Toro 5210/5410/5510/5610 manual

Part No. 06148S L (Rev . C) Service Manual Reelmaster R 5210/5410/5510/5610 Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation for t roubles hooting, t est ing, and repair of maj or syst ems and co mponents on the Reelmast er 5010 s eries: the 5210, 5410, 5510 and 5610. REFE R TO T HE TRA CTI O N UN[...]

Reelmast er 5010 Ser ies This page is intent ionall y blank .[...]

Rev . C Reelmast er 5010 Ser ies T able Of Contents Chapter 1 - - Safety Safe ty Ins tructi on s 1 - - 2 .......................... Jackin g Instructions 1 - - 4 ......................... Safet y and I nst ruc tion Dec als 1 - - 4 ................ Cha pter 2 - - Product R ec ords a nd Ma inte nance Produc t Records 2 - - 1 .........................[...]

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Rev . B Reelmast er 5010 Ser ies Page 1 - - 1 Safety 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 2 ............................. Maint enance and Ser vice 3 .................... JACKI NG I NST RUCTI O NS 4 ..................... SAF ET Y AN[...]

Rev . B Reelmast er 5010 Ser ies Page 1 - - 2 Safe ty Safety Instructions Reelmast er mac hines meet or ex ceed safet y standard specif icat ions when weight s are ins talled ac cording to infor mat ion in the Traction Unit O perat or ’ s Manual. A l- though hazar d cont rol and ac cident prevent ion are par- tially dependent upon the des ign and[...]

Reelmast er 5010 Ser ies Page 1 - - 3 Safety 6. Anytime the machine i s pa rked (short o r long term), the cut t ing units should be lowered to the ground. T his relieves press ure fr om t he hydr aulic lif t cir cuit and elimi- nates t he risk of t he cut ting unit s unexpect edly lowering to t he ground. 7. Do not par k on slopes unless wheels ar[...]

Rev . B Reelmast er 5010 Ser ies Page 1 - - 4 Safe ty Jacking Instructions Wh en ch ang i ng at tach ment s, ti res or p erfo rm - in g o t her servi ce, u se co rrect b l ocks, h oi sts and j acks. Make su re machi ne is parked on a sol id , level su rface such as a co n crete fl o or . Prio r t o rai sin g machi n e, remo ve any attach - me nts t[...]

Rev . B Reelmaster 5010 Series Page 2 - - 1 Product Records and 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 Series Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions[...]

Rev . B Reelmaster 5010 Series Page 2 - - 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, 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[...]

Rev . B Reelmaster 5010 Series Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Zinc 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 Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs & [...]

Reelmaster 5010 Series Page 2 - - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Series) T h r e a d S i z e Class 8.8 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Class 10.9 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Thread Size Regular Height Nuts (Class 8[...]

Reelmaster 5010 Series Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws T h r e a d S i z e Recommended T orque Thread Size Square Head Hex Socket 1/4 - - 20 UNC 140 + 20 in - - lb 73 + 12 in - - lb 5/16 - - 18 UNC 215 + 35 in - - lb 145 + 20 in - - lb 3/8 - - 16 UNC 35 + 10 ft - - lb 18 + 3f t [...]

Reelmast er 5010 Ser ies Pa ge 3 - - 1 Kubota D i esel Eng i ne Chapter 3 Kubota Diesel Engine T able of Contents GENE RAL IN FORMA TION 1 ..................... T ract ion Unit Oper ator ’s Manual 1 ............... Stopping t he Engine ( Reelmast er 5610) 1 ........ SPECIFICA TIO NS 2 ............................ Reelmast er 5210 2 ..............[...]

Reelmast er 5010 Ser ies Page 3 - - 2 K ubota Di esel Engi n e Specifications: Reelmaster 5210 Item Descri ptio n Make / D es ignation Kubota D 1 105, 4 - - str ok e, Liquid Cooled, O HV Dies el Number of C y linders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) T otal D isplac ement 68.53 in 3 (1 123 cc ) Com pression Ra tio 22.0:1 Firing O [...]

