa (1,000 psi) is displayed on the tester pressure gauge. Ensure that the front wheels are not rotating and record the flow meter reading. 8. Release the traction pedal, shut off the engine, rotate both the front wheels 90° and then test again.
Testing the Rear Wheel Motors (continued) g217938 Figure 118 1. 2. Upper hydraulic fitting Right rear wheel motor 1. To test the right rear wheel motor, disconnect the hose from the upper hydraulic fitting of the wheel motor (Figure 118). g217944 Figure 119 1. Left rear wheel motor 2. Lower hydraulic fitting 2. To test the left rear wheel motor, disconnect the hose from the lower hydraulic fitting of the wheel motor (Figure 119). 3.
Testing the Rear Wheel Motors (continued) CAUTION The rear wheel motors will try to move the machine forward. Use extreme caution when performing the test. 7. Slowly press the traction pedal in the forward direction until 6,900 kPa (1,000 psi) is displayed on the tester pressure gauge. Ensure that the rear wheels are not rotating and record the flow meter reading. 8. Release the traction pedal, shut off the engine, rotate both the front wheels 90° and then test again.
Testing the Traction Circuit–Piston Pump/Hydrostat Flow and Relief Pressure (5610-D) g216148 Figure 120 The hydrostat flow test is the third in a series of tests recommended to determine the traction circuit performance. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the piston pump/hydrostat. A worn hydrostat or malfunctioning relief valve is less efficient.
Test Procedure (continued) 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 from the Hydraulic System (page 6–8). 2. Park the machine on a level surface, lower the cutting units, shut off the engine. Ensure that the mow speed limiter is in the TRANSPORT position to allow full movement of the traction pedal. 3.
Test Procedure (continued) CAUTION During this procedure, all the wheels will be off the ground and rotating. Ensure that the machine is well supported so it will not move and accidentally fall to prevent injuring anyone around the machine. 9. Start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks from the test connections and correct before continuing the test. 10. With the engine running, press the engine speed switch to full speed (3,005 to 3,055 rpm) position.
Testing the Mow Circuit–Circuit Pressure (5610-D) g216141 Figure 122 The cutting unit circuit pressure is the first in a series of tests recommended 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: Pressure gauge with extension hose.
Test Procedure 1. Ensure that the hydraulic fluid is at normal 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, set the mow speed limiter to the MOW position, and set the parking brake. 3. Ensure that the mow/backlap lever on the mow control manifold is in the MOW position. 4. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Test Procedure (continued) 9. Disengage the cutting units, press the engine speed switch to the low speed (1,175 to 1,225 rpm) position, and shut off the engine. 10. If the pressure readings are within specifications and cutting reel performance is still in question, test the cutting reel motors individually; refer to Testing the Mow Circuit–Reel Motor Efficiency/Case Drain (5610-D) (page 6–116). 11. If the pressure specifications are not met, consider the following: A.
Testing the Mow Circuit–Reel Motor Efficiency/Case Drain (5610-D) g216142 Figure 124 The reel motor efficiency/case drain test is the second in a series of tests recommended to check the cutting unit circuit performance. Over a period of time, a reel motor can wear internally. This test measures case drain volume while restricting flow across the motor ports. Case drain volume under load of more than 9% of total motor flow indicates the gears and wear plates in the motor have worn.
One method to find a failing or malfunctioning cutting reel motor is to have another person observe the machine while mowing in dense turf. A bad motor will run slower, produce fewer clippings and may cause a different appearance on the turf. Special Equipment Required: Flow meter with pressure gauge that has at least a 45 L/minute (12 gallons/minute) capacity. Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2.
Test Procedure (continued) 6. Disconnect the case drain hose and put a steel cap on the fitting at the traction unit. Leave the case drain hose from the motor open and place the open end of the disconnected hose into a drain pan. IMPORTANT Ensure that the fluid flow indicator arrow on the flow gauge is showing that the fluid will flow from the reel motor, through the tester, and into the return hose. 7.
Test Procedure (continued) 17. Connect the return hose to the reel motor, remove the plug from the machine bulkhead fitting, and connect case drain hose to the fitting. 18. If necessary, perform the motor efficiency test on the other reel motors. IMPORTANT When testing more than one cutting unit motor, check and adjust the hydraulic-fluid level in the tank after testing each motor. 19.
Testing the Mow Circuit–Reel Motor Cross−Over Relief Pressure (5610-D) g219145 Figure 126 Note: One method to find a failing or malfunctioning cutting reel motor is to have another person observe the machine while mowing in dense turf. A bad motor will run slower, produce fewer clippings and may cause a different appearance on the turf.
Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2. Determine which of the reel motor is suspect and begin testing with that motor. 3. Park the machine on a level surface with the reel engage switch off, lower the cutting units, shut off the engine, mow speed limiter is in the MOW position, and set the parking brake.
Test Procedure (continued) 7. 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. 8. Start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks from the test connections and correct before continuing the test. CAUTION The adjacent cutting unit reels will rotate when you perform the cross-over relief pressure test.
Testing the Mow Circuit–Relief Valve (RV1) and (RV2) Pressure (5610-D) g216149 Figure 128 Test the performance of the mow control manifold relief valve (RV1) and (RV2) to ensure that the maximum amount of fluid is available to the cutting reel motors up to the set relief pressure. This test also ensures that pump (P1) and (P2) are capable of generating enough pressure to open properly functioning relief valves.
Test Procedure 1. Park the machine on a level surface with the reel engage switch off, lower the cutting units, shut off the engine, mow speed limiter is in the MOW position, and set the parking 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 from the Hydraulic System (page 6–8). 2.
Test Procedure (continued) g217937 Figure 130 1. Reel motor inlet hose 2. #2 cutting reel motor 4. To test the rear cutting unit circuit relief valve RV1, clean and disconnect the inlet hose to the #2 (rear left) cutting unit motor (Figure 130). IMPORTANT Ensure that the fluid flow indicator arrow on the flow meter is showing that the fluid will flow from the disconnected hose, through the tester, and into the reel motor. 5.
Test Procedure (continued) IMPORTANT Do not hold over relief for longer than necessary to obtain the pressure reading, while you perform this test. 10. Monitor the pressure gauge carefully while you slowly close the tester flow control valve. As the relief valve lifts, the pressure gauge needle will momentarily stop. Note: The system pressure will continue to increase, once the relief valve is opened. 11.
Testing the Mow Circuit–Gear Pump (P1) and (P2) Flow (5610-D) g216143 Figure 131 The gear pump (P1) and (P2) flow test is the last in a series of tests recommended to determine cutting unit circuit performance. The gear pump P1 supplies hydraulic flow to the rear cutting units, while gear pump P2 provides hydraulic flow to the front cutting units. This test compares fluid flow at No Load with fluid flow Under Load.
Test Procedure 1. Park the machine on a level surface with the reel engage switch off, lower the cutting units, shut off the engine, mow speed limiter is in the MOW position, and set the parking 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 from the Hydraulic System (page 6–8). 2.
Test Procedure (continued) 8. Start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks from the test connections and correct before continuing the test. 9. With the engine running, press the engine speed switch to full speed (3,005 to 3,055 rpm) position. Do not engage the cutting units. Use the InfoCenter to check that the engine speed is correct. 10. Verify the pump flow at No Load as follows: Record the tester pressure and flow readings at no load.
Testing the Steering Circuit–Steering Control Valve, Relief Valve (R10) Pressure, and Steering Cylinder (5610-D) g216151 Figure 133 Unit steering performance can be affected by incorrect rear tire pressure, binding in the hydraulic 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 steering system hydraulic testing.
Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2. Drive the machine slowly in a figure eight on a flat level surface. A. There should be no shaking or vibration in the steering wheel or rear wheels. B. The steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn. 3. Stop unit with the engine running.
Test Procedure (continued) IMPORTANT As the steering wheel is turned, ensure that the pressure gauge is not contacted by any machine parts. C. Monitor the pressure gauge carefully when turning the steering wheel for a right hand turn (clockwise) and holding. D. The system pressure should be approximately 6,990 to 7,500 kPa (1,015 to 1,088 psi) as the relief valve lifts. E. Return the steering wheel to the NEUTRAL position, shut off the engine, and record the test results. 6.
Testing the Steering Circuit–Gear Pump (P3) Flow (5610-D) g216144 Figure 134 The gear pump (P3) is designed to satisfy the steering cylinder needs (at full speed). The gear pump (P3) flow test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.
Test Procedure (continued) 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 from the Hydraulic System (page 6–8). g217941 Figure 135 1. 2. Gear pump (P3) Hydraulic tube 3. Lift and support the operator seat to get access to the hydraulic pump assembly. 4.
Test Procedure (continued) 9. With the engine running, press the engine speed switch to full speed (3,005 to 3,055 rpm) position. Use the InfoCenter to check that the engine speed is correct. 10. Verify the pump flow at No Load as follows: Record the tester pressure and flow readings at no load. Unrestricted pump output should be approximately 18.5 L/minute (4.9 gallons/minute). 11. Verify the pump flow Under Load as follows: CAUTION Do not close the tester valve fully when performing this test.
Testing the lift Circuit–Relief Valve (SVRV) Pressure (5610-D) g216147 Figure 136 Perform the lift relief valve (SVRV) pressure test to ensure that the lift circuit relief pressure is correct. Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2.
Test Procedure (continued) g217946 Figure 137 1. Lift control manifold 2. SVRV solenoid 3. Test port (G4) 4. Clean the test port (G4) on the bottom of lift control manifold, and then connect a 35,000 kPa (5,000 psi) pressure gauge to the test port (Figure 137). 5. After installing the pressure gauge to the manifold test port, start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks from the test connections and correct before continuing the test. 6.
Test Procedure (continued) (5610-D) (page 6–139). The gear pump (P4) could also be suspected for wear, damage or inefficiency; refer to Testing the Lift Circuit–Gear Pump (P4) Flow (5610-D) (page 6–142). 12. After you complete the testing, shut off the engine, and disconnect the pressure gauge from the lift control manifold test port. 13.
Testing the Lift Circuit–Lift Cylinder Internal Leakage (5610-D) g216146 Figure 138 Perform the lift cylinder internal leakage test if you identify a cutting reel raise and lower problem. This test determines if the lift cylinder being 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 binding of the lift components.
Test Procedure Note: When performing the lift cylinder internal leakage test, the cutting units should be attached to the lift arms. 1. Park the machine on a level surface with the reel engage switch off, position the cutting units in the turn-around position, shut off the engine, and set the parking brake. 2. For the lift cylinder that is to be tested, use a jack to raise the lift arm slightly. This removes the load from the lift cylinder and releases the lift cylinder hydraulic pressure. 3.
Test Procedure (continued) 9. Once the lift cylinder condition is determined, use a jack to raise lift arm slightly which removes the load from the lift cylinder. 10. Support the lift arm with jack stands to prevent it from lowering. 11. Remove the cap from the cylinder fitting and the plug from the hydraulic hose. 12. Connect the hydraulic hose to the lift cylinder fitting. 13. Carefully remove the jack from under the lift arm.
Testing the Lift Circuit–Gear Pump (P4) Flow (5610-D) g216145 Figure 140 The gear pump (P4) is designed to satisfy the lift cylinder needs (at full speed). The gear pump (P4) flow test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.
Test Procedure (continued) 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 from the Hydraulic System (page 6–8). 2. Read all Warning, Cautions, and precautions listed at the beginning of this section. 3. Lift and support the operator seat and remove the floor plate to get access to the hydraulic pump. g217942 Figure 141 1. 2. Gear pump (P4) Hydraulic hose 4.
Test Procedure (continued) 9. Verify the pump flow Under Load as follows: CAUTION Do not close the tester valve fully when performing this test. In this test, the hydraulic tester is positioned before the manifold relief valve. Pump damage can occur if the fluid flow is fully restricted by fully closing the tester flow control valve. A. Monitor the tester pressure gauge carefully while you slowly close the flow control valve until you get 8,274 kPa (1,200 psi). B.
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, 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. Clean the machine before you disconnect, remove, or disassemble the hydraulic components.
After Repairing or Replacing the Components (continued) 4. Remove all the caps or plugs from the hydraulic tubes, hydraulic fittings, and components before connecting them again. 5. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 6–11) and Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 6–13). 6.
Priming the Hydraulic Pumps (continued) (traction) pump have sufficient fluid during initial start-up and running. The pumps can be primed by using a remote starter switch (refer to Remote Starter Switch (page 6–49)) to crank the engine which allows the pumps to prime. Use the following procedure to prime the hydraulic pumps: 1. Ensure that the key switch is in the OFF position and the key is removed from the key switch. 2.
Flushing the Hydraulic System (continued) IMPORTANT If a component failure occurs in the traction circuit; refer to the Traction Circuit Component Failure (page 6–9) for information regarding the importance of removing contamination from the traction circuit. 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 20 minutes.
Flushing the Hydraulic System (continued) 9. Fill the hydraulic tank with the correct quantity of new hydraulic fluid. 10. Prime the hydraulic pumps; refer to Priming the Hydraulic Pumps (page 6–146). 11. Start the engine and operate it at low-idle speed for a minimum of 2 minutes. Increase the engine speed to high idle for a minimum of 1 minute under no load. 12. Raise and lower the cutting units several times. Turn the steering wheel fully left and right several times. 13.
Filtering the Closed-Loop Traction Circuit (continued) g217797 Figure 143 1. Traction pump 4. Hydraulic hose (forward) 2. Left elbow fitting 5. Right elbow fitting 3. Hydraulic hose (reverse) 3. Clean the junction of the hydraulic hose and 90° hydraulic fitting at the bottom of the traction pump (Figure 143). Disconnect the hose from the pump fitting. 4. Connect the Toro high flow hydraulic filter in series between the traction pump fitting and disconnected hose.
Filtering the Closed-Loop Traction Circuit (continued) IMPORTANT While engaging the traction circuit, monitor the indicator on the high flow hydraulic filter. If the indicator shows red, either reduce the pressure on the traction pedal or reduce the engine speed to decrease the hydraulic flow through the filter. 7. With the engine running at low-idle speed, slowly move the traction pedal to the forward direction to allow flow through the traction circuit and high-flow filter.
Charging the Hydraulic System (continued) 2. After the hydraulic system components have been properly installed and if the traction pump was rebuilt or replaced, ensure that the traction pump housing is at least half full of clean hydraulic fluid. 3. Ensure that all of the hydraulic connections, lines, and components are secured tightly.
Charging the Hydraulic System (continued) the traction pump and wheel motors. Correct the hydraulic line installation before you proceed. 14. Ensure that the traction pedal returns to the NEUTRAL position when released from the forward or reverse direction and adjust if necessary. 15. Check the operation of the traction interlock switches; refer to Checking the Operation of the Interlock Switches (page 7–45). 16. Shut off the engine and lower the machine to the ground. 17.
Hydraulic Tank g213697 Figure 144 1. Hydraulic tank cap 2. Hydraulic tank Hydraulic hose 17. O-ring 10. 9. O-ring 18. Adapter 3. O-ring 11. 90° hydraulic fitting 19. O-ring 4. Tank strainer 12. O-ring 20. Clamp (2 each) Recess bumper 21. Washer-head screw (2 each) 22. Screen filter 5. Clamp (2 each) 13. 6. Hydraulic hose 14. Flat washer 7. Gear pump 15. Bolt 8. Flange nut (3 each) 16.
Removing the Hydraulic Tank 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. Clean the hydraulic hose ends and fittings on the hydraulic tank to prevent contaminants from entering into the hydraulic system. 3. For assembly purposes, label all the hydraulic hoses and fittings. 4.
Piston (Traction) Pump Control Assembly g213707 Figure 145 1. Locknut 10. Flange-head screw (2 each) 19. Traction neutral switch 2. Pump lever 11. Guard hoop 20. Jam nut (2 each) 3. Locknut 12. Flange nut (2 each) 21. Lock washer (2 each) 4. Bolt (3 each) 13. Piston (traction) pump 22. Retaining ring 5. Pump plate 14. Flange nut 23. Lever damper 6. 7. Cable rod end Flat washer 15. 16. Traction cable bracket Flange-head screw (2 each) 24. 25. Bolt Carriage screw 8. 9.
Assembling the Piston (Traction) Pump Control Assembly IMPORTANT To prevent the traction neutral switch (item 19 in Figure 145) damage, ensure that no pump control components contact the switch through entire traction pump control arm movement. g213708 Figure 146 1. Pump lever 4. Cable jam nut (2 each) 2. 3. Cable rod end Traction control cable 5. Traction neutral switch 1. Install the components that were removed to the piston pump control assembly (Figure 145 and Figure 146).
Assembling the Piston (Traction) Pump Control Assembly (continued) g213686 Figure 147 1. Traction pump 2. Pump lever 3. Traction neutral switch 2. If the traction neutral switch was removed from the pump plate, adjust the location of the switch so that there is 2.4 to 2.5 mm (0.094 to 0.100 inch) clearance between the head 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.
Hydraulic Pump Driveshaft g213695 Figure 148 1. Hood saddle 6. Bolt (6 each) 11. Flange-head screw (2 each) 2. Flange nut (4 each) 7. Flange-head screw (8 each) 12. Piston (traction) pump 13. Guard hoop 3. Driveshaft assembly 8. Flange nut (6 each) 4. Flywheel adapter plate 9. Bolt (2 each) 5. Back-up ring Reelmaster® 5410/5510/5610 Series 15216SL Rev E 10.
g230303 Figure 149 1. Piston (traction) pump 5. Driveshaft assembly 2. Flange nut (2 each) 6. Bolt (2 each) 3. Flange-head screw (2 each) 7. Flange nut (2 each) 4. Guard hoop 8. Bolt (6 each) 9. 10. Engine flywheel Hood saddle Note: Machines with a Kubota gasoline or diesel engine use driveshaft assembly as shown in Figure 149. Machines with a Yanmar diesel engine use driveshaft assembly as shown in Figure 148. Removing the Hydraulic Pump Driveshaft 1.
Servicing the Driveshaft Cross and Bearing g213696 Figure 150 1. End yoke 4. Shaft yoke 2. Grease fitting 5. Cross and bearing kit 3. Snap ring (4 each) 1. Remove the snap rings that secure the bearings in the yokes. IMPORTANT Support the yokes when removing and installing the bearings to prevent damage. 2. Use a press to remove the cross and bearings from the yokes. Clean the driveshaft yokes. 3. Install new cross and bearings as follows: A.
Installing the Hydraulic Pump Driveshaft (continued) 4. On machines with a Yanmar diesel engine, apply medium strength threadlocker to the threads of the flange-head screws (item 7 in Figure 148). Secure the driveshaft assembly to the engine flywheel with the 8 flange-head screws; torque the flange-head screws to 24 to 28 N∙m (17 to 21 ft-lb) in a criss-cross pattern. 5. On machines with a Kubota gas or diesel engine, apply medium strength threadlocker to the threads of the bolts.
Hydraulic Pump Assembly g213693 Figure 151 1. Manifold tube 17. 90° hydraulic fitting 33. Hydraulic hose (2 each) 2. Hose clamp (2 each) 18. O-ring 34. Hydraulic tube 3. Hydraulic hose 19. Hydraulic tube 35. Hydraulic hose 4. Barbed fitting 20. Flange-head screw (2 each) 36. O-ring (2 each) 5. O-ring (2 each) 21. Flange-head screw (2 each) 37. Straight fitting (2 each) 6. Socket-head screw (2 each) 22. Guard hoop 38. O-ring (2 each) 7. Lock washer (2 each) 23.
Removing the Hydraulic Pump Assembly 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 from the Hydraulic System (page 6–8). 1. Park the machine on a level surface, set the parking brake, lower the cutting units, and shut off the engine, and remove the key from the key switch. 2. Raise and support the hood and operator seat.
Removing the Hydraulic Pump Assembly (continued) Note: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Figure 152). When the gear pump is removed from the piston pump, install plugs into the piston pump case drain hole and gear pump suction port to prevent draining the pumps. 14. Separate the traction and gear pumps as follows: A.
