Manuale d’uso / di manutenzione del prodotto 5010-H del fabbricante Toro
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Part No. 15212SL Service Manual Reelmast er R 5010 - H Preface The pur pose of t his public ation is to pr ovide the serv ice technic ian with i nfor mati on for tr oubleshooting, t est ing and repair of maj or syst ems and co mponents on the Reelmast er 5010- H (Hy brid).
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Reelmast er 5010- H T able Of Contents Chap ter 1 - Safet y Safe ty Instru ctio ns 1 - 2 .......................... Jackin g Instructions 1 - 5 ......................... Safet y and I nst ruc tion Dec als 1 - 6 ................ Cha pte r 2 - Product R ec ords a nd Mainte nance Produc t Records 2 - 1 .
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Reelmast er 5010- H T able Of Contents (Continued) Chap ter 8 - Gro omer Gener al Inf orm ation 8 - 2 ........................ Special T ools 8 - 3 .............................. Gr ooming Per for mance 8 - 4 ..................... T roubleshoot ing 8 - 5 .
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Reelmast er 5010- H Pag e 1 - 1 Safet y Chapter 1 Sa fety T able of Contents SAF ET Y INS TRUCT I ONS 2 ...................... Befor e Oper ating 2 ............................ While O perat ing 3 ............................. Maint enance and Serv ice 4 .
Reelmast er 5010- H Page 1 - 2 Safety Safety Instructions Reelmast er mac hines meet or exc eed safet y standard specif icat ions when weight s are ins talled ac cording to inform ation in t he Traction Unit O perat or ’ s M anual.
Reelmast er 5010- H Pag e 1 - 3 Safet y While Operating 1. Sit on t he seat when s tar ting and oper ating the m a- chine. 2. Bef ore st art ing t he engine: A.
Reelmast er 5010- H Page 1 - 4 Safety Maintenanc e and Ser vice 1. Befor e serv icing or m aking adjustm ents, lower cut - ting unit s, apply park ing brake, st op engine and remove key f rom t he ignit ion swit ch. 2. Make s ure machine is in safe operating condit ion by keeping all nut s, bolts and sc rews t ight .
Reelmast er 5010- H Pag e 1 - 5 Safet y Jacking Instructions Wh en ch ang in g ti res, att achmen ts or perf orm - in g o t her servi ce, u se correct ho i sts, jacks an d jack st and s. M ake sure mach i ne i s p arked o n a sol id , level surf ace such as a co ncret e fl oo r .
Reelmast er 5010- H Page 1 - 6 Safety Safety and Instruction Decals Numerous s afet y and instr uct ion dec als are affixed t o the t ract ion unit and t he cut ting unit s of y our Reelmaster. If any decal becomes illegible or damaged, ins tall a new decal.
Reelmaster 5010 - H Page 2 - 1 Product Records a nd Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 .............................. EQUIV ALENTS AND CONVERSIONS 2 ......
0.09375 Reelmaster 5010 - H Page 2 - 2 Product Records and Maintenance Equivalents and Conversions.
Reelmaster 5010 - H Page 2 - 3 Product Records a nd Maintenance T orque Specifications Recommended fastener torque val ues are listed in the following tables. For critical application s, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual.
Reelmaster 5010 - H Page 2 - 4 Product Records and Maintenance Standard T orque for Dry , Z inc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts SAE Gr.
Reelmaster 5010 - H Page 2 - 5 Product Records a nd Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Series ) Thre ad Siz e Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts ) Class 10.9 Bolts, Scr ews and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.
Reelmaster 5010 - H Page 2 - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque Square Head Hex Socket 1/4 - 20 UNC 140 + 20 in.
Reelmast er 5010- H Pa ge 3 - 1 Kubota D i esel E ng i ne Chapter 3 Kubota Diesel Engine T able of Contents SPECIFICA TIO NS 2 ............................ GENE RA L INFOR MA TION 3 ..................... T ract ion Unit O perat or ’ s Manual 3 .....
Reelmast er 5010- H Page 3 - 2 Kubota D i esel E ng i ne Specifications Item Descri ptio n Make / Des ignation Kubota Model D 1 105 - E4B : 4 - Cy c le, 3 C y linder , Water Cooled, T ier 4 Dies el Engine Number of C y linders 3 Bore x Stroke 3.07” x 3.
Reelmast er 5010- H Pa ge 3 - 3 Kubota D i esel E ng i ne General Information This Chapt er gives inf ormat ion about specific ations , tr oubleshooting, tes ting and repair of the Kubot a diesel engine used in Reelmas ter 5010 - H machines. Most r epairs and adjus tm ents r equire t ools whic h are comm only available in many service s hops.
Reelmast er 5010- H Page 3 - 4 Kubota D i esel E ng i ne Service and Repairs Air Cleaner Assem bly Figur e 2 1. Diesel eng ine 2. Air clean er assembly 3. Hose clamp (4 used) 4. Air intake ho se 5. Air intake ho se 6. Service i ndicat or 7. Indicat or adapter 8.
Reelmast er 5010- H Pa ge 3 - 5 Kubota D i esel E ng i ne Removal ( Fi g. 2) 1. Park machine on a level s urf ace, lower cut t ing units , st op engine, engage par king brak e and remov e key fr om t he ignition s witch. Rais e and suppor t hood. 2. Remove air cleaner c omponent s as needed us ing Figur e 2 as a guide.
Reelmast er 5010- H Page 3 - 6 Kubota D i esel E ng i ne Exhaust System Figur e 4 1. Diesel eng ine 2. Exhaus t muffler 3. Clamp 4. Hex nut (2 used) 5. Flange nut (4 used) 6. Carr iage b olt ( 4 used) 7. Bellhousing 8. T ail pipe br acket 9. Flange head screw 10.
Reelmast er 5010- H Pa ge 3 - 7 Kubota D i esel E ng i ne Removal ( Fi g. 4) CAUTION Th e muf fl er an d exh aust pip e may be h o t. T o av oid possible bur ns, allow the engine and ex- hau st system to coo l b efo re worki ng o n th e ex - hau st system.
Reelmast er 5010- H Page 3 - 8 Kubota D i esel E ng i ne Fuel System Figur e 6 1. Fuel tank 2. Fuel tan k cap 3. Screw (7 used ) 4. Str ap 5. Sender cover 6. Hose clamp 7. Fuel supply hose 8. Hose clamp 9. Fuel return hose 10. Clamp ( 2 used) 1 1. Fl ange head scr ew ( 2 used) 12.
Reelmast er 5010- H Pa ge 3 - 9 Kubota D i esel E ng i ne IMPOR T ANT : Follow all loca l code s and r egula- ti on s when recycl i ng o r di spo si ng w aste fu el. T o clean fuel tank , f lush tank out wit h clean diesel f uel. Make s ure t ank is f ree of all c ontam inates and debr is.
Reelmast er 5010- H Page 3 - 10 K ubota D i esel Eng i ne Radiator Assembly Figur e 8 1. Cool ant reser voir 2. Hose clamp (3 used) 3. Hose 4. Foam seal (2 u sed) 5. Oil co oler 6. Hose 7. Hose clamp (4 used) 8. Foam seal (2 u sed) 9. Radiat or cap 10.
Reelmast er 5010- H Pa ge 3 - 1 1 Kubota D i esel Eng i ne Removal ( Fi g. 8) 1. Par k m achine on a level surfac e, lower cut ting decks, st op engi ne, apply parking brake and remove key f rom t he ignit ion swit ch. 2. Unlatc h rear s creen, lif t s cr een fr om hinges and re- move s creen f rom mac hine.
Reelmast er 5010- H Page 3 - 12 K ubota D i esel Eng i ne 8. Connect air c leaner and m otor /gener ator int ake hoses t o fan shroud and secure wit h hose clamps (Fig. 9). T orque hos e clamps f rom 30 to 40 i n - lb (3. 4 to 4. 5 N- m ) . 9. Make s ure r adiator drainc ock is clos ed ( thr eaded out fully) .
Reelmast er 5010- H P age 3 - 13 Kubota D i esel E ng i ne This page is intent ional ly blank . Kubota D i esel Engine.
Reelmast er 5010- H Page 3 - 14 K ubota D i esel Eng i ne Engi ne Figur e 10 FRON T RIGH T 1. Diesel eng ine 2. Cap scr ew ( 12 used) 3. Flange head screw (4 used) 4. Snubbing washer (4 used) 5. Cap scr ew ( 4 used) 6. Flange nut (8 used) 7. Flange nut (8 used) 8.
Reelmast er 5010- H P age 3 - 15 Kubota D i esel E ng i ne Eng i ne Removal ( Fi g . 10) 1. Park machine on a level s urf ace, lower cut t ing units , stop engine and remove k ey from t he ignition swit ch. Chock wheels t o keep the m achine f rom mov ing.
Reelmast er 5010- H Page 3 - 16 K ubota D i esel Eng i ne 9. Disconnec t hydr aulic pum p drive shaf t fr om 48 VDC motor /gener ator (s ee Hydraulic Pump Dr ive Shaf t in the Servic e and Repairs sec tion of Chapter 4 - Hydr aulic Sys tem ). Pos ition and s upport driv e s haft away from mot or/ generat or and engine.
Reelmast er 5010- H P age 3 - 17 Kubota D i esel E ng i ne CAUTION One per son should oper ate lift or hoist while a se cond per son guides the engine int o the ma- chi ne. IMPOR T ANT : Make sur e to not dama ge the engine, fu el ho ses, hyd rau li c li nes, el ectri cal harn ess, ra - diator or ot her pa rt s while inst alling the e ngine.
Reelmast er 5010- H Page 3 - 18 K ubota D i esel Eng i ne Engine B ellhousing Assembly Figur e 14 1. Diesel eng ine 2. Motor /gen erato r assembly 3. Flange head screw 4. Collar 5. Coupler hub 6. W oodruff key 7. Bellhousing 8. Cap scr ew ( 2 used) 9.
Reelmaster 5010 - H Hydraulic System Page 4 - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TI ON 3 ..................... T raction Unit Operator ’s Manual 3 ......... ..... 48 VDC Battery Disco nnect 3 .
Reelmaster 5010 - H Hydraulic System Page 4 - 2 Specifications Item Description Piston (Traction) Pump Closed Circuit Axial Piston Design Maximum Pump Displacement (per revolution) 2.14 Cubic Inches (35 cc) Gear Pump 2 Section, Positive Displacement Gear T ype Pump Section P1 Displacement (per revolution) (all models) 0.
Reelmaster 5010 - H Hydraulic System Page 4 - 3 General Information T raction Unit Oper ator ’ s Manual The T raction Unit Operator’s Manual provides inf orma- tion regarding the opera tion, general mainte nance and maintenance intervals for your Reelmaster machin e.