Reelmast er 5010 Ser ies Pa ge 3 - - 3 Kubota D i esel Eng i ne Specifications: Reelmaster 5410 and 5510 Item Descri ptio n Make / D es ignation Kubota V1505, 4 - - str oke, Liquid Cooled, O HV Dies el Number of C y linders 4 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) T otal D isplac ement 91.4 in 3 (1498 c c ) Com pression Ra tio 21.0:1 Fir[...]

Reelmast er 5010 Ser ies Page 3 - - 4 K ubota Di esel Engi n e Specifications: Reelmaster 5610 Item Descri ptio n Make / D es ignation Kubota V1505, 4 - - str oke, Liquid Cooled, O HV , Turbocharged D iesel Number of C y linders 4 Bore x Stroke 3.07” x 3.09“ (78 mm x 78.4 mm) T otal D isplac ement 91.4 in 3 (1498 c c ) Com pression Ra tio 21.0:[...]

Reelmast er 5010 Ser ies Pa ge 3 - - 5 Kubota D i esel Eng i ne Adjustments Adjust Thr ottle Contr ol Proper thrott le operat ion is dependent upon proper ad- justmen t of throttle control . Make sure throttle control is operat ing properly . NOT E: T he thr ott le cable swivel should be positioned in the lowest hole in t he speed c ontr ol lever .[...]

Reelmast er 5010 Ser ies Page 3 - - 6 K ubota Di esel Engi n e Service and Repairs Fuel System Figur e 2 1. Fuel cap 2. Bushi ng 3. Washer head screw ( 3 used) 4. Flange nut (3 used) 5. Clamp (3 used) 6. Re turn fitting 7. Suct ion fit tin g 8. Hose cl amp 9. Hose cl amp 10. Fuel tank 1 1. G r ommet 12. Fuel gauge 13. Hose clamp 14. Drai ncock 15. [...]

Reelmast er 5010 Ser ies Pa ge 3 - - 7 Kubota D i esel Eng i ne DANGER Because d i esel f uel is h ig h ly f lammab l e, u se ca ution when s tor ing or ha ndling it. Do not sm oke while filling the fue l tank . Do not fill f uel ta nk while engine is running, when engine is hot or wh en mach in e is i n an enclo sed area. Always fill fuel ta nk ou[...]

Reelmast er 5010 Ser ies Page 3 - - 8 K ubota Di esel Engi n e Air Cleaner Figur e 3 1. Air cl eaner assembly 2. Hex nut 3. Bolt 4. Spri ng 5. Indicat or 6. Adapt er 7. Hose 8. Hose 9. Mount bracket 10. Air cleaner st and 11 . H o s e c l a m p 12. Flange nut 13. Cap screw ( 2 used) 14. Flange head scr ew (4 used) 15. Flange head scr ew (2 used) 16[...]

Reelmast er 5010 Ser ies Pa ge 3 - - 9 Kubota D i esel Eng i ne Removal ( Fi g. 3) 1. Park machine on a lev el surf ace, lower c utt ing unit s, stop engine, engage parking brak e and rem ove key fr om t he ignition swit ch. Rais e hood. 2. Remove air cleaner c omponent s as needed using Figur es 3, 4 and 5 as guides. 3. See Traction Unit Oper ator[...]

Reelmast er 5010 Ser ies Page 3 - - 10 Kubota D i esel Eng i ne Exhaust System Figur e 6 1. Gasket 2. Lock w asher ( 4 used) 3. Flange nut (4 used) 4. Cap scr ew ( 4 used) 5. Car riag e screw (4 used) 6. Flange nut (4 used) 7. Lock w asher 8. Cap scr ew 9. Isolator plate 10. Hex nut (2 used) 11 . C l a m p 12. Flange nut (2 used) 13. Flat w asher ([...]

Reelmast er 5010 Ser ies Pa ge 3 - - 1 1 Kubota D i esel Eng i ne Removal ( Fi g. 6) 1. Park machine on a lev el surf ace, lower c utt ing unit s, stop engine, engage parking brak e and rem ove key fr om t he ignition swit ch. Rais e hood. CAUTION Th e mu ffl er an d exh au st p ip e may be ho t. T o av oid possible bur ns, allow the engine and ex-[...]