Installing the Hydraulic Pump Assembly (continued) A. Lubricate and position new O-ring (item 10 in Figure 151) between the pumps. B. Position the gear pump to the traction pump and secure with the 2 socket-head screws (item 6 in Figure 151), 2 lock washers, and 2 flat washers. C. If the pump support bracket was removed from the gear pump, install the 2 flat washers (item 39 in Figure 151) and bracket to the gear pump and secure the pump with the 2 locknuts.
Servicing the Piston (Traction) Pump g213710 Figure 153 1. Relief valve (2 each) 13. 25. Seal nut Backup washer 37. Slotted pin 2. Seal kit (2 each) 14. Screw (4 each) 26. Retaining ring (2 each) 38. Needle bearing 3. Charge relief poppet 15. Trunnion cover 27. Retaining ring (2 each) 39. Loop flushing spool 4. Spring 16. Seal 28. Trunnion cover 40. Spring 5. Shim kit 17. O-ring (2 each) 29. Screw (4 each) 41. Plug 6. Charge relief plug 18. Bearing (2 each) 30.
Servicing the Piston (Traction) Pump (continued) IMPORTANT If a piston (traction) pump failure occurs, refer to Traction Circuit Component Failure (page 6–9) for information regarding the importance of removing contamination from the traction circuit.
Servicing the Gear Pump g213689 Figure 154 1. Front cover 2. Dowel pin (16 each) 3. 4. 5. Body (P1 section) 6. Flange (3 each) 7. Splined connecting shaft (3 each) 8. Drive gear Body (P2 section) 17. Body (P4 section) 10. Driven gear (2 each) 18. Washer (4 each) Thrust plate (8 each) 11. Pressure seal (8 each) 19. Stud bolt (2 each) Driveshaft 12. Back-up ring (8 each) 20. Nut (2 each) 13. Square section seal (8 each) 21. Bolt (2 each) 14. Drive gear 22. Rear cover 15.
Disassembling the Gear Pump Note: The gear pump must be replaced as a complete assembly. Individual gears, housings, and thrust plates are not available separately. Disassemble the gear pump for cleaning, inspection, and seal replacement only. IMPORTANT Keep bodies, gears, flanges, and thrust plates for each pump section together; do not mix the parts between the pump sections. 1. Plug the pump ports and clean the outer surface of the pump with cleaning solvent. Ensure that the work area is clean.
Disassembling the Gear Pump (continued) 7. Remove the thrust plates and seals from each pump section. Before removing each gear set, apply marking dye to the mating teeth to retain timing. The pump efficiency may be affected if the teeth are not installed in the same position during assembly. Keep the parts for each pump section together; do not mix the parts between sections. Inspecting the Gear Pump 1. Remove any nicks and burrs from all the gear pump parts with emery cloth.
Assembling the Gear Pump 1. Apply clean hydraulic fluid to all the parts before you assemble them. Note: The pressure seals and back-up rings fit in the grooves machined into the thrust plates. The body seals fit in the grooves machined in the body faces. 2. Assemble the pump 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 bolts and nuts by hand.
Front Wheel Motors g213688 Figure 157 1. Hydraulic tube 7. Left brake assembly 13. Left wheel motor 2. O-ring (2 each) 8. Bolt (4 each per brake assembly) 14. Locknut (4 each per wheel motor) 3. 90° hydraulic fitting 9. Wheel hub 15. O-ring (2 each) 10. Locknut 16. Hydraulic tube 4. Square key 5. Brake adapter 11. Brake drum 6. Bolt (4 each per wheel motor) 12.
Removing the Front Wheel Motor (continued) 3. Loosen, but do not remove the locknut (item 10 in Figure 157) that secures the wheel hub to the wheel motor. 4. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 6–145). 5. Remove the front wheel, brake drum, wheel hub, and brake assembly from the machine; refer to Servicing the Brakes (page 8–10). 6.
Installing the Front Wheel Motor (continued) 6. Clean the tapers of the wheel hub and wheel motor shaft. 7. Install the brake assembly, and wheel hub. 8. Tighten the wheel hub locknut (item 10 in Figure 157) to 407 to 542 N∙m (300 to 400 ft-lb). 9. Install the brake drum and front wheel to the machine; refer to Installing the Wheel (page 8–6). 10. Charge the hydraulic system; refer to Charging the Hydraulic System (page 6–151).
Servicing the Front Wheel Motor g186198 Figure 158 1. Bolt (7 each) 8. Valve 15. Bearing race (2 each) 2. End cap 9. Dowel pin (4 each) 16. Thrust bearing 3. O-ring (3 each) 10. Balancing ring 17. Output shaft 4. Geroler assembly 11. Bearing 18. Drive 5. Valve plate 12. Grease seal 19. Back-up ring (2 each) 6. Thrust bearing 13. Housing 20. O-ring 7. Bearing 14. Shaft seal 21.
Servicing the Front Wheel Motor (continued) IMPORTANT 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.
Rear Wheel Motors (Machine with CrossTrax AWD) g217167 Figure 159 5. Hydraulic hose (2 each per motor) 9. Locknut 1. Wheel motor (right) 2. O-ring (2 each per motor) 6. Wheel motor (left) 10. Bolt (4 each per motor) 3. 45° hydraulic fitting (2 each per motor) 7. Woodruff key 11. Lock washer (4 each per motor) 4. O-ring (2 each per motor) 8. Wheel hub 12.
Removing the Rear Wheel Motor (continued) 3. Loosen, but do not remove the locknut (item 9 in Figure 159) that secures the wheel hub to the wheel motor. 4. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 6–145). IMPORTANT Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–6). 5. Lift the machine with a jack to remove the rear wheel, support the machine with jack stands. 6.
Installing the Rear Wheel Motor IMPORTANT Because of the internal differences in the wheel motors, do not interchange the wheel motors on the machine (e.g., do not put the right motor on the left side of the machine). If necessary, use the Parts Catalog and Part Number on the wheel motor to identify the right and left motors, there is also a yellow dot on the left motor. 1. If the hydraulic fittings were removed from the wheel motor, lubricate and install new O-rings to the fittings.
Installing the Rear Wheel Motor (continued) 13. Start the engine, check 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.
Servicing the Rear Wheel Motor (Machine with CrossTrax AWD) g186199 Figure 160 1. Dirt and water seal 9. Thrust bearing 2. 3. Outer bearing 10. Coupling shaft 18. Manifold Housing 11. Thrust bearing 19. Stator 17. Commutator ring 4. Back-up ring 12. Drive link 20. Vane (7 each) 5. Back-up washer 13. Bolt (7 each) 21. Wear plate 6. 7. Shaft seal Inner bearing 14. 15. End cover Body seal (5 each) 22. 23. Rotor Commutator ring 8. Thrust washer (2 each) 16.
Servicing the Rear Wheel Motor (Machine with CrossTrax AWD) (continued) IMPORTANT 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.
CrossTrax™ AWD Control Manifold Assembly g186174 Figure 161 1. Hydraulic hose (4 each) 6. Hydraulic tube 11. O-ring (2 each) 2. Straight fitting (7 each) 7. O-ring (7 each) 12. Frame bracket 3. AWD control manifold 8. O-ring (7 each) 13. Bolt (3 each) 4. Hydraulic tube 9. Dust cap (2 each) 14. Lock washer (3 each) 5. Hydraulic tube 10. Diagnostic fitting (2 each) 15. Spacer (3 each) Removing the CrossTrax AWD Control Manifold Assembly 1.
Removing the CrossTrax AWD Control Manifold Assembly (continued) 5. Disconnect the hydraulic hoses and tubes from the fittings in the AWD control manifold assembly. Allow the lines to drain into a suitable container. Remove and discard the O-rings from the fittings. 6. Install clean caps or plugs on the hydraulic lines and fittings to prevent system contamination. 7. Support the AWD control manifold assembly to prevent it from falling. 8.
Servicing the CrossTrax AWD Control Manifold Assembly g186173 Figure 162 1. Seal kit (2 each) 5. O-ring 2. Check valve (2 each) 6. #8 zero-leak plug 9. 3. O-ring (3 each) 7. #4 zero-leak plug (2 each) 11. Bi-directional relief valve 4. #6 zero-leak plug (3 each) 8. O-ring (2 each) 12. Seal kit 10. Orifice (0.040) AWD control manifold For the control manifold service procedures; refer to Servicing a Control Manifold Cartridge Valve (page 6–199).
Mow Control Manifold Assembly g213706 Figure 163 1. Dust cap (2 each) 8. Hydraulic tube 15. Hydraulic tube 2. Diagnostic fitting (2 each) 9. Hydraulic tube 16. Hydraulic hose 3. O-ring 10. Hydraulic fitting (2 each) 17. O-ring (2 each) 4. 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-ring 21.
Removing the Mow Control Manifold Assembly 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 from the Hydraulic System (page 6–8). 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.
Installing the Mow Control Manifold Assembly (continued) 9. Operate the machine functions slowly until air is out of system; refer to Charging the Hydraulic System (page 6–151).
Servicing the Mow Control Manifold Assembly g216663 Figure 164 1. Backlap spool (front cutting units) 6. Backlap spool (rear cutting units) 11. Nut (2 each) 2. #4 zero-leak plug 7. #6 zero-leak plug 12. Solenoid proportional valve (SP2) 3. Orifice (0.040) (2 each) 8. Mow control manifold 13. Relief valve (RV1) 4. Spool handle 9. Solenoid proportional valve (SP1) 14. Relief valve (RV2) 5. Spring pin (2 each per spool) 10.
WARNING Before opening the hydraulic system, operate all the hydraulic controls to release all the pressure in the system and avoid injury from pressurized hydraulic 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 (2 each) 3. Check valve (2 each) 6. O-ring (2 each) 9.
g216665 Figure 166 1. Retaining ring 3. Back-up ring 2. O-ring 4. Handle 5. Mow/backlap spool For the mow control manifold cartridge valve service procedures; refer to Servicing a Control Manifold Cartridge Valve (page 6–199). Refer to Figure 164 and Figure 165 for cartridge valve and plug installation torque. Note: The mow control manifold uses several zero-leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening.
Servicing the Mow/Backlap Spool (continued) D. Pull the spool up and out of the mow manifold. Remove the O-rings and back-up ring from the spool. E. Discard the O-rings and back-up rings that were removed. 2. Visually inspect the manifold port for damage to the sealing surfaces, damaged threads, and contamination. 3. Install the mow/backlap spool in the mow control manifold as follows: A. Install the O-rings and back-up ring to the upper grooves on the spool. Apply a light coating of grease to the O-rings.
Lift Control Manifold g216666 Figure 167 1. Hydraulic hose 9. 2. O-ring (6 each) 3. O-ring (2 each) O-ring 17. Flange-head screw (2 each) 10. Hydraulic hose 18. Hydraulic hose 11. O-ring 19. Hydraulic hose 4. Hydraulic tube 12. 90° hydraulic fitting 20. Hydraulic hose 5. Hydraulic tube 13. O-ring 21. Hydraulic hose 22. O-ring 6. O-ring (2 each) 14. Diagnostic fitting 7. 45° hydraulic fitting 15. Dust cap 8. Hydraulic hose 16.
Removing the Lift Control Manifold (continued) 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 from the Hydraulic System (page 6–8). 5. Disconnect the hydraulic hoses and tubes from the fittings in the manifold. Allow the lines to drain into a suitable container. Remove and discard the O-rings from the fittings. 6.
Installing the Lift Control Manifold 1. If the hydraulic fittings were removed from the lift control manifold, do the following: A. Lubricate new O-rings with clean hydraulic fluid, install the lubricated O-rings onto the fittings. IMPORTANT When installing the orifice in the manifold (Figure 168), ensure that the orifice is flat in the base of the fitting cavity. Letting the orifice stay cocked in the cavity can damage the manifold. B.
Servicing the Lift Control Manifold g216667 Figure 169 1. Lift control manifold 5. Solenoid coil spacer 2. Check valve (4 each) 6. Nut 9. 10. Nut 13. O-ring Solenoid relief valve (SVRV) 14. Pilot piston (4 each) 3. Solenoid valve (SV3) 7. Solenoid valve (SV2) 11. Solenoid valve (SV1) 15. O-ring 4. Solenoid coil 8. Solenoid coil 12. Relief valve (R7) 16. Hex plug (4 each) Note: The ports on the lift control manifold are marked for easy identification of the components.
Servicing the Lift Control Manifold (continued) Note: Do not adjust the relief valve (R7). g217168 Figure 170 1. Straight fitting (2 each) 3. Orifice (0.046) (2 each) 5. Straight fitting (6 each) 2. O-ring (8 each) 4. Orifice (0.028) (3 each) 6. Orifice (0.055) (3 each) IMPORTANT A flow control orifice is placed below several hydraulic fittings on the lift control manifold (Figure 170). The lift control manifold uses 3 different orifice sizes.
Servicing a Control Manifold Cartridge Valve 1. Ensure that the entire outer surface of the manifold is clean before you remove the cartridge valve. WARNING Before opening the hydraulic system, operate all the hydraulic controls to release all the pressure in the system and avoid injury from pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 2. If the solenoid cartridge valve is being serviced, remove the nut that secures the solenoid coil to the cartridge valve.
Servicing a Control Manifold Cartridge Valve (continued) IMPORTANT Particles as fine as talcum powder can affect the operation of high-pressure hydraulic valves. If the cartridge design allows, use a wood or plastic probe to press the internal spool in and out for 20 to 30 times to flush out contamination. Ensure that you do not damage the cartridge. Use the compressed air for cleaning. 7. Install the cartridge valve as follows: A.
Cutting Reel Motor g216668 Figure 171 Reelmaster 5510/5610 series cutting reel motors #5 hydraulic reel motor 6. O-ring 11. Hydraulic hose 16. Hydraulic hose 2. O-ring 7. Hydraulic fitting 12. #3 hydraulic reel motor 17. Hydraulic hose 3. 90° hydraulic fitting 8. O-ring 13. #2 hydraulic reel motor 18. Hydraulic hose 1. 4. O-ring 5. Hydraulic hose 9. Hydraulic hose 14. #4 hydraulic reel motor 19. 90° hydraulic fitting 10. Hydraulic hose 15. Hydraulic fitting 20.
Removing the Cutting Reel Motor (continued) 3. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines from the reel 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 Releasing Pressure from the Hydraulic System (page 6–8). 4. Disconnect the hydraulic hoses from the fittings in the reel motor.
Installing the Cutting Reel Motor (continued) IMPORTANT When installing the hydraulic hoses, ensure that the hydraulic hoses are straight (not twisted) before tightening the hoses to the motor fittings. 4. Lubricate and install new O-rings to the fittings on the reel motor. Use the labels that you attached during the removal process to correctly connect the hydraulic hoses to the motor fittings.
Servicing the Cutting Reel Motor (Casappa) g230321 Figure 173 1. Body 2. Front flange 3. Front wear plate 8. Flat washer (4 each) 15. Retaining ring 9. Lock washer (RM 5410 series) 16. Back-up seal 10. O-ring 17. Back-up seal 4. Rear wear plate 11. Pressure seal 18. Flange washer 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.
Note: Casappa cutting reel motors used on Reelmaster 5410 series machines are different than reel motors used on Reelmaster 5510 and 5610 series machines. The motors used on Reelmaster 5510 and 5610 series have a separate rear cover that includes 2 cross-over relief valves. Both cutting reel motors are shown in Figure 173. The following disassembly, inspection, and assembly procedures can be used for either motor.
Disassembling the Cutting Reel Motor (continued) IMPORTANT Before removing the wear plates, note the position of the open and closed side of the wear plates. Also identify the wear plates (front and rear) with a marker for proper assembly. IMPORTANT Mark the relative positions of the gear teeth and wear plates so that you can assemble them in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 9.
Inspecting the Cutting Reel Motor (continued) CAUTION Use eye protection such as goggles when using compressed air. 2. Clean all the motor parts with solvent and dry them with compressed air. g216672 Figure 176 1. Gear shaft spline 3. Gear teeth 2. Gear face edge 4. Gear shaft 3. Inspect the drive gears and idler gears for the following (Figure 176): A. Gear shafts must be free of scoring, rough surfaces, and excessive wear at the bushing points and sealing areas.
Assembling the Cutting Reel Motor (continued) A. Press the shaft seal into the front flange until it reaches the bottom of the bore. B. Install the flange washer into the front flange and then install the retaining ring into the groove of the front flange. C. Install new dust seals into the front flange. The inner dust seal should have the seal lip and spring toward the installed retaining ring. The outer dust seal should have the seal lip and spring toward the outside of the motor. 3.
Assembling the Cutting Reel Motor (continued) IMPORTANT When you clamp the motor in a vise, clamp the front flange only to prevent damage. Also, use a vise equipped with soft jaws. 17. Clamp the front flange of the motor in a vise equipped with soft jaws. 18. Alternately torque the bolts to 45 N∙m (33 ft-lb). 19. On Reelmaster 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.
Servicing the Cutting Reel Motor (Sauer-Danfoss) Note: Sauer-Danfoss cutting reel motors are used on Reelmaster 5410/5410-G/5410-D machines with serial numbers below 313999999. g228844 Figure 177 1. Seal 5. Front bearing block 9. Dowel pin (4 each) 13. Drive gear 14. Tab washer 2. Front flange 6. Body 10. Rear cover 3. Back-up ring (2 each) 7. Idler gear 11. Bolt (4 each) 4. Pressure seal (2 each) 8. O-ring (2 each) 12.
Disassembling the Cutting Reel Motor g228845 Figure 178 1. Diagonal line 1. Plug motor ports and clean the outside of the motor. After cleaning, remove plugs and drain any fluid out of the motor. 2. Use a marker to make a diagonal line across the front flange, body and rear cover for assembly purposes (Figure 178). IMPORTANT Avoid using excessive clamping pressure on the motor flange to prevent damage. 3. Clamp front flange of motor in a vise with the shaft end down.
Disassembling the Cutting Reel Motor (continued) 7. Place motor on its side and push on the rear bearing block to remove bearing block and gear set (Figure 179). g228847 Figure 180 Note: Pressure seals and back-up rings fit in grooves machined into front flange and rear cover (Figure 180). 8. Carefully remove and discard O-rings, pressure seals and back-up rings from motor. Be careful to not damage the machined grooves.
Inspecting the Cutting Reel Motor (continued) g228848 Figure 181 1. Drive gear 2. Idler gear 3. Bearing block 3. Inspect drive gear, idler gear and bearing blocks (Figure 181) for the following: A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces or wear on gear shafts indicates need for replacement. B. Gear teeth should be free of excessive scoring and wear. Any broken or nicked gear teeth must be replaced. C.
Assembling the Cutting Reel Motor (continued) 5. Lubricate gear faces and bearing surfaces of drive gear, idler gear, and bearing blocks with clean hydraulic fluid. Carefully assemble bearing blocks and gears noting identification marks made during disassembly. 6. Position the motor body on its side. Carefully slide bearing block and gear assembly into the body cavity using identification marks made during disassembly. 7.
Lift Cylinder g216673 Figure 182 1. Cylinder pin 6. Cylinder slide pin 11. O-ring (2 each) 16. Flat washer 2. Lift cylinder 7. #4 lift arm 12. O-ring (2 each) 17. Bolt 18. Locknut 3. Carriage screw 8. Hydraulic hose 13. Flange nut 4. Retaining ring (2 each) 9. Hydraulic hose 14. R-clamp 5. Thrust washer (2 each) 10. 90° hydraulic fitting (2 each) 15.
Removing the Lift Cylinder (continued) 4. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines from the lift cylinder. 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 from the Hydraulic System (page 6–8).