Reelmaster 5010 - H Hydraulic System Page 4 - 4 T owing T raction Unit IMPORT ANT : If towing limits are exceeded, severe damage to the piston (traction) pump m ay occur . If it becomes necessary to tow or push t he machine, tow or push at a spe ed below 3 mph (4.
Reelmaster 5010 - H Hydraulic System Page 4 - 5 Hydraulic Hose and T ube Installation (O - Ring Face Seal Fitting) 1. Make sure threads and sealing sur faces of the hose/ tube and the fitting are free of burrs, nicks, scratches o r any foreign material.
Reelmaster 5010 - H Hydraulic System Page 4 - 6 Hydraulic Fitting Installation (SAE S traight Thread O - Ring Fitting into Component Port) Non - Adjustable Fitting (Fig. 7) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign m aterial.
Reelmaster 5010 - H Hydraulic System Page 4 - 7 Adjustable Fitting (Fig. 9) 1. Make sure all threads and sealing sur faces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O- ring be replaced an y time the connection is opened.
Reelmaster 5010 - H Hydraulic System Page 4 - 8 Relieving Hydraulic System Pressu re Before disco nnecting or performing any work on th e hy- draulic system, all pressure in the hydraulic system must be relieved. Park machin e on a level surface, lower cutting units fully , stop engine and engage parking brake.
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Reelmaster 5010 - H Hydraulic System Page 4 - 10 Hydraulic Schematic NOTE: A larger hydraulic sc hematic is included in Chapter 9 - Foldout Drawings LIFT CONTROL MANIFOLD.
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Reelmaster 5010 - H Hydraulic System Page 4 - 12 Hydraulic Flow Diagrams Figure 1 1 Working Pressure Low Pressure (Charge ) Return or Suction Flow T raction Circuit (Forward Shown) Reelmaster 5010 - H.
Reelmaster 5010 - H Hydraulic System Page 4 - 13 T raction Ci rcuit The hydra ulic traction circu it consists of a vari able dis- placement piston pump (P3) connected in a closed loop, parallel circuit to two (2) orbital roll er vane wheel motors.
Reelmaster 5010 - H Hydraulic System Page 4 - 14 Figure 13 Working Pr essure Low Pressure (Charge) Return or Suction Flow Lift Circuit: Rais e Cutting Units Reelmaster 5010 - H T C4 P4 C5 C1 C2/3 C2/3.
Reelmaster 5010 - H Hydraulic System Page 4 - 15 Lift Circuit: Raise Cutting Units A two section gear p ump is coup led to the pisto n (trac- tion) pump. Gear pu mp section (P1) supplies hydraulic flow to the lift contr ol manifold and ultimately for the lift cylinders.
Reelmaster 5010 - H Hydraulic System Page 4 - 16 Figure 14 Working Pr essure Low Pressure (Charge) Return or Suction Flow Lift Circuit: Lower Cutting Units Reelmaster 5010 - H T C4 P4 C5 C1 C2/3 C2/3 .
Reelmaster 5010 - H Hydraulic System Page 4 - 17 Lift Circuit: Lower Cutting U nits A two section gear p ump is coup led to the pisto n (trac- tion) pump. Gear pu mp section (P1) supplies hydraulic flow to the lift contr ol manifold and ultimately for the lift cylinders.
Reelmaster 5010 - H Hydraulic System Page 4 - 18 Figure 15 Working Pressure Low Pressure (Char ge) Return or Suction Flow Steering Circuit Reelmaster 5010 - H STEERING CYLINDER PISTON MOVEMENT STEERIN.
Reelmaster 5010 - H Hydraulic System Page 4 - 19 Steering Circuit A two section gear p ump is coup led to the pisto n (trac- tion) pump . Gear pum p section P2 su pplies hydraulic flow to the steerin g control valve and for t he traction charge circuit.
Reelmaster 5010 - H Hydraulic System Page 4 - 20 Special T ools Order these special tools f rom your T oro Distributor . Hydraulic Pressure T est Kit T oro Part Number: TOR47009 Use to take vario us pressur e readings for dia gnostic tests.
Reelmaster 5010 - H Hydraulic System Page 4 - 21 40 GPM Hydraulic T ester (Pressure and Fl ow) T oro Part Number: A T40002 Use to test hydraulic circu its and components for flow and pressure capacities as reco mmended in the T esting section of this cha pter .
Reelmaster 5010 - H Hydraulic System Page 4 - 22 High Flow Hydraulic Filter Kit T oro Part Number: TOR 60 11 The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and hig h pressure ( 5000 PSI/345 bar) capabilities.
Reelmaster 5010 - H Hydraulic System Page 4 - 23 Hydraulic T est Fitting Kit T oro Part Number: TOR4 07 9 This kit includes a variety of O - r ing 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.
Reelmaster 5010 - H Hydraulic System Page 4 - 24 Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft.
Reelmaster 5010 - H Hydraulic System Page 4 - 25 T roubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a th orough understanding of the com- plete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for failure.
Reelmaster 5010 - H Hydraulic System Page 4 - 26 T raction C ircuit Problems Problem Possible Cause Neutral is dif ficult to find or unit oper- ates in one direction only T raction control link age is misadjusted, disconnected , binding or damaged .
Reelmaster 5010 - H Hydraulic System Page 4 - 27 T raction Cir cuit Problems (Continue d) Problem Possible Cause Wheel motor will n ot turn Bra kes are binding.
Reelmaster 5010 - H Hydraulic System Page 4 - 28 Lift Circuit Problems (Continued) Problem Possible Cause None of the front cutting units will raise or lower but the re ar cutting units will raise and lower Solenoid valve SV1 on lift control manifold is faulty .
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Reelmaster 5010 - H Hydraulic System Page 4 - 30 Te s t i n g The most effective method for isolating problems in the hydraulic system is by using hydr aulic test equip ment such as pressure ga uges and flow meters in the circuits during va rious oper ational ch ecks (see the Special T ools section in this chapter).
Reelmaster 5010 - H Hydraulic System Page 4 - 31 Which Hydraulic T ests Are Necessar y? Before beginning any hydraul ic test, identify if th e prob- lem is related to the t raction cir cuit, lift circuit or steering circuit. Once the faulty system has been ide ntified, per- form tests that relate to that circuit.
Reelmaster 5010 - H Hydraulic System Page 4 - 32 T raction Circuit Rel ief V alve (R3) and (R4) Pressure T est Figure 26 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 INTERNAL CASE DRAIN TRACTIO N W.
Reelmaster 5010 - H Hydraulic System Page 4 - 33 NOTE: If machine is equipped with opti onal CrossT rax TM AWD, re verse relief pressure test ports are located on CrossT rax TM hydraulic m anifold. 3. Thoroughly clean traction circuit test port o n hydrau- lic tube for direction to be checked (F ig.
Reelmaster 5010 - H Hydraulic System Page 4 - 34 T raction Circuit C harge Pressure T est Figure 29 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 INTERNAL CASE DRAIN TRACTION WHEEL MOTORS G5 G6 B R5.
Reelmaster 5010 - H Hydraulic System Page 4 - 35 5. Start engine a nd run at idle s peed. Check f or any hy- draulic leakage from test con nections and correct be- fore proceeding with te st. 6. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load fo r approximately ten (10) minutes.
Reelmaster 5010 - H Hydraulic System Page 4 - 36 Gear Pump (P2) Flow T est (Using T ester with P ressure G auges and Flow Me ter) Figure 32 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 INTERNAL CAS.
Reelmaster 5010 - H Hydraulic System Page 4 - 37 3. Raise and prop op erator seat to a llow access to hy - draulic pump assembly . 4. Thoroughly clean the ends of the hydraulic tubes connected to the oil filter and piston pump inlets (Fig. 33). Disconnect hydraulic tubes from oil filter inlet and piston pump inlet.
Reelmaster 5010 - H Hydraulic System Page 4 - 38 Front Wheel Motor Efficiency T est Figure 35 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 INTERNAL CASE DRAIN TRACTI ON WHEEL MOTORS G5 G6 B R5 R4 R.
Reelmaster 5010 - H Hydraulic System Page 4 - 39 NOTE: If machine is equipped with opti onal CrossT rax TM AWD, jack up and support the rear wheels off the ground to allow flow thro ugh the rear wheel mo- tors. 6. Thoroughly clean junction of hydraulic hose and right side elbow fitting on bottom of piston (traction) pump (Fig.
Reelmaster 5010 - H Hydraulic System Page 4 - 40 Piston (T raction) Pump Flow T est (Using T ester with Flow Meter and Pressur e Gauge) Figure 37 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 INTERN.
Reelmaster 5010 - H Hydraulic System Page 4 - 41 5. Thoroughly clean junction of hydraulic hose and right side fitting on bottom of piston (traction) pump (Fig.
Reelmaster 5010 - H Hydraulic System Page 4 - 42 Lift Relief V alve (SVR V) Pressure T est Figure 39 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT I.
Reelmaster 5010 - H Hydraulic System Page 4 - 43 The lift relief valve (SVR V) pressure test should be per- formed to make sure that the lift circuit relief pressure is correct. Procedure for Lift Relief V alve (SVR V) Pressur e Te s t 1 . P a r km a c h i n eo nal e v e ls u r f a c ew i t ht h ec u t t i n gu n i t s lowered and disengag ed.
Reelmaster 5010 - H Hydraulic System Page 4 - 44 Gear Pump (P1) Flow T est (Using T ester with P ressure G auges and Flow Me ter) Figure 41 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTE.
Reelmaster 5010 - H Hydraulic System Page 4 - 45 The gear pump sectio n (P1) flow test should be per- formed to make s ure that the cut ting unit lift circuit h as adequate hydraulic flow . Procedure for Gear Pump (P1) Flow T est 1 . P a r km a c h i n eo nal e v e ls u r f a c ew i t ht h ec u t t i n gu n i t s lowered and disengag ed.
Reelmaster 5010 - H Hydraulic System Page 4 - 46 Lift Cylinder Internal Leakage T est Figure 43 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3.
Reelmaster 5010 - H Hydraulic System Page 4 - 47 4. Thoroughly clean the area ar ound the end of the h y- draulic hose at the rod end of the lift cylinder for the sup- ported lift arm. Disconnect the hydraul ic hose from the lift cylinder rod end fitting (Fig.
Reelmaster 5010 - H Hydraulic System Page 4 - 48 Steering Relief V alve (R10) Pressure T est Figure 47 STEERING WHEEL TURNED FOR RIGHT TURN OUT IN V1 RL STEERING R10 TP CYLINDER CONTRO L STEERING VA L.
Reelmaster 5010 - H Hydraulic System Page 4 - 49 The steering relief valve (R10) pressure test should be performed to make sure that th e steering circuit relief pressure is correct.
