Page 1: Service Manual
The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
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Page 3: Table Of Contents
SAUER- DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON PUMPS SERVICE INSTRUCTIONS EATON DELTA MOTORS PARTS AND REPAIR MANUAL PARKER TORQMOTOR SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES) SAUER- DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Reelmaster 5010- H...
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Page 5 ....... 8 - 7 Service and Repairs ......8 - 8 Reelmaster 5010- H...
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Page 7: Safety Instructions
..... SAFETY AND INSTRUCTION DECALS ..Reelmaster 5010- H Page 1 - 1 Safety...
Page 8: Safety Instructions
Additional copies of the Operator’s Manual are B. Do not remove machine fuel tank cap while en- available on the internet at www.Toro.com. gine is hot or running. 2. Keep all shields, safety devices and decals in place.
Page 9: While Operating
7. Do not park on slopes unless wheels are chocked or blocked. 3. Do not run engine in a confined area without ade- quate ventilation. Exhaust fumes are hazardous and could possibly be deadly. Reelmaster 5010- H Page 1 - 3 Safety...
Page 10: Jacking Instructions
To assure op- timum performance and continued safety certification of 11. Shut engine off before checking or adding oil to the the machine, use genuine Toro replacement parts and engine crankcase. accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance 12.Disconnect 12 VDC battery located at the rear of the...
Page 11: Jacking Instructions
2. Place jack securely at the center of the rear axle un- der the axle pivot bracket. Jack rear of machine off the ground. 3. To support the raised machine, position jack stands under the frame rail next to the axle support bracket. Reelmaster 5010- H Page 1 - 5 Safety...
Page 12: Safety And Instruction Decals
Reelmaster. If any decal becomes illegible or damaged, install a new decal. Part numbers for decals are listed in your Part Catalogs. Order replacement decals from your Autho- rized Toro Distributor. Safety Page 1 - 6 Reelmaster 5010- H...
Page 13: Product Records
Manual. Refer to that publication when performing regular equipment maintenance. Several maintenance procedures have break- in intervals identified in the Op- erator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures. Reelmaster 5010- H Page 2 - 1 Product Records and Maintenance...
Page 14: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - 2 Reelmaster 5010- H...
Page 15: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 16 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance Page 2 - 4 Reelmaster 5010- H...
Page 17 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Reelmaster 5010- H Page 2 - 5 Product Records and Maintenance...
Page 18 Conversion Factors in- lb X 11.2985 = N- cm N- cm X 0.08851 = in- lb ft- lb X 1.3558 = N- m N- m X 0.7376 = ft- lb Product Records and Maintenance Page 2 - 6 Reelmaster 5010- H...
Page 19 ........Engine Bellhousing Assembly ....KUBOTA WORKSHOP MANUAL, DIESEL ENGINE, 05- E4B SERIES Reelmaster 5010- H Page 3 - 1 Kubota Diesel Engine...
Page 20: Specifications
These three (3) machine components determine engine/generator speed during use and modify fuel settings at the fuel ac- tuator as necessary to maintain appropriate engine speed based on load. Kubota Diesel Engine Page 3 - 2 Reelmaster 5010- H...
Page 21: General Information
Service and repair parts for Kubota diesel engines are troubleshooting, testing and repair of the Kubota diesel supplied through your local Toro Distributor. If an engine engine used in Reelmaster 5010- H machines. parts list is not available, be sure to provide your distrib- utor with the Toro model and serial number.
Page 22: Service And Repairs
4. Air intake hose 10. Compression spring 16. Air cleaner bracket 5. Air intake hose 11. Air cleaner mounting band 17. Air cleaner stand 6. Service indicator 12. Flange nut (6 used) Kubota Diesel Engine Page 3 - 4 Reelmaster 5010- H...
Page 23: Air Cleaner Assembly
C. Torque hose clamps from 30 to 40 in- lb (3.4 to 4.5 N- m). 2. After air cleaner has been properly installed, lower and secure hood. Reelmaster 5010- H Page 3 - 5 Kubota Diesel Engine...
Page 24: Exhaust System
10. Flange nut 16. Washer head screw (2 used) 5. Flange nut (4 used) 11. Exhaust header 17. Muffler bracket 6. Carriage bolt (4 used) 12. Flange nut (4 used) Kubota Diesel Engine Page 3 - 6 Reelmaster 5010- H...
Page 25 E. Tighten flange head screw and flange nut that se- cures exhaust muffler to tailpipe bracket. F. Tighten flange head screws that secure tailpipe bracket to engine bellhousing. Reelmaster 5010- H Page 3 - 7 Kubota Diesel Engine...
Page 26: Fuel System
Use diesel fuel for the engine only; contaminated or if the machine is to be stored for an ex- not for any other purpose. tended period. Kubota Diesel Engine Page 3 - 8 Reelmaster 5010- H...
Page 27 2. Fuel supply fitting 6. Remove fuel tank using Figure 6 as a guide. IMPORTANT: If fuel sender is removed from fuel tank, note orientation of fittings for assembly pur- poses (Fig. 7). Reelmaster 5010- H Page 3 - 9 Kubota Diesel Engine...
Page 28: Radiator Assembly
29. Foam seal (2 used) 9. Radiator cap 20. Reservoir bracket 30. Mount plate (2 used) 10. Flange nut (14 used) 21. Reservoir bracket 31. Washer head screw (6 used) 11. Rear screen Kubota Diesel Engine Page 3 - 10 Reelmaster 5010- H...
Page 29 Torque hose clamps from 11. Carefully raise radiator assembly (radiator, fan 30 to 40 in- lb (3.4 to 4.5 N- m). shroud, coolant reservoir and radiator frame) from the machine. Reelmaster 5010- H Page 3 - 11 Kubota Diesel Engine...
Page 30 Service and Repairs section of Chapter 5 - Electri- fully). cal System). 10.Fill radiator and coolant reservoir with coolant. 14.Install and latch rear screen. 11. Lower and secure hood. Kubota Diesel Engine Page 3 - 12 Reelmaster 5010- H...
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Page 32: Engine
44. Flange head screw (6 used) 14. Flange nut (4 used) 30. Air cleaner mounting band 45. Carriage bolt (4 used) 15. Tailpipe bracket 16. Service indicator 31. Cap screw (2 used) 46. Shoulder bolt Kubota Diesel Engine Page 3 - 14 Reelmaster 5010- H...
Page 33 Position discon- Figure 13 nected hoses away from engine. 1. Engine mount (4 used) 4. Lock washer 2. Screw (2 per mount) 5. Ground cable 3. Nut (2 per mount) Reelmaster 5010- H Page 3 - 15 Kubota Diesel Engine...
Page 34 6. Connect suitable lift or hoist to the engine lift brack- the engine mounts. ets. CAUTION One person should operate hoist or lift while a second person guides the engine out of the ma- chine. Kubota Diesel Engine Page 3 - 16 Reelmaster 5010- H...
Page 35 B. Connect upper and lower radiator hoses to the engine. Secure hoses with hose clamps. Torque hose clamps from 30 to 40 in- lb (3.4 to 4.5 N- m). Reelmaster 5010- H Page 3 - 17 Kubota Diesel Engine...
Page 36: Engine Bellhousing Assembly
48 VDC Motor/Generator Assembly in the Service and Re- pairs section of Chapter 5 - Electrical System. Kubota Diesel Engine Page 3 - 18 Reelmaster 5010- H...
Page 37 PISTON PUMPS SERVICE INSTRUCTIONS EATON DELTA MOTORS PARTS AND REPAIR MANUAL PARKER TORQMOTOR SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES) SAUER- DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Reelmaster 5010- H Page 4 - 1 Hydraulic System...
Page 38: Specifications
Hydraulic Filter (Steering Circuit) Spin- on Cartridge Type with 25 PSI (1.7 bar) Relief in Adapter Hydraulic Oil See Traction Unit Operator’s Manual Hydraulic Reservoir Capacity 11 U.S. Gallons (41.6 L) Hydraulic System Page 4 - 2 Reelmaster 5010- H...
Page 39: General Information
1. RH frame rail 2. 48V battery disconnect Check Hydraulic Fluid The hydraulic system on Reelmaster 5010- H machines is designed to operate on high quality hydraulic fluid. The hydraulic system reservoir holds approximately 11 gallons (41.6 liters) of hydraulic fluid. Check level of hy- draulic fluid daily.
Page 40: Towing Traction Unit
If the hose has an elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
Page 41: Hydraulic Hose And Tube Installation
85 to 105 ft- lb (116 to 142 N- m) 1 7/16 - 12 110 to 136 ft- lb (150 to 184 N- m) 1 11/16 - 12 140 to 172 ft- lb (190 to 233 N- m) Figure 6 Reelmaster 5010- H Page 4 - 5 Hydraulic System...
Page 42: Hydraulic Fitting Installation
121 to 149 ft- lb (165 to 202 N- m) 1 5/8 - 12 247 to 303 ft- lb (335 to 410 N- m) 149 to 183 ft- lb (202 to 248 N- m) Figure 8 Hydraulic System Page 4 - 6 Reelmaster 5010- H...
Page 43 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Reelmaster 5010- H Page 4 - 7 Hydraulic System...
Page 44: Relieving Hydraulic System Pressure
Traction Circuit Component Failure The traction circuit on Reelmaster 5010- H series ma- all wheels off the ground. Then, operate the traction cir- chines is a closed loop system that includes the piston cuit to allow oil flow throughout the circuit.
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Page 46: Hydraulic Schematic
Hydraulic Schematic LIFT CONTROL MANIFOLD Hydraulic System Page 4 - 10 Reelmaster 5010- H...
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Page 48: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams LIFT CONTROL MANIFOLD Figure 11 Hydraulic System Page 4 - 12 Reelmaster 5010- H...
Page 49: Traction Circuit
The charge system re- plenishes oil that is bled from the traction circuit by the Figure 12 flushing valve. Reelmaster 5010- H Page 4 - 13 Hydraulic System...