Installing the Lift Cylinder (continued) the one end) through the lift cylinder and lift arm. Install the second thrust washer on pin and secure with the retaining ring. 6. Remove the caps and plugs that were installed to the hydraulic hoses and fittings during the removal process. 7. Put a coating of clean hydraulic fluid on new fitting O-rings, install the O-rings, and connect the hydraulic hoses to the fittings on the lift cylinder.
Servicing the Lift Cylinder g217164 Figure 183 1. Grease fitting 5. BP seal 2. Retaining ring 6. O-ring 9. 10. Dust seal 13. Head BS seal 14. Locknut 15. Barrel 3. Wear ring 7. Shaft 11. Back-up washer 4. Piston 8. Grease fitting 12. O-ring Note: The front, outside lift cylinders 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 (continued) IMPORTANT When you clamp the lift cylinder in a vise, clamp the clevis end of the barrel only to prevent damage. 2. Mount the lift cylinder in a vise. Use a vise equipped with soft jaws. 3. Use a spanner wrench, rotate the head clockwise until the edge of the retaining ring (item 2 in Figure 183) appears in the barrel opening. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening.
Assembling the Lift Cylinder (continued) IMPORTANT Clamping the vise jaws against the shaft surface could damage the shaft. When securing the shaft in a vise, clamp the shaft clevis only. 3. Mount the shaft in a vise by clamping on the clevis of the shaft, and do the following steps: A. Put a coating of clean hydraulic fluid on the shaft. B. Slide the head onto the shaft. Note: Ensure that you do not damage the seals. C. Install the piston onto the shaft and secure the piston with the locknut.
Steering Control Valve g185938 Figure 184 1. Steering wheel cover 6. Flange nut (6 each) 11. Flange-head screw (2 each) 2. Locknut 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 screw (4 each) Reelmaster® 5410/5510/5610 Series 15216SL Rev E 10.
Removing the Steering Control Valve 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. g185930 Figure 185 1. Platform shroud 3. Washer (2 each) 5. Cover plate 7. Spacer (2 each) 2. Washer-head screw (6 each) 4. Screw (2 each) 6. Bushing (2 each) 8. Flange nut (2 each) 2. Remove the fasteners that secure the shroud to the front of the machine (Figure 185).
Removing the Steering Control Valve (continued) g193311 Figure 186 8. For assembly purposes, label all the hydraulic connections. Note the port designations on the steering control valve (Figure 186). 9. Clean the hydraulic connections before loosening the hydraulic lines. CAUTION Before opening hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 6–8). 10.
Installing the Steering Control Valve (continued) 3. Apply loctite to four (4) socket-head screws. Slide the steering control valve input shaft into the steering column universal joint. Position the control valve with the ports toward front of the machine. Secure the steering control valve to the steering column with the 4 socket-head screws. Torque the socket-head screws to 8 to 11 N·m (6 to 8 ft-lb) in a criss-cross pattern. 4. Position the steering column assembly to the machine.
Servicing the Steering Control Valve g193310 Figure 187 10. Plug 19. Bearing O-ring (5 each) 11. Plug 20. Ring End cover 12. O-ring 21. Cross pin 4. O-ring 13. Spring 22. Sleeve 5. Outer gearwheel 14. Relief valve 23. Spool 6. Inner gearwheel 15. Dust seal ring 24. Spring set 7. Distributor plate 16. Housing 25. Thrust washer 26. Shaft seal 1. Screw (5 each) 2. 3. 8. O-ring 17. Check ball 9. Cardan shaft 18.
Steering Cylinder g217320 Figure 188 1. Steering cylinder 8. Retaining ring 15. Right drag link 2. O-ring (2 each) 9. Ball joint 16. Seal 3. 90° hydraulic fitting (2 each) 10. Rear axle 17. Hex nut 4. O-ring (2 each) 11. Jam nut (2 each) 18. Ball joint 5. Hydraulic hose 12. Slotted hex nut 19. Grease fitting 6. Hydraulic hose 13. Cotter pin 20. Bolt 7. 90° grease fitting 14. Washer Removing the Steering Cylinder 1.
Removing the Steering Cylinder (continued) 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 from the Hydraulic System (page 6–8). 3. For assembly purposes, label all the hydraulic hoses and tubes that are connected to the fittings on the steering cylinder. 4. Clean the hydraulic hose ends before you disconnect the hoses from the steering cylinder. 5.
Installing the Steering Cylinder (continued) the center to center length is as measured during removal process. Tighten the bolt and hex nut. 4. Clean the tapers on the ball joints and axle assembly. 5. Position the steering cylinder to the machine. 6. Secure the steering cylinder to the axle with the 2 jam nuts (item 11 in Figure 188). Tighten the first jam nut and then, while holding the first jam nut with wrench, tighten the second jam nut. 7.
Servicing the Steering Cylinder g217166 Figure 190 1. Barrel 6. O-ring 11. Head 2. Locknut 7. O-ring 12. Retaining ring 3. Piston 8. Back-up ring 13. BS seal 4. Wear ring 5. BP seal 9. 10. Dust seal Shaft Disassembling the Steering Cylinder 1. Slowly pump the cylinder shaft to remove the hydraulic fluid from the steering cylinder into a drain pan. Plug both the ports and clean the outer surface of the cylinder.
Disassembling the Steering Cylinder (continued) beveled edge of the retaining ring to start the retaining ring through the opening. Rotate the head counterclockwise to remove the retaining ring from the barrel and head.. 4. Remove the plugs from the ports. Carefully twist and pull the shaft and remove the shaft with head and piston. IMPORTANT Clamping the vise jaws against the shaft surface could damage the shaft. When securing the shaft in a vise, clamp the shaft clevis only. 5.
Assembling the Steering Cylinder (continued) 4. Use a wrench on the shaft flats to prevent the shaft from rotating, secure the piston with the locknut. Torque the locknut to 54 N∙m (40 ft-lb). IMPORTANT When you clamp the steering cylinder in a vise, clamp the clevis end of the barrel only to prevent damage. 5. Mount the barrel in a vise by clamping on the clevis end of the barrel.
Oil Cooler (5410/5510/5610) g228842 Figure 191 Reelmaster 5410 and 5510 1. Rear screen 2. Detent ball pin Wire form clamp (2 each) 17. Oil cooler mount plate (2 each) 10. 9. Bolt (2 each) 18. Bolt (4 each) 3. Draw latch 11. Washer (4 each) 19. Oil cooler bracket 4. Pop rivet (2 each) 12. Flange nut (4 each) 20. Radiator frame Radiator assembly 5. Oil cooler 13. Bolt (4 each) 21. 6. Hydraulic hose (2 each) 14. Flat washer (8 each) 22. Foam seal (2 each) 7. Cable tie 15.
g228843 Figure 192 Reelmaster 5610 6. Hose clamp 1. Oil cooler 2. O-ring 7. Hydraulic fitting (2 each) 12. Screw (8 each) 3. Hydraulic fitting (2 each) 8. Flat washer 13. Oil cooler bracket 4. O-ring 9. Flange nut (4 each) 14. Mount plate (2 each) 5. Hydraulic fitting (2 each) 10. 11. Bolt (2 each) Clamp (2 each) Note: The oil cooler used on Reelmaster 5410 and 5510 machines with a Kubota diesel engine is Figure 191.
Inspecting the Oil Cooler 1. Back flush oil cooler with cleaning solvent. After cooler is clean, ensure all solvent is drained from the cooler. CAUTION Use eye protection such as goggles when using compressed air. 2. Dry inside of oil cooler using compressed air in the opposite direction of the oil flow. 3. Plug both ends of oil cooler. Carefully clean exterior of cooler. Ensure oil cooler fins are clear of dirt and unwanted material. 4.
Radiator and Oil Cooler Assembly (5410-G/5410-D/5510-G/5510-D/5610-D) g188098 Figure 193 1. Screen 10. Washer-head screw (6 each) 19. Hose clamp (4 each) 28. Reservoir bracket 2. Pop rivet (2 each) 11. Mounting bracket (2 each) 20. Lower radiator hose 29. Button-head screw (5 each) 3. Detent ball pin 12. Foam seal (2 each) 21. Upper radiator hose 30. Reservoir cap 4. Draw latch 13. Foam seal (2 each) 22. Draincock 31. Pipe plug 5. Foam seal (2 each) 14.
Radiator and Oil Cooler Assembly (5410-G/5410-D/5510-G/5510-D/5610-D) (continued) Note: For Reelmaster machines with either a Yanmar diesel or Kubota gasoline engine, the hydraulic 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 information on removal and installation of the radiator and oil cooler assembly.
Chapter 7 Electrical System Table of Contents General Information .............................................................................................................................. 7–3 Electrical Schematic and Wire Harness Drawings/Diagrams ............................................................. 7–3 Toro Electronic Controller (TEC) ........................................................................................................ 7–3 CAN-bus Communications............................
Headlight Switch .............................................................................................................................. 7–72 Seat Switch ...................................................................................................................................... 7–74 Cutting Unit Down Limit Switch ........................................................................................................ 7–76 Traction Neutral Switch ..............................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Schematic and Wire Harness Drawings/Diagrams The electrical schematics and wire harness drawings/drawings for Reelmaster 5410, 5410-G, 5410-D, 5510, 5510-G, 5510-D, 5610, and 5610-D machines are located in Appendix A (page A–1).
CAN-bus Communications (continued) components of the machine and bring them together as one. The CAN-bus system reduces the number of electrical components and connections that are used on the machine and allows the number of wires in the wire harness to be significantly reduced. The integration of the electrical functions also allows the InfoCenter display to assist with the electrical system diagnostics. The CAN identifies the controller area network that is used between control components on the machine.
Yanmar Engine Electrical Components When operating a machine with a Yanmar diesel engine, if an engine electrical component fault occurs, the machine InfoCenter display can be used to identify the engine fault. When servicing or troubleshooting the engine electrical components use the Yanmar Engine Service Manual and Troubleshooting Manual. Contact your Toro distributor for additional engine troubleshooting assistance. Kubota Gasoline Engine Electronic Control Unit (ECU) g228829 Figure 196 1.
Kubota Gasoline Engine Electrical Components (continued) gasoline engine service 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.
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter The meter can test the electrical components and circuits for current, resistance, or voltage. You can get the digital multimeter locally. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter.
Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug 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 effective results.
InfoCenter Display g190807 Figure 197 1. InfoCenter display 2. Control arm The InfoCenter display used on your Reelmaster is a LCD device that is located on the control arm (Figure 197). The InfoCenter provides information to the operator during the operation of the machine, provides the electrical system diagnostic assistance for the technicians, and allows inputs for the adjustable machine settings (Figure 198).
g213684 Figure 198 Electrical System: InfoCenter Display Page 7–10 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Splash Screen g189679 Figure 199 1. Battery voltage 4. Glow plugs energized 2. Fuel gauge 5. Left/right button 3. Hour meter 6. Down button 7. Menu/back button g189680 Figure 200 1. Engine RPM 3. Down button 5. Battery voltage 2. Left/right button 4. Menu/back button 6.
Splash Screen (continued) • Glow plug indicator (displayed only while glow plugs are energized) • Engine RPM (displayed after 5 seconds) After the splash screen has been displayed for 10 seconds, the main information screen will appear on the InfoCenter. Main Information Screen g223016 Figure 201 1. Engine coolant temperature 5. Down button 2. Fuel gauge 6. Menu/back button 3. Reels (engaged) 7. Parking brake (engaged) 4. Left/right button 8. Traction system (neutral) 9. 10.
Main Information Screen (continued) g189676 Figure 202 1. Navigation pane 2. Left/right button 3. Menu/back button Press the menu/back button once to expose the navigation pane, then press the left/right button (as indicated by the in the navigation pane) to toggle between the main information screen and the splash screen (tachometer) (Figure 202). The navigation pane will close automatically if another button is not pressed within 6 seconds. Operator Advisory Screen g187150 Figure 203 1.
Operator Advisory Screen (continued) An advisory qualifier denotes the condition(s) that triggered the advisory and provides instruction on eliminating the advisory. An operator advisory may involve one or more advisory qualifier. Typically, an advisory can be eliminated by changing the position of the operator control(s) referenced by the advisory qualifier.
Main Menu Screen (continued) The main menu screen (Figure 205) is accessed from the InfoCenter main information screen. Press the menu/back button once to expose the navigation pane (Figure 204), then press the menu/back button again (as indicated by in the navigation pane).
Faults Screen Machine Faults g189674 Figure 206 1. 2. Fault menu Left/right button 3. Down button 4. 5. Menu/back button Fault items g189673 Figure 207 1. Fault description The faults screen (Figure 206 and Figure 207) will list all machine electrical faults that have occurred since the faults were last cleared from the InfoCenter. The faults will be identified 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).
Machine Faults (continued) 3. Allow the machine to remain OFF for at least 1 minute. 4. Restart the engine and check the machine operation. 5. If a fault continues to occur, further system evaluation and possible component repair or replacement will be necessary. To view a description of a fault that has occurred since the faults were last cleared from the InfoCenter, press the down button (as indicated by the at the bottom of the screen) to highlight the desired fault, then press the left/right ).
Service Screen g189677 Figure 209 1. Service screen (hours) 4. Menu/back button 2. Left/right button 5. Service items 3. Down button The service screen (Figure 209) contains operational information of the machine including hours, counts, and DPF regeneration. Values listed for these service menu items cannot be changed.
Service Screen (continued) • PTO Starts identifies the number of times that the reel engage switch has been engaged. • Tap Offs DPF Regeneration (PIN required) allows the operator or technician to initiate a parked (stationary) diesel exhaust particulate filter (DPF) regeneration on machines with Yanmar Tier 4F compliant engines. The parked (stationary) regeneration icon will appear in the InfoCenter display and the engine power will be de-rated to 85% when a parked (stationary) regeneration is necessary.
Diagnostics Screen (continued) necessary components and circuit wiring are functioning correctly (refer to Troubleshooting (page 7–26)). To scroll through the list of operations and select (highlight) the operation to be viewed, press the down button (as indicated by at the bottom of the screen). the To return to the previous screen, press the menu/back button (as indicated by the at the bottom of the screen). For each of the diagnostics screen items, inputs, qualifiers, and outputs are identified.
Diagnostics Screen (continued) Backlap identifies the requirements necessary to allow the TEC to engage the cutting units in the reverse direction for backlapping cutting 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 menu 4. Menu/back button 2. Left/right button 5. Settings items 3.
Settings Screen (continued) g213685 Figure 212 1. Settings menu 4. Menu/back button 2. Left/right button 5. Settings items 3. Down button The settings screen (Figure 211 and Figure 212) allows the operator or technician to customize the InfoCenter display, modify a variety of machine functions, and provides access to unlock various protected menus and settings.
Settings Screen (continued) • DPF Regeneration • DPF Ash Entering the correct PIN will also reveal and allow adjustment of various machine functions on the settings screen if Protect Settings is set to ON (refer to the Protected Menus in the Settings Screen (page 7–21)). Use the down button and left/right button (as indicated by the and the at the bottom of the screen) to enter the 4 digit passcode (PIN).
Settings Screen (continued) Blade Count: The blade count setting should match the number of blades on the cutting unit reels installed on the machine. The blade count setting is used by the TEC to manage the cutting unit reel speed. Use the left/right button (as indicated by the at the bottom of the screen) to select 8 or 11. The fault indicator will illuminate and an operator advisory #176 (Reel Speed Changed) will appear on the InfoCenter display to confirm that the change has been recorded.
About Screen g213674 Figure 213 1. 2. About menu Left/right button 3. Down button 4. 5. Menu/back button About items The about screen (Figure 213) identifies the machine model number, serial number, and software revision for the machine. If the correct passcode (PIN) has been entered (refer to the Protected Menus in the Settings Screen (page 7–21)), the InfoCenter software is displayed, and the CAN−bus status will be visible.
Troubleshooting CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine; refer to the Electrical Schematic and Wire Harness Drawings/Diagrams in Appendix A (page A–1).
Operator Advisories (continued) Advisories Table (continued) Advisory Number Reelmaster® 5410/5510/5610 Series 15216SL Rev E Advisory Description Possible Reason for Advisory 171 Auto idle engaged Engine RPM has been reduced to low idle speed as machine has been inactive for the set period of time. Inactive means the traction pedal is in the NEUTRAL, reel engage switch is in the DISENGAGED position, joystick is in the NEUTRAL position, and the engine speed switch is not pressed.
Using the InfoCenter Display for Troubleshooting g189681 Figure 214 1. Diagnostics menu 4. Menu/back button 2. Left/right button 5. Diagnostics items 3. Down button The diagnostics screen of the InfoCenter display can be very helpful when troubleshooting machine operation issues (refer to Diagnostics Screen (page 7–19)).
Using the InfoCenter Display for Troubleshooting (continued) g189682 Figure 215 1. Diagnostics items 3. Down button 2. Left/right button 4. Menu/back button 3. Select (highlight) the malfunctioning machine operation and press the left/right button (as indicated by the at the bottom of the screen). For this example, the PTO operation has been selected (Figure 215). 4. Select (highlight) the Inputs and press the left/right button (as indicated by at the bottom of the screen).
Using the InfoCenter Display for Troubleshooting (continued) In the PTO operation example, the only input is the reel engage switch. If ON and OFF do not alternate when the switch is moved back and forth from ENABLE to DISABLE, the switch or the circuit wiring for the switch is damaged and should be tested as described. 6. Press the menu/back button (as indicated by the at the bottom of the screen).
Using the InfoCenter Display for Troubleshooting (continued) • Engine temperature is ok • Engine must be running Engine RPM above 800 as reported by engine ECU • Cutting units must be lowered below turn-around position (cutting unit down limit switch) If and do not alternate when the qualifier condition is changed, the qualifier or the circuit wiring for the qualifier is damaged and should be tested as described. at the bottom of the 8. Press the menu/back button (as indicated by the screen).
Machine Faults The Machine Fault Table (page 7–33) identifies the fault codes that are generated by the Toro Electronic Controller (TEC) to identify an electrical system fault (malfunction) that occurred during the operation of the machine. Use the InfoCenter display to view faults that have occurred since the faults were last cleared from the InfoCenter; refer to Faults Screen (page 7–16). The Yanmar engine ECU can also generate electrical faults.
Using Machine Faults (continued) The Machine Fault Table (page 7–33) identifies the fault codes that are generated by the TEC to identify an electrical system malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval. Note: The following list of fault codes identifies electrical problems that typically will prevent normal machine operation. The InfoCenter Display will identify existing faults if they should occur.
Using Machine Faults (continued) Machine Fault Table (continued) Fault Code 9 10 Fault Description Engine alternator charging is too low Engine has not been seen on the CAN-bus for 10 seconds (machines with Yanmar diesel or Kubota gasoline engine) Service Suggestions Check the alternator drive belt Check the engine alternator and circuit wiring Check CAN-bus connection to engine ECU Verify battery power exists at engine ECU Check CAN-bus terminator resistors 12 InfoCenter has not been seen on the CAN-
Engine Faults g187359 Figure 218 1. Engine fault (Yanmar diesel engine) The engine faults are generated by the Yanmar engine ECU to identify an electrical system malfunction (fault) pertaining to the engine during operation. When an engine fault occurs, the fault indicator will flash and the InfoCenter will display information about the fault. The number of flashes and/or the flashing pattern vary depending on the type or source of the fault, enabling quick-fix.
Engine Faults (continued) Starting Problems Problem Possible Causes All the electrical power is dead, including the InfoCenter display. • The battery is discharged or damaged. • The battery cables are loose or corroded. • The fuse F1-1 (15 A) or F1-2 (10 A) is damaged. • The ground connection is loose or corroded. • The key switch or circuit wiring is damaged. • The in-line main power supply fuse (25 A) is damaged (machine with gasoline engine).
Engine Faults (continued) Starting Problems (continued) Problem Possible Causes The glow plug circuit does not operate properly. • The wiring in the engine glow circuit is loose, corroded, or damaged; refer to the Electrical Schematic in Appendix A (page A–1). • The engine glow plugs are damaged. • The glow relay is damaged. • The fusible link harness at the engine starter motor is damaged. • The TEC fuses are damaged. • The TEC is damaged.