Reelmast er 5010 Ser ies Page 3 - - 12 Kubota D i esel Eng i ne Radi ator Figur e 7 1. Over flo w bott le 2. Hose cl amp (3 used) 3. Hose 4. Foam seal ( 2 used) 5. Foam seal ( 2 used) 6. Foam seal ( 2 used) 7. Oi l cooler 8. Foam seal ( 2 used) 9. Flat w asher (8 used ) 10. Hose clamp ( 4 used) 1 1. Foam seal (2 u sed) 12. Flange nut (4 used) 13. F[...]

Reelmast er 5010 Ser ies Pa ge 3 - - 13 Kubota D i esel Eng i ne CAUTION Do not ope n ra diat or c ap or dr ain c oolant if the radi ato r o r eng i ne i s hot . P ressuri zed , h ot cool - ant can escap e an d cau se b urn s. Ethy lene- - glycol ant ifre eze is pois onous. Dis- pose of coola nt prope rly , or stor e it in a proper ly labe led cont[...]

Reelmast er 5010 Ser ies Page 3 - - 14 Kubota D i esel Eng i ne Engi ne Figur e 9 1. Engi ne assembly 2. Cap scr ew ( 12 used) 3. T emperatu re sender 4. Engine mount (4 used) 5. Cap screw (2 used per mount) 6. Snubbing washer (4 used) 7. Cap scr ew ( 4 used) 8. Flange nut (4 used) 9. Lock nut (2 used per mount) 10. Fan spacer 1 1. Cap scr ew ( 4 u[...]

Reelmast er 5010 Ser ies Pa ge 3 - - 15 Kubota D i esel Eng i ne Removal ( Fi g. 9) 1. Park machine on a lev el surf ace, lower c utt ing unit s, stop engine and remove k ey from t he ignition swit ch. Chock wheels t o keep t he mac hine fr om mov ing. 2. Open hood. 3. Disconnect negat ive ( - - ) and then positiv e (+ ) batter y cables fr om the b[...]

Reelmast er 5010 Ser ies Page 3 - - 16 Kubota D i esel Eng i ne 9. Disconnect hydraulic tr ansmis sion driv e shaft f rom engine (see Hy draulic Transmiss ion Drive S haft Re- moval in t he Ser vice and Repair s sec tion of Chapt er 4 - - Hydraulic Sys tem ). S upport dr ive shaf t away from en- gine. 10. Disconnect wir e harnes s c onnect ors f ro[...]

Reelmast er 5010 Ser ies Pa ge 3 - - 17 Kubota D i esel Eng i ne 7. Remove plugs installed in hoses during dis assem - bly . Connec t hos es t o the engine: A. Connect fuel supply and f uel ret urn hoses to en- gine fit tings (F ig. 1 1). Secur e with hos e clamps . B. Connect upper and lower radiat or hoses to the engine. S ecure wit h hose clam p[...]