Reelmaster 5010 - H Hydraulic System Page 4 - 50 Steeri ng Cylinder Inter nal Leakage T est Figure 49 STEERING CYLINDER STEERING CONTROL VA LV E (FULL Y EXTENDED) LOOK FOR LEAKAGE PLUG STEERING WHEEL .
Reelmaster 5010 - H Hydraulic System Page 4 - 51 The steer ing cylinder inte rnal leaka ge test should be performed if a steering probl em is identified.
Reelmaster 5010 - H Hydraulic System Page 4 - 52 Service and Repairs General Preca utions for Removing a nd Installing Hydrauli c System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraul ic sys- tem, park machine on a level surface, lower cutting units, engage parking brake and stop engine.
Reelmaster 5010 - H Hydraulic System Page 4 - 53 Check Hydraul ic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
Reelmaster 5010 - H Hydraulic System Page 4 - 54 Flush Hydraulic System IMPORT ANT : Flush the hydraulic system any time there is a sever e component failure or the system is contaminated. Conta minated oil appears milk y or black or contains metal par ticles.
Reelmaster 5010 - H Hydraulic System Page 4 - 55 Filtering Closed - Loop T raction Circuit Filtering of a closed - loop hydraulic system after a major component failure (e. g. traction (piston ) pump or wheel motor) is a requirement to pre vent debris from transmit- ting throughout the system.
Reelmaster 5010 - H Hydraulic System Page 4 - 56 Hydraulic System Start - up NOTE: When initially starting th e hydraulic system with new or rebuilt components such as pumps, w heel mo- tors or lift cylinders, it is important that this start - up pro- cedure be used.
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Reelmaster 5010 - H Hydraulic System Page 4 - 58 Hydraulic Reservoir 1. Suction strainer 2. Hydraulic reservoir 3. Recess bumper 4. Clamp (2 used) 5. Suction hose 6. Hose clamp (2 used) 7. Reservoir cap 8. Washer he ad scr ew (2 u sed) 9. Flange nut ( 3 used) 10.
Reelmaster 5010 - H Hydraulic System Page 4 - 59 Removal (Fig. 52) 1. Thoroughly clean hydraulic hose ends and fittings on hydraulic reservoir to prev ent hydraulic system contami- nation. 2. Drain hydraulic oil from reservoir . 3. Disconnect hydraulic lines from fittings on the reser- voir .
Reelmaster 5010 - H Hydraulic System Page 4 - 60 Piston (T raction) Pump Control Assembly 1. Flange head screw (2 used) 2. Piston (traction) pu mp 3. Lever damper 4. Flange nut 5. Pump plate 6. Cap screw (3 used) 7. Carriage screw 8. Lock nut 9. Pu mp lever 10.
Reelmaster 5010 - H Hydraulic System Page 4 - 61 Disassembly (Fig. 53) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition s witch. 2. Remove components from piston (traction) pump control assembly as needed using Figures 53 and 54 as guides.
Reelmaster 5010 - H Hydraulic System Page 4 - 62 Hydraulic Pump Assembly 1. Gear pump assembly 2. O - rin g 3. O - rin g 4. Flat washer (4 used) 5. O - rin g 6. Hydraulic fitting 7. Piston (traction) pump assembly 8. Socket head screw (2 used) 9. Lock washer (2 used) 10.
Reelmaster 5010 - H Hydraulic System Page 4 - 63 Removal (Fig. 56) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition s witch. 2. Raise and support hood and operator seat. Lift hood saddle from frame bracke ts and remove from machine.
Reelmaster 5010 - H Hydraulic System Page 4 - 64 13. Remove two (2) socket head screws, lock washers and flat w ashers that secure gear pump to pi ston (trac- tion) pump. Remove gear pump fro m piston (traction) pump. Locate and discard O - ring (item 15) from be- tween pumps.
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Reelmaster 5010 - H Hydraulic System Page 4 - 66 Piston (T raction) Pump Service 1. Piston (traction) pu mp housing 2. Auxiliary shaft 3. Retaining ring 4. Ball bearing 5. Retaining ring 6. Seal 7. Backup washer 8. Bearing (2 used) 9. O - rin g 10. T runnion cover 1 1 .
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Reelmaster 5010 - H Hydraulic System Page 4 - 68 Gear Pump Se rvice 1. Front cover 2. Dowel pin (4 used) 3. Square section seal (4 used) 4. Back - up seal (4 used) 5. Pressure seal (4 used) 6. Thrust pla te (4 used) 7. Drive shaft 8. Dr iven g ear 9. Body 10.
Reelmaster 5010 - H Hydraulic System Page 4 - 69 IMPORT ANT : Mark the relative positions of the gear teeth and the thrust plates so they can be reassem- bled in the same position. Do not touch the gear sur- faces as residue on hands may be corrosiv e to gear finish.
Reelmaster 5010 - H Hydraulic System Page 4 - 70 Hydraulic Pump Drive Shaft 1. Hood saddle 2. Air intake hose 3. Hose clamp (2 used) 4. Flange head screw (4 used) 5. Flange nut (4 u sed) 6. Upper intake shroud 7. Lower intake shroud 8. Br ush sea l (2 use d) 9.
Reelmaster 5010 - H Hydraulic System Page 4 - 71 Removal (Fig. 62) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition s witch. 2. Raise and support hood and operator seat. Lift hood saddle (item 1) from frame brac kets and remove from machine.
Reelmaster 5010 - H Hydraulic System Page 4 - 72 Hydraulic Pump Drive Shaft Cr oss and Bearing Service 1. End yoke (motor/generator) 2. Grease fitting (2 used) 3. Snap ring (4 per cross and bearing) 4. Cross and bearing assembly 5. Sh aft yok e (male) 6.
Reelmaster 5010 - H Hydraulic System Page 4 - 73 Disassembly (Fig. 64) 1. Remove hydraulic pump drive shaft from vehicle (see Hydraulic Pump Drive Shaft in this section). IMPORT ANT : When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent yoke damage.
Reelmaster 5010 - H Hydraulic System Page 4 - 74 Front Wheel Motors 1. Wheel motor (LH shown) 2. Lug nut (5 used per wheel) 3. Hub 4. Wheel stud (5 used per wheel) 5. Wheel assembly 6. Brake drum 7. Front wheel shield (2 used) 8. Cap screw (2 used per shield) 9.
Reelmaster 5010 - H Hydraulic System Page 4 - 75 Removal (Fig. 65) 1. Park the machin e on a level su rface, lower the cut - ting units and stop the engine. Remove th e key from the ignition switch. 2. Chock rear wheels to prevent machine from moving or shifting.
Reelmaster 5010 - H Hydraulic System Page 4 - 76 Front Wheel Motor Service 1. Cap screw (7 used) 2. End cap 3. O - ring (3 used) 4. Geroler assembly 5. V alve plate 6. Thrust bearing 7. Bearing 8. V a lve 9. Dowel pin (4 used) 10. Bal ancing r ing 1 1.
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Reelmaster 5010 - H Hydraulic System Page 4 - 78 Rear Wheel Motors (Machines with Optional CrossT rax TM Kit) 1. Lug nut (5 used per wheel) 2. Rear wheel assembly 3. Wheel hub assembly 4. Lock nut 5. Woodruff key 6. 45 o hydraulic fitting (2 per motor) 7.
Reelmaster 5010 - H Hydraulic System Page 4 - 79 6. Remove wheel hub from rear wheel motor: IMPORT ANT : DO NOT hit wheel hub, puller or wheel motor with a hammer during wheel hub removal or installation. Hammering m ay cause damage to the wheel motor .
Reelmaster 5010 - H Hydraulic System Page 4 - 80 Rear Wheel Motor Ser vice (Mach ines with Optional CrossT rax TM Kit) 1. Cap screw (7 used) 2. End cover 3. Body seal (5 used) 4. Commutator ring 5. Commutator 6. Commutator ring 7. Manifold 8. Stator 9.
Reelmaster 5010 - H Hydraulic System Page 4 - 81 Control Manifold Cartr idge V alve Ser vice 1. Make sure the control manifold is clean before re- moving the cartridge valve from the con trol manifold. 2. If cartridge valve is solenoid operated, remove n ut securing solenoid coil to th e cartridge valve.
Reelmaster 5010 - H Hydraulic System Page 4 - 82 Lift Control Manifold 1. Lift control manifold 2. Flange head screw 3. O - rin g 4. Hydraulic hose 5. Hydraulic hose 6. Hydraulic hose 7. Hydraulic hose 8. Hydraulic hose 9. Hydraulic hose 10. Hydraulic tube 1 1.
Reelmaster 5010 - H Hydraulic System Page 4 - 83 Removal (Fig. 69) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine.
Reelmaster 5010 - H Hydraulic System Page 4 - 84 Lift Control Manifold Service 1. Lift control manifold 2. Check valve (4 used) 3. Solenoid valve (SV3) 4. Solenoid coil (2 used) 5. Solenoid coil spacer (2 used) 6. Nut (3 used) 7. Solenoid valve (SV2) 8.
Reelmaster 5010 - H Hydraulic System Page 4 - 85 For lift control manifold service procedures, see Control Manifold Cartridge V alve Service in this section. Refer to Figure 7 1 for cartridg e valve installation to rque. Refer to Figures 71 and 72 for hydraulic fitting installation torque values.
Reelmaster 5010 - H Hydraulic System Page 4 - 86 CrossT rax TM A WD Manifold (Machines with Optional CrossT rax TM Kit) 1. CrossT rax A WD manifold 2. Hydraulic tube 3. Hydraulic tube 4. Hydraulic tube 5. O - rin g 6. Hydraulic fitting (7 used) 7. O - ring 8.
Reelmaster 5010 - H Hydraulic System Page 4 - 87 6. Put caps or plugs on disconnected lines and fittings to prevent contamination. 7. Support manifold to prevent it from falling. Remo ve three (3) cap screws and lock washers that secure man- ifold to machine fra me.
Reelmaster 5010 - H Hydraulic System Page 4 - 88 CrossT rax TM A WD Manifold Service (Machines with Optional Cr ossT rax TM Kit) 1. CrossT rax A WD manifold 2. O - rin g 3. Plug (NWD #6) 4. Seal kit 5. Check valve 6. Plug (NWD #4) 7. O - ring 8. Orifice (.
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Reelmaster 5010 - H Hydraulic System Page 4 - 90 Lift Cylinders 1. Lift cylinder 2. Cylinder pin 3. Flange head screw 4. Li ft arm ( #4 show n) 5. Fl at washe r 6. Hydraulic hose 7. O - ring 8. 90 o hydraulic fitting 9. O - ring 10. Hydraulic hose 1 1.
Reelmaster 5010 - H Hydraulic System Page 4 - 91 Removal (Fig. 75) 1. Park the machine on a level su rface, engage th e parking brake, l ower the cutting units and stop the en- gine.