Engine Faults (continued) Starting Problems (continued) Problem Possible Causes Nothing happens when you attempt to start the engine. The InfoCenter display operates with the key switch in the RUN position. • The traction pedal is not in the NEUTRAL position. Note: An operator advisory is displayed on the InfoCenter if the interlock switches for engine start are not functioning. Use the InfoCenter display to assist with identifying the problem.
General Run and Transport Problems Problem Possible Causes The engine continues to run, but should not, when the key switch is turned to the OFF position. • The engine fuel stop solenoid is damaged (machine with diesel engine). • The key switch or circuit wiring is damaged. • The main power relay or circuit wiring is damaged. • The engine or fuel system is malfunctioning; refer to Chapter 4: Yanmar Diesel Engine (page 4–1).
General Run and Transport Problems (continued) Problem Possible Causes The engine shuts off when the traction pedal is pressed. • The parking brake is engaged. Note: If the machine controls are not in the correct position for operating the machine (e.g., the parking brake is engaged), an advisory message may be displayed on the InfoCenter display. • The operator is not fully pressing the seat switch. • The seat switch or circuit wiring is damaged. • The key switch or circuit wiring is damaged.
General Run and Transport Problems (continued) Cutting Unit Operating Problems (continued) Problem Possible Causes None of the cutting units operate. Cutting units are able to raise and lower. • The reel engage switch is in the OFF position. Note: For cutting unit operation, the operator seat needs to be occupied, mow speed limiter needs to be in MOW position, cutting units need to be fully lowered, and the reel engage switch needs to be engaged. • The operator seat is unoccupied.
General Run and Transport Problems (continued) Cutting Unit Operating Problems (continued) Problem Possible Causes The cutting units do not run when placed in the backlap direction. • The parking brake is not applied. • The reel engage switch is in the OFF position. • The cutting units are not fully lowered to ground. • The joystick is not in the center position. • High engine coolant temperature has disabled cutting unit operation. • The front or rear backlap switch or circuit wiring is damaged.
General Run and Transport Problems (continued) Cutting Unit Lift/Lower Problems Problem Possible Causes None of the cutting units will lower. • The seat switch or circuit wiring is damaged. • The mow speed limiter is in the TRANSPORT position. • The lower/mow switch on the joystick or circuit wiring is damaged. • The mow/transport switch or circuit wiring is damaged. • The lift control manifold SVRV solenoid coil or circuit wiring is damaged.
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 7–44). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F). Ensure that the key switch is in the OFF position and all the accessories are turned off.
Testing the Charging System (continued) Battery Voltage Table At least 0.50 V over the initial battery voltage. Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.55 V Testing the Glow Plug System (Machines with Kubota Diesel Engine) This is a fast, simple test that can help to determine the integrity and operation of your Reelmaster glow plug system used on a Kubota diesel engine.
Adjustments Traction Neutral Switch g213687 Figure 219 1. Jam nut (2 each) 4. Switch LED location 2. Lock washer (2 each) 5. Pump plate 3. Traction neutral switch 6. Pump lever 7. Traction pump The 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 sensing plate for the traction neutral switch is the pump lever that is secured to the traction pump.
Adjusting the Traction Neutral Switch 1. Before adjusting the traction neutral switch, check and adjust the traction system neutral position; refer to the Traction Unit Operator’s Manual. IMPORTANT To prevent the traction neutral switch damage, ensure that no components contact switch through entire traction pump control arm movement. 2. Park the machine on a level surface, set the parking brake, lower the cutting units, shut off the engine, and remove the key from the key switch. g213686 Figure 220 1.
Parking Brake Switch g213680 Figure 221 1. Switch LED location 3. Lock washer (2 each) 5. Brake pedal 2. Parking brake switch 4. Jam nut (2 each) 6. Parking brake detent The parking brake switch is a normally open proximity switch. The 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 that the switch is closed.
Adjusting the Parking Brake Switch IMPORTANT To prevent the parking brake switch damage, ensure that no components contact switch through entire brake pedal movement. 1. Park the machine on a level surface, set the parking brake, lower the cutting units, shut off the engine, and remove the key from the key switch. g213870 Figure 222 1. Parking brake detent 4. Jam nut (2 each) 2. Brake pedal 5. Parking brake switch 3. Lock washer (2 each) 2.
Cutting Unit Down Limit Switch g213676 Figure 223 1. Switch LED location 3. Lock washer (2 each) 5. Lift arm 2. Down limit switch 4. Jam nut (2 each) 6. Bracket The cutting unit down limit switch is a normally 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 tube.
Adjusting the Cutting Unit Down Limit Switch Note: The vertical location of the down limit switch on the switch bracket will determine the turn-around position of the front, outside cutting units (cutting units #4 and #5). Raising the switch on the bracket will allow a lower turn-around position of the cutting units. Lowering the switch on the bracket will allow a higher turn-around position of the cutting units.
Mow/Transport Switch g213679 Figure 225 1. Traction pedal 4. Mow speed limiter tab 2. Mow speed limiter 5. Jam nut (2 each) 3. Mow/transport switch 6. Lock washer (2 each) 7. Switch LED location The mow/transport switch is a normally closed proximity switch that opens when the mow speed limiter is placed in the TRANSPORT position. The switch 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 (continued) g213869 Figure 226 1. Mow speed limiter 2. Gap 3. Mow/transport switch 2. The gap (Figure 226) between the mow/transport switch and the mow speed limiter should be 2.4 to 2.5 mm (0.094 to 0.100 inch). 3. If gap is incorrect, loosen the jam nuts that secure the switch to the footrest platform. Position the switch with jam nuts to allow correct gap between the switch and the mow speed limiter. Tighten the jam nuts to secure the adjustment.
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Note: Use the InfoCenter display to test the TEC inputs and outputs before further troubleshooting of an electrical problem on your Reelmaster. Note: For engine component testing information; refer to the Yanmar Engine Service Manual or Troubleshooting Manual.
of these links fail, current to the protected circuit stops; refer to the Electrical Schematic in Appendix A (page A–1) for additional circuit information. Testing the Fusible Link Harness 1. Ensure that the key switch is in the OFF position, disconnect the negative battery cable from the battery terminal, and then disconnect the positive cable from the battery; refer to Servicing the Battery (page 7–125). 2. Locate and unplug the fusible link connector P1 from the main wire harness. 3.
System Fuses Note: For gasoline engine fuses; refer to Engine Fuses (Gasoline Engine) (page 7–59). g213678 Figure 229 1. Control arm 2. Fuse block 3. TEC (Toro Electronic Controller) 3. 2 A fuse g213681 Figure 230 1. Starter motor 2. 10 A fuse The fuse block is located behind the control arm access cover (Figure 229). In addition to the fuses in the fuse block, there are 2 additional fuses included in the engine wire harness.
Identification and Function g190996 Figure 231 Refer to Figure 231 to identify each individual fuse and its correct amperage. The fuses have the following functions. F1-1 (15 A): Protects starter circuit power supply. F1-2 (10 A): Protects main power supply. F1-3 (10 A): Protects power supply for headlights. F1-4 (10 A): Protects power supply for power point. F2-1 (7.5 A): Protects power supply for TEC outputs. F2-2 (7.5 A): Protects power supply for TEC outputs. F2-3 (7.
Testing the Fuses (continued) 5. After you complete the fuse testing, install the control arm access cover.
Engine Fuses (Gasoline Engine) g228827 Figure 232 1. In-line fuse holder 2. 60 A maxi-fuse 3. Power center location The engine fuses that protect Kubota gasoline engine electrical circuits are installed in the engine power center located on the engine (Figure 232). In addition to the fuses 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 232).
Identification and Function (continued) Use Figure 233 to identify each individual fuse and its correct amperage. Engine fuses have the following function: Fuse F-1 (5 A): Protects engine VSW (key switch voltage) circuit power supply. Fuse F-2 (10 A): Protects engine ECU power supply. Fuse F-3: Not used. Fuse F-4 (15 A): Protects power supply for engine electrical system. Fuse F-5 (15 A): Protects fuel pump circuit power supply. Fuse F-6 (25 A): Protects starter motor circuit power supply.
Toro Electronic Controller (TEC) g213677 Figure 234 1. Fuse block 2. Control arm 3. TEC (Toro Electronic Controller) The Reelmaster 5010 machines use a Toro Electronic Controller (TEC) to monitor the condition of various 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 display when checking the inputs and outputs of the TEC used on your machine.
Toro Electronic Controller (TEC) (continued) The logic power is provided to the controller as long as the battery cables are connected to the battery. Circuit protection for this logic power to the controller is provided by 2 A fuse. The inputs from the key, neutral, parking brake, reel engage, seat, mow/transport, joystick lower/raise, cutting reels down limit, engine speed (if equipped), temperature sender, and engine oil pressure switches are all monitored by the controller.
Toro Electronic Controller (TEC) (continued) IMPORTANT Before performing any welding on the machine, disconnect both negative and positive battery 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 electrical system of your Reelmaster. g321413 Figure 237 1. 2. TEC controller Machine harness connector 3.
Key Switch g190808 Figure 238 1. Key switch 2. Control arm g190999 Figure 239 The key switch (Figure 238) is located on the control arm and has three positions: OFF, RUN, and START (Figure 239). The Toro Electronic Controller (TEC) monitors the operation of the key switch. Testing the Key Switch 1. Park the machine on a level surface, lower the cutting units, set the parking brake, and shut off the engine. Remove the key from the key switch. 2.
Testing the Key Switch (continued) Circuit Logic Table Switch Position Circuits OFF None RUN B+C+F, D+E START A+B+C 8. Replace the key switch if testing determines that it is damaged. 9. If the key 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 Appendix A (page A–1). 10. After you complete the testing, connect the main wire harness connector to the key switch. 11.
Reel Engage Switch g191000 Figure 240 1. Reel engage switch 2. Control arm The reel engage switch is located on the control arm (Figure 240) and allows the cutting units to operate when the front of the switch is pressed. An indicator light on the switch identifies when the reel engage switch is engaged. The TEC monitors the position of the reel engage switch (up or down).
Testing the Reel Engage Switch (continued) 7. The reel engage switch terminals are identified in Figure 241 and the circuitry of the switch is shown in the Circuit Logic Table (page 7–67). With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals.
Engine Speed Switch (If Equipped) g190806 Figure 242 1. 2. Control arm Engine speed switch The engine speed switch is used on machines with either a Yanmar diesel engine or Kubota gasoline engine. The engine speed switch is used as an input for the TEC to signal the engine ECU via the CAN-bus to increase or decrease the engine speed. When the switch is pressed and held in the forward position, the engine speed will increase.
Testing the Engine Speed Switch (continued) Circuit Logic Table Switch Position Normal Circuits Other Circuits DECREASE 2+1 5+4 OFF None None INCREASE 2+3 5+6 Note: The engine speed switch terminals 4, 5, and 6 are not used on the Reelmaster machines. 8. Replace the engine speed switch if testing determines that the switch is damaged. 9.
Lower/Raise Joystick Switches g190998 Figure 244 1. Joystick 2. Control arm g191007 Figure 245 1. Joystick 4. 2. Switch lever 5. 3. Common terminal 6. Normally Open (NO) terminal Normally Closed terminal (not used) 7. Lower switch Raise switch The 2 micro switches for the joystick are located on the lower mow/raise lever that is attached to the control arm (Figure 244). When the joystick is pushed forward, the rear switch on the control is used to lower (and engage) the cutting units.
Testing the Lower/Raise Joystick Switches 1. Park the machine on a level surface, lower the cutting units, set the parking brake, and shut off the engine. 2. Before you disconnect the joystick switches for testing, ensure that you test the switches and its circuit wiring as TEC input with the InfoCenter display; refer to Using the InfoCenter Display for Troubleshooting (page 7–28). 3.
Headlight Switch g190997 Figure 246 1. 2. Control arm Headlight switch The headlight switch is located on the operator side of the control arm (Figure 246). This rocker switch allows the headlights to be turned on and off. Testing the Headlight Switch 1. Park the machine on a level surface, lower the cutting units, set the parking brake, and shut off the engine. 2. Remove the left control arm cover to get access to the headlight switch; refer to Disassembling the Control Arm (page 8–23). 3.
Testing the Headlight Switch (continued) 6. If the 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 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 machine; refer to Assembling the Control Arm (page 8–25).
Seat Switch g190802 Figure 248 1. Main wire harness 2. Seat switch connector g190803 Figure 249 1. Operator seat 3. Washer-head screw (2 each) 2. Seat switch harness 4. Seat switch The seat switch is normally open and closes when the operator is on the seat. If the traction system or reel engage switch is engaged when the operator raises out of the seat, an operator advisory will be displayed on the InfoCenter.
Testing the Seat Switch 1. Park the machine on a level surface, lower the cutting units, set the parking brake, and shut off the engine. 2. Before you disconnect the seat switch for testing, ensure that you test the switch and its circuit wiring as a TEC electrical input with the InfoCenter display; refer to Using the InfoCenter Display for Troubleshooting (page 7–28). 3. If the InfoCenter verifies that the seat switch and circuit wiring are functioning correctly, no further switch testing is necessary. 4.
Cutting Unit Down Limit Switch g213676 Figure 250 1. Switch LED location 3. Lock washer (2 each) 5. Lift arm 2. Down limit switch 4. Jam nut (2 each) 6. Bracket The cutting unit down limit switch is a normally 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 tube.
Testing the Down Limit Switch (continued) B. Ensure that the key switch is in the OFF position and disconnect the down limit switch connector from the main wire harness. C. Use a 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 check with a multimeter that the main wire harness connector terminal for pink wire has system voltage (12 VDC) present. E.
Traction Neutral Switch g213687 Figure 251 1. Jam nut (2 each) 4. Switch LED location 2. Lock washer (2 each) 5. Pump plate 3. Traction neutral switch 6. Pump lever 7. Traction pump The 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 251). The sensing plate for the traction neutral switch is the pump lever that is secured to the traction pump.
Testing the Traction Neutral Switch (continued) 8. If the neutral switch LED did not function correctly, do the following: A. Ensure that the neutral switch is properly adjusted; refer to Adjusting the Traction Neutral Switch (page 7–47). If necessary, adjust the switch and return to step 6. B. Ensure that the key switch is in the OFF position and disconnect the traction neutral switch connector from the main wire harness. C.
Parking Brake Switch g213680 Figure 252 1. Switch LED location 3. Lock washer (2 each) 5. Brake pedal 2. Parking brake switch 4. Jam nut (2 each) 6. Parking brake detent The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the brake pedal (Figure 252). The machine is equipped with an interlock switch on the parking brake.
Testing the Parking Brake Switch (continued) 6. Turn the key switch to the RUN position (do not start the engine) and check the LED on the cable end of the parking brake switch. The LED should be illuminated when the parking brake is not set. 7. With the key switch still in the RUN position (do not start the engine), set the parking brake and check the LED on the cable end of the parking brake switch. The LED should not be illuminated when the parking brake is set. 8.
Mow/Transport Switch g213679 Figure 253 1. Traction pedal 4. Mow speed limiter tab 2. Mow speed limiter 5. Jam nut (2 each) 3. Mow/transport switch 6. Lock washer (2 each) 7. Switch LED location The mow/transport switch is a normally closed proximity switch that opens when the mow speed limiter is placed in the TRANSPORT position. The switch mounts to a bracket on the footrest platform (Figure 253). The sensing plate for the mow/transport switch is the mow speed limiter.
Testing the Mow/Transport Switch (continued) D. Turn the key switch to the RUN position (do not start the engine) and check with 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 pink wire has system voltage present, and the switch LED did not function, replace the mow/transport switch.
Backlap Switches g214065 Figure 254 1. Ball 4. Dowel pin 7. Rear backlap lever 2. Front backlap switch 5. Mow control manifold 8. Front backlap lever 3. O-ring 6. Rear backlap switch The front and rear backlap switches are normally closed ball switches that are in the normal, closed state when a backlap lever on the hydraulic mow control manifold is in the BACKLAP position. When a backlap lever is in the MOW position, the switch opens.
Testing the Backlap Switches (continued) 11. Replace the backlap switch if testing determines that the switch is damaged; refer to Backlap Switches (page 7–122). 12. If the backlap 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 Appendix A (page A–1). 13. After you complete the testing, connect the wire harness connector to the backlap switch. 14. Lower and secure the operator seat.
Oil Pressure Switch (Machine with Kubota Engine) g228837 Figure 255 1. Oil pressure switch 2. Oil filter The engine oil pressure switch is a normally closed switch that opens with pressure during normal engine operation. The oil pressure switch is located on the engine near the oil filter (Figure 255). On machines with a Kubota diesel engine, the Toro Electronic Controller (TEC) monitors the operation of the oil pressure switch.
Testing the Oil Pressure Switch (continued) 4. Replace the oil pressure switch if testing determines that the switch is damaged. 5. If testing of oil pressure switch determines that switch operation is normal and the InfoCenter display is identifying 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. Lower and secure hood.
Relays with 4 Terminals g230518 Figure 257 1. Kubota diesel relays 4. Main power relay 2. Yanmar diesel relays 5. Glow relay 3. Kubota gas relays A number of electrical relays that have 4 terminals are used in the machine electrical system. A tag near the wire harness relay connector can be used to identify each relay. The main power relay is used to provide current to the operator seat, InfoCenter, TEC, headlights, power point, and optional electric equipment.
Testing the Relays with 4 Terminals (continued) positive (+) cable from the battery; refer to Servicing the Battery (page 7–125). 4. Locate the relay that is to be tested. 5. Disconnect the wire harness electrical connector from the relay. Remove the relay from the mounting bracket for testing. Note: Before taking the small resistance readings with a digital multimeter, short the multimeter test leads together. The meter displays a small resistance value (usually 0.5 ohms or less).
Relays with 5 Terminals (Diesel Engine) g230517 Figure 259 1. Kubota diesel relays 3. Start relay 2. Yanmar diesel relays 4. EGR relay The electrical system in machines with a Kubota or Yanmar diesel engine include electrical relays that have 5 terminals. A tag near the wire harness relay connector can be used to identify each relay. The start relay is used to provide current to the engine starter solenoid.
Testing the Relays with 5 Terminals (continued) g223021 Figure 260 1. Coil terminal 3. Normally open term 2. Normally closed term 4. Common terminal 6. Check the coil resistance between the terminals 85 and 86 with a multimeter (ohms setting). The resistance must be approximately 71 to 88 ohms (Figure 260). 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.
Engine Relays with 5 Terminals (Gasoline Engine) g228830 Figure 261 1. Engine power center 3. Power relay 2. Start relay 4. Fuel pump relay The engine electrical system in machines with a Kubota gasoline engine includes 3 electrical relays that have 5 terminals. These relays are installed in the engine power center located on the engine (Figure 261). The start relay is used to provide current to the engine starter solenoid. The start relay is energized by the engine ECU.
Testing the Engine Relays with 5 Terminals (continued) g228831 Figure 262 Start relay g228832 Figure 263 Power and fuel pump relay 3. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Figure 262 or Figure 263). Resistance should be as listed in table below. Relay Coil Resistance Start 81 to 99 ohms Power or Fuel Pump 111 to 135 ohms 4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
Testing the Engine Relays with 5 Terminals (continued) 9. Secure relay to machine and connect machine wire harness connector to relay. 10. Install hood saddle. Lower and secure hood.
Hydraulic Solenoid Valve Coils g191003 Figure 264 g214067 Figure 265 1. Mow control manifold 2. MSV1 solenoid 3. MSV2 solenoid The Reelmaster hydraulic control manifolds use several hydraulic solenoid valve coils for system control. The mow control manifold includes 2 solenoid valves (Figure 265) and the lift control manifold includes 4 solenoid valves (Figure 266). When the solenoid coils are energized, the hydraulic valve shift occurs to control the hydraulic fluid flow.
