Toro 5010-H manual

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). REFE R TO T HE TRACT I ON UNI T AND CUT T ING UNIT OPE RA TOR’S MA NUALS F[...]

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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 ........................... Maint enance 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 ............................ Adjust ment s 8 - 7 ............................... Servic e and R[...]

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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 .................... JACKI NG I NST RUCTI O NS 5 ..................... SAF ET Y AND I NST RUCT [...]

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. A l- though haz ard cont rol and ac cident pr event ion are par- tially dependent upon the design and conf igurat io[...]

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. A pply t he parking br ake. B. M ake sur e the t rac tion pedal is in NE UTRA L, t he Enable/Dis able swit ch is in the dis abled posit ion and the engine speed swit ch is in t he mid - spe[...]

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 . 3. Never s tor e the m achine o[...]

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 . Prio r to raisi n g machi n e, remove an y attach - me nts tha t ma y[...]

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. P art num bers f or dec als ar e listed i n your Part Catalogs. O rder replac ement decals [...]

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 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric 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. T[...]

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 Grade 1 Bolts, Screws, Studs & Sems with Regular Heigh t Nuts (SAE J995 G rade 2 or St ronger Nut s) SAE Grade 5 Bolts, Sc rews, St uds & Sems w[...]

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 0.8 57 + 6i n -[...]

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 - lb 73 + 12 in - lb 5/16 - 18 UNC 215 + 35 in - lb 145 + 20 in - lb 3/8 - 16 UNC 35 + 10 ft - lb 18 + 3f t - l b 1/2 - 13 UNC 75 + 15 ft - lb 50 + 1[...]

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 ............... Kubota Wor kshop M anual 3 .................... 48 VDC Bat ter y Dis connect 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 3.09” ( 78 mm x 78. 4 mm) T otal Dis plac ement 68.5 in 3 (1 123 cc ) Firing O rder 1 (fan end)[...]

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. The u[...]

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. Shoulder bolt 9. Nut 10. Compr ession spr ing 1 1. Air cleaner mounting band 12. Flange[...]

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. 3. See Traction Unit O perat [...]

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. Flange nut 1 1. E xhaust header 12. Flange nut (4 used) 13. Exhaust gasket 14. Flange [...]

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. 1. Raise and suppor t hood t o gain access t o exhaust system. Allow engine and exhaus t syst[...]

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. Flange nut (3 used) 13. Drai ncock 14. Hose clamp 15. Cap screw 16. [...]

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. Prim ing the Fuel Sy st em The fuel system needs t o be pri[...]

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. Flange nut (14 used) 1 1. R ear screen 12. Foam seal 13. Spacer ( 5 used) 14. Flange head scr ew [...]

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. 3. Remove 12 v olt bat ter y f rom rear [...]

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) . 10. Fill radiat or and coolant r eserv[...]

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. Spacer (4 used) 9. Lock w asher ( 12 used) 10. Engine mount (2 used) 1 1. RH engine m[...]

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. 2. Disconnec t negat ive ( - ) and t hen positive ( +) batt ery cables f rom the 12 volt bat [...]

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. IMP ORT ANT : T o prevent d a[...]

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. 7. Car[...]

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. Flat w asher (2 used) 10. Flange head scr ew (7 used) 1 1. Flange nut (2 used) 12. R - clamp (for [...]

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 .................. Check Hydraulic Fluid 3 .................. ..... T owing Trac[...]

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) 0.24 Cubic Inches (3.96 cc) Se[...]

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. Refer to that publication for additional information when servicing the machin[...]

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 (4.8 k ph), and for a ve ry short distance. If the mach ine needs to be moved a con- side[...]

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. 2. As a preventative measure against leakage, it is rec- ommended that the face seal O- ring be [...]

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. 2. As a prevent ative me asure ag ainst[...]

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. 3. Li[...]

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. T o relieve hydraulic pressure in lif[...]

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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 LIFT CONTRO L MANIFOLD[...]

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. The piston (traction) pump inp ut shaft is rotated by a drive shaft connected to the mo tor/generator [...]

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 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 LIFT CONTROL MANIFOLD 100 MESH SUCT[...]