Reelmast er 5010 Ser ies Page 3 - - 18 Kubota D i esel Eng i ne This page is intent ionall y blank .[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... T raction Unit Operator ’s Manual 3 ............... Check Hydraulic Fluid 3 ....................... T owing T r action Unit 3 ....................[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 2 Specifications Item Description Piston (T raction) Pump Sauer - - Danfoss, LPV Closed Circuit Axial Piston Design Maximum Pump Displacement (per revolution) 2.14 Cubic Inches (35 cc) Gear Pump Casappa 4 section, posit ive displacement gear type pump Section P1/P2 Displacement (per revol[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 3 General Information T raction Unit Operator ’ s Manual The T raction Unit Operator ’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publication for additional information when servicing[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 4 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance. These conditions can cause damage or premature dete[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 5 SAE Straight Thread O - - Ring Port - - Non - - adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches or any foreign material. 2. Always replace the O- - ring seal when this type of fit- ting shows signs of leakage. 3. Lubricate the O- - ring with[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 6 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- draulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting units fully , stop engine and engage parking brake. T o relieve hydraulic pres[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 7 Hydraulic Schematics The hydraulic schematics for Reelmaster 5010 series machines are located in Chapter 9 - - Foldout Drawings. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 8 Hydraulic Flow Diagrams Figure 8 Working Pressure Low Pressure (Charge) Return or Suction Flow T raction Circuit (Forward Shown) Reelmaster 5010 (5510/5610 Shown) FORW ARD M7 M6 OUT IN V1 R L STEERING T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR R10 R8 C4 L C5 L C1[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 9 T raction Circuit The hydraulic traction circuit consists of a variable dis- placement piston pump (P5) connected in a closed loop, parallel circuit to two (2) orbital roller vane wheel motors. The traction pump input shaft is rotated by a drive shaft that is driven from the engine flyw[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 10 Figure 10 Working Pressure Low Pressure (Charge) Return or Suction Flow Mow Circuit (Mow Shown) Reelmaster 5010 (5510/5610 Shown) FORW ARD M7 M6 OUT IN V1 R L STEERING T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR R10 R8 C4 L C5 L C1 L REAR LEFT RIGHT T P REAR MOW [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 1 Mow Circuit A four section gear pump is coupled to the piston (trac- tion) pump. Gear pump sections (P1) and (P2) supply hydraulic flow for the mow circuit. These gear pumps take their suction from the hydraulic reservoir . The mow control manifold contains two independent control cir[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 12 Figure 1 1 Working Pressure Low Pressure (Charge) Return or Suction Flow Lift Circuit: Raise Cutting Units Reelmaster 5010 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 100 MESH SUCTION STRAINER[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 13 Lift Circuit: Raise Cutting Units A four section gear pump is coupled to the piston (trac- tion) pump. Gear pump section (P4) supplies hydraulic flow to the lift control manifold and ultimately for the lift cylinders. The gear pump takes its s uction from the hy- draulic reservoir . Li[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 14 Figure 12 Working Pressure Low Pressure (Charge) Return or Suction Flow Lift Circuit: Lower Cutting Units Reelmaster 5010 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 100 MESH SUCTION STRAINER [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 15 Lift Circuit: Lower Cutting Units A four section gear pump is coupled to the piston (trac- tion) pump. Gear pump section (P4) supplies hydraulic flow to the lift control manifold and ultimately for the lift cylinders. The gear pump takes its s uction from the hy- draulic reservoir . Li[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 16 Figure 13 Working Pressure Low Pressure (Charge) Return or Suction Flow Steering Circuit Reelmaster 5010 STEERING CYLINDER PISTON MOVEMENT STEERING CYLINDER STEERING VA LV E PISTON MOVEMENT STEERING VA LV E R10 R10 FROM PUMP (P3) FROM PUMP (P3) TO TRACTION CHARGE CIRCUIT TO TRACTION CH[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 17 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. Gear pump section P3 supplies hydraulic flow to the steering control valve and for the traction charge circuit. The gear pump takes its suction from the hydraulic reservoir . Steering circuit pressure[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 18 Special T ools Order these special tools from your T oro Distributor . Hydraulic Pressure T est Kit T oro Part Number: T OR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports witho[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 19 40 GPM Hydraulic T ester (Pressure and Flow) T oro Part Number: A T40002 Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the T esting section of this chapter . This tester includes the following: 1. LOAD V AL VE: A simulated working load[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 20 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi - - direc- tional filtration which prevents filtered debris from being allowed back into the circui[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 21 Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft. T oro Part Number: T OR6004 Figure 21 Measuring Container Part Number: TOR4077 