Note: If electrical problems exist with a solenoid valve coil, a fault may have occurred that would be indicated by a fault code on the InfoCenter display. Before considering that solenoid valve coil service work is necessary, check for any existing fault codes.
Testing the Hydraulic Solenoid Valve Coils (continued) Solenoid Valve Coil Specifications Table Solenoid Valve Coil Diameter Height Resistance MSV1 and MSV2 (mow) 46.7 mm (1.84 inches) 49.9 mm (1.96 inches) 7.1 ohms SV2 and SVRV (lift) 46.7 mm (1.84 inches) 49.9 mm (1.96 inches) 7.1 ohms SV1 and SV3 (lift) 35.8 mm (1.41 inches) 36.3 mm (1.43 inches) 8.8 ohms 6. If the solenoid coil resistance is incorrect, replace the solenoid coil; refer to Hydraulic Solenoid Valve Coils (page 7–120). 7.
Temperature Sender (Machine with Kubota Diesel Engine) g228833 Figure 267 1. Temperature sender 2. Water flange The temperature sender used on machines with a Kubota diesel engine is attached to the water flange on the engine (Figure 267). The Toro Electronic Controller (TEC) monitors the operation of the temperature sender. The resistance of the temperature sender reduces as the engine coolant temperature increases.
Testing the Temperature Sender (continued) CAUTION Ensure engine is cool before removing the temperature sender from engine. g228834 Figure 268 4. Put sender in a container of oil with a thermometer and slowly heat the oil (Figure 268). CAUTION Handle the hot oil with extreme care to prevent personal injury or fire. Note: Prior to taking resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.
Engine Run Solenoid (Machine with Kubota Diesel Engine) g228835 Figure 269 1. Injection pump 2. Fuel stop solenoid The engine run solenoid used on a machine with a Kubota diesel engine must be energized for the diesel engine to run. The Toro Electronic Controller (TEC) controls the operation of the engine run solenoid. The solenoid is mounted to the injection pump on the engine (Figure 269). Testing the Engine Run Solenoid 1.
Testing the Engine Run Solenoid (continued) (Figure 270). The resistance of the pull coil should be less than 1 ohm (but not zero). 5. Use a digital multimeter (ohms setting), touch one test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame (ground) (Figure 270). The resistance of the hold coil should be approximately 15 ohms. 6. If either coil resistance is incorrect, replace fuel stop solenoid. 7.
Fuel Sender (Diesel Engine) g213683 Figure 271 1. Fuel sender cap 3. Fuel tank 5. Sender cover 7. Fuel return hose 2. Fuel sender 4. Fuel sender gasket 6. Screw (5 each) 8. Fuel supply hose On machine with a diesel engine, the fuel sender is a variable resistance device that is located in the fuel tank (Figure 271). The resistance of the fuel sender increases as the fuel level in the fuel tank decreases.
Testing the Fuel Sender (continued) 4. To test the circuit wiring and InfoCenter fuel gauge, use a jumper wire to connect the 2 terminals in the wire harness connector. Ensure that the jumper wire connections are secure. 5. Turn the key switch to the RUN position. The InfoCenter display should indicate a full fuel tank if the circuit wiring and InfoCenter are working correctly. Turn the key switch to the OFF position and continue testing fuel sender if the circuit wiring and InfoCenter are acceptable. 6.
Testing the Fuel Sender (continued) g191009 Figure 273 1. Sender full position 2. Sender empty position 9. Use a multimeter to check the resistance of the fuel sender across the 2 sender terminals (Figure 273). A. The resistance with the float in the full position (completely up) should be 5 to 8 ohms. B. The resistance with the float in the empty position (completely down) should be 89 to 95 ohms. 10. Replace the fuel sender if testing determines that it is damaged. 11.
Fuel Sender (Gasoline Engine) g228841 Figure 274 1. 2. Fuel tank Fuel tank cap 5. 6. Sender cover Fuel fitting 9. 10. Fuel vent hose Fuel pump cap 3. Screw (7 each) 7. Hose clamp 11. Fuel pump assembly 4. Strap 8. Fuel supply hose 12. Gasket On a machine with a 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 tank decreases.
Testing the Fuel Sender 1. Park the machine on a level surface, lower the cutting units, shut off the engine, and set the parking brake. Remove the key from key switch. Raise the operator seat and hood. g229530 Figure 275 1. Fuel sender connector 3. Full position 2. Fuel pump connector 4. Empty position 2. Carefully disconnect both machine wire harness connectors from the fuel pump assembly. The fuel pump assembly connectors for the fuel sender and fuel pump are identified in Figure 275. 3.
Testing the Fuel Sender (continued) IMPORTANT Note orientation of fitting on fuel pump assembly for installation purposes (Figure 276). 5. Remove fuel pump cap and carefully lift fuel pump assembly and gasket from fuel tank. Clean all fuel from the pump assembly including fuel sender. CAUTION Ensure that the fuel sender is completely dry (no fuel on it) before testing. Perform test away from the fuel tank to prevent an explosion or fire from sparks. 6.
Fuel Pump (Machine with Yanmar Diesel Engine) g213682 Figure 277 1. Pump discharge hose 2. 3. Fuel/water separator Fuel pump On machines with a Yanmar diesel engine, the fuel pump is attached to the air cleaner stand adapter below the fuel/water separator (Figure 277). Electrical current is available for the fuel pump when the key switch is in either the RUN or START position. The Toro Electronic Controller (TEC) energizes the fuel pump.
Testing the Fuel Pump Capacity (continued) 4. Disconnect the fuel pump discharge hose from the inlet fitting of the fuel/water separator. 5. Place the disconnected end of the pump discharge hose into a large, graduated cylinder sufficient enough to collect 0.9 L (32 fl oz). IMPORTANT When testing the fuel pump output, do not turn the key switch to the START position. 6. Turn the key switch to the ON position and collect the fuel in the graduated cylinder.
Fuel Pump (Machine with Kubota Diesel Engine) g228839 Figure 278 1. Fuel pump 3. Inlet fitting 2. Fuel/water separator 4. Fuel supply hose On a machine with a Kubota diesel engine, the fuel pump is attached to the inside of the left side frame rail near the fuel tank (Figure 278). IMPORTANT When testing fuel pump, ensure that pump is not operated without fuel. DANGER Because diesel fuel is highly flammable, use caution when handling it. Do not smoke while testing the fuel pump.
Testing the Fuel Pump Capacity (continued) 4. Disconnect fuel supply hose (pump discharge) from the fuel/water separator inlet fitting (Figure 278). 5. Place disconnected fuel hose into a large, graduated cylinder sufficient enough to collect 0.95 L (32 fl oz). IMPORTANT When testing the fuel pump, Do not turn key switch to START . 6. Collect fuel in the graduated cylinder by turning key switch to the ON/RUN position. Allow pump to run for 15 seconds, then return switch to OFF. 7.
Fuel Pump (Machine with Kubota Gasoline Engine) The electric fuel pump assembly used on machines with a Kubota gasoline engine is a combination positive displacement fuel pump and a fuel level sending unit. The fuel pump assembly provides pressurized fuel to the engine fuel rail in a return-less system and includes a regulator to maintain fuel pressure of approximately 276 kPa (40 psi). The fuel pump/sender assembly is attached to the top of the fuel tank.
Testing the Fuel Pump (continued) 5. If fuel pump pressure is low, ensure that electrical power is available to fuel pump and then consider a clogged fuel filter 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 secure with hose clamp. 7. Lower and secure hood.
CAN-bus Terminator Resistor g223018 Figure 280 1. 2. CAN-bus terminator resistor Keyway The system communication between the electrical components on the Reelmaster machine is accomplished on a CAN-bus communication system. The 2 specially designed, twisted cables form the bus for the network are used on the machine. These wires provide the data pathways between the machine components. The 120 ohm CAN-bus terminator resistor plugs into the main wire harness in the control arm.
Testing the CAN-bus Terminator Resistor (continued) 4. After you complete 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.
Resistor Assembly (Machine with Yanmar Diesel or Kubota Gasoline Engine) g213673 Figure 281 1. Engine 2. 3. Engine ECU 75 ohm resistor On machines with a Yanmar diesel engine or Kubota gasoline engine, a 75 ohm resistor (Figure 281) is necessary for proper key switch operation on all Reelmaster machines. The resistor plugs into the engine wire harness near the engine ECU; refer to the Engine Wire Harness Drawing/Diagram in Appendix A (page A–1). g223022 Figure 282 1. End of the resistor body 2.
Testing the Resistor Assembly (continued) 4. If the testing determines that the resistor is damaged, 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.
Diode Assemblies (Diesel Engine) g223019 Figure 283 1. End of the diode body 3. Male terminal 2. Diode assembly 4. Female terminal g213675 Figure 284 1. Diesel-particulate filter (DPF) 2. Diode (2 each) 3. Engine ECU The engine wire harness on machines with either a Kubota or Yanmar diesel engine includes 2 identical diodes. The maximum current allowed through any of the diodes is 6 A.
Testing the Diode Assembly (continued) 2. Locate the diode assembly that is to be tested and remove the cable tie that secures the diode to the wire harness. Unplug the diode from the wire harness for testing. 3. The diode (Figure 283) can be tested by using a digital multimeter (diode test or ohms setting) and the Diode Test Table (page 7–119). 4. Replace the diode assembly if testing determines that the diode is damaged. 5.
Service and Repairs Note: Refer to the appropriate engine service manual for engine electrical component repair information. Hydraulic Solenoid Valve Coils g214062 Figure 285 1. 2. 3. 4. Mow control manifold Solenoid coil MSV1 Nut Solenoid coil MSV2 g214063 Figure 286 1. 2. Solenoid coil SV3 Coil spacer 4. 5. Solenoid coil SV1 Solenoid coil SV2 3. Nut 6. Nut Electrical System: Service and Repairs Page 7–120 7. 8.
You can replace a hydraulic solenoid valve coil on the mow control manifold (Figure 285) or lift control manifold (Figure 286) without opening the hydraulic system. Removing the Hydraulic Solenoid Valve Coils 1. Park the machine on a level surface, lower the cutting units, set the parking brake, shut off the engine, and remove the key from the key switch. 2. Locate the solenoid valve coil that you replace. A. Tilt the operator seat up to get access to the mow control manifold.
Backlap Switches g214064 Figure 287 1. Front backlap switch 4. Rear backlap lever 2. Front backlap lever 5. Mow control manifold 3. Rear backlap switch The backlap switches are attached to the hydraulic mow control manifold under the operator seat on the right side of the machine.
Installing the Backlap Switches g214065 Figure 288 1. Ball 3. O-ring 5. Mow control manifold 2. Front backlap switch 4. Dowel pin 6. Rear backlap switch 1. Ensure that the dowel pin and ball are placed in the manifold port as shown in Figure 288. 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.
Battery Storage If you store the machine for more than 30 days: 1. Ensure that the key switch is in the OFF position. Remove the battery and charge it fully; refer to Servicing the Battery (page 7–125). 2. Either store the battery on a shelf or on the machine. 3. Disconnect the cables if the battery is kept on the machine. 4. Store the battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
Battery Care (continued) WARNING Connecting the cables to the wrong battery post could result in personal injury and/or damage to the electrical system. Ensure that the cables are properly connected to the correct battery posts before operating the machine. 4. If corrosion occurs at the battery terminals, disconnect the cables. Always disconnect the negative (-) cable first. Clean the cable clamps and terminals separately. Connect the cables with the positive (+) cable first.
Removing and Installing the Battery g191002 Figure 289 1. Cord grip locknut 5. Carriage screw 2. Negative cable 6. Battery mat 3. Cord grip 7. Battery retainer 4. Positive cable 8. Flange nut 9. 10. Battery (rear location) Battery cover g230305 Figure 290 1. Battery (under hood) 4. Flange nut 2. Battery tray 5. Carriage screw 3. Retainer 6. Negative battery cable 7.
Removing and Installing the Battery (continued) 2. Open screen at rear of the machine or raise and support hood to access the battery. Remove the battery cover (if equipped). IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 3. Loosen and remove the negative (-) cable from the battery. After you disconnect the negative cable from the battery, loosen and remove the positive cable (+) from the battery. 4.
Inspecting, Maintaining, and Testing the Battery (continued) IMPORTANT Ensure that the area around the cells is clean before opening the battery caps. A. Use a hydrometer to measure the specific gravity of each cell. Pull the electrolyte in and out of the hydrometer barrel before taking a reading to warm-up the hydrometer. At the same time, take the temperature of the cell. B. Temperature correct each cell reading. For each 5.5°C (10°F) above 27°C (80°F) add 0.004 to the specific gravity reading.
Inspecting, Maintaining, and Testing the Battery (continued) E. If you charge the battery, apply a 150 A load for 15 seconds to remove the surface charge. Wait for 10 minutes before proceeding with load test. F. Apply a test load of 270 A (1/2 the cranking performance rating of the battery) for 15 seconds. G. After test load has been applied for 15 seconds, take a test voltage reading and then remove the load. Record the test voltage reading. H.
Charging the Battery (continued) 2. Determine the charging time and rate using the manufacturer's battery charger instructions or the following Battery Charge Level Table (page 7–130). Battery Charge Level Table Battery Reserve Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs 7.5 hrs 11.3 hrs 15 hrs @ @ @ @ 3 A 3 A 3 A 3 A 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs @ @ @ @ 4 A 4 A 4 A 4 A 5.5 hrs 11 hrs 16.5 hrs 22 hrs @ @ @ @ 5 A 5 A 5 A 5 A 5.8 hrs 11.5 hrs 17.
Charging the Battery (continued) 6. Three hours before the end of the charging, measure the specific gravity 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 readings.
Electrical System: Service and Repairs Page 7–132 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Chapter 8 Chassis Table of Contents Specifications ....................................................................................................................................... 8–2 Chassis .............................................................................................................................................. 8–2 General Information ..............................................................................................................................
Specifications Chassis Item Description Front tire pressure (26.5×14.0-12, 4 ply, tubeless) 83 to 103 kPa (12 to 15 psi) Rear tire pressure (20×12.0-10, 4 ply, tubeless) 83 to 103 kPa (12 to 15 psi) Wheel lug nut torque 95 to 122 N∙m (70 to 90 ft-lb) Steering control valve mounting screws Steering wheel mounting nut Chassis: Specifications 9.5 to 13.
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Reelmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Special Tools You can order the special tools from your Toro Distributor. Wheel Hub Puller Toro Part No. TOR6004 The 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 rear wheel hub from the rear wheel motor.
Service and Repairs Wheels g185942 Figure 291 Drive axles from machines with 4-wheel drive 1. Rear wheel 5. Brake assembly (left) 2. Wheel-lug nut (5 each per wheel) 6. Wheel stud (5 each per hub) 10. Locknut 3. 4. Locknut Front wheel motor (left) 7. 8. Front wheel hub Brake drum 11. 12. Rear wheel hub Rear wheel motor (left) Reelmaster® 5410/5510/5610 Series 15216SL Rev E Page 8–5 9.
Removing the Wheel 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. Block the wheels that are not removed with chocks to prevent the machine from moving. 3. Loosen, but do not remove the 5 wheel-lug nuts that attach the wheel to the machine. IMPORTANT Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–6). 4.
Steering Column g185938 Figure 292 1. Steering wheel cover 6. Flange nut (6 each) 11. Flange-head screw (2 each) 2. Locknut 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 screw (4 each) Reelmaster® 5410/5510/5610 Series 15216SL Rev E 10.
Removing the Steering Column 1. Park the machine on a level surface, set the parking brake, lower the cutting units, shut off the engine, and remove the key from the key switch. 2. Remove the steering wheel cover (item 1 in Figure 292) from the steering wheel by carefully prying up on one of the cover spokes. 3. Remove the locknut (item 2 in Figure 292) and flat washer that secure the steering wheel to the steering column. 4.
Installing the Steering Column g185937 Figure 294 1. Steering column 5. Cylinder shaft Pin 13. Spring 2. Pin 6. Jam nut 10. 9. Pedal block 14. Universal joint 3. Lock washer (2 each) 7. Cylinder 11. Pedal cover 15. Pin 4. Release pin 8. Bolt (2 each) 12. Pedal 1. Assemble the steering column (Figure 294). After assembly, ensure that the release pin on the end of the cylinder shaft is positioned against the pedal.
Servicing the Brakes g215442 Figure 295 1. Locknut (2 each per wheel shield) 10. Bolt (4 each per brake assembly) 19. Brake return spring (2 each) 2. Wheel shield (right rear) 11. Left spring clip 20. Bolt (2 each) 3. Flange-head screw (2 each per wheel shield) 12. Front wheel (left) 21. Jam nut (2 each) 4. Locknut (4 each per wheel motor) 13. Wheel-lug nut (5 each per wheel) 22. Right spring clip 5. Left wheel motor 14. Brake drum (2 each) 23. Flange nut (2 each) 6.
Disassembling the Brake (continued) 5. Remove the brake return spring (item 19 in Figure 295) and clevis pin that attach the brake cable to the brake actuator lever. 6. Remove the brake drum (item 14 in Figure 295) from the brake assembly. IMPORTANT Do not hit the wheel hub, wheel-hub puller, or wheel motor with a hammer while removing or installing the wheel hub. Hammering can damage the wheel motor. 7.
Assembling the Brake (continued) 2. Visually examine the brake shoes and contact surfaces of the brake drum for excessive wear. Replace the parts that are worn and damaged. 3. If the brake backing plate was removed from the machine, secure the backing plate to the brake adapter with the 4 bolts (item 10 in Figure 295). 4. Lightly lubricate the brake shoe pivot points with general purpose grease. 5. Position the brake shoe to the backing plate.
Assembling the Brake (continued) 8. Install new locknut (item 15 in Figure 295) onto the wheel motor shaft to secure the wheel hub to the motor shaft. 9. Install the brake drum (item 14 in Figure 295). 10. Position the end of the brake cable to the brake actuator lever (item 12 in Figure 296). Attach the cable to the brake actuator lever with the clevis pin and brake return spring. 11. Install the front wheel assembly; refer to Installing the Wheel (page 8–6). 12.
Rear Wheel Bearings (Machines with 2-Wheel Drive) g228650 Figure 298 1. Dust cap 6. 2. Cotter pin 7. Bearing cup 12. Housing 3. Retainer 8. Wheel hub 13. Wheel stud (5 each) 4. 5. Jam nut Tab washer 9. 10. Bearing cone 11. Flange-head screw (4 each) Seal Spindle Disassembling the Rear Wheel Bearings (Machines with 2-Wheel Drive) 1. Chock front wheels to prevent machine from shifting. 2. Remove rear wheel; refer to Wheels (page 8–5). Ensure to support machine with jack stands. 3.
Assembling the Rear Wheel Bearings (Machines with 2-Wheel Drive) 1. If bearing cups were removed from the wheel hub, press new cups into the hub until they seat against the shoulder of the hub. IMPORTANT The lip of the seal must be toward the bearing. The seal should be pressed in so it is flush with the end of the wheel hub. 2. Pack both bearings with grease. Install one bearing into the bearing cup on inboard side of the wheel hub.
Rear Axle Motor Housings g215440 Figure 299 Machines with CrossTrax AWD 1. Steering cylinder 8. Left drag link 15. Lock washer (4 each per 22. motor) 2. Flange-head screw (2 each) 9. Woodruff key 16. Rear wheel motor (left) 23. Right drag link 3. Spindle cap (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.
g228647 Figure 300 Machines with 2-wheel drive 1. Motor housing 2. Hub and spindle assembly 3. Flange-head screw (7 each per side) Removing the Rear Axle Motor Housings 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. Block the front wheels with chocks to prevent the machine from moving. 3. Remove the rear wheel assembly; refer to Removing the Wheel (page 8–6). 4.