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. The hydraulic rese rvoir provides fluid for t he gear pump through the suction [...]

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 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 LIFT CONTROL MANIFOLD 100 MESH SUCTI[...]

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. The hydraulic rese rvoir provides fluid for t he gear pump through the suction[...]

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 STEERING CYLINDER PISTON MOVEMEN T STEERING VA LV E R10 R10 FROM PUMP (P2) FROM PUMP (P2) TO TRACTION CHARGE CIRCUIT TO TRACTION CHARGE CIRCUIT LEFT TURN RIG[...]

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. The hydraulic reservoir provid es fluid for the gear pum p through t he suction hose. Ste ering [...]

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. Quick disconnect fitti ngs provided attach directly to mating fittings on m achine test p orts without too ls[...]

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 . This tes ter includes the following: 1. LOAD V AL VE: A simulated working load is create[...]

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. This kit provides for bi - direc- tional filtration which prevents filtered debris from being allowed back i[...]

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. Figure 22 TORO TEST FITTING KIT (T OR4079) Me[...]

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. T oro Part Number: TOR 60 0 4 Figure 25[...]

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. Should ei[...]

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 . Piston (traction) pump check relief valve i s not seating or is dam- aged (NOTE: Piston (traction) p[...]

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. Wheel motor is worn o r damaged. (NOTE: If a traction circuit com ponent has internal wear or dam- age, it is possible that other traction components ar e also dam- aged) Lift Circuit Pr ob[...]

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 . An electrical problem exists that prevents S V1 solenoid coil on the lift control manif[...]

Reelmaster 5010 - H Hydraulic System Page 4 - 29 This page is intentionally blank. Hydraulic System[...]

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). Before Performing Hydraulic T es[...]

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. 1. If a t raction circuit proble m [...]

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 WHEEL MOTORS G5 G6 B R5 R4 R3 A B A B LH RH A P3 TO LIFT CONTROL M ANIFOLD TO STEERING CO NTROL V AL VE AND CHARGE CIRCUIT PRESSURE GAUGE FORW ARD (R3)[...]

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. 27). Connec t a 5000 PSI (350 b ar) pressure gaug[...]

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 R4 R3 A B A B LH RH A P3 TO LIFT CONTROL M ANIFOLD TO STEERING CO NTROL V AL VE A ND CHARGE CIRCUIT PRESSURE GAUGE 100 MESH SUCTION STRAINE R P1 P2 T[...]

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. 7. Make sure that tra[...]

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 CASE DRAIN TRACTIO N WHEEL MOTORS G5 G6 B R5 R4 R3 A B A B LH RH A P3 TESTER OIL FIL TER REMOVED AND TUBE TO LIFT CONTROL MANIFO LD TO STEERING CONTROL V[...]

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. Remove two (2) flange head screws[...]

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 R3 A B A B LH RH A P3 TESTER CAP CAP RH FRONT WHEEL MOTOR EFFICIENCY TEST SHOWN TO LIFT CONTROL M ANIFOLD TO STEERING CONTROL V AL VE AND CHARGE CIRCUI[...]

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. 36). Disconnect hose [...]

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 INTERNAL CASE DRAIN TRACTION WHEEL MOTORS G5 G6 B R5 R4 R3 A B A B LH RH A P3 TESTER TO LIFT CONTROL MANIFO LD TO STEERING CONTROL V AL VE AND CHARGE CIRCUI[...]

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. 38). Disconnect hose from righ t side pump fitting. IMPORT ANT : Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the pump, through the t[...]

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 INTERN AL CASE DRAIN G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 PUMP (P3) PRESSURE GAUGE LIFT CONTROL MANIFOLD TO STEERING C ONTROL V AL VE AND CHARGE CIR[...]

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. Make[...]

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 CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 TESTER (NOT ENERGI ZED) LIFT CONTROL MANIFOLD TO STEERING C ONTROL V AL [...]

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. Make sure [...]

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 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 CHECK FOR CYLINDER (P ARTIALL Y RAISE D) LEFT FRONT (#5) LIFT CYLINDER TEST SHOWN PLUG LIFT CONTRO L MANIFOLD CAP EX[...]