Reelmaster 5010 - H Hydraulic System Page 4 - 92 Lift Cylinder Service 1. Grease fitt ing 2. Shaft 3. Dust seal 4. Head 5. BS se al 6. Retaining ring 7. Back up washer 8. O - ring 9. Piston 10. Wear r ing 1 1. B P seal 12. O - ring 13. Lock nut 14. Barrel 15.
Reelmaster 5010 - H Hydraulic System Page 4 - 93 3. Using a spanner wrench, rotate he ad clockwise until the edge of the retaining ri ng appears in the barrel o pen- ing. Insert a screwdriver un der the beveled edge of the retaining ring to start the retainin g ring through the open- i n g .
Reelmaster 5010 - H Hydraulic System Page 4 - 94 Steering Contro l V alve 1. Steering control valve 2. Flange head screw (2 used) 3. Socket head screw (4 used) 4. Steering wheel 5. Flat washer 6. Lock nut 7. St eering w heel co ver 8. Steering column 9.
Reelmaster 5010 - H Hydraulic System Page 4 - 95 CAUTION Before openi ng hydraulic sy stem, operate all hy - draulic controls to relieve system pressur e and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pr essure in the Gen- eral Information se ction of this chapter .
Reelmaster 5010 - H Hydraulic System Page 4 - 96 Steering Contro l V alve Service 1. Screw (5 used) 2. O - ring (5 used) 3. End cover 4. O - rin g 5. Outer gearwheel 6. Inner gearwheel 7. Distributor plate 8. O - rin g 9. Cardan shaft 10. Spool 1 1. Sleeve 12.
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Reelmaster 5010 - H Hydraulic System Page 4 - 98 Steer ing Cylinder 1. Steering cylinder 2. Retaining ring 3. Grease fitting 4. Hydraulic hose 5. O - rin g 6. 90 o hydraulic fitting 7. O - ring 8. Hydraulic hose 9. Grease fitt ing 10. Bal l join t 1 1.
Reelmaster 5010 - H Hydraulic System Page 4 - 99 3. Label all hydraulic connections for assembly pur- poses. Thoroughly clean hydra ulic hose ends prior to disconnecting hoses from the steering cylinder . 4. Disconnect hydraulic hose s from fittings in ste ering cylinder .
Reelmaster 5010 - H Hydraulic Syst em Page 4 - 100 Steering Cylinder Service 1. Shaft 2. Dust seal 3. BP seal 4. Head 5. Retaining ring 6. Ba ck - up ring 7.
Reelmaster 5010 - H Hydraulic System Page 4 - 101 Inspection CAUTION Use eye protection such as goggles when using compressed air to clean steering cylinder com- ponents. 1. Wash all cyl inder components in solvent. Dry p arts with compressed air . 2.
Reelmaster 5010 - H Hydraulic Syst em Page 4 - 102 Hydraulic Oil Cooler Figure 85 1. Oil cooler 2. Hose clamp (4 used) 3. Hydraulic hose (2 used) 4. Radiator 5. Cooler clamp (16 used) 6. Fl at wash er (8 used ) 7. Cap screw (4 used) 8. F lange n ut ( 10 used ) 9.
Reelmaster 5010 - H Hydraulic System Page 4 - 103 Removal (Fig. 85) 1. Park machine on a level surface, lowe r cutting units, stop engine, engag e parking brake and re move key from the ignition s witch.
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Reelmaster 5010 - H Page 5 - 1 Electri cal Syste m Chapter 5 Electrical System T able of Contents GENERAL INFORMA TI ON 2 ..................... Operator ’s Manu al 2 .......................... Electrical Drawings 2 ..................... ..... 48 VDC Battery Disco nnect 2 .
Reelmaster 5010 - H Page 5 - 2 Electrical System General Information Operator ’ s Manual The Operator’s Manual provi des information regard ing the operation, general maintenance and maintenance intervals for your Reel master mach ine. Refer to that publication for addition al information whe n servicing the machine.
Reelmaster 5010 - H Page 5 - 3 Electri cal Syste m T oro Electronic Controller (TEC) Reelmaster 5010 - H machines use a T oro Electronic Controller (TEC) to manage machine electrical func- tions. The controller is microprocessor controlled that senses the condition of variou s switches and sensors (inputs).
Reelmaster 5010 - H Page 5 - 4 Electrical System Electrical System Operation Reelmaster 5010 - H machines use two (2) separate electrical systems. Most mach ine functions operate on a typical 12 VDC system. The second system exists to operate the electric cutti ng reels and is a 48 V DC electri- cal system.
Reelmaster 5010 - H Page 5 - 5 Electri cal Syste m 48 VDC System Operation The Reelmaster 5010 - H 48 VDC system includes a 48 VDC battery pack, an engine driven motor/generator as- sembly , five (5) cutting ree l motors, a main co ntactor used to energize the system and ad ditional circuit con- trol components.
Reelmaster 5010 - H Page 5 - 6 Electrical System Special T ools Order Special T ools from yo ur T oro Distributor . Digital Mul timeter The multimet er can test elec trical comp onents an d cir- cuits for current, resista nce or voltage. Obtain t his tool locally .
Reelmaster 5010 - H Page 5 - 7 Electri cal Syste m Cutting Reel Motor Rotor T ool Set T oro Part Number: 127 - 2574 (for both 5” and 7” cutting unit motors) The rotor tool set for the cutting reel motor is required to remove and install the rotor from the reel motor housing.
Reelmaster 5010 - H Page 5 - 8 Electrical System Generator Rotor T ool Set T oro Part Number: TOR 60 2 9 The generato r rotor tool set is required to remove and install the rotor f rom the motor/ generator h ousing. T o ol set includes base plate, threaded shaft and handle (Fig.
Reelmaster 5010 - H Page 5 - 9 Electri cal Syste m Battery Hydrometer Use the bat tery hydr ometer whe n measuring s pecific gravit y of battery electr olyte in the machine 12 VDC bat- tery . Obtain this t ool locally . NOTE: A battery hydrometer is not usable for the bat- teries in the Reelmaster 5010 - H 48 VDC battery sys- tem.
Reelmaster 5010 - H Page 5 - 10 Ele ctrical System InfoCenter Display The InfoCenter Disp lay used on your Reelma ster is a LCD device that is located on the console.
Reelmaster 5010 - H Page 5 - 1 1 Electrical Sys tem Main Information Scr eens The two (2) InfoCenter main information screens (Figs. 13 and 14) are displayed afte r the initial splash scree n has been disp layed for seve ral seconds. Dur ing normal machine operation, the main information screens provide machine informatio n for the operator .
Reelmaster 5010 - H Page 5 - 12 Ele ctrical System Access Protected Display Screens The protected display screens are availab le on the Info- Center to view the electrical status of the 48 VDC p ower circuit.
Reelmaster 5010 - H Page 5 - 13 Electrical S ystem Main Menu Scr een The main m enu screen ca n be accessed fro m the Info- Center main information by pressing and releasing the menu/back button (left button) on the display twice. Once at the main men u screen (Fig.
Reelmaster 5010 - H Page 5 - 14 Ele ctrical System Service Screen The service scree n (Fig. 20) contains mac hine opera- tional information includin g hours, counts, reset defa ults and cutting unit backlap en gage. V alues listed for these service menu items cannot be changed.
Reelmaster 5010 - H Page 5 - 15 Electrical S ystem Diagnostics Scr een The diagnostics screen (Fig. 21) lists the various states of machine electrical components. The diagnostics screen should be used to check o peration of machine controls and to verify that switches and circuit wiring are functioning correctly .
Reelmaster 5010 - H Page 5 - 16 Ele ctrical System Settings Sc reen The settings scre en identifies the Inf oCenter units (En- glish or Metric) and language . The settin gs screen also allows the operator t o customize t he backlight (bright- ness) and contrast settings for the InfoCenter display .
Reelmaster 5010 - H Page 5 - 17 Electrical S ystem Height of Cut (HOC) identifies the setting for cutting unit height o f cut. This info rmation is us ed by machine controllers to determin e cutting unit reel speed .
Reelmaster 5010 - H Page 5 - 18 Ele ctrical System T roubleshooting CAUTION Remove all jew elry , especially ring s and watches, before doing any electrical tr ouble - shooting or testing. Disconnect the battery cables unless the test requir es battery voltage.
Reelmaster 5010 - H Page 5 - 19 Electrical S ystem Advisory Number Advisory Description Possible Reason for Advisory 160 Start D enied Neither seat occupied nor parking brake applied T raction pedal i.
Reelmaster 5010 - H Page 5 - 20 Ele ctrical System Fault Codes The InfoCenter Display will identify electrical system malfunctions (faults) if they occur . Should a fault occur during machine operatio n, the InfoCenter indicator light will illuminate and the fault will be displayed on the Info- Center Display (Fig.
Reelmaster 5010 - H Page 5 - 21 Electrical S ystem Fault Code Fault Description Service Suggestions 1 Excessive engine coolant temperature (above 105 o C) caused PTO to disen gage Check radiator and s.
Reelmaster 5010 - H Page 5 - 22 Ele ctrical System Fault Code Fault Description Service Suggestions 28 48 VDC devices (motor/generator and all cut- ting reel motors) are all off - line Make sure that .
Reelmaster 5010 - H Page 5 - 23 Electrical S ystem Fault Code Fault Description Service Suggestions 43 CAN - bus fault for motor/generator Check CAN- bus connection to motor/generator V erify battery .
Reelmaster 5010 - H Page 5 - 24 Ele ctrical System Fault Code Fault Description Service Suggestions 63 48 VDC pre - charge fault Disconnec t one cutting r eel motor at a tim e until the fault is no lo.
Reelmaster 5010 - H Page 5 - 25 Electrical S ystem Fault Code Fault Description Service Suggestions 68 M o t o rs t a l l e do n# 4c u t t i n gu n i t Check #4 cutting unit for excessive rotating res.
Reelmaster 5010 - H Page 5 - 26 Ele ctrical System Fault Code Fault Description Service Suggestions 72 High temperature warn ing for #3 cutting unit Let machine cool to lower cutting unit motor temper.
Reelmaster 5010 - H Page 5 - 27 Electrical S ystem Fault Code Fault Description Service Suggestions 75 High temperature warnin g for motor/generator Make sure that hood screen is clean Check that air .
Reelmaster 5010 - H Page 5 - 28 Ele ctrical System Fault Code Fault Description Service Suggestions 79 System voltag e under 32 VDC has d isabled #4 cutting unit Check logic power conne ction to #4 cu.
Reelmaster 5010 - H Page 5 - 29 Electrical S ystem Fault Code Fault Description Service Suggestions 83 Logic vol tage over 67.5 V DC has disa bled #2 cutting unit If multiple cutting units are report .