Removing the Rear Axle Motor Housings (continued) 13. Clean the rear axle bore and inspect the flange bushings (item 5 in Figure 299) in the rear axle for wear or damage. If the bushings need replacement, do the following steps: Note: Do not damage the bore of the axle tube during bushing removal. A. Use a bushing removal tool to extract both the flange bushings from the axle tube. B. Clean the inside of the axle tube to remove any dirt or unwanted material. C.
Rear Axle g215432 Figure 301 Machines with CrossTrax AWD 1. Axle pivot pin 10. Retaining ring (2 each) 19. Locknut 28. Rear axle 2. Roll pin 11. Flange bushing (4 each) 20. Wheel hub 29. Jam nut (2 each) 3. 90° grease fitting 12. Grease fitting (5 each) Woodruff key 30. Tie rod 21. 4. Retaining ring 13. Thrust washer (2 each) 22. Bolt (4 each per motor) 31. Right drag link 5. Ball joint 14. Left drag link 23. Lock washer (4 each per motor) 32. Steering cylinder 6.
g228648 Figure 302 Machines with 2-wheel drive 1. Rear axle assembly 4. Jam nut 7. Cotter pin 2. Tab washer 5. Nut retainer 8. Wheel-lug nut (5 each per wheel) 3. Wheel assembly 6. Dust cap 9. Wheel hub assembly Removing the Rear Axle 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. Block the front wheels with chocks to prevent the machine from moving. 3.
Servicing the Rear Axle (continued) 2. Clean the rear axle bushings and inspect the axle bushings (item 7 in Figure 301) for wear or damage. If the bushings need replacement, do the following steps: Note: Do not damage the bore of the axle during bushing removal. A. Use a bushing removal tool to extract both the axle bushings from the axle pivot. B. Clean the inside of the axle pivot to remove any dirt or unwanted material. C. Apply grease to the inner and outer surfaces of new axle bushings. D.
Installing the Rear Axle (continued) 3. On machines with CrossTrax AWD, do as follows: g185918 Figure 304 1. Frame bracket 3. Lock washer (3 each) 2. Bolt (3 each) 4. Spacer (3 each) 5. AWD control manifold A. Raise the CrossTrax AWD control manifold to the frame. Position the spacers between the manifold and the frame (Figure 304). Secure the manifold to the frame with the 3 bolts and 3 lock washers. B. Close and latch the radiator screen assembly. 4.
Control Arm g185923 Figure 305 1. Arm rest 12. Right control arm cover 23. Retainer bracket 2. Locknut 13. Swell latch (2 each) 24. Clevis pin 3. Engine speed switch 14. Access cover 25. Bolt 4. Reel engage switch 15. Washer-head screw (10 each) 26. Latch 5. InfoCenter display 16. Foam seal 27. Cotter pin 6. Control arm 17. Platform wire harness 28. Spacer 7. Key switch 18. Flange nut (3 each) 29. Flat washer 8. TEC (Toro Electronic Controller) 19. Spring 30.
Disassembling the Control Arm (continued) 3. Loosen the 2 swell latches (item 13 in Figure 305) and remove the access cover from outside of the control arm. 4. At the front of the control arm, remove the screw (item 11 in Figure 305) and locknut that secure the control arm covers to each other. 5. Remove the 5 washer-head screws (item 15 in Figure 305) that secure each cover to the control arm. 6. Remove the control arm covers from the machine.
Disassembling the Control Arm (continued) g185936 Figure 307 1. Foam seal 2. Platform wire harness Assembling the Control Arm 1. Install all the electrical components that were removed from the control arm (Figure 305). 2. Position the covers to the control arm. As the left control arm cover (item 32 in Figure 305) is placed, connect the wire harness connector to the headlight switch.
Operator Seat g185929 Figure 308 1. Seat 10. Seat belt 19. Seat suspension 2. Bolt 11. Lock washer (2 each) 20. Flange nut (4 each) 3. Left armrest 12. Bolt (2 each) 21. Manual tube 4. Flange 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. 8. Flat washer Spacer 16. 17. Seat switch harness Seat switch 25. Seat base 9.
IMPORTANT The operator seat, seat base, and control arm assembly are attached to the machine with the same fasteners. Support the seat base and control arm to prevent them from shifting when removing the seat. Damage to the control arm electrical components and platform wiring harness, and throttle cable (if equipped) can occur if the seat base and control arm are not properly supported during seat removal. Removing the Operator Seat 1.
Removing the Operator Seat (continued) g185921 Figure 310 1. Seat base 3. Bushing (2 each) 5. Flat washer (2 each) 2. Control arm 4. Retainer bracket 6. Flange-head screw (2 each) 5. Remove the 2 flange-head screws and 2 flat washers that secure the control arm assembly to the seat base (Figure 309 and Figure 310). IMPORTANT Do not damage the platform wire harness when removing the seat and control arm assembly from the machine. 6. Carefully slide the control arm assembly from the seat base.
Installing the Operator Seat (continued) 4. Connect the seat switch wire harness connector to the platform wire harness (Figure 309). 5. Connect the negative battery cable to the battery; refer to Servicing the Battery (page 7–125).
Mechanical Seat Suspension g187025 Figure 311 1. Rivet (2 each) 13. Roll pin 25. Lower shock bolt (2 each) 37. Flat washer 2. Cotter pin 14. Weight adjust spacer 26. Lower housing 38. Spring shaft 3. Roll pin 15. Weight adjust shaft 27. Shaft block (4 each) 39. Extension spring (2 each) 4. Up-stop bumper block 16. Weight adjuster 28. Scissor assembly 40. Spring bushing (2 each) 5. Flat washer 17. Weight adjust nut 29. Lower shock bushing (2 each) 41. Flat washer 6.
Removing the Mechanical Seat Suspension 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. Remove the seat from the machine; refer to Removing the Operator Seat (page 8–27). IMPORTANT Do not damage the platform wire harness when removing the seat suspension from the machine. 3. Tilt and support the seat frame to get access to the seat suspension fasteners. 4.
Installing the Mechanical Seat Suspension 1. Install all the seat suspension components that were removed (Figure 311 and Figure 312). If removed, use the seat adjuster mounting holes that were recorded during removal. IMPORTANT Do not damage the electrical harness when installing the seat suspension to the machine. 2. Position the seat base cover and 4 spacers (item 7 in Figure 312) to the seat frame. 3.
Front Lift Arms g215433 Figure 313 1. Roll pin (3 each) 10. Flat washer (1 each per lift arm) 19. Flange nut (2 each per chain hoop) 2. Locknut (4 each) 11. Snapper pin (1 each per lift arm) 20. #5 lift arm 3. Lift arm pivot shaft (3 each) 12. Grease fitting 21. Jam nut (2 each) 4. #4 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.
Removing the Front Lift Arms 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. Remove the cutting unit from the front lift arm to be removed. g215434 Figure 314 1. #4 lift arm 4. Thrust washer (2 each) 2. Lift cylinder 5. Cylinder slide pin 3. Retaining ring (2 each) 3. Disconnect the lift cylinder from the lift arm (item 1 in Figure 314) as follows: A.
Removing the Front Lift Arms (continued) g215436 Figure 316 1. Upper bushing 3. Pivot yoke 2. Pivot yoke shoulder 4. Lower bushing 7. Inspect the flange bushings in the lift arm and pivot yoke for wear or damage. If necessary, replace the bushings as follows (Figure 315 and Figure 316): Note: Do not damage the bore of the lift arm and pivot yoke during bushing removal. A. Use a bushing removal tool to extract both the flange bushings from the lift arm or pivot yoke. B.
Installing the Front Lift Arms (continued) C. Install the second thrust washer on the pin and secure with the second retaining ring. 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 Cutting Unit Down Limit Switch (page 7–76).
Rear Lift Arms g215437 Figure 317 1. Flange-head screw (2 each) 2. Housing 3. Left torsion spring 4. 5. 9. Lynch pin (2 each) 17. Cap (1 each per yoke) 10. Bolt (2 each per chain hoop) 18. #2 lift arm 11. Washer (2 each per chain hoop) 19. #3 lift arm Washer (2 each) 12. Chain hoop (2 each) 20. Washer-head screw (1 each per shaft) Shoulder stud (6 each) 13. Chain (2 each) 21. Pivot shaft (2 each) Right torsion spring 6. Locknut (6 each) 14.
Removing the Rear Lift Arms 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. Remove the cutting unit from the rear lift arm to be removed. g215438 Figure 318 1. Lift cylinder 4. Cylinder pin 2. Retaining ring (2 each) 5. Pivot yoke bushing (2 each) 3. Washer (2 each) 6. #2 lift arm 7. Lift arm bushing (2 each) 3.
Removing the Rear Lift Arms (continued) B. Insert a nut driver or small piece of pipe onto the end of the torsion spring that is secured on the rear of the lift arm shoulder stud. C. Push down and rearward on the spring end to unhook the spring from the shoulder stud on the lift arm. Note: The Reelmaster machines use 1 of 2 methods to secure and center the torsion springs on the rear lift arms. One type (shown in Figure 317) uses a one piece housing to secure the springs.
Removing the Rear Lift Arms (continued) Note: Do not damage the bore of the lift arm or pivot yoke during bushing removal. A. Use the bushing removal tool to extract both the bushings from the lift arm or pivot yoke. B. Clean the inside of the bore to remove any dirt or unwanted material. C. Apply grease to the inner and outer surfaces of the new bushings. D. Use an arbor press to install the bushings into the lift arm or pivot yoke.
Hood g215441 Figure 321 1. Hood 8. Clevis pin (2 each) 15. Latch 2. Washer-head screw (12 each) 9. Bow tie pin (2 each) 16. Locknut (4 each) 3. Flange nut (12 each) 10. Rubber latch (2 each) 17. Flat washer (4 each) 4. Rear hood frame tube 11. Flange-head screw (2 each) 18. Washer-head screw (4 each) 5. Rubber 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.
Removing the Hood 1. Park the machine on a level surface, lower the cutting units, shut off the engine, and remove the key from the key switch. 2. Unlatch the hood. 3. Remove the bow tie pins (item 9 in Figure 321) and clevis pins to allow hood removal. 4. Lift the hood assembly from the machine. 5. Remove the hood components as necessary (Figure 321). 6. Check the condition of all seals on the hood. Replace the seals that are damaged or missing.
Chapter 9 Cutting Unit Table of Contents Specifications ....................................................................................................................................... 9–2 Cutting Unit Specifications ................................................................................................................. 9–2 General Information .............................................................................................................................. 9–4 Special Tools ....
Specifications Cutting Unit Specifications g214391 Figure 322 Frame construction: Precision machined die cast aluminum crossmember with 2 bolt-on side plates. Side plates are either cast ductile iron (painted) or aluminum (non-painted). Reel construction: The reels are 55.9 cm (22 inches) in length and are available in 12.7 cm (5 inches) and 17.8 cm (7 inches) in diameter. High strength, low alloy steel blades are through hardened and impact resistant.
Cutting Unit Specifications (continued) Bedknife: Replaceable, tool steel EdgeMax™ bedknife is fastened to a machined cast iron bedbar with 8 screws. Optional bedknives are available. Bedknife adjustment: Dual screw assemblies allow for precise bedknife adjustment. Adjustment detents correspond to bedknife movement for each indexed position as follows: • 0.018 mm (0.0007 inch) for 5 inch reel • 0.022 mm (0.
General Information The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting units on your Reelmaster 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 to the Cutting Unit Operator’s Manual for additional information when servicing the cutting units.
Special Tools You can order these special tools from your Toro Distributor. Some tools may have been supplied with your machine or are available as Toro parts. Gauge Bar Assembly Toro Part No. 108-6715 Use gauge bar to verify height-of-cut adjustment. Also used for adjustment of optional groomer. 1. Used for groomer adjustment 2. Used for height-of-cut adjustment Bedknife Screw Tool Toro Part No. TOR510880 This screwdriver-type bit is made to fit Toro bedknife attaching screws.
Plastic Plug Toro Part No. 94-2703 (for 7 inch reels) Toro Part No. 2410-30 (for 5 inch reels) This cap is used for placement into the cutting unit side plate when the cutting reel motor is removed. It prevents dirt and unwanted material from entering the cutting reel bearing area. Cutting Unit Kickstand Toro Part No. 119-8010-03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service.
Turf Evaluator Tool Toro Model No. 04399 Many turf discrepancies are subtle and require closer examination. In these instances, the turf evaluator grass viewing tool is helpful. It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height-of-cut of one mowed surface to another. This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the Turf Evaluator (Toro Part No. 97931SL).
Cutting Performance Paper Toro Part No. 125–5610 (300 strips) Cutting performance paper is used to test the cutting reel performance after adjusting the reel 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 alignment of groomer and/or rear roller brush drive and driven pulleys.
Angle Indicator and Magnetic Mount Angle Indicator: Toro Part No. 131–6828 Magnetic Mount: Toro Part No. 131–6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after-cut appearance, Toro has develop these service tools for accurately measuring the top grind angle on all bedknives. Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. g223327 1.
Aftercut Appearance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. The turf conditions such as excessive thatch, sponginess, or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit. It is important to remember that the lower the height-of-cut, the more critical these factors are. Refer to the Cutting Unit Operator’s Manual for detailed cutting unit adjustment procedures.
Factors That Can Affect Quality of Cut (continued) Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or rifling (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind the cutting reel to remove taper and/or rifling. Grind the bedknife to sharpen and/or remove rifling. Note: After grinding the reel and/or bedknife, check the reel to bedknife contact again after cutting 2 fairways.
Factors That Can Affect Quality of Cut (continued) Factor Possible Problem/Correction Turf compensation spring adjustment Refer to the Traction Unit Operator’s Manual for turf compensation spring adjustment procedure. Rear lift arm counterbalance 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 are available that can be used to enhance aftercut appearance.
Adjustments Characteristics CAUTION Do not install or work on the cutting units or lift arms with the engine running. Always shut off the engine and remove the key from the key switch. The dual knob bedknife-to-reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure necessary to deliver optimum mowing performance. The precise adjustment possible with this design gives the necessary control to provide a continual self-sharpening action.
Checking the Reel Bearing Adjustment (continued) 4. Use a suitable torque wrench and spline insert tool (refer to (page )), measure the rolling resistance of the cutting reel. The cutting reel rolling torque should not exceed 1.1 N∙m (10 in-lb). 5. If reel has end-play or if rolling torque is incorrect, perform the reel bearing adjustment; refer to Adjusting the Reel Bearing (page 9–14). 6. After checking or adjusting the reel bearings, adjust the cutting unit; refer to the Cutting Unit Operator’s Manual.
Adjusting the Reel Bearing (continued) 6. Use a suitable torque wrench and spline insert tool (refer to (page )), check that the reel rolling torque does not exceed 1.1 N∙m (10 in-lb). Also, check if reel bearing end-play exists. If end-play exists, replace the cutting reel bearings and seals; refer to Reel Assembly (cutting units with painted side plates) (page 9–29) and Reel Assembly Service (cutting units with painted side plates) (page 9–36). 7.
Leveling the Rear Roller (continued) 5. Adjust the position of the side plate to parallel the rear roller and cutting reel. Tighten the shoulder bolts to 37 to 44 N∙m (27 to 33 ft-lb). 6. After tightening the side plate, check the rear roller. If necessary, loosen and adjust the second side plate. g214395 Figure 327 1. Rear roller bracket 5. Rear roller assembly 2. 0.010 inch shim (if necessary) 6. Roller shim (2 each) 3. Flange nut (2 each) 7. Carriage screw (2 each) 4.
Service and Repairs Hydraulic Reel Motor IMPORTANT When performing the maintenance procedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removing the Hydraulic Reel Motor 1. Park the machine on a clean 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. g214396 Figure 328 Cutting unit with cast iron side plate 1.
Installing the Hydraulic Reel Motor (continued) g230062 Figure 329 1. Aluminum side plate 4. Set screw 2. 3. Threaded insert Grease fitting 5. Relief vent Note: Cutting units with aluminum side plates have threaded inserts for the reel motor mounting bolts (Figure 329). Check the condition of these inserts whenever the reel motor is removed. Replace the inserts if there is any damage. Tighter inserts to 48 to 54 N∙m (35 to 40 ft-lb) during installation. g214397 Figure 330 1. Weight location 2.
Backlapping DANGER To Avoid Personal Injury or Death • Never place hands or feet in the reel area while the engine is running. Stay away from the cutting reels when backlapping. • When backlapping, run engine at idle speed only. • While backlapping, the reels may stall and then restart. • Do not attempt to restart reels by hand or foot. • Do not adjust reels while the engine is running. • If a reel stalls, stop engine before attempting to clear the reel.
Bedbar Assembly g214400 Figure 332 1. Bedbar assembly 5. Plastic washer (4 each) 2. Locknut (2 each) 6. Rubber bushing (2 each) 3. Compression spring (2 each) 7. Flange bushing (2 each) 4. Washer (2 each) 8. Metal washer (2 each) 9. 10. Bedbar pivot bolt (2 each) Locknut (2 each) Removing the Bedbar Assembly 1. Park the machine on a clean and level surface, lower the cutting units, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the Bedbar Assembly (continued) 6. Carefully remove the bedbar assembly from the cutting unit. 7. Inspect the flange bushings (item 7) and rubber bushings (item 6) in the side plates for wear or damage. Remove the bushings and replace if necessary. Installing the Bedbar Assembly g214674 Figure 333 1. Cutting unit side plate 3. Bedbar pivot bolt 5. Metal washer 7. Rubber bushing 2. Locknut 4. Flange bushing 6. Plastic washer 8. Bedbar 1.
Installing the Bedbar Assembly (continued) IMPORTANT Do Not use a powered wrench or an impact wrench to install the bedbar pivot bolts. B. Start threading of one of the pivot bolts into the bedbar and continue until the pivot bolt bottoms out. Repeat for remaining pivot bolt. C. Make sure that plastic washers are not caught on the threads of the pivot bolts. D. Tighten each bedbar pivot bolt from 37 to 44 N∙m (27 to 33 ft-lbs). 8. Tighten both locknuts (item 10) until the outside metal washer just rotates.
Bedknife Replacement and Grinding Removing the Bedknife 1. Remove the bedbar from the cutting unit; refer to Bedbar Assembly (page 9–20). g214675 Figure 334 1. Screw (8 each) 2. Bedknife 3. Bedbar 2. Remove the screws from the bedbar with a socket wrench and bedknife screw tool (refer to (page )). Discard the screws. Remove the bedknife from the bedbar (Figure 334). 3. Refer to Grinding the Bedknife (page 9–24) for additional information. Installing the Bedknife 1.
Installing the Bedknife (continued) g251663 Figure 335 5. Using a torque wrench and bedknife screw tool, tighten the 2 outer screws to 1 N∙m (10 in-lb). 6. Working from the center of the bedknife toward each end, tighten screws from 23 to 28 N∙m (200 to 250 in-lb). 7. After installing the bedknife to the bedbar, grind the bedknife. Grinding the Bedknife g207291 Figure 336 1. Top angle 4. Front surface 2. Top surface 5. Front angle 3.
Grinding the Bedknife (continued) Since there can be variations in the mounting surface of the bedbar, a new bedknife will not be perfectly flat after it is installed to the bedbar. Because of this, it is necessary to grind a new bedknife after installing it to the bedbar. Follow the bedknife grinding specifications provided and grind only enough to ensure that the top surface of the bedknife is true; refer to Bedknife Grinding Specifications (page 9–24) and Figure 336.
Grinding the Bedknife (continued) g214496 Figure 338 1. Bedknife 2. Lead-in chamfer 2. A lead−in chamfer is ground into all new bedknives; refer to Figure 338. 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 the cutting unit; refer to Installing the Bedknife (page 9–23).
Servicing the Bedbar Adjuster g214497 Figure 339 1. Bedbar assembly 6. Cap screw 11. Washer 2. Compression spring 7. Detent 12. Lock nut 3. 4. Lock nut Bedbar adjuster screw 8. 9. Wave washer Retaining ring 13. 14. Flat washer Wave washer 5. Flange bushing (2 each) 10. Bedbar adjuster shaft Note: The bedbar adjuster system for early production DPA cutting units (Figure 339A) used a retaining ring on the end of the bedbar adjuster shaft.