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. 44). IMPORT ANT : When capping lift cylinder fitting and hydraulic hose end, use a steel [...]

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 LV E PRESSURE GAUGE MANIFOLD TO LIFT CO NTROL TO TRACTION CHARGE CIRCUI T 100 MESH SUCTION STRAINER P1 P2 INTERNAL CASE DRAIN PUMP (P3) PISTON[...]

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. Procedure for Stee ring Relief V alve (R10) Press ure 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 disenga[...]

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 TURNED FOR RIGHT TURN R10[...]

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. This test will determine if the steerin g cylinder is faulty . NOTE: Steering circuit operation wil l be affec ted by rear tire pr essure, stee ring cylinder b inding, extra weight on the vehicle [...]

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. Remove k[...]

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. Use pape r or cardboard, not hands, to search for leaks. Hydr aulic fluid escaping under pressure c an have sufficie nt force to penetrate the skin and cause seriou[...]

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. 1. Park machine on a level surface. Lower cutting units, stop engine, engage parkin g bra[...]

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. If a closed - loop hydraulic system filtering tool is n[...]

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. This procedure reduces the chance of damaging the system or its c omponents from n[...]

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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. Cap screw 11 . F l a t w a s h e r 12. Fil ter scr een 13. Hydraulic tube 14. O - ring[...]

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 . Allow hydraulic li nes to drain into a suita ble contain[...]

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. Flat w asher 1 1. Flange nut 12. Lock nut 13. Cap screw 14. Cap screw 15. T raction cabl[...]

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. Assembly (Fig. 53) IMPORT ANT :[...]

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. Lock nut (2 used) 1 1. Flange nut (2 used) 12. Carriage screw (2 used) 13. Hyd[...]

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. 3. Read the General Precautions for Re[...]

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. 14. If necessary , remove hydr aulic fittings fro m pumps. Note orientat[...]

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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 . Scr ew (4 us ed) 12. Plug (2 used) 13. O - ring 14. Seal 15. T runnion cover 16[...]

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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. Flan ge 1 1. Splined connecting shaft 12. Drive gear 13. Dri ven gea r 14. Bod y 15. Dowel[...]

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. 7. Remove the thrust plates and seals from each pump section. Before remo ving eac[...]

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. 48 VDC motor/generator assembly 10. Engine bellhousing 1 1. Hydraulic pump assembly 12. [...]

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. 3. Loosen h ose clamp that se[...]

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. Grease fitt ing 7. T elescop ing yoke (fem ale) 8. End yoke (pist on pump) Figure 64 2 3 6 1 5 [...]

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. Also, the use of a v ise with soft j aws is rec- ommended. 2. Lightly c[...]

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. Flat washer (2 used per shield) 10. Lock nut (2 used per shi eld) 1 1. Rear wheel shiel[...]

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. 3. Read the General Precautions for Removing and Installing Hydraulic Syst em Componen[...]

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. Val ve spring 12. Back - up ring 13. O - ring 14. Dri ve 15. Output shaft 16. Bearing race (2 use[...]

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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. O - ring 8. O - ring 9. Hydraulic hose (4 used) 10. Cap screw (4 per motor) 1 1. Lock washer ([...]

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 . A. Make sure that lock nut (item 4) on wheel motor shaft is loose. Use hub puller (see Special T[...]

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. Vane (7 used) 10. Rotor 11 . W e a r p l a t e 12. Drive link 13. Thrust bearing 14. Coupling sha[...]

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. Carefully s l i d ec o i lo f ft h ev a l v [...]

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. Hydraulic tube 12. O - ring 13. O - ring 14. 90 o hydraulic fitting (2 used) 15. O - rin[...]

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. Remove key from the ignition s witch. 2. Read the General Precautions for Removing and Installing Hydraulic Syst em Components at the begin- ning of the Service and Repairs section of [...]

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. Solenoid coil (2 used) 9. Nut 10. Sol enoi d relie f valve ( SVRV) 1 1. Sol enoid valve (SV1) 12[...]

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. NOTE: Solenoid valves SV1 and SV2 on the lift c ontr[...]