Page 50 CONTROL MANIFOLD RIGHT FRONT LEFT FRONT FRONT CENTER LEFT RIGHT REAR REAR Reelmaster 5010- H Lift Circuit: Raise Cutting Units Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 13 Hydraulic System Page 4 - 14 Reelmaster 5010- H...
Page 51: Lift Circuit: Raise Cutting Units
(SV1, SV2, SV3 and SVRV) are de- energized. Hydraulic flow from gear pump sec- tion (P1) by- passes the lift cylinders to the oil cooler and then to the hydraulic reservoir. Reelmaster 5010- H Page 4 - 15 Hydraulic System...
Page 52: Lift Circuit: Lower Cutting Units
CONTROL MANIFOLD RIGHT FRONT LEFT FRONT FRONT CENTER LEFT RIGHT REAR REAR Reelmaster 5010- H Lift Circuit: Lower Cutting Units Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 14 Hydraulic System Page 4 - 16 Reelmaster 5010- H...
Page 53 (SV1, SV2, SV3 and SVRV) position. are de- energized. Hydraulic flow from gear pump sec- tion (P1) by- passes the lift cylinders to the oil cooler and then to the hydraulic reservoir. Reelmaster 5010- H Page 4 - 17 Hydraulic System...
Page 54 Figure 15 Hydraulic System Page 4 - 18 Reelmaster 5010- H...
Page 55: Steering Circuit
T port and to the oil filter and traction charge circuit. The steering control valve returns to the neutral position when turning is completed. Reelmaster 5010- H Page 4 - 19 Hydraulic System...
Page 56: Special Tools
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 57 40 GPM Hydraulic Tester (Pressure and Flow) Toro Part Number: AT40002 Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow.
Page 58 NOTE: This kit does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft- lb (34 N- m). O- Ring Kit...
Page 59: Measuring Container
Hydraulic Test Fitting Kit Toro Part Number: TOR4079 TORO TEST FITTING KIT (TOR4079) This kit includes a variety of O- ring face seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
Page 60 Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft. Toro Part Number: TOR6004 Figure 25 Hydraulic System Page 4 - 24 Reelmaster 5010- H...
Page 61: Troubleshooting
Wheel motor(s) and/or piston (traction) pump are worn or damaged (NOTE: If a traction circuit component has internal wear or dam- age, it is possible that other traction components are also dam- aged). Reelmaster 5010- H Page 4 - 25 Hydraulic System...
Page 62: Traction Circuit Problems
(NOTE: If a traction circuit component has internal wear or dam- when load is applied age, it is possible that other traction components are also dam- aged) Hydraulic System Page 4 - 26 Reelmaster 5010- H...
Page 63: Lift Circuit Problems
An electrical problem exists that prevents SVRV solenoid coil on the lift control manifold from being energized (see Troubleshooting in Chapter 5 - Electrical System). Gear pump section for lift/lower function (P1) is worn or damaged. Reelmaster 5010- H Page 4 - 27 Hydraulic System...
Page 64: Steering Circuit Problems
Internal gear pump drive coupler is damaged. Gear pump section (P2) is worn or damaged (NOTE: A worn or damaged gear pump section (P2) will also affect the traction (charge) circuit). Hydraulic System Page 4 - 28 Reelmaster 5010- H...
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Page 66: Testing
Always keep sure that oil level is correct. in mind the need for cleanliness when working on hy- draulic equipment. Contamination can cause excessive wear or binding of hydraulic components. Hydraulic System Page 4 - 30 Reelmaster 5010- H...
Page 67 Gear Pump (P2) Flow Tests. Relief Valve (R3) and (R4) Pressure, Traction Circuit Charge Pressure, Gear Pump (P2) Flow, Front Wheel Motor Efficiency and/or Piston (Traction) Pump Flow Tests. Reelmaster 5010- H Page 4 - 31 Hydraulic System...
Page 68: Traction Circuit Relief Valve (R3) And (R4) Pressure Test
Information section of this chapter. gaged. Make sure engine is off. Apply the parking brake. 2. Read Precautions For Hydraulic Testing at the be- ginning of this section. Hydraulic System Page 4 - 32 Reelmaster 5010- H...
Page 69 (See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter). Remove pres- sure gauge from machine and install dust cap to test port. Reelmaster 5010- H Page 4 - 33 Hydraulic System...
Page 70: Traction Circuit Charge Pressure Test
(traction) pump and oil filter (Fig. 30). Con- nect a 1000 PSI (70 bar) pressure gauge to test port. 3. Raise and support operator seat to allow access to hydraulic pump assembly. Hydraulic System Page 4 - 34 Reelmaster 5010- H...
Page 71 (See Relieving Hydraulic System Pressure in the General Information section of this chapter). Remove pressure gauge from test port and in- stall dust cap to test port. 12.Lower and secure operator seat. Reelmaster 5010- H Page 4 - 35 Hydraulic System...
Page 72: Gear Pump (P2) Flow Test
Make sure engine is off. Apply Relieving Hydraulic System Pressure in the Gen- the parking brake. eral Information section of this chapter. 2. Read Precautions For Hydraulic Testing in this sec- tion. Hydraulic System Page 4 - 36 Reelmaster 5010- H...
Page 73 If intake is not restricted, remove gear pump and repair or replace pump as necessary (see Hydraulic Pump Assembly and Gear Pump Service in the Service and Repairs section of this chapter). Reelmaster 5010- H Page 4 - 37 Hydraulic System...
Page 74: Front Wheel Motor Efficiency Test
1. Make sure that traction pedal is adjusted to the neu- tral position (see Traction Unit Operator’s Manual). 5. Chock front wheels to prevent wheel rotation. Hydraulic System Page 4 - 38 Reelmaster 5010- H...
Page 75 (5.7 LPM), one or both of the motors may be faulty. Indi- vidual front wheel motor testing is necessary. Figure 36 1. Piston (traction) pump 4. LH elbow fitting 2. RH elbow fitting 5. Hyd hose (reverse) 3. Hyd hose (forward) Reelmaster 5010- H Page 4 - 39 Hydraulic System...
Page 76: Piston (Traction) Pump Flow Test
4. Raise and support machine so all wheels are off the ground (see Jacking Instructions in Chapter 1 - Safety). 2. Read Precautions For Hydraulic Testing in this sec- tion. Hydraulic System Page 4 - 40 Reelmaster 5010- H...
Page 77 1000 PSI (69 bar) is obtained. Verify with the 1. Piston (traction) pump 4. LH elbow fitting InfoCenter Display that the engine speed is still 3000 2. RH elbow fitting 5. Hyd hose (reverse) RPM. 3. Hyd hose (forward) Reelmaster 5010- H Page 4 - 41 Hydraulic System...
Page 78: Lift Relief Valve (Svrv) Pressure Test
C5 L PISTON 100 MESH PUMP (P3) SUCTION CV23 INTERNAL STRAINER CASE DRAIN LIFT C2/3 L CONTROL C2/3 MANIFOLD RIGHT FRONT LEFT FRONT FRONT CENTER LEFT RIGHT REAR REAR Figure 39 Hydraulic System Page 4 - 42 Reelmaster 5010- H...
Page 79 While holding lever rear- ward, watch pressure gauge carefully. As the cutting units raise fully and the lift relief valve lifts, system pres- sure should be: Approximately 2000 PSI (138 bar) Reelmaster 5010- H Page 4 - 43 Hydraulic System...
Page 80: Gear Pump (P1) Flow Test
C5 L 100 MESH PISTON SUCTION PUMP (P3) CV23 STRAINER INTERNAL CASE DRAIN LIFT CONTROL C2/3 L C2/3 MANIFOLD RIGHT FRONT LEFT FRONT FRONT CENTER LEFT RIGHT REAR REAR Figure 41 Hydraulic System Page 4 - 44 Reelmaster 5010- H...
Page 81 9. Increase engine speed to high idle speed (3000 Figure 42 RPM). Use the InfoCenter Display to verify that engine speed is correct. 1. 1 gear pump section 2. Hydraulic hose Reelmaster 5010- H Page 4 - 45 Hydraulic System...
Page 82: Lift Cylinder Internal Leakage Test
1. Park machine on a level surface with the cutting units disengaged and in the turn- around position. Turn the engine off and apply the parking brake. Hydraulic System Page 4 - 46 Reelmaster 5010- H...
Page 83 10.Remove jack from under the lift arm. Start engine and operate lift cylinders through several up and down Figure 46 cycles. Stop the engine and check for any hydraulic 1. Tape (after 2 hours) 2. Cylinder rod movement leakage. Reelmaster 5010- H Page 4 - 47 Hydraulic System...
Page 84: Steering Relief Valve (R10) Pressure Test
TO LIFT CONTROL MANIFOLD PISTON 100 MESH SUCTION PUMP (P3) STRAINER INTERNAL CASE DRAIN TO TRACTION CHARGE CIRCUIT STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE PRESSURE GAUGE STEERING CYLINDER Figure 47 Hydraulic System Page 4 - 48 Reelmaster 5010- H...
Page 85 Holding the steering wheel against the stop for an Figure 48 extended period may damage the steering control valve. 1. Steering cylinder 2. Rod end fitting Reelmaster 5010- H Page 4 - 49 Hydraulic System...
Page 86: Steering Cylinder Internal Leakage Test
Steering Cylinder Internal Leakage Test STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE PLUG LOOK FOR LEAKAGE STEERING CYLINDER (FULLY EXTENDED) Figure 49 Hydraulic System Page 4 - 50 Reelmaster 5010- H...
Page 87 7. Install a steel plug in the open end of the discon- Figure 50 nected hose to prevent leakage or contamination. 1. Steering cylinder 2. Rod end fitting Reelmaster 5010- H Page 4 - 51 Hydraulic System...
Page 88: Service And Repairs
6. Note the position of hydraulic fittings (especially el- bow fittings) on hydraulic components before removing the fittings. Mark parts if necessary to make sure that fit- tings will be aligned properly when reinstalling hydraulic hoses and tubes. Hydraulic System Page 4 - 52 Reelmaster 5010- H...
Page 89: Check Hydraulic Lines And Hoses
If fluid is in- jected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. Reelmaster 5010- H Page 4 - 53 Hydraulic System...
Page 90: Flush Hydraulic System
6. Fill hydraulic reservoir with new hydraulic oil to prop- er level. 7. Disconnect wire harness connector from the fuel ac- tuator to prevent the engine from starting. Hydraulic System Page 4 - 54 Reelmaster 5010- H...
Page 91: Filtering Closed- Loop Traction Circuit