Removing the Bedbar Adjuster 1. Remove the locknut (item 3) , compression spring, and washer from the bedbar adjuster screw (item 4). 2. Remove the bedbar assembly; refer to the Removing the Bedbar Assembly (page 9–20). 3. Remove bedbar adjuster screw (left hand threads) from the bedbar adjuster shaft (item 10). 4. Remove adjuster shaft from cutting unit frame: A. On early production cutting units (Figure 339A), remove retaining ring and wave washer from adjuster shaft.
Reel Assembly (cutting units with painted side plates) g214498 Figure 340 1. Bedbar assembly 9. Weight 17. Grease seal (2 each) 2. Flange bushing (2 each) 10. Cap screw(2 each) 18. Bearing (2 each) 3. Plastic washer (4 each) 11. O-ring 19. Bearing adjuster nut 4. Metal washer (2 each) 12. Cutting reel 20. Set screw 5. Bedbar pivot bolt (2 each) 13. Spline insert (left-hand thread) 21. Cap screw(2 each) 6. Lock nut (2 each) 14. RH side plate 22. Cutting unit frame 7.
Removing the Reel Assembly (continued) 2. Remove the cutting unit from the machine and place on a flat work surface. 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. Remove and discard O-ring from counter weight. Refer to Service and Repairs (page 10–6) for additional belt driven groomer information. Refer to Service and Repairs (page 10–6) for additional universal groomer information.
Removing the Reel Assembly (continued) IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. C. Move the pry bar against the weld side of the reel support plate closest to the spline insert being loosened. Use correct spline insert tool (see Special Tools (page 9–5)).
Removing the Reel Assembly (continued) g230064 Figure 342 1. Carrier frame 5. Flat washer 9. 2. Shim (if equipped) 6. Cap screw 10. Socket-head screw 11. Flange nut 3. Support tube 7. Flange-head screw 4. Frame spacer 8. Rear grass shield LH side plate 8. Remove the bolt and flat washer that secure the rear grass shield to the LH side plate. 9.
Removing the Reel Assembly (continued) 12. Inspect and service the cutting reel assembly as necessary; refer to Reel Assembly Service (cutting units with painted side plates) (page 9–36). Installing the Reel Assembly 1. Clean the side plates and other cutting unit components. Inspect the side plates for wear or damage and replace if necessary. Note: Check that the grease seals on the cutting reel shaft are flush to 1.5 mm (0.060 inch) away from the retaining ring on the reel shaft.
Installing the Reel Assembly (continued) 9. Install the bedbar assembly; refer to Installing the Bedbar Assembly (page 9–21). 10. Install the rear roller; refer to Installing the Rear Roller (page 9–50). 11. Install the front roller; refer to Installing the Front Roller (page 9–48). IMPORTANT Over tightening reel bearing adjuster nut may damage reel bearings. 12. Adjust the reel bearings; refer to Adjusting the Reel Bearing (cutting units with painted side plates) (page 9–13). 13.
Installing the Reel Assembly (continued) IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. B. Move the pry bar against the weld side of the reel support plate closest to the spline insert being tightened. IMPORTANT The spline insert on the left end of the cutting reel has left hand threads and the spline insert on the right end of the cutting reel has right hand threads. C.
Reel Assembly Service (cutting units with painted side plates) g252592 Figure 344 1. Cutting reel 6. Threaded insert (left-hand thread) 2. Threaded insert (RH thread) 7. Retaining ring groove 3. Retaining ring 8. Groove indicating LH threads 4. Grease seal 9. Bearing shoulder 5. Bearing 10. Reel spider Inspecting the Cutting Reel 1. Inspect reel bearings to insure that they spin freely and have minimal axial play. The bearing balls must be free of deformation and scoring. 2.
Assembling the Cutting Reel 1. If the seals and/or bearings were removed from the reel shaft, discard the components that were removed and replace. 2. Ensure that the 2 retaining rings are fully seated into the grooves on the cutting reel shaft. 3. If the bearings and seals were removed from the reel shaft, do the following steps: A. Ensure that the bore of the seals are clean with no grease or lubricant applied to the inner diameter of the seal.
Reel Assembly (cutting units with aluminum side plates) g252639 Figure 345 1. Bedbar assembly 7. Lock nut (2 each) 13. 2. Cutting unit frame 8. RH side plate 14. Cutting reel assembly 3. Flange bushing (2 each) 9. LH side plate 15. Wire spring 4. Plastic washer (4 each) 10. Weight 16. Flange nut (3 per side plate) 5. Metal washer (2 each) 11. Cap screw (2 each) 17. Cap screw (2 each) 6. Bedbar pivot bolt (2 each) 12. O-ring 18.
g252640 Figure 346 1. Frame 7. Flange bushing (2 each) 13. Special screw 2. LH side plate 8. Rear grass shield 14. Flat washer 3. RH side plate 4. Shoulder bolt (4 or 6 each) 5. 6. Spacer (2 each) 15. Cap screw 10. 9. Shim (0.060” – as required) 16. Washer (2 each) Carrier frame 11. Flange nut (2 each) Flange head screw (2 each) 12. Flange nut (4 each) Removing the Reel Assembly 1.
Removing the Reel Assembly (continued) CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when removing the cutting reel. IMPORTANT If the reel bearings or seals are being replaced, the reel spline inserts must be removed. Use the following procedure to restrain the reel and loosen the spline insert before removing the rollers. 4. Loosen the spline inserts: A. Tip the cutting unit to access the bottom of the reel. g325751 Figure 347 1.
Removing the Reel Assembly (continued) IMPORTANT The spline insert on the left end of the cutting reel has left hand threads and the spline insert on the right end of the cutting reel has right hand threads. D. Rest the handle of the pry bar against the front roller and loosen the spline insert closest to the pry bar. E. Position the pry bar in the same manner on the opposite end of the reel and loosen the remaining spline insert. F. Tip the cutting unit back onto its rollers. 5.
Reel Assembly Installation (continued) g252671 Figure 348 1. RH side plate 2. LH side plate 4. Apply a thin coat of antiseize lubricant to the reel bearing bore of each side plate. 5. Make sure that flat wire spring (item 14) is installed into LH side plate. CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when installing the cutting reel. 6.
Reel Assembly Installation (continued) 13. Install the bedbar assembly; refer to Installing the Bedbar Assembly (page 9–21). 14. Adjust the cutting unit; refer to the Cutting Unit Operator’s Manual. Note: The parallel position of the rear roller to the cutting reel is controlled by the precision machined frame and side plates of the cutting unit.
Reel Assembly Installation (continued) IMPORTANT The spline insert on the left end of the cutting reel has left hand threads and the spline insert on the right end of the cutting reel has right hand threads. C. Rest the handle of the pry bar against the front roller and tighten the spline insert closest to the pry bar. The spline inserts are installed with thread locking compound (Loctite #243 or equivalent). Tighten the spline insert from 115 to 128 N·m (85 to 95 ft-lb).
Inspecting the Reel Assembly 1. Inspect reel bearings to insure that they spin freely and have minimal axial play. 2. inspect the reel shaft as follows. If reel damage is detected, replace reel. A. Check the reel shaft for bending and distortion by placing the shaft ends in V-blocks. B. Check the reel blades for bending or cracking. C. Check the service limit of the reel diameter; refer to (page ). 3. Check the threaded inserts in the reel shaft for excessive wear or distortion.
Assembling the Cutting Reel (Cutting Unit with Aluminum Side Plates) (continued) IMPORTANT The flocked seal should be installed so that the flocked (red) side of the seal is toward the bearing location. 5. Slide the flocked seals (flocked (red) side orientated toward bearing location) and bearings 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 for Grinding (continued) Three types of cutting reel designs are used in cutting units for Reelmaster machines: scalloped radial reel, tapered radial reel, and tapered forward swept reel. The different types of individual reel blades are shown in Figure 352. The radial reel designs have blades that are placed in line with the center of the reel shaft. The rear of the blades either have a scalloped relief or a tapered relief.
Front Roller Removing the Front Roller g214676 Figure 354 1. Cap screw 5. Carriage screw 2. Flat washer 6. Cap screw 3. Flange nut 7. Flange nut 4. HOC (roller) bracket 8. Front roller assembly 1. Park the machine on a clean and 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 cutting unit from the machine and place on a level working surface.
Installing the Front Roller (continued) B. Apply anti-seize lubricant to the threads of the bolt that will extend into the height-of-cut (roller) bracket. C. Thread the bolt into the bracket. Note: When assembling the height-of-cut (roller) brackets to the side plate, ensure that the bolt head and 1 washer are above the adjustment flange on the side plate and second washer and flange nut are below the flange. 3.
Rear Roller Removing the Rear Roller g214395 Figure 355 1. Rear roller assembly 4. Flange nut (2 each) 2. Rear roller bracket 5. Roller shim (2 each) 3. Carriage screw (2 each) 6. 0.010 inch shim (if necessary) 1. Park the machine on a clean and 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 cutting unit from the machine and place on a level working surface.
Installing the Rear Roller (continued) screws and flange nuts to retain bracket in position. Do not fully tighten flange nuts. 3. Slide rear roller shaft into the rear roller bracket attached to the cutting unit. Slide second rear roller bracket onto the 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.
Servicing the Roller g195108 Figure 356 1. 2. Roller tube Roller shaft 5. 6. Outer seal Bearing lock nut 3. Inner seal 7. Grease fitting 4. Bearing Disassembling the Roller 1. Remove the bearing locknut from each end of the roller shaft. 2. Loosely secure the roller assembly in a bench vise and lightly tap one end of the roller shaft until the outer seals and bearing are removed from opposite end of the roller tube.
Assembling the Roller g195710 Figure 357 1. 2. Roller tube Inner seal 3. Inner seal tool 1. Install the inner seals into the roller tube and ensure that the seal lip (and garter spring) faces end of the tube. Use the inner seal tool and soft-faced hammer to fully seat seals against the roller shoulder; refer to (page ). Apply a small quantity of grease around the lip of both inner seals after installation.
Assembling the Roller (continued) g195712 Figure 359 1. 2. Roller tube Inner seal 3. Bearing 4. 5. Outer seal Bearing/outer seal tool C. Install the first outer seal into the roller tube and ensure that the seal lip (and garter spring) faces end of the tube. Use a bearing/outer seal tool and a soft-faced hammer to lightly seat seal against the roller shoulder; refer to (page ). Ensure that the bearing still freely rotates after the seal installation. D.
Assembling the Roller (continued) g252750 Figure 361 1. Roller tube 4. Bearing 2. 3. Roller shaft Inner seal 5. 6. Outer seal Bearing/outer seal tool D. Carefully install the first outer seal into the roller tube and ensure that the seal lip (and garter spring) faces end of the tube. Use a bearing/outer seal tool and a soft-faced hammer to lightly seat seal; refer to (page ). Ensure that the shaft and bearings still freely rotate after the seal installation. E.
Rear Roller Brush – Optional (cutting units with painted side plates) g252751 Figure 362 1. Roller brush shaft 13. Cap screw (2 each) 25. Idler arm 2. Roller brush 14. Flange bushing 26. Cap screw (4 each) 3. Lock nut (2 each) 15. Idler pulley 27. Flat washer (4 each) 4. J-bolt (2 each) 16. Lock nut 28. Drive bearing housing 5. Square key 17. Flat washer (2 each) 29. Mounting bracket (2 each) 6. Excluder seal (2 each) 18. Drive belt 30.
Note: The drive components for the rear roller brush are located on the opposite side of the cutting unit from the cutting reel hydraulic motor. Figure 362 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 regarding assembly and adjustment. Use those Instructions along with this Service Manual when servicing the rear roller brush. Disassembling the Rear Roller Brush 1.
Assembling the Rear Roller Brush (continued) g214677 Figure 364 1. Bearing 4. Housing (non-driven) 2. Inner grease seal 5. Housing (driven) 3. Outer grease seal 2. If seals or bearings were removed from brush bearing housings, install new components noting proper orientation. A. Pack bearings 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.
Assembling the Rear Roller Brush (continued) g214815 Figure 365 1. Bearing housing 6. Snap ring 2. Drive shaft 7. O-ring 3. Ball bearing 8. Side plate 4. Grease seal 9. Socket-head screw (2 each) 5. Retaining ring 10. Grommet 3. If drive bearing housing was disassembled, install new components noting proper orientation. A. Install bearing on shaft by pressing equally on the inner and outer bearing races.
Assembling the Rear Roller Brush (continued) C. Fill cavity between bearing location and grease seal 50% to 75% full with high temperature Mobil XHP-222 grease (or equivalent). D. Carefully slide shaft and bearing fully into pivot hub bore taking care to not damage the grease seal. Secure bearing in pivot hub with retaining ring. 4. Assemble roller brush components using Figure 373 as guides along with the following: A.
Assembling the Rear Roller Brush (continued) g214678 Figure 368 1. Rear roller brush 2. Rear roller IMPORTANT The roller brush shaft must nor contact the cutting unit side plate. Also, heavy brush contact on the rear roller will cause premature brush wear. 5. Check that brush 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.
Rear Roller Brush – Optional (cutting units with aluminum side plates) g252763 Figure 369 1. Brush bearing housing (non-driven) 8. Flat washer (4 each) 15. Lock nut 2. Brush bearing housing (drive) 3. O-ring Cap screw (4 each) 16. J-bolt (2 each) 10. 4. 5. 9. Spacer 17. Grease fitting (2 each) Roller brush shaft 11. Flat washer (for pulley alignment) 18. Grease seal (3 each) Flange nut (4 each) 12. Driven pulley 19. Ball bearing (2 each) 6. Mounting bracket (2 each) 13.
Disassembling the Rear Roller Brush (continued) C. Remove lock nut and J-bolt from both ends of the brush. D. While rotating brush, slide brush from the shaft. 3. Disassemble roller brush components as necessary. If brush bearing housing (item 2) or driven pulley (item 12) need to be removed, brush cover and drive belt removal will be necessary; refer to Disassembling the Drive System (page 9–65). Assembling the Rear Roller Brush g214814 Figure 370 1. 2. 3. 4.
Assembling the Rear Roller Brush (continued) C. Install grease seals so that seal lips are positioned toward the brush. Press seals into housing so that seal contacts bore shoulder. 3. Assemble roller brush components noting the following items: A. Apply coating of grease to lips of grease seals in brush bearing housing before inserting brush shaft into housing. B. Position excluder seals on brush shaft so that seals just touch bearing housings. C.
Disassembling the Drive System g252833 Figure 373 1. Carriage screw (2 each) 9. Idler spring 17. Drive pulley 2. Carriage screw (3 each) 10. Pivot washer 18. Spacer 3. Brush plate 11. Drive belt 19. Flange bushing 4. Cap screw (2 each) 12. Idler pulley 20. Cover 5. Flat washer (4 each) 13. Retaining ring 21. Flange nut (2 each) 6. Lock nut (6 each) 14. Bearing 22. Set screw (top of cover only) 7. 8. Idler arm Idler spacer 15. 16.
Disassembling the Drive System (continued) g230301 Figure 374 1. Drive housing 4. Socket-head screw 2. 3. Drive shaft O-ring 5. Grommet A. Remove socket head screws that secure drive housing to cutting unit side plate and remove housing from cutting unit. g228652 Figure 375 1. Drive shaft with right-hand threads (no groove) 2.
Assembling the Drive System (continued) C. Position housing to cutting unit side plate and secure to cutting unit with two (2) socket head screws. D. Make sure that grommet groove is correctly seated on flange in drive housing bore. 2. Assemble roller brush components using Figure 373 as guides along with the following: A. During assembly, apply Loctite #243 (or equivalent) where indicated and torque fasteners as shown. B.
Assembling the Drive System (continued) g214811 Figure 377 1. Flange nut 3. Flat washer 2. Driven pulley 4. Roller brush shaft B. If necessary to align pulleys, remove driven pulley from brush shaft and add or remove flat washer(s) until drive and driven pulleys are correctly aligned. C. If driven pulley was removed from roller brush shaft, apply antiseize lubricant to splines of pulley bore and slide pulley onto shaft.
Chapter 10 Belt Driven Groomer (Optional) Table of Contents General Information ............................................................................................................................ 10–2 Grooming Performance.................................................................................................................... 10–2 Groomer Reel Mechanical Problems ............................................................................................... 10–3 Adjustments .............
General Information Grooming Performance There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT Improper or overaggressive use of the groomer (e.g., too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Groomer Reel Mechanical Problems Problem No rotation of the groomer reel. Possible Causes Correction The groomer drive belt needs to be adjusted. Adjust the groomer drive belt. Failed groomer idler bearing(s) in the groomer side plate(s). Replace the bearing(s) that are damaged. Broken or damaged idler spring. Replace the spring. The groomer drive belt is worn, broken, or damaged. If the drive belt slips, it probably is out of adjustment or worn. Repair or replace the drive belt if necessary.
Adjustments 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 before working on the groomer. Note: The Installation Instructions for the groomer has detailed information regarding assembly and adjustment. Use those Instructions along with this Service Manual when servicing the groomer. Adjusting the Height/Depth of the Groomer Note: Grooming is performed above the soil level.
Adjusting the Height/Depth of the Groomer (continued) 5. Repeat step 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.
Service and Repairs 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 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. Refer to this publication for additional information when servicing the groomer.
Replacing the Groomer Drive Belt The groomer drive belt should be inspected/replaced annually or after 750 hours of operation. 1. Park the machine on a 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.
Replacing the Groomer Drive Belt (continued) 3. Remove the groomer belt tension by pivoting idler plate and pulley using a wrench on the pulley nut. Slip the groomer drive belt off the pulleys (Figure 380). Carefully 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 380). Ensure that the groomer drive belt is above the idler pulley after belt installation. 5.
Groomer Plate Assembly g215965 Figure 381 7 inch cutting reel with cast iron side plates 1. 9. Flange nut (2 each) 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 necessary) 4. O-ring (2 each) 12. Flange-head screw 20. Pulley spacer 5. Cutting reel 13. Locknut 21. Excluder seal (2 each) 6. Groomer shim 14. Idler pulley assembly 22. Groomer reel 7.
Disassembling the Groomer Plate Assembly 1. Park the machine on a clean 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. Note: If the cutting unit is equipped with the powered rear roller brush, removal of the roller brush components will be necessary to service the groomer plate assemblies; refer to the Rear Roller Brush – Optional (cutting units with painted side plates) (page 9–56). 2.
Disassembling the Groomer Plate Assembly (continued) Note: Cutting units with cast iron side plates (Figure 381) use a groomer driveshaft that is secured to the pivot hub assembly and is driven by the splined insert in cutting reel. Cutting units with aluminum side plates use a groomer driveshaft that threads into the cutting reel shaft so that the driveshaft will remain attached to the reel shaft when the pivot hub is removed. H. Remove the pivot hub and idler plate assembly from the cutting unit. I.
Disassembling the Groomer Plate Assembly (continued) g215589 Figure 384 Non-drive side groomer plate 1. Bushing 3. Seal (2 each) 2. Groomer plate 4. Bearing 5. Grease fitting 4. Inspect the seals, bearings, and bushing in the groomer plate(s) that were removed (Figure 383 and Figure 384). Remove and discard the components that are worn or damaged. Note: Groomer plates used on cutting units with cast iron side plates are shown in Figure 383 and Figure 384.
Assembling the Groomer Plate Assembly (continued) A. Pack the bearings with grease before installation. B. Press the bearings into the groomer plate so that the bearings contact the shoulder in the groomer plate bore. C. Install the grease seals so that the seal lips are positioned toward the groomer blade location. Seals should be flush with the surface of the groomer plate. D. Press the bushings into the groomer plate until the bushing contacts the shoulder in the groomer plate bore. 2.