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. Dust cap (2 used) 9. Diagnostic fitting ( 2 used) 10. O - ring 1 1. Cap scr ew (3 use d) 1[...]

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. Locate an d retrieve th ree (3) spacers from between frame bracke t and manifold. 8[...]

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 (.040) 9. Plug (NWD #8) 10. O - ring 1 1. Seal kit 12. Bi - Directional relief valve Figure 74 4[...]

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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. Retaining ring 12. Thrust washer 13. C ylinder slide pin 14. Carriage screw 15. Flange nut 16. R [...]

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. Remove the key from the ign ition switch. 2. T o prevent unexpected cutting unit operation , dis- connect the cutting units fro m the electrical power sup- ply by unp [...]

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. Grease fitting Figure 76 2 3 4 5 6 9 8 7 1 10 11 14 12 13 2 3 45 6 9 87 10 1 1 14 12 13 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 .R o t a t et h eh e a dc o u n t e r - c l o c k w i s et [...]

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. Socket head screw (4 used) 10. O - ring 1 1. Hydraulic fitting (4 used) 12. O - ring 1 3 . S t e[...]

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 . 7. Disconnect hydraulic lines from steering contro[...]

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. Cro ss pin 13. Spr ing set 14. Ring 15. Thrust washer 16. Beari ng 17. Shaft seal 18. Bal[...]

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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. Jam nut 12. Cot ter p in 13. Slotted hex nut 14. W asher 15. Ball j oint Figure 81 FRONT RIGHT 9 [...]

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 . 5. Put caps or plugs on disconnected hoses and fittings to prevent contamina[...]

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. O - ring 8. O - ring 9. Piston 10. BS seal 11 . B a r r e l 12. Wear ring 13. Lock nut Figure 84 4 6 9 8 7 11 3 5 2 1 12 13 10 40 ft - l b (54 N - m) 2 4 6 1 9 8 7 10 11 13 3 5 12 Disassembly [...]

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. Inspect internal surface of barrel for deep scr atches, out - of - roundness and bending. Replace [...]

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. T op cooler bracket 10. Cap screw (2 used) 1 1. W asher (4 used) 12. Clamp (2 used) 13[...]

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. 2. Unlatch and open the rear screen. 3. Remove battery to ease oil cooler removal (see 12 V olt Battery Service in the Service and Repairs section[...]

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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 .................. T oro Electronic Controller (TEC) 3 .............. CAN - [...]

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. Electrical Drawings The ele[...]

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). The controller then directs el ectrical p[...]

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. Basic information about the two systems i[...]

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. Circuit pro tection for the 48 VDC s[...]

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 . NOTE: T oro recommends the use of a DIGIT AL V olt - Ohm - Amp multimeter when test [...]

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. T ool set includes puller hub, threaded shaft, handle and four (4) scr[...]

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. 8). NOTE: For motor/generator service procedures, see Motor/Generator [...]

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. These batteries a[...]

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. The InfoCen t- er provides info rmation for the machine ope rator during machine operation, provides electrical system diag nos- tic assistance for technicians and allows inpu ts for [...]

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 . T ogg[...]

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. The protected displ ay screens can be v iewed af- ter the Protected Menus are available by entering the machine PIN (see Settin gs Sc reen in[...]

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. 18), navigatio n to the five (5) different menu items can occur . Pressing the move[...]

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. If the machine PIN has been ente red to allow access to pr otected men [...]

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 . For each of the diagnostics screen[...]

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 . If either the backlight (brightness) or contrast i[...]

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 . FR e e lR P M displays the front reel speed that has bee n determined by the ma chine controllers based on en- tered infor mation for[...]

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. For effective troublesho oting and repairs, there must be a good understand ing of the e[...]

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 is NOT in neutral position W ait to start until system functions have been initialized Joystick is in RAISE position Joystick is in LOWER position Reel[...]

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. 26). The InfoCen ter display faul[...]

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 screen for de bris buildup Check engine cooling f an and drive belt Check engine coolant level 2 Excessive engine coolant temperature (above 11 5 o C) [...]