To effectively remove contamination from 8. With engine running at high idle speed and traction closed- loop traction circuit, use of the Toro high flow hy- pedal moved to the forward direction, periodically apply draulic filter and hydraulic hose kits are recommended brakes to increase pressure in traction circuit.
Page 92: Hydraulic System Start- Up
Check hydraulic or broken parts. components for leaks and tighten any loose connec- tions. 6. Disconnect electrical connector to the engine fuel actuator to prevent the engine from starting. Hydraulic System Page 4 - 56 Reelmaster 5010- H...
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Page 94: Hydraulic Reservoir
11. Flat washer 18. O- ring 5. Suction hose 12. Filter screen 19. Bulkhead nut 6. Hose clamp (2 used) 13. Hydraulic tube 20. O- ring 7. Reservoir cap 14. O- ring Hydraulic System Page 4 - 58 Reelmaster 5010- H...
Page 95 7. Fill hydraulic reservoir with new hydraulic fluid. 8. Operate machine. Check hydraulic lines and fittings for leaks. Tighten any loose connections. Check hydrau- lic oil level in reservoir and adjust if necessary. Reelmaster 5010- H Page 4 - 59 Hydraulic System...
Page 96: Piston (Traction) Pump Control Assembly
20. Flat washer 6. Cap screw (3 used) 14. Cap screw 21. Jam nut (2 used) 7. Carriage screw 15. Traction cable bracket 22. Lock washer (2 used) 8. Lock nut Hydraulic System Page 4 - 60 Reelmaster 5010- H...
Page 97 (see Traction Unit Operator’s Manual). 0.094” to 0.100” (2.4 to 2.5 mm) Figure 55 1. Piston pump 3. Traction neutral switch 2. Pump lever Reelmaster 5010- H Page 4 - 61 Hydraulic System...
Page 98: Hydraulic Pump Assembly
26. Hydraulic hose (2 used) NOTE: Piston (traction) pump and gear pump should be removed from machine as an assembly. Once re- moved from machine, pumps can be separated for nec- essary service. Hydraulic System Page 4 - 62 Reelmaster 5010- H...
Page 99 11. Remove two (2) flange screws (item 27) and flange nuts (item 28) that secure piston (traction) pump flange to machine frame. Reelmaster 5010- H Page 4 - 63 Hydraulic System...
Page 100 4. Lubricate and position new O- ring (item 15) be- tween pumps. Position gear pump to piston (traction) pump and secure with two (2) socket head screws, lock washers and flat washers. Hydraulic System Page 4 - 64 Reelmaster 5010- H...
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Page 102: Piston (Traction) Pump Service
Traction Circuit Component Failure Pumps Repair Manual and Service Instructions at the in the General Information section for information end of this chapter. regarding the importance of removing contamina- tion from the traction circuit. Hydraulic System Page 4 - 66 Reelmaster 5010- H...
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Page 104: Gear Pump Service
2. Use a marker to make a diagonal line across the tions. Be careful to not drop parts or disengage gear gear pump for assembly purposes (Fig. 61). mesh. Hydraulic System Page 4 - 68 Reelmaster 5010- H...
Page 105 If any binding is noted, disas- semble the pump and check for assembly problems. 5. Tighten the cap screws and nuts evenly in a crossing pattern to a torque of 33 ft- lb (45 N- m). Reelmaster 5010- H Page 4 - 69 Hydraulic System...
Page 106: Hydraulic Pump Drive Shaft
8. Brush seal (2 used) 13. Cap screw (4 used) 4. Flange head screw (4 used) 9. 48 VDC motor/generator assembly 14. Flange nut (4 used) 5. Flange nut (4 used) 10. Engine bellhousing Hydraulic System Page 4 - 70 Reelmaster 5010- H...
Page 107 1. Male yoke (generator) 3. Inside of flange Position female yoke fully onto pump shaft so the shaft 2. Female yoke (pump) end is flush with the inside of the yoke flange. Reelmaster 5010- H Page 4 - 71 Hydraulic System...
Page 108: Hydraulic Pump Drive Shaft Cross And Bearing Service
4. Cross and bearing assembly 7. Telescoping yoke (female) 2. Grease fitting (2 used) 5. Shaft yoke (male) 8. End yoke (piston pump) 3. Snap ring (4 per cross and bearing) 6. Grease fitting Hydraulic System Page 4 - 72 Reelmaster 5010- H...
Page 109 4. Thoroughly clean and inspect all components. binding. 3. Install hydraulic pump drive shaft to vehicle (see Hy- draulic Pump Drive Shaft in this section). Reelmaster 5010- H Page 4 - 73 Hydraulic System...
Page 110: Front Wheel Motors
8. Cap screw (2 used per shield) 17. Spring clip (LH shown) 26. Test fitting 9. Flat washer (2 used per shield) 18. Lock nut (4 used per motor) 27. O- ring Hydraulic System Page 4 - 74 Reelmaster 5010- H...
Page 111 11. Remove wheel motor from machine. 12.If hydraulic fittings are to be removed from wheel mo- tor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O- rings. Reelmaster 5010- H Page 4 - 75 Hydraulic System...
Page 112: Front Wheel Motor Service
NOTE: For front wheel motor repair procedures, see the Eaton Delta Motors Parts and Repair Manual at the end of this chapter. Hydraulic System Page 4 - 76 Reelmaster 5010- H...
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Page 114: Rear Wheel Motors (Machines With Optional Crosstrax Tm Kit)
2. Chock rear wheels to prevent machine from moving or shifting. 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. Hydraulic System Page 4 - 78 Reelmaster 5010- H...
Page 115 13.If hydraulic fittings are to be removed from wheel mo- system (see Charge Hydraulic System in this section). tor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O- rings. Reelmaster 5010- H Page 4 - 79 Hydraulic System...
Page 116: Rear Wheel Motor Service (Machines With Optional Crosstrax Tm Kit)
B port. NOTE: For Parker wheel motor repair procedures, see the Parker Torqmotor Service Procedure (TC, TB, TE, TJ, TF, TG, TH and TL Series) at the end of this chapter. Hydraulic System Page 4 - 80 Reelmaster 5010- H...
Page 117: Control Manifold Cartridge Valve Service
60 in- lb (6.8 N- m). 9. If problems still exist after assembly, remove valve Use eye protection such as goggles when using compressed air for cleaning manifold compo- and clean again or replace valve. nents. Reelmaster 5010- H Page 4 - 81 Hydraulic System...
Page 118: Lift Control Manifold
16. Hydraulic tube 4. Hydraulic hose 11. Hydraulic tube 17. Hydraulic hose 5. Hydraulic hose 12. O- ring 18. Plug 6. Hydraulic hose 13. O- ring 19. O- ring 7. Hydraulic hose Hydraulic System Page 4 - 82 Reelmaster 5010- H...
Page 119 4. Orifice (0.028) 2. O- ring 5. Fitting (6 used) A. Lubricate new O- rings with clean hydraulic oil. 3. Orifice (0.046) 6. Orifice (0.055) Install lubricated O- rings on fittings. Reelmaster 5010- H Page 4 - 83 Hydraulic System...
Page 120: Lift Control Manifold Service
SV2 is the location for solenoid valve SV2 (see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location). Hydraulic System Page 4 - 84 Reelmaster 5010- H...
Page 121 4. Orifice (0.028) the fitting cavity. Manifold damage is possible if the 2. O- ring 5. Fitting (6 used) 3. Orifice (0.046) 6. Orifice (0.055) orifice is cocked in the cavity. Reelmaster 5010- H Page 4 - 85 Hydraulic System...
Page 122 Allow lines to drain into a suitable container. Remove and discard O- rings. 4. Label all hydraulic connections for assembly pur- poses. Thoroughly clean hydraulic connections prior to loosening hydraulic lines. Hydraulic System Page 4 - 86 Reelmaster 5010- H...
Page 123 (see Hydraulic Fitting Installation in the Gener- al Information section of this chapter). 2. Position manifold and three (3) spacers to frame bracket. Install three (3) lock washers and cap screws but do not fully tighten. Reelmaster 5010- H Page 4 - 87 Hydraulic System...
Page 124 Control Manifold Cartridge Valve Service in this section. Refer to Figure 74 for cartridge valve and plug installation torque. NOTE: Adjustment of bi- directional relief valve (item 12) is NOT recommended. Hydraulic System Page 4 - 88 Reelmaster 5010- H...
Page 125 This page is intentionally blank. Reelmaster 5010- H Page 4 - 89 Hydraulic System...
Page 126: Lift Cylinders
12. Thrust washer 18. Lock nut NOTE: The procedure for lift cylinder removal and installation is the same for all Reelmaster 5010- H lift cyl- inders. Figure 75 shows the lift cylinder for the #4 cutting unit (left front). Hydraulic System...
Page 127 (item 12) from the cylinder slide pin (item 13) that se- cures lift cylinder to lift arm. Pull slide pin from the lift cylinder and lift arm. Locate and retrieve second thrust washer. Reelmaster 5010- H Page 4 - 91 Hydraulic System...
Page 128: Lift Cylinder Service
Use of a vise with soft jaws is recommended. 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. Hydraulic System Page 4 - 92 Reelmaster 5010- H...
Page 129 Assembly (Fig. 76) 1. Make sure all lift cylinder parts are clean before as- sembly. Reelmaster 5010- H Page 4 - 93 Hydraulic System...
Page 130: Steering Control Valve
Note port designations on steering control valve (Fig. 79). Thoroughly clean hydraulic connections prior 3. Slide rubber bellows up from bottom of steering col- to loosening hydraulic lines. umn. Support steering column to prevent it from falling. Hydraulic System Page 4 - 94 Reelmaster 5010- H...
Page 131 6. Lubricate new O- rings and connect hydraulic lines to fittings on steering control valve. Tighten connections (see Hydraulic Hose and Tube Installation in the Gener- al Information section of this chapter). Figure 79 Reelmaster 5010- H Page 4 - 95 Hydraulic System...
Page 132: Steering Control Valve Service
26. Plug 9. Cardan shaft 18. Ball stop NOTE: For repair of the steering control valve, see the Sauer- Danfoss Steering Unit Type OSPM Service Manual at the end of this chapter. Hydraulic System Page 4 - 96 Reelmaster 5010- H...
Page 133 This page is intentionally blank. Reelmaster 5010- H Page 4 - 97 Hydraulic System...
Page 134: Steering Cylinder