Reelmaster 5010 - H Page 5 - 30 Ele ctrical System Fault Code Fault Description Service Suggestions 86 Logic voltage over 67.5 VDC has disabled #5 cutting unit If multiple cutting units are reporting .
Reelmaster 5010 - H Page 5 - 31 Electrical S ystem Fault Code Fault Description Service Suggestions 93 System bus vol tage under 36 VDC has disabled moto r/generator (main conta ctor is engaged) Check.
Reelmaster 5010 - H Page 5 - 32 Ele ctrical System Fault Code Fault Description Service Suggestions 97 System bus voltage over 67.5 VDC has disabled #4 cuttin g unit If multiple cutting units are repo.
Reelmaster 5010 - H Page 5 - 33 Electrical S ystem Fault Code Fault Description Service Suggestions 108 Excessive voltage occurred at internal motor regulator for #3 cu tting unit #3 cutting unit moto.
Reelmaster 5010 - H Page 5 - 34 Ele ctrical System Fault Code Fault Description Service Suggestions 11 7 Insufficient voltage occur red at inter nal motor/ generator regulator a nd disabled moto r/ ge.
Reelmaster 5010 - H Page 5 - 35 Electrical S ystem Starting Problems Problem Possible Causes All electrical power is dea d, including InfoCenter Display . 12 VDC battery is disc harged. Ignition switch or circuit wiring is faulty . Fusible link harness at the engine starter motor is faulty .
Reelmaster 5010 - H Page 5 - 36 Ele ctrical System Starting Pr oblems (Continue d) Problem Possible Causes Nothing happens when start attempt is made. InfoCenter Display operates with t he ignition switch in RUN. NOTE: If machine controls are not in the correct position to start the engine (e .
Reelmaster 5010 - H Page 5 - 37 Electrical S ystem General Run and T ransport Pr oblems Problem Possible Causes Engine continu es to run, but should n ot, when the ignition switch is turned off. Engine fuel actuator or circuit w iring is faulty . Ignition switch or circuit wiring is faulty .
Reelmaster 5010 - H Page 5 - 38 Ele ctrical System Cutting Unit Operating Problems Problem Possible Causes The cutting units remain eng aged, but should not, with no operator in the seat. Seat switch or circuit wiring is faulty . TEC controller is faulty .
Reelmaster 5010 - H Page 5 - 39 Electrical S ystem Cutting Unit Operating Pr oblems (Continued) Problem Possible Causes T h ec u t t i n gu n i t sd on o tr u nw h e np l a c e di nt h e backlap direction. The parking br ake is not applied. Reel engage/dise ngage switch is in the OFF position.
Reelmaster 5010 - H Page 5 - 40 Ele ctrical System Electrical System Quick Checks 12 VDC Battery T est (Open Circuit T est) Use a digital multimeter to measure the battery voltage. Remove battery cover to access the b attery at the rear of the machine.
Reelmaster 5010 - H Page 5 - 41 Electrical S ystem Check Operation of Interlock Switches CAUTION The interlock switches are for the protection of the operator and bystanders and to ensure cor- rect operation of the machine. Do not bypass or disconnect switches.
Reelmaster 5010 - H Page 5 - 42 Ele ctrical System Adjustments T raction Neutr al Switch The traction neutral switch is a normally open p roximity switch that closes when the tractio n pedal is in the neu- tral position. The switch mounts to a bracke t on the trac- tion pump.
Reelmaster 5010 - H Page 5 - 43 Electrical S ystem Parking Brake Switch The parking brake switch is a normall y open proximity switch. The parking brake switch is at tached to the bot- tom of the brake pedal (Fig.
Reelmaster 5010 - H Page 5 - 44 Ele ctrical System Cutting Unit Down Limit Switch The cutting unit down limit switch is a normally open proximity switch that closes when the front, outside cut- ting units are in the tu rn - around position. The down limit switch is attached to a frame brac ket inside the fr ont, right lift arm pivot tube.
Reelmaster 5010 - H Page 5 - 45 Electrical S ystem Mow/T ransport Switch The mow/transport switch is a normally closed proximity switch that is attac hed to the bottom of the floor platfo rm (Fig.
Reelmaster 5010 - H Page 5 - 46 Ele ctrical System Component T esting For accurate resistance and/ or continuity checks, elec- trically disconnect th e component being tested from the circuit (e.g. unplug the ignitio n switch connector before doing a continuity c heck of the switch).
Reelmaster 5010 - H Page 5 - 47 Electrical S ystem 12 VDC System Fuses The fuse block is located beh ind the control arm access cover (Fig. 32). In addition to the 12 VDC fus es in the fuse block, a 2 Amp fuse is included in the wire harne ss to protect the logic power circuit for the TEC controller .
Reelmaster 5010 - H Page 5 - 48 Ele ctrical System 48 VDC System Fuses Several fuses are used in t he 48 VDC system (motor/ generator an d cutting unit m otors) for circuit protec tion. Fuse Identification and Function 35 Amp Reel Moto r Fuse s: Protect the 48 VDC power supply circuits fo r the electric reel mo tors.
Reelmaster 5010 - H Page 5 - 49 Electrical S ystem Engine Speed Switch The engine s peed switch is a mom entary switch that is used as an inpu t for the TEC controlle r to raise or lower the engine speed. Whe n the switch is depressed and held in the forwar d position, the engine s peed will in- crease.
Reelmaster 5010 - H Page 5 - 50 Ele ctrical System Reel Engage /Disengage Switch The reel engage/disenga ge switch is used to allow the cutting units to operate. A n indicator light on the switch identifies whe n the engage/disengage switch is en- gaged.
Reelmaster 5010 - H Page 5 - 51 Electrical S ystem Headlight Switch The headlight switch allows the headlights to be turned on and off. This rocker switch is locate d on the operator side of the control arm (Fig. 41). NOTE: The T oro Electronic Controller (TEC) does not monitor the operati on of the headlight switch.
Reelmaster 5010 - H Page 5 - 52 Ele ctrical System Seat Switch The seat switch is normally open and closes when the operator seat is occu pied. If the traction sy stem or reel engage/disengag e switch is engaged wh en the opera- tor raises out of the s eat, the engine will stop.
Reelmaster 5010 - H Page 5 - 53 Electrical S ystem Parking Brake Switch The parking brake switch is a normall y open proximity switch. The parking brake switch is at tached to the bot- tom of the brake pedal (Fig. 44). The T oro Electronic Controller (TEC) monitors the operation of the parking brake s witch.
Reelmaster 5010 - H Page 5 - 54 Ele ctrical System T raction Neutr al Switch The traction neutral switch is a normally open p roximity switch that closes when the tractio n pedal is in the neu- tral position. The switch mounts to the pump plate on the piston (tr action) pum p.
Reelmaster 5010 - H Page 5 - 55 Electrical S ystem Cutting Unit Down Limit Switch The cutting unit down limit switch is a normally open proximity switch that closes when the front, outside cut- ting units are in the t urn - around position. The down limit switch is at tached to a frame bra cket inside the front, right lift arm pivot tube.
Reelmaster 5010 - H Page 5 - 56 Ele ctrical System Joystick Raise and L ower Switches T wo (2) micro swi tches for the joystick are locate d on the lower mow/raise lev er that is attached t o the control arm. The rear switch on the control is used to lo wer (and en- gage) the cutting un its and the front switch to raise (an d disengage) them.
Reelmaster 5010 - H Page 5 - 57 Electrical S ystem Mow/T ransport Switch The mow/transport switch is a normally closed proximity switch that opens when the mow stop lever is placed i n the transport po sition. The se nsing plate for the mow/ transport switch is the mow stop lever (Fig.
Reelmaster 5010 - H Page 5 - 58 Ele ctrical System Main Power , Glow and 48 VDC Logic Relays Y our Reelmaster uses three (3) identical electrical re- lays that have four (4) termi nals. The main power and glow relays are attached to a frame b racket under the hood near the engine exhaust muf fler (Fig.
Reelmaster 5010 - H Page 5 - 59 Electrical S ystem 5. Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should have continuity be- tween terminals 30 and 87 as +12 VDC is applie d to ter- minal 85.
Reelmaster 5010 - H Page 5 - 60 Ele ctrical System Start Relay The start relay is used in the engine starting circuit. When energized by the TEC controller , the start relay provides a current path to energize the engine starter solenoid.
Reelmaster 5010 - H Page 5 - 61 Electrical S ystem Main Contactor The main contactor provides curren t to the 48 VDC sys- tem circuits ( e.g. motor/generator , reel motors).
Reelmaster 5010 - H Page 5 - 62 Ele ctrical System T oro Electronic Controller (TEC) Reelmaster 5010- H machines use a T oro Electronic Controller (TEC) to control e lectrical system operation. The TEC controller senses the condition of variou s switches (inputs) and directs power outp ut to allow cer- tain machine functions.
Reelmaster 5010 - H Page 5 - 63 Electrical S ystem Because of the solid state cir cuitry built into the TEC controller , there is no method to test it directly . The TEC may be damag ed if an attemp t is made to test it with an electrical test device, such as a di gital multimeter .
Reelmaster 5010 - H Page 5 - 64 Ele ctrical System Fusible Link Harness The Reelmaster 5010- H uses three (3) fusible links for circuit protection. These f usible links are located in a harness that connects the sta rter B+ terminal to the main wire harness (Fig.
Reelmaster 5010 - H Page 5 - 65 Electrical S ystem Diode Assembly A diode assembly is used in the Ree lmaster main wire harness (Fig. 62). The diode is used for circuit protection from voltage spikes that occur when t he starter solenoid is de - energized.
Reelmaster 5010 - H Page 5 - 66 Ele ctrical System 48 VDC System Protection Diode The Reelmaster 5010 - H 48 VDC system includes a diode that is used for circuit pro tection from voltage spikes when the m ain contactor is de - ener gized.
Reelmaster 5010 - H Page 5 - 67 Electrical S ystem Location ID Module The location ID module e xists in the 48 VDC electrical circuit to identify th e location of the five (5) cutting reel motors. This module allows such machine features as starting and sto pping the rear cutti ng units slightly la ter than the front cu tting units.
Reelmaster 5010 - H Page 5 - 68 Ele ctrical System Cutting Reel Motor The five (5) cutting reel motors are identical 48 VDC, brushless, per manent mag net motors.
Reelmaster 5010 - H Page 5 - 69 Electrical S ystem CAN - bus T ermination Resistors System communication between ele ctrical components on Reelmaster 5010 - H machines is accomplished on two (2) CAN - bu s communication sys tems: one fo r the 12 VDC system and one for the 48 VDC system.
Reelmaster 5010 - H Page 5 - 70 Ele ctrical System Hydraulic Solenoid V alve Coil The Reelmaster hydraulic lif t control manifold includes four (4) solenoid valves for system control (Fig. 71). When the solenoid coi ls are energized, hydraul ic valve shift occurs to control hyd raulic flow .