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 48 VDC bat tery discon nect is securely plugged in Check 10A logic relay fuse Check 48 VDC master fuse (250A maxi f use) Check 48 VDC battery system v[...]

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 power exists a t motor/generator Check CAN - bus termination resistors 44 CAN - bus fault for InfoCenter Check CAN - bus connection to InfoCenter Disp[...]

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 nger active to identify faulty motor NOTE: If cutting reel motor is faulty , additional fault codes will likely be displayed 64 Motor/generator temp [...]

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 resistance Check #4 cutting unit bedknife adjustme nt and reel condition Check #4 cutting unit motor for exce ssive ro- tating resistance Check that #4 c[...]

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 temperat ure Open the rear discharge of the cutting unit Reduce reel spee d if possible Reduce mow speed if po ssible If fault does not seem to be related t[...]

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 intake to motor/generator is no t restricted or blocked and that air is moving through int ake when e ngine is r unning Check for motor/generator cool[...]

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 cutting unit If this fault is displayed for more than one cutting unit, check 48 VDC battery voltage when engine is OFF and a lso check 48 VDC logic rel[...]

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 ing this fault, check 48 VDC batterie s and motor/ge nerator operation If 48 VDC batteries are at c orrect voltage with engine OFF , consider connecti[...]

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 this fault, check 48 VDC batteries and motor/generator operation If 48 VDC batteries are at co rrect voltage with engine OFF , consider connections be[...]

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 to see if a pre- charge fault (fault 63) has occurred Check that main contactor is functional Check the mo tor/gener ator conne ctions NOTE: If all 4[...]

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 reporting this fault, check 48 VDC batteries and motor/generator operation If 48 VDC batteries are at co rrect voltage with engine OFF , consider connecti[...]

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 motor is likely faulty if this fault continues to occur 109 Excessive voltage occurred at internal motor regulator for #4 cu tting unit #4 cutting unit mo[...]

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/ generator Check electrical connections to motor/generator If fault occurs for mu ltiple cutting u nit motors and motor/generator , check 48 VDC logic re[...]

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 . 12 VDC battery cables are loose or cor roded. Main fuse ([...]

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 .g. the traction pedal is pressed), an advisory message [...]

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 . Main power relay or circuit wi ring is faulty . Engine co[...]

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 . Cutting units run, but s hould not, when raised . Cutting units shut off with reel engage/dis[...]

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. High engine coolan t temperatur e has disabled cuttin g[...]

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. Set th e multimeter to the DC volts set- ting. The battery should be at a temperature of 6 0 o to[...]

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. Check the opera tion of the interlock switches daily for proper operation. Re- place any[...]

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. The se nsing element for the traction neu tral switch is the traction pum[...]

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. 28). When the parking br ake is not applied, the parking brake detent is positioned near the target end o f the parking brake switch so [...]

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. A bracket[...]

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. 30). When the mow stop lever is in the MOW positio n, the tab on the mow stop lever is positioned away from the targ et end of the mow/transport switch s[...]

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). NOTE: Electrical troubleshooting of any 12 volt power connection [...]

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 . This fuse re- sides in a fuse holder near the e[...]

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. The reel motor fuses are locate[...]

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. Conversely , when the rear of the switch is d[...]

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. The reel engag e/disengage switch is mou nted on the control pa nel (Fig. 39). The T oro Electr[...]

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. Te s t i n g 1. Park the machin[...]

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. The seat switch is located directly under the operator seat. The T oro[...]

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. When the parking br ake is not applied, [...]

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. The se nsing ele ment for the tr ac- tion neutral switch is the traction[...]

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. A bracke [...]

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. A nor[...]

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. 49). The T oro Electronic Contro ller (TEC) mo nitors the opera[...]

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. 50). The 48 VDC logic rela y is attached to a [...]

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. The relay should not ha ve continuity between terminals 30 and 87 a[...]

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. The sta rt relay ha s five (5) terminals and is at- tached to a frame bracke t under the hood near th e en- gin[...]

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). When the ignition switch is ON, the 48 VDC logic relay is ener- gized by the TEC controller whi ch allows the main con- tactor to be energized if allowed by the motor/generato [...]