See Installing Hydraulic System Components at the begin- Relieving Hydraulic System Pressure in the Gen- ning of the Service and Repairs section of this chapter. eral Information section of this chapter. Hydraulic System Page 4 - 98 Reelmaster 5010- H...
Page 135 7. Secure steering cylinder to RH drag link with washer (item 14) and slotted hex nut (item 13). Install cotter pin MEASURE CENTER TO CENTER LENGTH (item 12). FOR ASSEMBLY PURPOSES Figure 83 Reelmaster 5010- H Page 4 - 99 Hydraulic System...
Page 136: Steering Cylinder Service
9. Discard removed seals and O- rings. ing. Rotate the head counter- clockwise to remove re- taining ring from barrel and head. Hydraulic System Page 4 - 100 Reelmaster 5010- H...
Page 137 B. Carefully install back- up ring, O- ring, BS seal and dust seal to the head. 3. Coat shaft with clean hydraulic oil. Slide head and piston onto the shaft. Reelmaster 5010- H Page 4 - 101 Hydraulic System...
Page 138: Hydraulic Oil Cooler
10. Cap screw (2 used) 16. Rear screen 5. Cooler clamp (16 used) 11. Washer (4 used) 17. Hydraulic tube (2 used) 6. Flat washer (8 used) 12. Clamp (2 used) Hydraulic System Page 4 - 102 Reelmaster 5010- H...
Page 139 5. Close and secure rear screen. cooler. 6. Check oil level in hydraulic reservoir and add correct oil if necessary. Reelmaster 5010- H Page 4 - 103 Hydraulic System...
Page 140 This page is intentionally blank. Hydraulic System Page 4 - 104 Reelmaster 5010- H...
Page 141 ..... . Toro Electronic Controller (TEC) ....
Page 142: General Information
Reelmaster machine. Refer to that publication for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for Reelmaster 5010- H machines are located in Chapter 9 - Foldout Drawings. 48 VDC Battery Disconnect CAUTION FRONT Before installing, removing or servicing compo- nents in the 48 VDC system (e.g.
Page 143: Toro Electronic Controller (Tec)
Toro Electronic Controller (TEC) Reelmaster 5010- H machines use a Toro Electronic Controller (TEC) to manage machine electrical func- tions. The controller is microprocessor controlled that senses the condition of various switches and sensors (inputs). The controller then directs electrical power to control appropriate machine functions (outputs) based on the input state.
Page 144: Electrical System Operation
Electrical System Operation Reelmaster 5010- H machines use two (2) separate electrical systems. Most machine functions operate on a typical 12 VDC system. The second system exists to operate the electric cutting reels and is a 48 VDC electri- cal system. Basic information about the two systems is included below.
Page 145: 48 Vdc System Operation
48 VDC System Operation The Reelmaster 5010- H 48 VDC system includes a 48 The 48 VDC system is an isolated system so the vehicle VDC battery pack, an engine driven motor/generator as- frame is not used for any ground connections in this sys- sembly, five (5) cutting reel motors, a main contactor tem.
Page 146: Special Tools
The multimeter can test electrical components and cir- cuits for current, resistance or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt- Ohm- Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 147 Cutting Reel Motor Rotor Tool Set Toro Part Number: 127- 2574 (for both 5” and 7” cutting 2. Make sure that threaded shaft is installed into base unit motors) plate so that the end of the threaded shaft prevents the rotor body from entering the motor housing.
Page 148 Generator Rotor Tool Set Toro Part Number: TOR6029 IMPORTANT: The rotor magnets are very powerful and can cause the rotor to shift position very rapidly The generator rotor tool set is required to remove and during installation. Be cautious during rotor instal- install the rotor from the motor/generator housing.
Page 149 Obtain this tool locally. NOTE: A battery hydrometer is not usable for the bat- teries in the Reelmaster 5010- H 48 VDC battery sys- tem. These batteries are valve regulated, sealed lead acid batteries that are maintenance free with no provi- sion for checking or adjusting electrolyte level.
Page 150: Infocenter Display
Figure 12 1. 12 VDC battery voltage 5. Right button 2. Hour meter 6. Middle button 3. Fuel gauge 7. Menu/back button 4. Glow plugs energized Electrical System Page 5 - 10 Reelmaster 5010- H...
Page 151: Main Information Screens
Figure 14 1. Engine RPM 5. 48 VDC battery voltage 2. Coolant temperature 6. Right button 3. Indicator light 7. Middle button 4. Generator temperature 8. Menu/back button Reelmaster 5010- H Page 5 - 11 Electrical System...
Page 152: Access Protected Display Screens
2. Motor/generator 5. Energy flow 3. Reel motor circuit - 80A 2850 46.0 Figure 17 1. 48V battery pack status 4. Engine RPM 2. Motor/generator 5. Energy flow 3. Reel motor circuit Electrical System Page 5 - 12 Reelmaster 5010- H...
Page 153: Main Menu Screen
If a fault continues to occur, further system evaluation and possible component re- pair or replacement will be necessary. To return to the main menu screen from the faults screen, press the back button (left button). Reelmaster 5010- H Page 5 - 13 Electrical System...
Page 154: Service Screen
D Engine Coolant Caution identifies the number of times that engine coolant temperature was elevated. Electrical System Page 5 - 14 Reelmaster 5010- H...
Page 155: Diagnostics Screen
Outputs indicate that the fuel actuator is ener- gized and, when the ignition switch is in the START posi- tion, that the start output is energized. Reelmaster 5010- H Page 5 - 15 Electrical System...
Page 156: Settings Screen
PIN has been changed and is forgotten, a temporary 1. Settings menu 5. Decrease setting 2. Settings items 6. Back button PIN can be obtained from your Toro distributor. 3. Current settings 7. PIN activated 4. Increase setting To change the machine PIN, access the protected menu items by entering the current PIN.
Page 157: About Screen
To return to the main menu screen from the about screen, press the back button (left button). Figure 24 1. About menu 4. Choose menu item 2. About items 5. Back button 3. Move to menu items Reelmaster 5010- H Page 5 - 17 Electrical System...
Page 158: Troubleshooting
NOTE: Icons that are used on the InfoCenter display are identified in the Traction Unit Operator’s Manual. Figure 25 1. Indicator light 3. Advisory description 2. Advisory number 4. Reason for advisory Electrical System Page 5 - 18 Reelmaster 5010- H...
Page 159 Reel Speed Changed Identifies that reel speed has been changed Reel Speed Changed Out Of Range Low 48 VDC Battery Heavy 48 VDC battery pack use has decreased battery pack charge Reelmaster 5010- H Page 5 - 19 Electrical System...
Page 160: Fault Codes
S When machine electrical issues occur and fault codes have been displayed on the InfoCenter display, consider If an electrical fault is identified by the machine con- contacting your Toro Distributor for additional assis- trollers (TEC, motor/generator, cutting unit motors), the tance.
Page 161 Check ignition switch and circuit wiring Check fuel actuator and fuel pump TEC software needs to be reprogrammed Contact Toro Distributor for reprogramming assistance Engine alternator charging is too high Check engine alternator Engine alternator charging is too low...
Page 162 If engine is running when fault occurred, check internal motor/generator connections Consider that motor/generator is faulty Cutting unit fault Contact Toro distributor for cutting unit service assistance Motor/generator fault Contact Toro distributor for motor/generator service assistance...
Page 163 Verify battery power exists at InfoCenter Display Check CAN- bus termination resistors Software version incompatible with #1 cutting Contact Toro distributor to update software reel motor Software version incompatible with #2 cutting Contact Toro distributor to update software reel motor...
Page 164 Check #3 cutting unit motor for excessive ro- tating resistance Check that #3 cutting unit motor can rotate without load Replace #3 cutting unit motor if above items do not identify problem and issue is not resolved Electrical System Page 5 - 24 Reelmaster 5010- H...
Page 165 48 VDC ground for #2 cutting unit motor Consider replacement of #2 cutting unit motor if this fault continues to occur NOTE: A faulty sensor will not cause this fault Reelmaster 5010- H Page 5 - 25 Electrical System...
Page 166 48 VDC ground for #5 cutting unit motor Consider replacement of #5 cutting unit motor if this fault continues to occur NOTE: A faulty sensor will not cause this fault Electrical System Page 5 - 26 Reelmaster 5010- H...
Page 167 OFF and also check 48 VDC logic relay and circuit wiring If 48 VDC battery voltage is correct when en- gine is OFF but drops when engine is ON, con- sider that motor/generator is faulty Reelmaster 5010- H Page 5 - 27 Electrical System...
Page 168 NOTE: If all 48 VDC components (motor/gen- erator and cutting unit motors) generate this fault, system fault 31 will be displayed on the InfoCenter Electrical System Page 5 - 28 Reelmaster 5010- H...
Page 169 NOTE: If all 48 VDC components (motor/gen- erator and cutting unit motors) have this fault, system fault 31 will be displayed on the Info- Center Reelmaster 5010- H Page 5 - 29 Electrical System...
Page 170 Check the 2 pin 48 VDC bus connector for the engaged) #5 cutting unit NOTE: If all 48V components (motor/generator and cutting unit motors) have this fault, system fault 29 will be displayed on the InfoCenter Electrical System Page 5 - 30 Reelmaster 5010- H...
Page 171 NOTE: If all 48V components (motor/generator and cutting unit motors) have this fault, system fault 30 will be displayed on the InfoCenter Reelmaster 5010- H Page 5 - 31 Electrical System...