Reelmaster 5010 - H Page 5 - 71 Electrical S ystem T emperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 72). The T oro Electronic Controller (TEC) monitors the operat ion of the tem peratur e sender .
Reelmaster 5010 - H Page 5 - 72 Ele ctrical System Oil Pressure Switch The engine oil pressure switch is a normally closed switch that opens with pressure during normal engine operation. Th e oil pressure swit ch is located on the en- gine near the oil filter (Fig.
Reelmaster 5010 - H Page 5 - 73 Electrical S ystem Fuel Actuator The fuel actuator used on your Reelmaster must be en- ergized by the TEC controller for the diesel engi ne to run. The actuator is mounted to t he injection pump on t h ee n g i n e( F i g .
Reelmaster 5010 - H Page 5 - 74 Ele ctrical System Fuel Sender The fuel sender is a variable resi stance device that al- lows the InfoCenter display to sh ow level of the fuel tank.
Reelmaster 5010 - H Page 5 - 75 Electrical S ystem 8. Use a multimeter to check resistance of the fuel sender across the two (2) sen der terminals (Fig. 80). A. Resistance with the float in the full position (com- pletely up) shou ld be from 5 to 8 ohms.
Reelmaster 5010 - H Page 5 - 76 Ele ctrical System Fuel Pump The Reelmast er electr ic fuel p ump is att ached to the in- side of the left sid e frame rail nea r the fuel ta nk (Fig. 81). IMPORT ANT : When testing fuel pump, make sure that pump is not operated without fuel.
Reelmaster 5010 - H Page 5 - 77 Electrical S ystem Service and Repairs NOTE: See the Kubota W orkshop Manual, Diesel E n- gine, 05 - E4B Series for engine electrical component re- pair information . Hydraulic Solenoid V alve Coils A hydraulic solenoid valve co il on the lift control manifol d (Fig.
Reelmaster 5010 - H Page 5 - 78 Ele ctrical System 12 VDC Battery Service The battery is the heart of the 12 VDC electrical system. With regular and p roper service, battery life ca n be ex- tended. Additio nally , battery and electrical compone nt failure can be pr evented.
Reelmaster 5010 - H Page 5 - 79 Electrical S ystem Battery Storage If the machine will be stored for mor e than thirty (30 ) days: 1. Charge battery fully before storing the machine (see Battery Service in this section). 2. Either remove battery from machine and store on a shelf or leave battery on the machine.
Reelmaster 5010 - H Page 5 - 80 Ele ctrical System Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charg ed, the slow ch arging meth- od is presented here. This charg ing method can be a c- complished with a constant curren t battery charger which is readily available.
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Reelmaster 5010 - H Page 5 - 82 Ele ctrical System 48 VDC Battery Pack Service (Cutting Reel and M otor/Generator Systems) 1. Battery (4 used) 2. Battery tray 3. Push nut (2 u sed) 4. Carriage screw (2 used) 5. Flange nut (6 u sed) 6. Carriage bolt (4 used) 7.
Reelmaster 5010 - H Page 5 - 83 Electrical S ystem The 48 volt battery pack used in the Reelmaster 5010- H electric reel drive system is compo sed of four (4) 12 volt batteries that are co nnected in series.
Reelmaster 5010 - H Page 5 - 84 Ele ctrical System 48 VDC Battery P ack Installation (Fig. 85) 1. Make sure that the 4 8 VDC battery disconnect is sep- arated to prevent unexp ected 48 VDC system compo- nent operation (see 48 VDC Batte ry Disconnect in the General Inf ormation sectio n of this chapte r).
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Reelmaster 5010 - H Page 5 - 86 Ele ctrical System 48 VDC Electrical Power Conn ections 1. Bracket 2. Main contactor 3. Holder bracket (3 used) 4. Jumper strap holder (3 used) 5. Jumper strap (positive connections) 6. Isolator 7. Flange head screw 8. Flat washer (9 used) 9.
Reelmaster 5010 - H Page 5 - 87 Electrical S ystem Disassembly 1. Park machine on level surface, lower cutting units, stop engine, apply pa rking brake and remove key fro m ignition switch. 2. Separate syst em components from the 48 VDC bat- tery pack by unplu gging the 48 VDC batter y disconnect.
Reelmaster 5010 - H Page 5 - 88 Ele ctrical System Cutting Reel Motor NOTE: If electrical problems exist with a cutting reel motor , a fault may have occurred that would be indicated by a fault code on the InfoCen ter Display .
Reelmaster 5010 - H Page 5 - 89 Electrical S ystem 8. If cutting reel motor is to be removed from machine, disconnect r eel motor cable from machin e wire harness (Figs. 92 and 93): A. Locate reel motor cable electrical connections at machine wire harness for motor that is to be re- moved.
Reelmaster 5010 - H Page 5 - 90 Ele ctrical System Cutting Reel Motor Service 1. T orx head screw (12 used) 2. Motor cover 3. O - rin g 4. Wa ve washer (2 used) 5. Bearing (2 used) 6. Rotor 7. Be arin g (2 used ) 8. O - ring (2 u sed) 9. Housing/controller/cable asse mbly 10.
Reelmaster 5010 - H Page 5 - 91 Electrical S ystem 6. Use cutting reel motor rot or tool set (see Special T ools in this chap ter) to ca refully remo ve rotor assembly (items 5, 6 and 7) and motor cover (i tem 2) from motor housing. 7. Remove motor cover and wave washer (item 4) from rotor assembly .
Reelmaster 5010 - H Page 5 - 92 Ele ctrical System Moto r/Ge nera tor As semb ly Figure 97 1. Diesel engine 2. Motor/generator assembly 3. Flange head screw 4. Collar 5. Coupler h ub 6. Woodruff key 7. Engine bellhousing 8. Cap screw (2 used) 9. Flat washer (2 used) 10.
Reelmaster 5010 - H Page 5 - 93 Electrical S ystem 4. Disconnect hydraulic pump drive shaft from 48 VDC motor/generator output shaft (see Hydra ulic Pump Drive Shaft in the Service and Repairs se ction of Chap- ter 4 - Hydraulic System). Position drive shaft away from engine.
Reelmaster 5010 - H Page 5 - 94 Ele ctrical System CAUTION Support motor/generator and bellhousing as - sembly when installing it to prevent it from falling and causing personal injury .
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Reelmaster 5010 - H Page 5 - 96 Ele ctrical System Motor/Generator Assem bly Service 1. Controller assembly 2. Motor/generator assembly 3. Motor/generator cover 4. Flange head screw (3 used) 5. Wa sher head screw (6 used) 6. Wa sher head screw (2 used) 7.
Reelmaster 5010 - H Page 5 - 97 Electrical S ystem Disassembly (Fig. 99) 1. Remove motor/generator cover (item 3) fr om motor/ generator assembly . 2. Remove acces s cover (item 7) and cover gasket from controller . Discard cover gasket. 3. Carefully remove motor/generator and contr oller harness connectors from controller op ening.
Reelmaster 5010 - H Page 5 - 98 Ele ctrical System C. Lubricate n ew O - rin g (item 2) with dielect ric lubri- cant (see Special T ools in this chapter) and install into groove in hous ing bearing bo re. IMPORT ANT : The rotor magnets are very power- ful and can cause the rotor to shift position very rapidly during installation.
Reelmaster 5010 - H Page 6 - 1 Chassis Chapter 6 Chassis T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TI ON 2 ..................... T raction Unit Operator ’s Manual 2 ......... ..... 48 VDC Battery Disco nnect 2 .
Reelmaster 5010 - H Page 6 - 2 Chas sis Specifications Item Description Front Tire Pressure 12 to 15 PSI (83 to 10 3 kPa) (26.5 x 14.0 - 12, 4 ply , tubeless) Rear T ire Pressure 12 to 15 PSI (83 to 10 3 kPa) (20 x 12.
Reelmaster 5010 - H Page 6 - 3 Chassis Special T ools Order T oro special too ls from your T oro Distributo r . Wheel Hub Puller The wheel hub puller all ows safe removal of the front wheel hub from th e wheel motor sha ft.
Reelmaster 5010 - H Page 6 - 4 Chas sis Service and Repairs Wheels 1. Front wheel motor 2. Brake assembly 3. Front wheel hub 4. Lock nut 5. Brake drum 6. Front wheel 7. Lug nut ( 5 used per wheel) 8. Rear wheel hub 9. Spindle washer 10. Rear wheel 11 .
Reelmaster 5010 - H Page 6 - 5 Chassis Removal (Fig. 3) 1. Park machine on a level surface, lowe r cutting units, stop engine, engag e parking brake and re move key from the ignition s witch. 2. Chock wheels to prevent machine from shifting. 3. Loosen, but do not remove, wheel lug nuts.
Reelmaster 5010 - H Page 6 - 6 Chas sis Steering Column 1. Steering column 2. Steering wheel 3. Steering wheel cover 4. Lock nut 5. Flat washer 6. Socket head screw (4 used) 7. Steering control valve 8. Co lumn b race 9. Flange nut ( 6 used) 10. Flan ge hea d scr ew (2 us ed) 1 1.
Reelmaster 5010 - H Page 6 - 7 Chassis 6. Slide rubber bellows up steering column t o allow ac- cess to fasteners that secure steering column to ma- chine. 7. Support steering con trol valve to preven t it from shift- ing during steering col umn removal.
Reelmaster 5010 - H Page 6 - 8 Chas sis Brake Servi ce 1. Wheel motor (LH shown) 2. Lug nut (5 used per wheel) 3. Wheel hub 4. Wheel stud (5 used per wheel) 5. Wheel assembly 6. Brake drum 7. Front wheel shield (2 used) 8. Ca p screw (2 us ed per sh ield) 9.
Reelmaster 5010 - H Page 6 - 9 Chassis Removal (Fig. 7) 1. Park the machin e on a level su rface, lower the cut - ting units and stop the engine. Remove th e key from the ignition switch. 2. Chock wheels to prevent machine from shifting. 3. Loosen, but do not remove, lock nut (item 12) from wheel motor shaft.
Reelmaster 5010 - H Page 6 - 10 Chassis IMPORT ANT : Before wheel hub is installed, thor- oughly clean tapers of wheel hub and wheel motor shaft. Make sure that taper s are free of grease, oil and dirt. DO NOT use antiseize lubricant when installing wheel hub.
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Reelmaster 5010 - H Page 6 - 12 Chassis Rear Wheel Bearings (2 Wheel Drive) 1. Dust cap 2. Cotter pin 3. Retainer 4. Jam nut 5. Spindle washer 6. Be arin g cone 7.