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. T he TEC is attached t[...]

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 . IMPORT ANT : Before per forming welding on the ma- chine, disconne[...]

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. 60). If any of these links should fail, current to the protected circuit will cease. R[...]

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. Te s t i n g 1. Park the machine on a level su rface, engage th e parking brake, l ower the c[...]

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. The diode plugs into the main wire harness near the 48 V DC battery disconne ct and main contactor under the op[...]

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. The location mo[...]

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. Each m otor has its own integral inve rtor and on - board controller . The In- foCenter Display can be used to monitor the speed and current draw for the five (5) cutting unit motors du r[...]

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. T wo (2) specially designed, twisted cables fo rm the bus for [...]

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 . T esting of the coils c a nb ed o n ew i t ht h ec o i li[...]

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 . The resistance of the temperature s ender reduces as the engine c[...]

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.74). The T oro Electronic Con- troller (TEC) monitors the operation of the oil pressu[...]

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 .7 6 ) . The fuel actuator and TEC controlle r work together to maintain engine speed by adjusti[...]

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. The fuel sende r is located in the fu el tank (Fig. 78). T esting 1. Park the machine on a level surface, engage the parking bra ke, lower the cu tting units and st op [...]

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. B. Resistance with the float in the empty position (completely down) should b e from 89 to 95 o[...]

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. DANGER Because diesel fuel is flamm able, use caution when handling it. Do [...]

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. 83) can be replaced without opening the hydraulic [...]

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. CAUTION When working with batteries, use ex treme cau- tion to avoid splas[...]

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. If t he battery is stored on the m ac[...]

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. CAUTION Follow the manufacturer?[...]

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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. Flange nut (2 u sed) 8. Battery cover (2 used) 9. Hex nut (2 used) 10. Flat was her (2 us[...]

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. The batteries are absorbed glass mat (AGM), valve regulated batteries that are maintenance fr ee with no provision for checking or adjusting e[...]

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). 2. Make sure the batter y tray is clean an d[...]

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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. Flange nut ( 3 used) 10. Nut (2 used) 1 1. Flange nut (6 used) 12. Con tact[...]

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. (see 48 VDC Battery Disconnect in the General Infor[...]

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 . Before consid- ering that reel motor servi ce work is necessary , check for any existing fault codes that i ndicate proble[...]

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. B. Discon nect two (2 ) motor cable con nectors fr om machi[...]

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. O - ring 1 1. Output gear 12. Gea rbox co ver 13. Shaft seal 14. O - ring[...]

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 . Remove and discard O - ri ngs (items 14 and 3) f[...]

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. Flange head screw (7 used) 1 1. Flange nut (2 used) 12. R - clamp (for generato[...]

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. 5. Remove exhaust muff ler from machine (see Exhaust System in the Servi [...]

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 . Assembly weighs approximately 69 pounds (31 kg). IMPORT ANT : Make sure to not damage the motor/ generator , fuel lines, hydraulic hoses, electrical har- ness, con[...]

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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. Access cover 8. Cover gasket 9. Flat washer (2 used) 10. Flange nut (2 used) 1 1. Cap screw (2[...]

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. Note posi- tion[...]

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. Use generator r ot[...]

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 .................. SPECIAL TO OLS 3 ............................. SERVICE AND REP AIRS 4 .........[...]

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 12.0 - 10, 4 ply , tubeless) Wheel Lug Nut T orque 70 to 90 ft- lb (95 to 122 N - m) Wheel Mot or/W heel Hub Lo ck N ut T or que 315 to[...]

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. If machine is equipped with optional CrossT rax TM Kit, this wheel hub puller is nee ded for removin g rear wheel hub from the[...]

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 . J a m n u t 12. Retainer 13. Cotter pin 14. Dust cap Figure 3 FRONT RIGHT 70 to 90 ft - lb (95 to[...]

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. When changing tires, attachments or perform- ing other service[...]

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. Socket head s crew (4 used) 12. O - ring 13. Hyd raulic fit ting ( 4[...]

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. 8. Loosen and re move four ( 4) socket head sc rews (item 6) that secure steering control va lv[...]