Page 172 #1 cutting unit continues to occur Excessive voltage occurred at internal motor #2 cutting unit motor is likely faulty if this fault regulator for #2 cutting unit continues to occur Electrical System Page 5 - 32 Reelmaster 5010- H...
Page 173 If fault occurs for multiple cutting unit motors, check 48 VDC logic relay and circuit wiring Check 48 VDC battery system cables for proper connections Consider that #5 cutting unit motor is faulty Reelmaster 5010- H Page 5 - 33 Electrical System...
Page 174 Motor/generator is likely faulty if this fault viding different feedback continues to occur NOTE: If engine speed is erratic when this fault is displayed, the motor/generator will likely need to be replaced Electrical System Page 5 - 34 Reelmaster 5010- H...
Page 175: Starting Problems
Engine or fuel system is malfunctioning (see Chapter 3 - Kubota Diesel Engine). Engine cranks, but should not, when the traction pedal Traction neutral switch is out of adjustment. is depressed. Traction neutral switch or circuit wiring is faulty. Reelmaster 5010- H Page 5 - 35 Electrical System...
Page 176 Wiring to start circuit components is loose, corroded or damaged (see electrical drawings in Chapter 9 - Foldout Drawings). Temperature sender or circuit wiring is faulty. Starter solenoid or starter motor is faulty. TEC controller is faulty. Electrical System Page 5 - 36 Reelmaster 5010- H...
Page 177: General Run And Transport Problems
Alternator belt is loose or damaged. 12 VDC battery cables are loose or corroded. Fusible link harness at the engine starter motor is faulty. Alternator is faulty. 12 VDC battery is faulty. Reelmaster 5010- H Page 5 - 37 Electrical System...
Page 178: Cutting Unit Operating Problems
Problem exists with affected cutting unit (see Chapter 7 - Cutting Units). Cutting unit motor is damaged. NOTE: If appropriate, transfer a suspected damaged motor to another cutting unit. If problem follows the motor, motor needs repair or replacement. Electrical System Page 5 - 38 Reelmaster 5010- H...
Page 179 Binding of lift cylinder or lift components for affected lower, but all other cutting units will raise and lower. cutting unit exists. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System). Reelmaster 5010- H Page 5 - 39 Electrical System...
Page 180: Electrical System Quick Checks
This is a fast, simple test that can help to determine the ammeter pickup around the main glow plug power sup- integrity and operation of your Reelmaster 5010- H glow ply wire and read the meter prior to activating the glow plug system.
Page 181: Component Testing
Interlock switch operation is described in the Traction Unit Operator’s Manual. Your Reelmaster is equipped with an Toro Electronic Controller (TEC) which monitors interlock switch operation. Information on the TEC is de- scribed in the Traction Unit Operator’s Manual and in the Component Testing section of this Chapter.
Page 182: Adjustments
4. After adjustment to the traction neutral switch, use the InfoCenter Display to verify that traction neutral switch and circuit wiring are functioning correctly (see Diagnostics Screen (Engine Run item) in the InfoCenter Display section of this chapter). Electrical System Page 5 - 42 Reelmaster 5010- H...
Page 183: Parking Brake Switch
2. Lock washer (2 used) 5. Brake pedal wiring are functioning correctly (see Diagnostics Screen 3. Jam nut (2 used) 6. Switch LED location (Engine Run item) in the InfoCenter Display section of this chapter). Reelmaster 5010- H Page 5 - 43 Electrical System...
Page 184: Cutting Unit Down Limit Switch
After adjustment to the down limit switch, use the Info- Center Display (see Diagnostics Screen (PTO item) in the InfoCenter Display section of this chapter) to verify that down limit switch and circuit wiring are functioning correctly. Electrical System Page 5 - 44 Reelmaster 5010- H...
Page 185: Mow/Transport Switch
After adjustment to the mow/transport switch, use the InfoCenter Display to verify that mow/transport switch and circuit wiring are functioning correctly (see Diag- nostics Screen (Hi/Low Range item) in the InfoCenter Display section of this chapter). Reelmaster 5010- H Page 5 - 45 Electrical System...
Page 186: Component Testing
The ignition (key) switch has three (3) positions (OFF, POSITION CIRCUIT ON/PREHEAT and START). The switch is mounted on NONE the control console. The Toro Electronic Controller ON/PREHEAT B + I + A, X + Y (TEC) monitors the operation of the ignition switch. START...
Page 187: 12 Vdc System Fuses
3. Remove fuse(s) from the fuse block for testing. Fuse should have continuity between fuse terminals. 7.5A 4. After fuse testing is completed, install control arm ac- cess cover. 7.5A 7.5A Figure 34 Reelmaster 5010- H Page 5 - 47 Electrical System...
Page 188: 48 Vdc System Fuses
4. After fuse testing is completed, install removed cov- ers and plug the 48 VDC battery disconnect into the socket. Figure 36 1. RH frame rail 3. 250A fuse 2. 48V battery disconnect 4. Main contactor Electrical System Page 5 - 48 Reelmaster 5010- H...
Page 189: Engine Speed Switch
Figure 38 position. Verify continuity between switch terminals. Re- place switch if testing identifies that switch is faulty. NOTE: Reel engine speed switch terminals 4, 5 and 6 are not used on Reelmaster 5010- H machines. SWITCH CLOSED OPEN POSITION...
Page 190: Reel Engage/Disengage Switch
The reel engage/disengage switch is mounted cuit problem still exists, check circuit wire harness (see on the control panel (Fig. 39). The Toro Electronic Con- Electrical Schematic and Circuit Drawings in Chapter 9 troller (TEC) monitors the operation of the reel engage/ - Foldout Drawings).
Page 191: Headlight Switch
The headlight switch allows the headlights to be turned on and off. This rocker switch is located on the operator side of the control arm (Fig. 41). NOTE: The Toro Electronic Controller (TEC) does not monitor the operation of the headlight switch. Testing 1.
Page 192: Seat Switch
The seat switch is located directly under the operator seat. The Toro Electronic Controller (TEC) monitors the operation of the seat switch. Testing...
Page 193: Parking Brake Switch
C. Using a multimeter, verify that the machine wire switch. The parking brake switch is attached to the bot- harness connector terminal for black wire is closed tom of the brake pedal (Fig. 44). The Toro Electronic (continuity) to ground. Controller (TEC) monitors the operation of the parking D.
Page 194: Traction Neutral Switch
(do not start engine) and verify with a multimeter that cured to the pump control arm (Fig. 45). The Toro machine wire harness connector terminal for neutral Electronic Controller (TEC) monitors the operation of switch pink wire has system voltage (12 VDC) pres- the traction neutral switch.
Page 195: Cutting Unit Down Limit Switch
E. Turn ignition switch to the OFF position. (Fig. 46). The Toro Electronic Controller (TEC) monitors the operation of the cutting unit down limit switch. F. If black wire is closed to ground, pink wire has...
Page 196: Joystick Raise And Lower Switches
Drawings). has orange/white and black harness wires connected to it. The Toro Electronic Controller (TEC) monitors the op- 9. After switch testing is completed, connect wire har- eration of the joystick switches.
Page 197: Mow/Transport Switch
The sensing plate for the mow/ (continuity) to ground. transport switch is the mow stop lever (Fig. 49). The Toro D. Turn ignition switch to the ON/PREHEAT position Electronic Controller (TEC) monitors the operation of (do not start engine) and verify with a multimeter that the mow/transport switch.
Page 198: Main Power, Glow And 48 Vdc Logic Relays
4. Verify coil resistance between terminals 85 and 86 with a multimeter (ohms setting) (Fig. 52). Resistance Figure 52 should be approximately 72 ohms. Electrical System Page 5 - 58 Reelmaster 5010- H...
Page 199 30 and 87 as +12 VDC is removed from termi- harness connector to relay. Install hood saddle to ma- nal 85. chine if it was removed. Lower and secure hood. Reelmaster 5010- H Page 5 - 59 Electrical System...
Page 200: Start Relay
30 and 87 as +12 VDC is applied to ter- Figure 54 minal 85. The relay should not have continuity between terminals 30 and 87 as +12 VDC is removed from termi- nal 85. Electrical System Page 5 - 60 Reelmaster 5010- H...
Page 201: Main Contactor
(Fig. 56). The resistance should be approximately 126 ohms. 9. Replace main contactor if testing determines that it is faulty. Figure 56 1. Main contact posts 2. Contactor coil posts Reelmaster 5010- H Page 5 - 61 Electrical System...
Page 202: Toro Electronic Controller (Tec)
Toro Electronic Controller (TEC) Reelmaster 5010- H machines use a Toro Electronic Controller (TEC) to control electrical system operation. The TEC controller senses the condition of various switches (inputs) and directs power output to allow cer- tain machine functions. The TEC is attached to the con- trol arm behind the access panel on the outside of the control arm (Fig.
Page 203 TEC controller and disconnect the terminal connector from the alterna- tor to prevent damage to the electrical system. NOTE TAB POSITION Figure 59 Reelmaster 5010- H Page 5 - 63 Electrical System...
Page 204: Fusible Link Harness
Fusible Link Harness The Reelmaster 5010- H uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the FRONT main wire harness (Fig. 60). If any of these links should fail, current to the protected circuit will cease.
Page 205: Diode Assembly
5. After diode testing is complete, make sure that diode is fully installed into wire harness connector and se- 1. Diode 3. Female terminal 2. Male terminal cured to harness with cable tie. Reelmaster 5010- H Page 5 - 65 Electrical System...
Page 206: 48 Vdc System Protection Diode