Reelmaster 5010 - H Page 6 - 13 Chassis Disassembly (Fig. 10) 1. Chock f ront wheels to prevent machine from shifting. 2. Remove rear wheel (see Wheels in this section). Make sure to support machine with jack stands. 3. Remove the dust cap from the wheel hub.
Reelmaster 5010 - H Page 6 - 14 Chassis Rear Axle 1. Lug nut (5 used per wheel) 2. Rear axle assembly 3. D ust cap 4. Hydraulic fitting 5. Tie rod 6. Axle pivot pin 7. Thrust washer 8. Roll pin 9. Thrust washer 10. Jam nut 11 . G r e a s e f i t t i n g 12.
Reelmaster 5010 - H Page 6 - 15 Chassis Removal (Fig. 1 1) 1. Park machine on a level surface, lowe r cutting units, stop engine, engag e parking brake and re move key from the ignition s witch. 2. Chock f ront wheels to prevent machine from shifting.
Reelmaster 5010 - H Page 6 - 16 Chassis Rear Axle Service 1. Rear axle 2. Housing (2 used) 3. RH drag link 4. Tie rod assembly 5. Pivot bushi ng (2 use d) 6. Grease fitting (2 used) 7. Flange bushing (4 used) 8. Flange head screw (7 used per side) 9. LH drag link 10.
Reelmaster 5010 - H Page 6 - 17 Chassis Axle Pivot Bushings (Fig. 12) T h er e a ra x l em u s tb eh e l di np l a c es n u g l yb yt h ea x l e pivot pin. Excessive movement of the axle, which is characteri zed by erratic ste ering, might in dicate worn axle pivot bushings (item 5).
Reelmaster 5010 - H Page 6 - 18 Chassis Control Arm 1. Control arm frame 2. InfoCenter display 3. Headlight switch 4. Reel engage/disengage switch 5. Screw (4 used) 6. Carriage screw (2 used) 7. Latch 8. Joystick assembly 9. Flange nut (2 u sed) 10. Screw (2 used) 1 1.
Reelmaster 5010 - H Page 6 - 19 Chassis Disassembly (Fig. 13) 1. Park machine on a level surface, lowe r cutting units, stop engine and enga ge parking brake. Remove key from ignition switch. 2. Loosen latches and remove access cover fro m out- side of control arm.
Reelmaster 5010 - H Page 6 - 20 Chassis Operator Seat 1. Operator seat 2. Seat base 3. Seat adjuster w/latch 4. Flat washer (4 used) 5. Seat switch harness 6. Seat switch 7. Wa sher head screw (2 used) 8. Armrest bracket 9. Spacer 10. Armrest 1 1. Cap screw 12.
Reelmaster 5010 - H Page 6 - 21 Chassis Removal (Fig. 15) 1. Park machine on a level surface, lowe r cutting units, stop engine, engag e parking brake and re move key from the ignition s witch.
Reelmaster 5010 - H Page 6 - 22 Chassis Mechanical Seat Suspension 1. Upper housing 2. Weight adjust knob 3. Lower housing 4. Scissor assembly 5. Lock nut 6. Weight adjuster 7. Drive arm 8. Extens ion spring (2 us ed) 9. Roller guide 10. Weight adjust knob 11 .
Reelmaster 5010 - H Page 6 - 23 Chassis IMPORT ANT : When removing th e seat susp ensio n, make sure to support the control arm to preve nt damage to the control arm electrica l components and control arm wiring har ness.
Reelmaster 5010 - H Page 6 - 24 Chassis Front Lift Arms 1. #1 lift arm 2. #4 lift arm 3. #5 lift arm 4. Li ft arm pivo t shaft (3 us ed) 5. Roll pin (3 used) 6. Lock nut (4 u sed) 7. Cap screw (4 used) 8. Bridge plate 9. Cap screw (1 used per lift arm) 10.
Reelmaster 5010 - H Page 6 - 25 Chassis 8. Inspect bushings in lift arm and pivot yoke for wear or damage. If necessary , replace bushing s (Figs. 22 and 23). A. Use bushing removal tool to extract bushings from the lift arm or pivot yoke. T ake care to not dam- age the bore.
Reelmaster 5010 - H Page 6 - 26 Chassis Rear Lift Arms 1. Housing 2. #2 lift arm 3. #3 lift arm 4. Washer (2 used per chain hoop) 5. Wa sher (2 used) 6. Flange head screw (2 used) 7. Shoulder stud (6 used) 8. Grease fitting 9. Pivot shaft (2 used) 10.
Reelmaster 5010 - H Page 6 - 27 Chassis 5. Remove lynch pin (item 12) and rear thrust washer (item 13) fro m rear of pivo t yoke. Slide pivot yoke as - sembly from lift arm. Locate and retrieve front thrust washer (item 1 3). CAUTION Be careful when rem oving tension from the tor - sion spring on the rear lift arm s.
Reelmaster 5010 - H Page 6 - 28 Chassis Installation (Fig. 24) 1. Position re ar lift arm to frame and slide pivot shaft through frame bosse s and lift arm. S ecure shaft with washer head screw (item 10). 2. Place washer (item 5) over rear of each pivot shaft.
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Reelmaster 5010 - H Page 6 - 30 Chassis Hood 1. Sealed foam 2. Hood saddle 3. Hood 4. Catch (2 used) 5. Rubber latch (2 u sed) 6. T ube 7. Bow tie pin (2 used) 8. Deflector bracket (2 used) 9. T ube (2 used) 10. W asher head screw (8 used) 1 1. Flange head screw (10 used) 12.
Reelmaster 5010 - H Page 6 - 31 Chassis Removal (Fig. 29) 1. Park the machin e on a level su rface, lower the cut - ting units and stop the engine. Remove th e key from the ignition switch. 2. Unlatch hood. 3. Remove bow tie pin (item 7) and yoke pin (item 16) to allow hood removal.
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Reelmaster 5010 - H Cutting Units Page 7 - 1 Chapter 7 Cutting Units T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TI ON 3 ..................... Cutting Unit Op erator ’ s Manual 3 ............... 48 VDC Battery Disco nnect 3 .
Reelmaster 5010 - H Cutting Units Page 7 - 2 Specifications Figure 1 Frame Constr uction: Precision machined die cast alu- minum cross member with two (2) bolt- on aluminum side plates. Reel Construction: Reels are 22 inches (55.9 cm.) in length and are ava ilable in 5 inch (12.
Reelmaster 5010 - H Cutting Units Page 7 - 3 General Information Cutting Unit Operator’ s Manual The Cutting Unit Operator ’s Manual provi des informa- tion regarding the opera tion, general mainte nance and maintenance int ervals for the cutting units on your Reel- master machine.
Reelmaster 5010 - H Cutting Units Page 7 - 4 Special T ools Order special tools fo r your Reelmaster from your T oro Distributor . Some tools may h ave been supplied with y o u rm a c h i n eo ra r ea v a i l a b l ea sT o r op a r t s . Gauge Bar Assembly T oro Part Number: 108 - 67 15 Use gauge bar to verify height - of - cut adjustment.
Reelmaster 5010 - H Cutting Units Page 7 - 5 Bedknife Screw T ool T oro Part Number: TOR510880 This screwdriver - type bit is made to fit T oro bedknife at- t a c h i n gs c r e w s .U s et h i sb i tw i t hat o r q u ew r e n c ht os e - cure the bedknife to the bedbar .
Reelmaster 5010 - H Cutting Units Page 7 - 6 Spline Inser t T ool T oro Part Number: TOR 4112 ( 8t o o t hf o r5i n c hr e e l s ) TOR 40 7 4 ( 9t o o t hf o r7i n c hr e e l s ) Use spline insert to ol for rotati ng cutting reel when motor is removed.
Reelmaster 5010 - H Cutting Units Page 7 - 7 Pulley Alignment T ool T oro Part Number: 1 14 - 5446 Use pulley alignment tool to verify alignment of groomer and/or rear roller brush d rive and driven pulleys.
Reelmaster 5010 - H Cutting Units Page 7 - 8 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions.
Reelmaster 5010 - H Cutting Units Page 7 - 9 Factor Possible Problem/Corr ection Reel and bedknife sh arpness NOTE: After grinding the reel and/or bedknife, check the reel to bedknife contact aga in after cutting two (2) fairways.
Reelmaster 5010 - H Cutting Units Page 7 - 10 Factor Possible Pro blem/Correctio n Cutting unit alignment and carrier frame ground following Check carrier frames and lift arms for damage , binding conditions or bushing wear . Repair if necessary . Roller condition and roller type Make sure rollers rotate freely .
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Reelmaster 5010 - H Cutting Units Page 7 - 12 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running.
Reelmaster 5010 - H Cutting Units Page 7 - 13 Leveling Rear Roller The precision m achined compon ents of the cutting un it frame keep the rear ro ller and cutting reel in alignme nt (para llel).
Reelmaster 5010 - H Cutting Units Page 7 - 14 Service and Repairs Cutting Reel Motor NOTE: If electrical problems exist with a cutting reel motor , a fault should have occurre d that would be indi- cated by a fault code on the InfoCenter Display .
Reelmaster 5010 - H Cutting Units Page 7 - 15 Backlapping DANGER TO A VOID PERSONAL INJURY OR DEA TH: D Never place hands or feet in the reel area while the engine is running or if the 48 VDC bat- tery pack is connected.
Reelmaster 5010 - H Cutting Units Page 7 - 16 Bedbar Assembly 1. Bedbar assembly 2. Flange bushing (2 u sed) 3. P lastic w asher ( 4 used) 4. Metal washer (2 used) 5. Bedbar pivot bolt (2 used) 6. Lock nut (2 used) 7. Lock nut (2 used) 8. Compression spring (2 used) 9.
Reelmaster 5010 - H Cutting Units Page 7 - 17 6. Remove two (2) bedbar pivot bolts (item 5), two (2) metal washers (item 4) a nd four (4) plastic washe rs (item 3) from the cutting unit side plates. CAUTION Contact wit h the reel, b edknife o r other cutti ng unit parts can result in personal injur y .
Reelmaster 5010 - H Cutting Units Page 7 - 18 Bedknife Replace ment and Grinding 1. Screw ( 8 used) 2. Bedbar 3. Bedknife Figure 23 v 1 2 3 Antiseize Lubricant 200 to 250 in - lb ( 2 3t o2 8N - m ) Lightly Oil Bedbar Surface Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar A s- sembly in this section).
Reelmaster 5010 - H Cutting Units Page 7 - 19 4. After installing bedknife to bedbar , grind bedkni fe. Bedknife Grinding Since there can be variations in the mo unting surface of the bed bar , a new bedknif e will not b e perfect ly flat aft er it is installed to the bedb ar .
Reelmaster 5010 - H Cutting Units Page 7 - 20 Bedbar Adjuster Service Figure 27 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster screw 5. Keyed flange bushing (2 used) 6. Ca p screw 7. Deten t 8. Fl at washe r 9. Lock nut 10. Bedbar adjuster shaft 1 1.