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. Flat washer (2 used per shield) 10. Lock nut (2 used per shi eld) 1 1. Rear wheel shield (L[...]

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. 4. Remove front wheel assembly (see Whe[...]

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. 6. Mount square key in the wheel motor shaft, t hen install the wheel hub on to the wheel[...]

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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. Be arin g cup 8. Wh eel hub 9. Seal 10. Spi ndle 1 1. Wheel stud (5 used) Figure 10 1 3 2 8 4 5 7 6 6 10 9 7 11 See text for tightening procedure[...]

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. 4. Remove the cotter pin, retainer , jam nut and spindle washer . Slide the wheel hub f ro[...]

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. T ab washer 13. Wheel hub assembly 14. Grease fitting 15. O - ring 16. Jam nut 17. Nut retai[...]

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. 3. Thoroughly clean hydraulic hose ends and fittings on steering cylinder to prevent hydraulic sys[...]

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. Hub and spindle assembly (2 used) 1 1. Retaining ring 12. Spindle cap 13. Flange h[...]

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). T o correct the problem, re- place the bus hings. 1. Remove rear [...]

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. Swell latch (2 used) 12. W asher head screw (10 used) 13. Bushing (2 used) 14. F[...]

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. 3. At front of control arm, remove screw (item 28) an d lock nut (item 23) that secu[...]

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. Flange nut 13. Flat was her (4 us ed) 14. Flan ge hea d scr ew (3 us ed) 15. Socket head[...]

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. 2. Disconnect negative b attery cable fr om 12 volt bat- t e r ya tr e a ro fm a c h i n e( s e e1 2V o l tB a t t e r yS e r v i c ei nt h e Service and Re[...]

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 . C a p 12. Suspension boot 13. Pivot block (2 used) 14. Damper 15. Lower shock bolt 16. U[...]

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. Removal (Figs. 18 and 19) 1. Park machine on a level surface, lowe r cutting units, stop engine, engag e parking brake and re mo[...]

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. Chain hoop (3 used) 1 1. W asher (2 used per chain hoop) 12. Cap screw (2 used per chain hoop[...]

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. B. Clean the inside of the bore to remove any dirt or foreign mat erial. [...]

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. W asher head screw (1 used per shaft) 1 1 . Piv ot yoke ( 2 used) 12. L ynch pin (2 used) 13. Thru[...]

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. The spring is un - der heavy lo[...]

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. 3. Place torsions spr ings (items 14 and 15) on to hous- ing (item 1). Position long leg [...]

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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. Flange nut (10 used) 13. W asher head screw (4 used) 14. Flat was her (4 [...]

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. 4. Lift hood assembly from machine. 5. Remove hood components as n[...]

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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 .................. SPECIAL TO OLS 4 ............................. F ACTORS THA T CAN A[...]

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 (12.7 cm) and 7 inch (17.8 cm) diameters. High str ength, low a lloy steel [...]

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. Additionally , if optional kits have b een installed on the cut[...]

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. Also use[...]

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 . IMPORT ANT : T o p revent damage to the bedbar , DO NOT use an air or manual [...]

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. Also use this tool for installati on of threaded inserts into cutting reel shaf t. Figure 9 Rear [...]

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. Figure 12 Diameter/Circ umference Measur ing T ape T oro Part Number: TOR6 02 3 Spring steel measur ing tape for accur ately measur ing the ci[...]

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. T urf conditions such as excessive thatch, “sponginess” o r attempting t o cut off too much grass height may not always be overcome b[...]

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. During this initial use, any burrs will be removed from reel an d bedknife which may create improper reel to bedkn ife [...]

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 . Repair roller beari ngs as necessar[...]

Reelmaster 5010 - H Cutting Units Page 7 - 1 1 This page is intentionally blank. Cutting Units[...]

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. Always stop en - gine and remove key first. Also, before installing, removing or working on the cutting units, disconnect the cutting units from the electrical power supply by [...]

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). If th e side plat es are disassem bled or as the cutting reel wea rs, a limited a mount of side plate adjust- ment is possible to make sure tha t the cutt[...]