48 VDC System Protection Diode The Reelmaster 5010- H 48 VDC system includes a diode that is used for circuit protection from voltage spikes when the main contactor is de- energized. The diode plugs into the main wire harness near the 48 VDC battery disconnect and main contactor under the opera- tor seat (Fig.
Page 207: Location Id Module
2. ID module connector 7. Replace ID module if testing determines that it is faulty. NOTE: Do not attempt to remove cover of location ID module. There are no replaceable parts under cover. Reelmaster 5010- H Page 5 - 67 Electrical System...
Page 208: Cutting Reel Motor
VDC ground terminal (black wire) in the 2 wire connector 3. Location ID (blue) 6. CAN- bus (yellow) and location ID terminal (blue wire) in 4 wire connector (Fig. 69). Resistance should be approximately 18.8 K- ohms. Electrical System Page 5 - 68 Reelmaster 5010- H...
Page 209: Can- Bus Termination Resistors
B. Refer to Fig. 70 to determine terminal locations. A. In the control arm next to the operator seat. Terminal C is not used on Reelmaster 5010- H ma- chines. B. Near the wire harness connectors for the #3 (right...
Page 210: Hydraulic Solenoid Valve Coil
SV2 and SVRV 7.1 ohms 5. If solenoid coil resistance is incorrect, replace sole- noid coil (see Hydraulic Solenoid Valve Coil in the Ser- vice and Repairs section of this chapter). Electrical System Page 5 - 70 Reelmaster 5010- H...
Page 211: Temperature Sender
C. The meter should indicate from 0.6 to 0.7 ohms at on the water flange attached to the engine cylinder head F (100 (Fig. 72). The Toro Electronic Controller (TEC) monitors 6. Replace temperature sender if specifications are not the operation of the temperature sender.
Page 212: Oil Pressure Switch
The oil pressure switch is located on the en- identifying low engine oil as the cause of engine shut- gine near the oil filter (Fig.74). The Toro Electronic Con- down, check for faulty wire in the oil pressure switch cir- troller (TEC) monitors the operation of the oil pressure cuit.
Page 213: Fuel Actuator
This resistance is due to the internal re- sistance of the meter and test leads. Subtract this value from the measured value of the component you are test- ing. Reelmaster 5010- H Page 5 - 73 Electrical System...
Page 214: Fuel Sender
2. Fuel supply fitting Make sure fuel sender is completely dry (no fuel on it) before testing. Perform test away from the tank to prevent an explosion or fire from sparks. Electrical System Page 5 - 74 Reelmaster 5010- H...
Page 215 11. Install fuel hoses to fittings on sender and secure with hose clamps. Connect fuel sender connector to wire harness. 12.Secure sender cover to fuel tank with removed Figure 80 screws. 1. Sender full position 2. Sender empty position Reelmaster 5010- H Page 5 - 75 Electrical System...
Page 216: Fuel Pump
9. When testing is complete, install fuel hose to the fuel/ water separator. Make sure to secure fuel hose with Figure 82 hose clamp. 1. Fuel hose (from pump) 3. Fuel/water separator 2. Hose clamp 4. Fuel return hose Electrical System Page 5 - 76 Reelmaster 5010- H...
Page 217: Service And Repairs
3. Install the nut onto the valve and torque nut 60 in- lb (6.7 N- m) (do not over tighten). 4. Connect the machine wire harness connector to the solenoid coil. Reelmaster 5010- H Page 5 - 77 Electrical System...
Page 218: 12 Vdc Battery Service
7. Coat battery posts and cable connectors with Battery Terminal Protector (Toro Part No. 107- 0392) or petro- leum jelly to prevent corrosion. 8. Install battery cover. Close and secure screen.
Page 219 0.050. If these charging conditions can not be G. Take a battery voltage reading at fifteen (15) se- met, replace the battery. conds, then remove the load. Reelmaster 5010- H Page 5 - 79 Electrical System...
Page 220 23 hrs 6 Amps 6 Amps 6 Amps 6 Amps above 6 hrs 12 hrs 18 hrs 24 hrs @ 10 @ 10 @ 10 @ 10 Amps Amps Amps Amps Electrical System Page 5 - 80 Reelmaster 5010- H...
Page 221 This page is intentionally blank. Reelmaster 5010- H Page 5 - 81 Electrical System...
Page 222: Vdc Battery Pack Service
7. Flange nut (2 used) 16. Battery jumper cable 24. Carriage screw (4 used) 8. Battery cover (2 used) 17. Foam strip (4 used) 25. Positive battery cable 9. Hex nut (2 used) Electrical System Page 5 - 82 Reelmaster 5010- H...
Page 223 The 48 volt battery pack used in the Reelmaster 5010- H electric reel drive system is composed of four (4) 12 volt batteries that are connected in series. The batteries are absorbed glass mat (AGM), valve regulated batteries that are maintenance free with no provision for checking or adjusting electrolyte level.
Page 224 70 in- lb (5.7 to 7.9 N- m). 48 VDC Battery Pack Storage 8. Apply Toro battery terminal protector (see Special There are no special procedures or precautions for bat- Tools in this chapter) to all battery posts and cable con- tery storage less than six (6) months.
Page 225 This page is intentionally blank. Reelmaster 5010- H Page 5 - 85 Electrical System...
Page 226: 48 Vdc Electrical Power Connections
20. Flange nut (8 used) 6. Isolator 14. 250 amp fuse 21. Positive battery cable 15. Flange head screw (2 used) 22. Negative battery cable 7. Flange head screw 8. Flat washer (9 used) Electrical System Page 5 - 86 Reelmaster 5010- H...
Page 227 Figures 88, 89 and 90 as guides. Use torque specifications identified in Figure 88 when installing fasteners. 2. Apply Toro battery terminal protector (see Special Tools in this chapter) to all cable connectors to reduce corrosion after cable connections are made. Make sure that terminal boots and connection covers are posi- tioned over all cable connections.
Page 228: Cutting Reel Motor
1. Cable from motor 4. 4 wire connector 2. Bulkhead nut 5. 2 wire connector vent debris entry into reel bearing area. 3. Bulkhead fitting 6. Connector plate Electrical System Page 5 - 88 Reelmaster 5010- H...
Page 229 B. Rotate the motor counterclockwise until the mo- tor flanges are encircling the cap screws in the cut- ting unit side plates. Tighten two (2) cap screws to secure cutting reel motor to cutting unit. Reelmaster 5010- H Page 5 - 89 Electrical System...
Page 230: Cutting Reel Motor Service
Be cautious during rotor removal to prevent compo- box cover (item 12) to front of motor housing. nent damage or personal injury. 2. Carefully slide gearbox cover from front of motor. Electrical System Page 5 - 90 Reelmaster 5010- H...
Page 231 (see Special Tools in this chapter) and Figure 96 install O- rings to grooves in motor cover. Place wave 1. Output gear 3. Shaft seal washer (item 4) in cover. 2. Gearbox cover Reelmaster 5010- H Page 5 - 91 Electrical System...
Page 232: Motor/Generator Assembly
3. Raise and support hood and operator seat. assembly before removing the motor/generator from the bellhousing. Electrical System Page 5 - 92 Reelmaster 5010- H...
Page 233 Use suitable puller to remove coupler hub from motor/generator shaft. Locate and retrieve woodruff key from motor/generator shaft. Reelmaster 5010- H Page 5 - 93 Electrical System...
Page 234 6. Secure bellhousing to engine plate with removed fasteners. Make sure that r- clamps are in locations not- ed during disassembly (Fig. 98). R- clamp that secures motor/generator wire harness connection should cover red tape on harness. Electrical System Page 5 - 94 Reelmaster 5010- H...
Page 235 This page is intentionally blank. Reelmaster 5010- H Page 5 - 95 Electrical System...
Page 236: Motor/Generator Assembly Service
Also, any metallic debris that gets attracted to the rotor can damage the motor/generator after assembly. Electrical System Page 5 - 96 Reelmaster 5010- H...
Page 237 Secure isolator with spacers and screws. Torque bearings if removed. screws from 35 to 45 in- lb (4.0 to 5.0 N- m). F. If necessary, remove isolator from housing as- sembly. Reelmaster 5010- H Page 5 - 97 Electrical System...
Page 238 (item 19). Torque nut from 95 to 105 ft- lb (129 to 142 N- m). 4. Lubricate new O- ring with dielectric lubricant (see Special Tools in this chapter) and install into groove on isolator. Electrical System Page 5 - 98 Reelmaster 5010- H...
Page 239 ........Reelmaster 5010- H...
Page 240: Specifications
48 VDC system is completed. Figure 1 1. RH frame rail 2. 48V battery disconnect Chassis Page 6 - 2 Reelmaster 5010- H...
Page 241: Special Tools
Special Tools Order Toro special tools from your Toro Distributor. Wheel Hub Puller The wheel hub puller allows safe removal of the front wheel hub from the wheel motor shaft. If machine is equipped with optional CrossTrax Kit, this wheel hub puller is needed for removing rear wheel hub from the rear wheel motor.
Page 242: Service And Repairs
7. Lug nut (5 used per wheel) 12. Retainer 3. Front wheel hub 8. Rear wheel hub 13. Cotter pin 4. Lock nut 9. Spindle washer 14. Dust cap 5. Brake drum 10. Rear wheel Chassis Page 6 - 4 Reelmaster 5010- H...
Page 243 4. Using a jack, raise machine so wheel is off ground (see Jacking Instructions in Chapter 1 - Safety). Sup- port machine with jack stands. 5. Remove wheel lug nuts and then remove wheel from machine. Reelmaster 5010- H Page 6 - 5 Chassis...
Page 244: Steering Column
B. Remove fasteners that secure platform shroud to 3. Remove lock nut and flat washer that secure steer- machine and remove platform shroud ing wheel to steering column. C. Retrieve two (2) rubber bushings and spacers. Chassis Page 6 - 6 Reelmaster 5010- H...
Page 245 10.Install steering wheel cover to steering wheel. 4. Pin 12. Spring 5. Lock washer (2 used) 13. Release pin 6. Cylinder 14. Cylinder shaft 7. Bolt (2 used) 15. Jam nut 8. Pin Reelmaster 5010- H Page 6 - 7 Chassis...
Page 246: Brake Service