Reelmaster 5010 - H Cutting Units Page 7 - 21 Removal (Fig. 27) 1. Remove lock nut (item 3), compression spring (item 2) and washer (item 12) from bedba r adjuster screw (item 4). 2. Remove bedbar (see Bedbar Assembly in this sec- tion). NOTE: Inside threads in bedbar adjuster shaft (item 10) are left- hand threads.
Reelmaster 5010 - H Cutting Units Page 7 - 22 Cutting Reel Assembly Removal and Installation 1. Bedbar assembly 2. Cutting unit frame 3. Flange bushing (2 u sed) 4. P lastic w asher ( 4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7. Lock nut (2 used) 8.
Reelmaster 5010 - H Cutting Units Page 7 - 23 4. If cutting unit is equipped with a weight on LH sid e plate, remove the two (2) flange nuts securing th e weight to the side plate and remove weight from the cut- ting unit. Remove and discard O- ring from weight.
Reelmaster 5010 - H Cutting Units Page 7 - 24 Reel Assembly Installation (Fig. 28) 1. Thoroughly clean side p lates and othe r cutting unit components. Inspe ct side plates for wear or damage and replace if n eeded. CAUTION Contact wi th the reel , bedkni fe or othe r cutting unit parts can result in personal injury .
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Reelmaster 5010 - H Cutting Units Page 7 - 26 Cutting Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Bearing 4. Flocked seal 5.
Reelmaster 5010 - H Cutting Units Page 7 - 27 Assembly of Cutting Reel (Fig. 31) 1. If removed, install new reel shaft plugs into cutting reel shaft. Plugs should be r ecessed into ree l shaft from 1.370” to 1.630” (3 4.8 to 41.4 mm) (Fig. 33). 2.
Reelmaster 5010 - H Cutting Units Page 7 - 28 Prepari ng Reel for Grinding Three (3) types of cutting re el designs are used in cutting units for Reelmaster 5010 - H machines: scalloped radi- al reel, taper ed radial reel and tapered forwar d swept reel.
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Reelmaster 5010 - H Cutting Units Page 7 - 30 Front Roller Removal (Fig. 36) 1. Position machine on a clean and level surface, lower cutting units, sto p engine, engage parking bra ke and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working surface.
Reelmaster 5010 - H Cutting Units Page 7 - 31 Rear Roller Removal (Fig. 37) 1. Position machine on a clea n and level surface, lower cutting units, stop engi ne, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place o nal e v e lw o r k i n gs u r f a c e .
Reelmaster 5010 - H Cutting Units Page 7 - 32 Roller Service Disassembly (Fig. 38) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely secur e roller assembly in bench vise and lightly tap one end of roller shaft un til outer seals and bearing are removed from opposite end of rolle r tube.
Reelmaster 5010 - H Cutting Units Page 7 - 33 3. From the roller tube end with only the in ner seal installed, carefully install th e roller shaft into the roller tube. Make sure that seals are not damag ed as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: A.
Reelmaster 5010 - H Cutting Units Page 7 - 34 Rear Roller Brush (Optional) 1. Brush bearing housing (non - drive) 2. Brush bearing housing (drive) 3. O - rin g 4. Roller brush shaft 5. Flange nut (4 u sed) 6. Mounting bracket (2 used) 7. Excluder seal (2 used) 8.
Reelmaster 5010 - H Cutting Units Page 7 - 35 4. Disassemble roller b rush components as ne cessary using Figures 44 as a guide. If dri ve brush bearing hous- ing (item 2) or driven pulley ( item 12) need to be re- moved, br ush cover an d drive belt rem oval will be necessary (see Rear Roller Brush Drive System in this section).
Reelmaster 5010 - H Cutting Units Page 7 - 36 Rear Roller Br ush Drive System (Optional ) 1. Carriage screw (2 used) 2. Carriage screw (3 used) 3. Brush plate 4. Cap screw (2 used) 5. Flat washer (4 used) 6. Lock nut (6 u sed) 7. Idler arm 8. Idler spacer 9.
Reelmaster 5010 - H Cutting Units Page 7 - 37 Assembly (Fig. 48) 1. I nstall drive shaft if it was removed (Fig. 49): IMPORT ANT : If rear roller brush drive is on lef t side of cutting unit, drive shaft has left hand threads and can be identified by a groove on the flange.
Reelmaster 5010 - H Cutting Units Page 7 - 38 3. After assembly ( including drive belt in stallation), check alignment of pulleys with a straight edge placed along the outer face of the drive pulley (Fig. 51). A. The outer faces of the drive and driven pulleys (not the idler pulley) should be in- line within 0.
Reelmaster 5010 - H Groomer Page 8 - 1 Chapter 8 Groomer T able of Contents GENERAL INFORMA TI ON 2 ..................... Groomer Kit Installation Instructions 2 ........... 48 VDC Battery Disco nnect 2 .................. SPECIAL TO OLS 3 ............
Reelmaster 5010 - H Groomer Page 8 - 2 General Information Groomer Kit Install ation Instructions The groomer kit installation instructi ons provides infor- mation regarding the i nstallation, set - up and operation of the optional groom er on your Reelmaster m achine.
Reelmaster 5010 - H Groomer Page 8 - 3 Special T ools Order Special T ools from your T oro Distributor . Some tools may have been supplie d with your machine or are available as T oro parts.
Reelmaster 5010 - H Groomer Page 8 - 4 Grooming Performance There are a number o f factors that can affec t the perfor- mance of grooming. These factors vary fo r different golf courses and from fairway to fairway . It is important to in- spect the turf frequen tly and vary the grooming practice with turf needs.
Reelmaster 5010 - H Groomer Page 8 - 5 T roubleshooting Groomer Reel Mec hanical Proble ms Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt need s to be adjusted. Failed groomer idler bearing(s) in groom er side p late(s).
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Reelmaster 5010 - H Groomer Page 8 - 7 Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine, remov e the key from the ignition switch and wait for all machine movem ent to stop before wor king on the groomer .
Reelmaster 5010 - H Groomer Page 8 - 8 Service and Repairs CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer .
Reelmaster 5010 - H Groomer Page 8 - 9 NOTE: The groomer drive is loca ted on the opposite side of the cutting unit from the cuttin g reel motor . Figure 6 shows components u sed when the groom er drive is o n t h el e f ts i d eo ft h ec u t t i n gu n i t .
Reelmaster 5010 - H Groomer Page 8 - 10 Groomer Reel and Groomer Plate Assembly Figure 8 1. Groomer reel 2. Pu lley spac er 3. Washer (for pulley alignment) 4. Driven pulley 5. Flange nut 6. Excluder seal (2 used) 7. O - ring 8. Idler plate 9. Extension spring 10.
Reelmaster 5010 - H Groomer Pa ge 8 - 1 1 E. Remove two ( 2) socket head screws (item 1 1) that secure pivot hub to cutting unit side plate. F . Remove pivot hub with a ttached idler plate as- sembly from cutting unit. G. Support groomer shaft t o p revent it from falling.
Reelmaster 5010 - H Groomer Page 8 - 12 2. If removed, install groomer plate (item 18) to groom- er non - drive sid e of cutting unit: A. Position non - drive side groomer plate to cutting unit side plate. B. Slide O - ring onto pivot hub and then ap ply anti- seize lubricant on to pivot hub flan ge.
Reelmaster 5010 - H Groomer Page 8 - 13 7. Check that excluder seals just touch groomer plate assembly (Fig. 13). Reposition e xcluder seals on groomer shaft if neede d. Excluder seal ID sho uld be lo- cated on groomer shaf t surface that is rece ssed slightly .
Reelmaster 5010 - H Groomer Page 8 - 14 Groomer Reel Ser vice Figure 14 1. G roome r shaft 2. Lock nut (2 used) 3. Spacer (thick) (41 used) 4. Spacer (thin) (2 u sed) 5. Groomer blade (40 used) 6. Broomer brush (5 used) 7. Broomer strap (4 used) 4 3 1 2 5 7 6 Inspect groomer r eel blades fr equently f or damage and wear .
Reelmaster 5010 - H Groomer Page 8 - 15 4. Using wrench on shaft flats to prevent shaft from turning, torque second lo ck nut from 375 to 425 in - lb ( 4 3t o4 8N - m ) . After torquing lock nut, spa cers should not be free to rotate and groomer blades sho uld be cen- t e r e do ns h a f t .
Reelmaster 5010 - H Groomer Page 8 - 16 Height Adjuster Assembly Figure 18 1. Groomer plate ( drive side) 2. Shoulder bolt 3. Ball joint rod 4. Jam n ut 5. Compression spring 6. Flange head screw 7. LH l ower r amp 8. Ext ernal snap r ing 9. LH upper ramp 10.
Reelmaster 5010 - H Groomer Page 8 - 17 Assembly (Fig. 18) 1. Assemble height adjuster using Figure 18 as a guide noting the following items: NOTE: On 7” cutting units, the ball joint rod on the cut- ting unit motor side is lon ger that the ba ll joint rod used on the groomer drive side of the cutting unit.
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Reelmaster 5010 - H Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings T able of Contents ELECTRICAL DRA WING DESIGNA TIONS 2 ....... HYDRAULIC SCHEMA TIC 3 ..................... ELECTRICAL SCHEMA TIC 4 ......... ........... WIRE HARNESS DRA WINGS Main Wire Harness Drawing 6 .
Reelmaster 5010 - H Foldout Drawings Page 9 - 2 Electrical Drawing Designations The following a bbreviations are u sed for wire harness colors on the electrical schematics and wire harn ess drawings in this chapter .
Page 9 - 3 Hydr aulic Sche ma tic Reelmaster 5010 - H LIFT CONTROL MANIFO LD POWER STEERI NG VA LV E.
Page 9 - 4 Electr ical Schem atic Reelmaster 5010 - H All r elays and so lenoids are shown as de - energized. All gr ound wir es are black. W IRE COLOR ABBREVIA TIONS.
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Page 9 - 6 Reelmaster 5010 - H Main Wire Har ness Drawing.
Page 9 - 7 Reelmaster 5010 - H Ma in Wi re Ha rn es s Di ag ra m DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WI RE GAUGE SIZE AND WIRE COLOR.
Page 9 - 8 Reelmaster 5010 - H Seat Wir e Har ness Drawing NOTE CLO CK POSITION.
Page 9 - 9 Reelmaster 5010 - H Sea t Wi re Harn e ss D ia g ram DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WI RE GAUGE SIZE AND WIRE COLOR.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Toro 5010-H è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Toro 5010-H - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Toro 5010-H imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Toro 5010-H ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Toro 5010-H, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Toro 5010-H.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Toro 5010-H. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Toro 5010-H insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