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 . Before considering that reel motor service work i s necessary , check for any existing fault codes tha[...]

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. Disconnect the cutting units from the electrical power supply by sepa- rating the 48 VDC battery disconnect (see 48 VDC Battery D[...]

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. Washer (2 use d) 10. Bedbar adjuster screw (2 used) 1 1. Cutting unit frame 12. [...]

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 . Use heavy gloves when handling the bedbar . 7.[...]

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). 2. Remove screws from bedbar us[...]

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 . Because of this, it is neces- sary to grind a new bedknife after instal[...]

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. Wave washer 12. W asher FRONT RIGHT 14 to 16 ft - lb ( 1 9t o2 1N - m ) An[...]

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. 3. Unscrew bedbar adjuster screw[...]

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. RH side plate 9. LH side plate 10. Weight 1 1. Cap screw (2 used) 12. O - ring [...]

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. CAUTION Contact wit h the reel, b edknife o r other cutti ng unit parts can result in p[...]

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 . Use heavy gloves when installi[...]

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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. Special washer 6. Retaining ring 7. Re el shaf t plug 8. Threaded insert (LH thread) Figure 31 85 to 95 ft - lb (1 15 to 128 N - m) 85 to 95 ft - lb (1 15 to 128 N - m) Loctite #242 Loctite #242 3 [...]

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. Install two (2) new retaining rings onto cutting ree l shaft. Make sure th at the retaining rings [...]

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. The dif ferent types of individual ree l blades are shown in Figure 34. The radia l reel design[...]

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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. Use cutting unit kickstand (see Special T[...]

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 .P lace support blocks under b[...]

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. Remove second set of oute r seals and bear[...]

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. Position a second new bearing to roller shaft [...]

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. Flat washer (4 used) 9. Ca p screw (4 us ed) 10. Spacer 1 1. Flat washer (for pulley a[...]

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). Assembly (Fig. 44)[...]

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. Idler spring 10. Pivot washer 11 . D r i v e b e l t 12. Idl er pulle y 13. Retaining ring [...]

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. If the rear roller brush drive is on right side of cutting unit, drive shaf[...]

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 0.030” (0.76 mm). B. If necessary to a[...]

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 ............................. GROOMING PERFORMANCE 4 .................. TROUBLESHOOTING 5 .............. ......[...]

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. Refer to this p ublication f or addition al informat ion when servicing the groo[...]

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. Spline Insert T ool T oro Part Number: TOR4112 (8 tooth for 5 inch reels) TOR4 074 (9 tooth for 7 inch reels) Use spline insert tool for rotating cutting reel [...]

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. IMPORT ANT : Improper or overaggre s[...]

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). Broken or damaged i dler spring. The groom er drive belt is wor n, bro- ken or damage[...]

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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 . Also, before installing, removing or working on the cutting units, disconnect the cutting units fro[...]

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 . Also, before installing, removing or working on the cutting units, disconnect the electrical p[...]

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 . Disassembly (Fig. 6) 1 . P a r km a c h i n eo nac l e a na nd level surfa ce, lower cutti[...]

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. Retaining ring 1 1. Socket head screw (2 used per hub) 12. Pivot hub (drive side) 13.[...]

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. Carefully slide drive side groomer plate from groo m- er shaft and cutting u[...]

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. Position pivot hub to groomer plate and cuttin g[...]

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 . 8. Check groomer reel height and mower height - of - cut settings. Adjus t as needed. 9[...]

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 . Straigh ten bent blade s w[...]

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 . 5. If groomer reel is equipped with broomer kit, position[...]

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. Bus hing 11 . F l a t w a sh e r 12. Groomer adjuster 13. Detent spring 14. W asher head s[...]

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. On 5” cut- ting units, the ball j oin[...]

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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 ............. ..... Main Wire Harness Diagram 7 .................. Sea[...]

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 . ABBREVIA TION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRA Y OR ORANGE PK PINK Ro rR D R E D TT A N VIO VIOL ET Wo rW H W H [...]

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. NOTE: REFER TO ELE CTRICAL DRA WING DESIGNA TIONS IN THIS CHAPTER FOR[...]

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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. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

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. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]