Assembling the Groomer Plate Assembly (continued) D. Connect the extension spring (item 9 in Figure 381) to the stud on the groomer plate. Ensure that the spring is in the stud groove and that the spring hook is positioned toward the drive pulley. E. Secure the quick-up ball joint rod to the drive side of the groomer plate with the shoulder bolt (Figure 382). Apply anti-seize lubricant to the shoulder of the shoulder bolt before installation; torque the shoulder bolt to 23 to 28 N∙m (17 to 21 ft-lb). F.
Assembling the Groomer Plate Assembly (continued) 6. Check that the groomer reel height and mower height-of-cut settings. Adjust as necessary. 7. Lubricate the groomer bearings. Note: After greasing the groomer bearings, operate the groomer for 30 seconds, stop the machine, and remove the unwanted grease from the groomer shaft and seals. Groomer Reel g215965 Figure 388 7 inch cutting reel with cast iron side plates Extension spring 17. Flange nut 10. Retaining ring 18.
Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer blades can be reversed on the shaft to provide additional blade life. Note: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic motor. Figure 388 shows the components used when the groomer reel drive is on the left side of the cutting unit. Removing the Groomer Reel 1.
Installing the Groomer Reel (continued) g215593 Figure 389 1. 2. Groomer plate Excluder seal 6. Check that the excluder seals just touch the groomer plate assembly (Figure 389). Position the excluder seals on the groomer shaft if necessary. 7. Check the groomer reel height and mower height-of-cut settings. Adjust as necessary. 8. Lubricate the groomer bearings.
Servicing the Groomer Reel g236520 Figure 390 1. Broomer brush (5 each) 5. Spacer (43 each) 9. 2. Broomer strap (4 each) 6. Locknut (2 each) 10. 3. Groomer shaft 7. Excluder seal (2 each) 4. Groomer blade (42 each) 8. O-ring groove Dull (rounded) edge Sharp edge Inspect the groomer reel blades frequently for damage and wear. Straighten the bent blades with a pliers. Either replace the worn blades or reverse the blades to put the sharpest blade edge forward (Figure 390).
Assembling the Groomer Reel (continued) 3. When all the blades have been installed, place the final spacer on the shaft and then thread the second locknut onto the shaft. Center the blades on the shaft with the locknuts. 4. Use a wrench on the shaft flats to prevent the shaft from turning, torque the second locknut to 23 to 28 N∙m (16 to 21 ft-lb). After you torque the locknut, the spacers should not be free to rotate and the groomer blades should be centered on the shaft. 5.
Assembling the Groomer Reel (continued) 10. Lubricate the groomer bearings. Note: After greasing the groomer bearings, operate the groomer for 30 seconds, stop the machine, and remove the unwanted grease from the groomer shaft and seals. Groomer Pivot Hub g215597 Figure 392 Pivot hub for cutting reel with cast iron side plates 1. Retaining ring 5. Pivot hub 9. 2. Retaining ring 6. Grease seal 3. Ball bearing 7. Extension spring 4. O-ring 8. Retaining ring 10.
g228651 Figure 393 Pivot hub for cutting reel with aluminum side plates 7. 1. Groomer driveshaft 4. O-ring 2. Pivot hub 5. Extension spring 3. Socket-head screw 6. Retaining ring Idler plate g228652 Figure 394 1. Driveshaft with right-hand threads (no groove) 2. Driveshaft with left-hand threads (with groove) Note: Cutting units with aluminum side plates use a groomer driveshaft that threads into the cutting reel shaft (Figure 393).
Disassembling the Groomer Pivot Hub (continued) B. Remove the retaining ring that retains the bearing on the driveshaft. Press the ball bearing from the shaft. Discard the bearing. C. Remove the grease seal from the pivot hub. Discard the seal. 5. Clean all the pivot hub components and inspect for wear or damage. Assembling the Groomer Pivot Hub g215598 Figure 395 Oil seal 4. Pivot hub 2. Driveshaft 5. Retaining ring 3. Bearing 6. Retaining ring 1. 7. Cavity 1.
Height Adjuster Assembly g215599 Figure 396 1. Washer-head screw 6. Upper ramp 11. Jam nut (2 each) 2. Detent spring 7. External snap ring 12. Ball joint rod 3. Groomer adjuster 8. Lower ramp 13. Shoulder bolt 4. Flat washer 9. Flange-head screw 14. Groomer plate (left drive) 5. Bushing 10. Compression spring Note: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic motor.
Assembling the Height Adjuster Assembly 1. Assemble the height adjuster (Figure 396) noting the following items: A. If the bushing (item 5 in Figure 396) was removed from the upper ramp, press a new bushing into the housing fully to the shoulder in the bore. B. If the 2 jam nuts (item 11 in Figure 396) were removed from the ball joint rod, apply anti-seize lubricant to the threads of the rod where the jam nuts will be positioned.
Servicing the Grooming Brush (Optional) (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).
Belt Driven Groomer (Optional): Service and Repairs Page 10–26 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Chapter 11 Universal Groomer (Optional) Table of Contents General Information ............................................................................................................................ 11–2 Factors Affecting Grooming ............................................................................................................. 11–2 Troubleshooting...................................................................................................................................
General Information Factors Affecting Grooming There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT Improper or overaggressive use of the groomer (e.g., too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Troubleshooting Groomer Reel Mechanical Problems Problem The groomer reel does not rotate. The turf is damaged or has uneven grooming. Reelmaster® 5410/5510/5610 Series 15216SL Rev E Possible Causes Correction The groomer drive is in neutral. Engage the groomer drive to forward or reverse. The groomer drive gears are damaged or seized. Repair the groomer drive. The groomer is set too aggressively. Refer to groomer Installation Instructions for groomer set-up information.
Service and Repairs g220498 Figure 398 1. Idler assembly 3. Button-head screw (2 each) 5. Groomer reel 2. Weight bracket 4. Gear box assembly 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 before working on the groomer.
Note: The Groomer Operator’s Manual provides information regarding the installation, set-up, operation, and maintenance of the universal groomer on your machine. Refer to these instructions for additional information when servicing the groomer.
Gear Box Assembly g220501 Figure 399 1. Input shaft 3. Button-head screw 5. Clevis pin 2. Rear roller brush drive shield 4. Groomer drive box assembly 6. Cotter pin Note: The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Removing the Gear Box Assembly 1.
Removing the Gear Box Assembly (continued) IMPORTANT The groomer gear box installed on the left side of the cutting unit use a left-hand thread. Turn the input shaft (rear roller brush driveshaft) clockwise to remove the gear box. The groomer gear box installed on the right side of the cutting unit use a right-hand thread. Turn the input shaft counterclockwise to remove the gear box. g326053 Figure 400 1. Square head set screw 4. Reel shaft 2. Input shaft assembly 5. Reel support plate 3.
Removing the Gear Box Assembly (continued) IMPORTANT You must use a 6-point socket with a heavy wall to remove the gear box from the reel. Do not use an impact wrench. Groomer gear boxes installed on the left side of the cutting unit use a left hand thread; turn the drive shaft in correct direction to remove the gear box. 10. Rest the handle of the pry bar against the front roller and turn the drive shaft in correct direction to loosen it from the reel.
Removing the Gear Box Assembly (continued) IMPORTANT To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. I. Move the pry bar against the weld side of the reel support plate closest to the drive shaft assembly. g326055 Figure 402 1. Damaged input shaft assembly 4. Reel support plate 2. Drive shaft removal tool 5. Pry bar 3. Reel shaft J.
Disassembling the Groomer Drive Assembly (continued) 6. Continue to disassemble the gear box as necessary. CAUTION Use the 1−3/8 inch flats on the input shaft to prevent the input shaft from rotating during adapter removal. Do not use the 1/2 inch hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur. 7.
Assembling the Groomer Drive Assembly g220511 Figure 403 1. Dowel pin 17. V-ring 33. Bushing 2. Retaining ring 18. O-ring (2 each) 34. Bearing 3. Thrust washer 19. Input shaft 35. Gasket 4. O-ring 20. Threaded adapter 36. Cover 5. Drain/fill plug (4 each) 21. Housing 37. Socket-head screw (4 each) 6. O-ring 22. Shield 38. Oil seal 7. Shifter shaft 23. Output shaft 39. Detent ball 8. Thrust washer 24. Oil seal 40. Detent spring 9. Bearing (3 each) 25.
Assembling the Groomer Drive Assembly (continued) 1. If the sun gear (item 10 in Figure 403), ring gear, or the gear box housing bearings are replaced, press the bearings all the way to shoulder in part. 2. If the flange bushings are replaced, ensure that the flange bushing is fully seated against the part. 3. Ensure that all the retaining rings and O-rings are fully seated in the ring groove. 4. Lubricate the seal lips and O-rings before installing the shafts. 5.
Installing the Gear Box Assembly (continued) IMPORTANT The groomer gear box installed on the left side of the cutting unit use a left-hand thread. Turn the input shaft (rear roller brush driveshaft) counterclockwise to install the gear box. The groomer gear box installed on the right side of the cutting unit use a right-hand thread. Turn the input shaft clockwise to install the gear box. g326056 Figure 404 1. Square head set screw 4. Reel shaft 2. Input shaft assembly 5. Reel support plate 3.
Installing the Gear Box Assembly (continued) Note: If the cutting unit is equipped with an optional powered rear roller brush, install the rear roller brush drive housing assembly, drive belt, and cover; refer to Rear Roller Brush – Optional (cutting units with painted side plates) (page 9–56) for additional information. 10. Install the groomer reel assembly; refer to Installing the Groomer Reel (page 11–18).
Idler Assembly g220503 Figure 405 1. Socket-head screw (2 each) 6. Threaded insert (right) 11. Clevis pin 2. Pivot hub 7. Shield 12. Cotter pin 3. O-ring 8. Stub shaft 13. Bearing 4. Idler arm 9. Flocked bearing shield (2 each) 14. Retaining ring 5. Threaded insert (left) Collar 15. Flange nut 10. Note: The groomer idler assembly is located on the same side of the cutting unit as the cutting unit hydraulic motor. Removing the Idler Assembly 1.
Installing the Idler Assembly 1. If the shields, bearing, or bushing was removed from the idler arm, install new components as follows: A. Press the bushing into a groomer plate until the bushing is centered in the idler arm bore. B. Press the bearing into the idler arm so that the bearing contacts the shoulder in idler arm bore and install the bearing retaining ring. C. Install the bearing shields with flocked side of shield toward the bearing. D.
Groomer Reel g220505 Figure 407 1. Jam nut (4 each) 2. Bolt (4 each) 3. Shaft clamp (4 each) 4. Groomer reel Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removing the Groomer Reel 1. Park the machine on a clean 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.
Installing the Groomer Reel 1. Position the cutting unit on a level surface. If the cutting unit is attached to the traction unit, shut off the engine, set the parking brake, and remove the key from the key switch. 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 (45 to 60 in-lb). 4. Check the groomer reel height and mower height-of-cut settings.
Servicing the Groomer Reel g220506 Figure 408 1. Groomer reel shaft 4. 6.3 mm (1/4 inch) spacer (2 each) 7. Sharp edge 2. Groomer blade (40 each) 5. Locknut (2 each) 8. Midpoint 3. 31.7 mm (1–1/4 inch) spacer (39 each) 6. Centered on shaft 9. Dull (rounded) edge Inspect the groomer reel blades frequently for any damage and wear. Straighten the bent blades. Either replace the worn blades or reverse the individual blades to put the sharpest blade edge forward (Figure 408).
Assembling the Groomer Reel (continued) 2. Alternately install 31.7 mm (1−1/4 inch) spacers and blades, ensure that all the blades are separated by a spacer. 3. When all the blades have been installed, place the remaining 6.3 mm (1/4 inch) spacer on the shaft. Install the second locknut onto the shaft. Center the blades on shaft by adjusting locknuts. 4. Use the through holes in shaft to prevent the shaft from rotating, tighten the second locknut to 42 to 48 N∙m (31 to 35 ft-lb).
Height Adjuster Assembly g220500 Figure 410 1. Button-head screw 2. Detent spring 3. Height adjuster knob 4. Quick up cover 11. Cotter pin 18. Flat washer 5. Quick up lever 12. Clevis pin 19. Groomer bumper (left) 6. Height adjustment bolt 13. Washer (2 each) 20. Locknut 7. Flange-head bolt 14. Height adjustment rod 21. Pinch bolt (front roller) 8. Washer (2 each) 15. Compression spring 9. Locknut 16. Compression spring Flange nut 17. Height-of-cut bracket 10.
Disassembling the Height Adjuster Assembly (continued) 6. Disassemble the height adjuster assembly (Figure 410). 7. Clean all the components and inspect for wear or damage. Replace all the components that are worn or damaged. Assembling the Height Adjuster Assembly 1. Apply anti-seize lubricant to the upper threads of the adjustment rod and lower threads of the height adjusters. Assemble the height adjuster assembly (Figure 410). 2.
Servicing the Grooming Brush (Optional) g229842 Figure 412 1. Brush element 3. Brush shaft 5. Locknut (2 each) 2. Roll pin (2 each) 4. J-bolt (2 each) 6. Spiral brush The optional grooming brush attaches to the groomer in place of the groomer reel. The grooming brush is removed and installed from the groomer in the same manner as the groomer reel; refer to Groomer Reel (page 11–17). The grooming brush element or shaft can be serviced separately (Figure 412).
Universal Groomer (Optional): Service and Repairs Page 11–24 Reelmaster® 5410/5510/5610 Series 15216SL Rev E
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Hydraulic Schematic-5410/5410-D ....................................................................................................A–3 Hydraulic Schematic-5510/5510-D/5610 ...........................................................................................A–4 Hydraulic Schematic-5610-D ..............................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Hydraulic Schematic-5410/5410-D g229522 Reelmaster (Models 5410/5410-D), Drawing 136-7951 Rev A, Sheet 1 of 1 15216SL Rev E Page A–3
Hydraulic Schematic-5510/5510-D/5610 g229528 Page A–4 15216SL Rev E Reelmaster (Models 5510/5510-D/5610), Drawing 127-2797 Rev A, Sheet 1 of 1
Hydraulic Schematic-5610-D g219149 Reelmaster 5610-D (Model 03679), Drawing 133-2949 Rev B, Sheet 1 of 1 15216SL Rev E Page A–5
Electrical Schematic-5410/5510/5610 (Models with Kubota Diesel Engine) (Serial Numbers Below 403430000) g229518 Page A–6 15216SL Rev E Reelmaster 5410/5510/5610 (Models with Kubota Diesel Engine) (Serial Numbers Below 403430000), Drawing 122-0380 Rev A, Sheet 1 of 1
Electrical Schematic-5410/5510/5610 (Models with Kubota Diesel Engine) (Serial Numbers Above 403430000) g325688 Reelmaster 5410/5510/5610 (Models with Kubota Diesel Engine) (Serial Numbers Above 403430000), Drawing 122-1539 Rev A, Sheet 1 of 1 15216SL Rev E Page A–7
Electrical Schematic-5410-D/5510-D/5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Below 403430000) g229521 Page A–8 15216SL Rev E Reelmaster 5410-D/5510-D/5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Below 403430000), Drawing 120-6345 Rev C, Sheet 1 of 1
Electrical Schematic-5410-D/5510-D/5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Above 403430000) g325685 Reelmaster 5410-D/5510-D/5610-D (Models with Yanmar Diesel Engine) (Serial Numbers Above 403430000), Drawing 122-1454 Rev A, Sheet 1 of 1 15216SL Rev E Page A–9
g326106 Page A–10 15216SL Rev E , Drawing Rev , Sheet
Electrical Schematic-5410-G/5510-G (Models with Kubota Gasoline Engine) g229525 Reelmaster 5410-G/5510-G (Models with Kubota Gasoline Engine), Drawing 120-6342 Rev B, Sheet 1 of 1 15216SL Rev E Page A–11
Wire Harness Drawing-Main (Serial Number Below 403430000) g219150 Page A–12 15216SL Rev E Reelmaster (All Models) (Serial Number Below 403430000), Drawing 120-6356 Rev D, Sheet 1 of 2
Wire Harness Drawing-Main (Serial Number Below 403430000) g219151 Reelmaster (All Models) (Serial Number Below 403430000), Drawing 120-6356 Rev D, Sheet 2 of 2 15216SL Rev E Page A–13
Wire Harness Drawing-Main (Serial Numbers 403430001 to 405680000) CV g325686 Page A–14 15216SL Rev E Reelmaster (All Models) (Serial Numbers 403430001 to 405680000), Drawing 122-1455 Rev A, Sheet 1 of 2
Wire Harness Drawing-Main (Serial Numbers 403430001 to 405680000) CV g325687 Reelmaster (All Models) (Serial Numbers 403430001 to 405680000), Drawing 122-1455 Rev A, Sheet 2 of 2 15216SL Rev E Page A–15
Wire Harness Drawing-Main (Serial Numbers Above 405680001) CV g325689 Page A–16 15216SL Rev E Reelmaster (All Models) (Serial Numbers Above 405680001), Drawing 122-1726 Rev A, Sheet 1 of 2
Wire Harness Drawing-Main (Serial Numbers Above 405680001) CV g325690 Reelmaster (All Models) (Serial Numbers Above 405680001), Drawing 122-1726 Rev A, Sheet 2 of 2 15216SL Rev E Page A–17
Wire Harness Drawing-Seat g219152 Page A–18 15216SL Rev E Reelmaster (All Models), Drawing 115-8081 Rev C, Sheet 1 of 2
Wire Harness Drawing-Seat g219153 Reelmaster (All Models), Drawing 115-80812 Rev C, Sheet 2 of 2 15216SL Rev E Page A–19
Engine Wire Harness Drawing-5410/5510/5610 (Models with Kubota Diesel Engine) g229520 Page A–20 15216SL Rev E Reelmaster 5410/5510/5610 (Models with Kubota Diesel Engine), Drawing 120-6346 Rev C, Sheet 1 of 2
Engine Wire Harness Diagram-5410/5510/5610 (Models with Kubota Diesel Engine) g229519 Reelmaster 5410/5510/5610 (Models with Kubota Diesel Engine), Drawing 120-6346 Rev C, Sheet 2 of 2 15216SL Rev E Page A–21
Engine Wire Harness Drawing-5410-D/5510-D (Models 03672 and 03687 with Yanmar Diesel Engine) g229524 Page A–22 15216SL Rev E 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 Diagram-5410-D/5510-D (Models 03672 and 03687 with Yanmar Diesel Engine) g229523 Reelmaster 5410-D/5510-D (Models 03672 and 03687 with Yanmar Diesel Engine), Drawing 122-0231 Rev C, Sheet 2 of 2 15216SL Rev E Page A–23
Engine Wire Harness Drawing-5410-D/5510-D/5610-D (Models 03606, 03607, and 03679) g219147 Page A–24 15216SL Rev E Reelmaster 5410-D/5510-D/5610-D (Models 03606, 03607, and 03679), Drawing 122-0893 Rev A, Sheet 1 of 2
Engine Wire Harness Diagram-5410-D/5510-D/5610-D (Models 03606, 03607, and 03679) g219148 Reelmaster 5410-D/5510-D/5610-D (Models 03606, 03607, and 03679), Drawing 122-0893 Rev A, Sheet 2 of 2 15216SL Rev E Page A–25
Engine Wire Harness Drawing-5410-G/5510-G (Models with Kubota Gasoline Engine) g229527 Page A–26 15216SL Rev E Reelmaster 5410-G/5510-G (Models with Kubota Gasoline Engine), Drawing 120-6357 Rev B, Sheet 1 of 2
Engine Wire Harness Diagram-5410-G/5510-G (Models with Kubota Gasoline Engine) g229526 Reelmaster 5410-G/5510-G (Models with Kubota Gasoline Engine), Drawing 120-6357 Rev B, Sheet 2 of 2 15216SL Rev E Page A–27