17. Spring clip (LH shown) 5. Wheel assembly 12. Lock nut 18. Lock nut (4 used per motor) 6. Brake drum 13. Square key 19. Brake adapter 7. Front wheel shield (2 used) Chassis Page 6 - 8 Reelmaster 5010- H...
Page 247 Make sure that brake shoes are properly positioned to brake shoe contact surfaces of the brake drum for ex- pivot and actuator points. cessive wear. Replace any worn or damaged brake parts. Reelmaster 5010- H Page 6 - 9 Chassis...
Page 248 8). Secure brake cable clevis to brake actuator lever with other persons and obstructions. clevis pin and extension spring. 10.Install front wheel assembly (see Wheels in this sec- tion). Chassis Page 6 - 10 Reelmaster 5010- H...
Page 249 This page is intentionally blank. Reelmaster 5010- H Page 6 - 11 Chassis...
Page 250: Rear Wheel Bearings (2 Wheel Drive)
1. Dust cap 5. Spindle washer 9. Seal 2. Cotter pin 6. Bearing cone 10. Spindle 3. Retainer 7. Bearing cup 11. Wheel stud (5 used) 4. Jam nut 8. Wheel hub Chassis Page 6 - 12 Reelmaster 5010- H...
Page 251 Lubricate the inside of a new seal and press it into the wheel hub with the seal lip toward the bearing. Reelmaster 5010- H Page 6 - 13 Chassis...
Page 252: Rear Axle
28. Slotted hex nut 8. Roll pin 19. O- ring 29. Slotted hex nut 9. Thrust washer 20. Cotter pin 30. Washer 10. Jam nut 21. Steering cylinder 31. Hydraulic hose 11. Grease fitting Chassis Page 6 - 14 Reelmaster 5010- H...
Page 253 8. Pull the axle pivot pin from frame and rear axle. This will release the rear axle and thrust washers (item 7) from the frame. Carefully pull the entire axle and wheel assembly out from under the machine. Reelmaster 5010- H Page 6 - 15 Chassis...
Page 254: Rear Axle Service
5. Pivot bushing (2 used) 12. Spindle cap 19. Washer 6. Grease fitting (2 used) 13. Flange head screw 20. Slotted hex nut 7. Flange bushing (4 used) 14. Thrust washer 21. Cotter pin Chassis Page 6 - 16 Reelmaster 5010- H...
Page 255 Slide the housing and wheel assembly out of the axle tube to expose the flange bushings. Locate and retrieve thrust washer (item 14) from housing shaft. Reelmaster 5010- H Page 6 - 17 Chassis...
Page 256: Control Arm
12. Washer head screw (10 used) 27. Flat washer 42. Latch 13. Bushing (2 used) 28. Screw 43. Cotter pin 14. Flange nut (5 used) 29. Access cover 15. RH control arm cover 30. Spacer 44. Nut Chassis Page 6 - 18 Reelmaster 5010- H...
Page 257 3. Secure each cover to control arm with five (5) washer head screws (item 12). Install screw (item 28) and lock nut (item 23) to secure covers at front of control arm. 4. Install access cover to outside of control arm. Reelmaster 5010- H Page 6 - 19 Chassis...
Page 258: Operator Seat
Damage to control arm electrical components and control arm wiring har- ness can occur if the seat base and control arm are not properly supported during seat removal. Chassis Page 6 - 20 Reelmaster 5010- H...
Page 259 3. Flange screw (2 used) to machine. 3. Make sure that two (2) bushings are positioned in control arm pivot area. Carefully slide control arm as- sembly onto seat base post. Reelmaster 5010- H Page 6 - 21 Chassis...
Page 260: Mechanical Seat Suspension
26. Spring bushing (2 used) 40. Roll pin (2 used) 13. Pivot block (2 used) 27. Shaft block (2 used) 41. Roll pin 14. Damper 28. Weight adjust spacer 42. Clip (20 used) Chassis Page 6 - 22 Reelmaster 5010- H...
Page 261 11. R- clamp (2 used) harness when installing seat suspension to ma- 5. Flange nut (8 used) 12. Seat adjuster 6. Seatbase cover 13. Seat adjuster w/latch chine. 7. Spacer (4 used) Reelmaster 5010- H Page 6 - 23 Chassis...
Page 262: Front Lift Arms
7. Slide front lift arm from lift arm pivot shaft. pin (item 5 in Fig. 21) that secures lift cylinder to lift arm. Pull slide pin from the lift cylinder and lift arm. Locate and retrieve second thrust washer. Chassis Page 6 - 24 Reelmaster 5010- H...
Page 263 6. Mount cutting unit to lift arm. Figure 23 7. Lubricate grease fittings on lift arm, pivot yoke and lift 1. Pivot yoke 3. Pivot yoke shoulder 2. Upper bushing 4. Lower bushing cylinder. Reelmaster 5010- H Page 6 - 25 Chassis...
Page 264: Rear Lift Arms
2. Remove cutting unit from rear lift arm that is to be re- 4. Pivot lift cylinder rod end away from lift arm. moved. Chassis Page 6 - 26 Reelmaster 5010- H...
Page 265 The upper pivot yoke bushing should be pressed ful- ly to the shoulder in the pivot yoke bore. The lower pivot yoke bushing should be flush with the yoke tube. Reelmaster 5010- H Page 6 - 27 Chassis...
Page 266 B. Push down and forward on the spring end to hook the spring to the stop bolt on the lift arm. 7. Mount cutting unit to lift arm. 8. Lubricate grease fittings on lift arm, pivot yoke and lift cylinder. Chassis Page 6 - 28 Reelmaster 5010- H...
Page 267 This page is intentionally blank. Reelmaster 5010- H Page 6 - 29 Chassis...
Page 268: Hood
13. Washer head screw (4 used) 20. Grommet 6. Tube 14. Flat washer (4 used) 21. Hex nut 7. Bow tie pin (2 used) 15. Lock nut (4 used) 22. Spacer 8. Deflector bracket (2 used) Chassis Page 6 - 30 Reelmaster 5010- H...
Page 269 4. Lift hood assembly from machine. 4. Latch hood. 5. Remove hood components as necessary using Fig- ure 29 as a guide. 6. Check condition of all seals on hood. Replace dam- aged or missing seals. Reelmaster 5010- H Page 6 - 31 Chassis...
Page 270 This page is intentionally blank. Chassis Page 6 - 32 Reelmaster 5010- H...
Page 271 ....... Rear Roller Brush Drive System (Optional) ..Reelmaster 5010- H Page 7 - 1 Cutting Units...
Page 272: Specifications
(2) vertical screws. Effective HOC available options for your Reelmaster cutting unit. may vary depending on turf conditions, type of bedknife, roller type and installed attachments. Page 7 - 2 Reelmaster 5010- H Cutting Units...
Page 273: General Information
48 VDC system is completed. Figure 2 1. RH frame rail 2. 48V battery disconnect Reelmaster 5010- H Page 7 - 3 Cutting Units...
Page 274: Special Tools
Special Tools Order special tools for your Reelmaster from your Toro Distributor. Some tools may have been supplied with your machine or are available as Toro parts. Gauge Bar Assembly Toro Part Number: 108- 6715 Use gauge bar to verify height- of- cut adjustment. Also used for adjustment of optional groomer.
Page 275: Handle Assembly
Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver- type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: To prevent damage to the bedbar, DO NOT use an air or manual impact wrench with this tool.
Page 276 Spline Insert Tool Toro Part Number: TOR4112 (8 tooth for 5 inch reels) TOR4074 (9 tooth for 7 inch reels) Use spline insert tool for rotating cutting reel when motor is removed. Also use this tool for installation of threaded inserts into cutting reel shaft.
Page 277 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL)
Page 278: Factors That Can Affect Cutting Performance
NOTE: For additional information regarding cutting unit cutting unit. It is important to remember that the lower troubleshooting, see Aftercut Appearance Trouble- the height- of- cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL). Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
Page 279 Repairs section of this chapter. Number of reel blades Use correct number of reel blades for clip frequency and optimum height- of- cut range. Refer to Clip Chart in Traction Unit Operator’s Manual. Reelmaster 5010- H Page 7 - 9 Cutting Units...
Page 280 Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance. Refer to Cutting Unit Operator’s Manual for a listing of available accessories. Page 7 - 10 Reelmaster 5010- H Cutting Units...
Page 281 This page is intentionally blank. Reelmaster 5010- H Page 7 - 11 Cutting Units...
Page 282: Set Up And Adjustments
In addition, the rear roller positioning system allows for various height-of-cut ranges and aggressiveness of cut selections. Page 7 - 12 Reelmaster 5010- H Cutting Units...
Page 283: Leveling Rear Roller
8. After leveling rear roller, complete cutting unit set- up and adjustment sequence. Figure 16 1. Rear roller assembly 5. Washer 2. Rear roller bracket 6. Roller shim 3. Carriage screw 7. 0.010” shim (if needed) 4. Flange nut Reelmaster 5010- H Page 7 - 13 Cutting Units...
Page 284: Service And Repairs
35 to 40 ft- lb (48 to 54 N- m) Figure 19 1. Side plate (LH shown) 4. Set screw 2. Threaded insert 5. Relief fitting 3. Grease fitting Page 7 - 14 Reelmaster 5010- H Cutting Units...
Page 285: Backlapping
VDC battery disconnect before attempting to clear the reel. NOTE: Instructions and procedures on backlapping are available in the Traction Unit Operator’s Manual and the Toro General Service Training Book, Reel Mower Basics (part no. 09168SL). Reelmaster 5010- H Page 7 - 15...
Page 286: Bedbar Assembly
5. Loosen the lock nuts (item 6) on each bedbar pivot ging the 48 VDC battery disconnect (see 48 VDC bolt (item 5). Battery Disconnect in the General Information section of this chapter). Page 7 - 16 Reelmaster 5010- H Cutting Units...
Page 287 (item 9) and 2. Rubber bushing 6. Bedbar adjuster screw flange (item 10). 3. Flange bushing 7. Bedbar pivot bolt 4. Washer (plastic) 8. Lock nut Reelmaster 5010- H Page 7 - 17 Cutting Units...
Page 288: Bedknife Replacement And Grinding
200 to 250 in- lb (23 to 28 N- m). Use a torquing pattern Figure 25 working from the center toward each end of the bedknife (Fig. 24). Page 7 - 18 Reelmaster 5010- H Cutting Units...
Page 289 (6.4 mm) Also, clean and dress grinding stone often during the grinding process. 1. Use Cutting Unit Operator’s Manual, Toro General 0.060” Service Training Book, Reel Mower Basics (part no. (1.5 mm) 09168SL) and grinder manufacturer’s instructions for...
Page 290: Bedbar Adjuster Service
5. Keyed flange bushing (2 used) 9. Lock nut 2. Compression spring 6. Cap screw 10. Bedbar adjuster shaft 3. Lock nut 7. Detent 11. Wave washer 4. Bedbar adjuster screw 8. Flat washer 12. Washer Page 7 - 20 Reelmaster 5010- H Cutting Units...
Page 291 1. If detent (item 7) was removed, secure detent to cut- 7. Adjust cutting unit (see Cutting Unit Operator’s ting unit side plate with cap screw. Torque cap screw Manual). from 14 to 16 ft- lb (19 to 21 N- m). Reelmaster 5010- H Page 7 - 21 Cutting Units...
Page 292: Cutting Reel Assembly Removal And Installation
The right side plate (item 8) does not have to be re- Battery Disconnect in the General Information section of moved from the frame. this chapter). 3. Remove the cutting unit from the machine and place it on a flat work area. Page 7 - 22 Reelmaster 5010- H Cutting Units...
Page 293 3. Frame spacer 8. Flat washer 4. Flange head screw 9. Cap screw 14.Inspect and service cutting reel assembly (see Cut- 5. Flange nut ting Reel Assembly Service in this section). Reelmaster 5010- H Page 7 - 23 Cutting Units...
Page 294: Reel Assembly Installation
0.065” (1.7 mm). Make sure that the carrier frame pivots freely after assembly. Page 7 - 24 Reelmaster 5010- H Cutting Units...
Page 295 This page is intentionally blank. Reelmaster 5010- H Page 7 - 25 Cutting Units...
Page 296: Cutting Reel Assembly Service
(flat side toward bearing location). Preparing a Reel for Grinding in this section). Carefully drive special washers from reel shaft. 5. If necessary, remove reel shaft plugs (item 7) from reel shaft. Page 7 - 26 Reelmaster 5010- H Cutting Units...
Page 297 6. Fill threaded insert splines with high temp Mobil XHP- 222 grease or equivalent. 1.370” to 1.630” (34.8 to 41.4 mm) Figure 33 1. Cutting reel shaft 2. Reel shaft plug Reelmaster 5010- H Page 7 - 27 Cutting Units...
Page 298: Preparing Reel For Grinding
Three (3) types of cutting reel designs are used in cutting SCALLOPED RADIAL REEL units for Reelmaster 5010- H machines: scalloped radi- al reel, tapered radial reel and tapered forward swept reel. The different types of individual reel blades are shown in Figure 34.
Page 299 This page is intentionally blank. Reelmaster 5010- H Page 7 - 29 Cutting Units...
Page 300: Front Roller
3. If both front height- of- cut (roller) brackets were re- moved from cutting unit side plate, position one of the brackets to side plate. Secure bracket to side plate with carriage screw and flange lock nut. Page 7 - 30 Reelmaster 5010- H Cutting Units...
Page 301: Rear Roller
Install two (2) carriage screws and flange nuts to retain bracket in position. Do not fully tight- en flange nuts. Reelmaster 5010- H Page 7 - 31 Cutting Units...
Page 302: Roller Service
D. Using the same process, install second outer 1. Roller tube 3. Bearing seal making sure to not crush the installed outer seal. 2. Inner seal 4. Bearing/outer seal tool Again, make sure that bearing still freely rotates. Page 7 - 32 Reelmaster 5010- H Cutting Units...
Page 303 Figure 43 1. Roller tube 4. Bearing 2. Roller shaft 5. Outer seal 3. Inner seal 6. Bearing/outer seal tool Reelmaster 5010- H Page 7 - 33 Cutting Units...
Page 304: Rear Roller Brush (Optional)
C. Remove lock nut and J- bolt from both ends of the cutting units, stop engine, engage parking brake and re- brush. move key from the ignition switch. D. While rotating brush, slide brush from the shaft. Page 7 - 34 Reelmaster 5010- H Cutting Units...
Page 305 Figure 47 5. Lubricate grease fittings on brush housings until 1. Rear roller brush 2. Rear roller grease purges past inboard seals. Wipe excess grease from seals and fittings. Reelmaster 5010- H Page 7 - 35 Cutting Units...
Page 306: Rear Roller Brush Drive System (Optional)
48 VDC battery disconnect (see 48 VDC (Fig. 50). Battery Disconnect in the General Information section of B. Loosen and remove drive shaft from cutting reel. this chapter). Page 7 - 36 Reelmaster 5010- H Cutting Units...
Page 307 Figure 51 1. Driven pulley 3. Straight edge 2. Drive pulley Reelmaster 5010- H Page 7 - 37 Cutting Units...
Page 308 Wipe excess grease from seals and fittings. 7. Once all rear roller brush service is completed, plug the 48 VDC battery disconnect back in before operating the machine. Page 7 - 38 Reelmaster 5010- H Cutting Units...
Page 309 ..... . Height Adjuster Assembly ....Reelmaster 5010- H Page 8 - 1 Groomer...
Page 310: General Information
48 VDC system is completed. Figure 1 1. RH frame rail 2. 48V battery disconnect Groomer Page 8 - 2 Reelmaster 5010- H...
Page 311: Special Tools
Toro parts. Spline Insert Tool Toro Part Number: TOR4112 (8 tooth for 5 inch reels) TOR4074 (9 tooth for 7 inch reels) Use spline insert tool for rotating cutting reel when motor is removed.
Page 312: Grooming Performance
9. The overall turf management program - irrigation, fertilizing, weed control, coring, overseeding, sand dressing, disease control and pest control. 10.Stress periods for turf - high temperatures, high hu- midity, unusually high traffic. Groomer Page 8 - 4 Reelmaster 5010- H...
Page 313: Troubleshooting
Grooming depth is not equal on Adjust depth if necessary. Also, both ends of groomer reel. check and adjust cutting unit set up (level bedknife to reel, level rear roller to reel, set height- of- cut, etc.). Reelmaster 5010- H Page 8 - 5 Groomer...
Page 314 This page is intentionally blank. Groomer Page 8 - 6 Reelmaster 5010- H...
Page 315: Adjustments
5. Measure the distance from the lowest tip of the groomer blade to the working surface. Turn groomer height adjuster to raise or lower the groomer blade tip to the desired height (Fig. 5). Reelmaster 5010- H Page 8 - 7 Groomer...
Page 316: Service And Repairs
13. Washer (for pulley alignment) 21. Groomer plate 6. Square key 14. Spacer 22. Pivot hub 7. Lock nut 15. Groomer drive shaft 23. Idler plate 8. Retaining ring 16. Groomer weight Groomer Page 8 - 8 Reelmaster 5010- H...
Page 317 Apply antiseize lubricant to splines of drive pulley, slide pulley onto groomer shaft and secure with flange nut. Torque flange nut from 27 to 33 ft- lb (37 to 44 N- m). Reelmaster 5010- H Page 8 - 9 Groomer...
Page 318: Groomer Reel And Groomer Plate Assembly
(see D. Disconnect idler extension spring (item 9) from Rear Roller Brush (Optional) in the Service and Repairs stud on groomer plate. section of Chapter 7 - Cutting Units). Groomer Page 8 - 10 Reelmaster 5010- H...
Page 319 Figure 11 groomer plate and torque from 14 to 18 ft- lb (19 to 1. Drive side groomer plate 3. Bearing 24 N- m). 2. Non- drive groomer plate 4. Grease seal Reelmaster 5010- H Page 8 - 11 Groomer...
Page 320 Make sure that spring is in the stud groove and that spring hook is positioned toward the Figure 13 drive pulley location. 1. Groomer plate 3. Groomer reel 2. Excluder seal Groomer Page 8 - 12 Reelmaster 5010- H...
Page 321 NOTE: After greasing groomer bearings, operate groomer for thirty (30) seconds, stop machine and wipe 8. Check groomer reel height and mower height- of- cut excess grease from groomer shaft and seals. settings. Adjust as needed. Reelmaster 5010- H Page 8 - 13 Groomer...
Page 322: Groomer Reel Service
Center blades on shaft 2. Groomer blade (40 used) 6. Excluder seal 3. Thick spacer (41 used) 7. O- ring groove with lock nuts. 4. Thin spacer (2 used) Groomer Page 8 - 14 Reelmaster 5010- H...
Page 323 10.Lubricate groomer bearings. 11. Install cutting unit back on machine. NOTE: After greasing groomer bearings, operate groomer for thirty (30) seconds, stop machine and wipe excess grease from groomer shaft and seals. Reelmaster 5010- H Page 8 - 15 Groomer...
Page 324: Height Adjuster Assembly
4. Clean all height adjuster components and inspect for switch. wear or damage. Replace all worn or damaged compo- nents. Groomer Page 8 - 16 Reelmaster 5010- H...
Page 325 (shown in Fig. 19 For 5” cutting unit and Fig. 20 For 7” cutting unit). 5. Plug the 48 VDC battery disconnect back in before operating the machine. Figure 20 1. Groomer handle 3. Upper jam nut 2. Compression spring Reelmaster 5010- H Page 8 - 17 Groomer...
Page 326 This page is intentionally blank. Groomer Page 8 - 18 Reelmaster 5010- H...
Page 327 ....Seat Wire Harness Diagram ....Reelmaster 5010- H Page 9 - 1 Foldout Drawings...
Page 328: 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 har- ness diagram (e.g. SP01 is splice number 1). Foldout Drawings Page 9 - 2 Reelmaster 5010- H...
Page 329: Hydraulic Schematic
LIFT CONTROL MANIFOLD POWER STEERING VALVE Reelmaster 5010- H Hydraulic Schematic Page 9 - 3...
Page 330: Electrical Schematic
Reelmaster 5010- H Electrical Schematic All relays and solenoids NOTE: REFER TO ELECTRICAL DRAWING are shown as de- energized. DESIGNATIONS IN THIS CHAPTER FOR All ground wires are black. WIRE COLOR ABBREVIATIONS. Page 9 - 4...
Page 331 This page is intentionally blank. Page 9 - 5...
Page 332: Main Wire Harness Drawing
Reelmaster 5010- H Main Wire Harness Drawing Page 9 - 6...
Page 333: Main Wire Harness Diagram
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Reelmaster 5010- H Main Wire Harness Diagram Page 9 - 7...
Page 334: Seat Wire Harness Drawing
NOTE CLOCK POSITION Reelmaster 5010- H Seat Wire Harness Drawing Page 9 - 8...
Page 335: Seat Wire Harness Diagram
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Reelmaster 5010- H Seat Wire Harness Diagram Page 9 - 9...

Toro Reelmaster 5010- H Service Manual

This Page Is Intentionally Blank.

Chapter 1 Safety

Chapter 3 Kubota Diesel Engine

Chapter 4 Hydraulic System

Chapter 5 Electrical System

Chapter 6 Chassis

Chapter 7 Cutting Units

Chapter 8 Groomer

Quick Links

Service Manual

Chapters

Troubleshooting

Related Manuals for Toro Reelmaster 5010- H

Summary of Contents for Toro Reelmaster 5010- H