Use this graduated container for doing hydraulic motor efficiency testing (motors with case drain lines [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 22 T roubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com- plete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for fail[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 23 T raction Circuit Problems Problem Possible Cause Neutral is difficult to find or unit oper- ates in one direction only T raction control linkage is misadjusted, disconnected, binding or damaged. Piston (traction) pump check relief valve is not seating or is dam- aged (NOTE: Piston (tr[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 24 T raction Circuit Problems (Continued) Problem Possible Cause Wheel motor will not turn Brakes are binding. Wheel motor is worn or damaged. (NOTE: If a traction circuit component has internal wear or dam- age, it is possible that other traction components are also dam- aged) Wheel moto[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 25 Lift Circuit Problems Problem Possible Cause Single cutting unit lifts slowly or not at all Cutting unit has excessive debris buildup. Lift arm or lift cylinder is binding. Pilot piston in lift control manifold is stuck or damaged. Lift cylinder leaks internally . Flow control orifice [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 26 Lift Circuit Problems (Continued) Problem Possible Cause Single cutting unit lowers very slowly or not at all Lift arm or lift cylinder is binding. Lift cylinder is damaged. Flow control orifice in lift control manifold for the affected cutting unit is plugged or damaged. Check valve i[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 27 This page is intentionally blank. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 28 T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special T ools section in this chapter). Before Performing Hydraulic[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 29 Which Hydraulic T ests Are Necessary? Before beginning any hydraulic test, identify if the prob- lem is related to the traction c ircuit, cutting (mow) circuit, lift circuit or steering circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1. I[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 30 T raction Circuit Relief V alve (R3) and (R4) Pressure T est Figure 24 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 B R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN (TO RESER VOIR) A P5 TO LIFT CONTROL[...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 31 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . NOTE: If machine is equipped wit[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 32 T raction Circuit Charge Pressure T est Figure 28 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 B R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN (TO RESER VOIR) A P5 TO LIFT CONTROL MANIFOLD TO STEERING[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 33 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . 5. Thoroughly clean ends of hydraulic tu[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 34 Gear Pump (P3) Flow T est (Using T ester with Pressure Gauges and Flow Meter) Figure 31 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 B R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN (TO RESER VOIR) A P[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 35 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . 4. Raise and prop operator seat to allow[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 36 Front Wheel Motor Efficiency T est Figure 33 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 B R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN (TO RESER VOIR) A P5 TO LIFT CONTROL MANIFOLD TO STEERING CONT[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 37 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . 5. Attach a heavy chain to the rear of t[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 38 Piston (T raction) Pump Flow T est (Using T ester with Flow Meter and Pressure Gauge) Figure 35 FORW ARD M7 M6 FROM STEERING CONTROL V AL VE R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 B R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN (TO RESER V[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 39 4. Make sure that traction pedal is adjusted to the neu- tral position. Also, ensure that traction pump is at full stroke when traction pedal is pushed into fully forward position. 5. Raise and support machine so all wheels are of f the ground (see Jacking Instructions in Chapter 1 - -[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 40 Relief V alve (R1) and (R2) Pressure T est Figure 37 FORW ARD M7 M6 R8 REAR MOW CIRCUIT FRONT MOW CIRCUIT R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 G2 EP2 MSV2 MSV1 OR2 OR4 MR2 FC2 CV EP1 G1 OR3 FC1 OR1 MR1 P2 T P1 M1 BKLP1 M2 BKLP2 B R2 R[...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 41 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . 4. Raise and prop operator seat [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 42 Gear Pump (P1) and (P2) Flow T est (Using T ester with Pressure and Flow Capabilities) Figure 39 FORW ARD M7 M6 R8 REAR MOW CIRCUIT FRONT MOW CIRCUIT R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 G2 EP2 MSV2 MSV1 OR2 OR4 MR2 FC2 CV EP1 G1 OR3 [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 43 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . 4. Raise and prop operator seat to allow[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 44 Reel Drive Motor Efficiency T est (Using T ester with Pressure Gauges and Flow Meter) High Pressure Low Pressure Flow Outlet Hose Case Drain Hose Case Drain Install tester in series between fitting and hose at motor outlet. NOTE: Outlet is rear hose. MOW CONTROL M4 R1 1 R1 1 M1 R1 1 R1[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 45 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . NOTE: The reel motors are connected in s[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 46 Reel Drive Motor Cross - - Over Relief Pressure T est (Reelmaster 5510 and 5610) Use a tee fitting to install pressure gauge in both inlet and outlet lines of motor being tested. NOTE: Inlet is front hose. Outlet is rear hose. High Pressure Low Pressure Flow MOW CONTROL M4 R1 1 R1 1 M1[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 47 Procedure for Reel Drive Motor Cross - - Over Relief Pressure T est 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. 2. Determine which reel motor is malfunctioning. 3. Park machine on a level s urfa[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 48 Lift Relief V alve (SVR V) Pressure T est Figure 45 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR R8 C4 L C5 L C1 L REAR LEFT RIGHT 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN P1 P2 P3 P4 G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 PUMP (P5) TO STEERING TO MOW CONTRO[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 49 5. Thoroughly clean test port (G4) on lift control man- ifold. Access to test port can be obtained from below the front of the machine. Connect a 5000 PSI (350 bar) pres- sure gauge to test port. 6. After installing pressure gauge to manifold test port, start engine and run at idle spe[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 50 Gear Pump (P4) Flow T est (Using T ester with Pressure Gauges and Flow Meter) Figure 46 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR R8 C4 L C5 L C1 L REAR LEFT RIGHT 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN P1 P2 P3 P4 G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 51 4. Raise and prop operator seat to allow access to hy- draulic pump. 5. Thoroughly clean both ends of the hydraulic tube that connects gear pump (P4) outlet (Fig. 47) and lift control manifold P4 port. Remove hydraulic tube. Ac- cess to hydraulic tube at lift control manifold can be ob[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 52 Lift Cylinder Internal Leakage T est Figure 48 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR R8 C4 L C5 L C1 L REAR LEFT RIGHT 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN P1 P2 P3 P4 G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 PUMP (P5) TO STEERING TO MOW CONTROL (RE[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 53 IMPORT ANT : When capping lift cylinder fitting and hydraulic hose end, use a steel cap and plug to en- sure that fluid leakage will not occur . Plastic plugs will not hold hydraulic pressure that will be devel - oped during this test procedure. 4. Place a steel cap on the open lift cy[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 54 Steering Relief V alve (R10) Pressure T est Figure 52 STEERING WHEEL TURNED FOR RIGHT TURN OUT IN V1 R L STEERING R10 TP 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN P1 P2 P3 P4 CYLINDER CONTROL STEERING VA LV E DRAIN PUMP (P5) PRESSURE GAUGE TO MOW CONTROL MANIFOLD (REAR CUTTING UNIT[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 55 Procedure for Steering Relief V alve Pressure T est: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. 2. Park machine on a level s urface with the cutting units lowered and PTO switch off . Make sure[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 56 Steering Cylinder Internal Leakage T est Figure 54 STEERING CYLINDER STEERING CONTROL VA LV E (FULL Y EXTENDED) LOOK FOR LEAKAGE PLUG STEERING WHEEL TURNED FOR RIGHT TURN R10 The steering cylinder internal leakage test should be performed if a steering problem is identified. This test [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 57 Procedure for Steering Cylinder Internal Leakage T est: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. 2. Park machine on a level s urface with the cutting units lowered and PTO switch off . Make s[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 58 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting units and stop engin[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 59 Check Hydraulic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and ca[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 60 Flush Hydraulic System IMPORT ANT : Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil appears milky or black or contains metal particles. 1. Park machine on a level surface. Lower cutting units, stop engine, engage p[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 61 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 prevent debris from transmit- ting throughout the system. If a closed - - loop hydraulic system f[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 62 Hydraulic System Start - - up NOTE: When initially starting the hydraulic system with new or rebuilt components such as pumps, wheel 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[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 63 This page is intentionally blank. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 64 Hydraulic Reservoir 1. Suction strainer 2. Breather adapter 3. Breather 4. Plastic plug 5. Oil reservoir 6. T ank cover 7. Hydraulic tee fitting 8. Hydraulic tube 9. O - - ring 10. Flange gasket 1 1. Socket head screw (6 used) 12. Bumper 13. Clamp (2 used) 14. Hydraulic hose 15. Hose c[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 65 Removal (Fig. 57) 1. T ilt hydraulic reservoir c over up to access reservoir . 2. Thoroughly clean hydraulic hose ends and fittings on hydraulic reservoir to prevent hydraulic system contami- nation. 3. Drain hydraulic oil from reservoir . 4. Label hydraulic hoses to assist in installa[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 66 Hydraulic Pump Drive Shaft 1. Piston (traction) pump 2. Flange nut (2 used) 3. Flange head screw (2 used) 4. Guard hoop 5. Cap screw (2 used) 6. Engine flywheel 7. Cap screw (6 used) 8. Drive shaft assembly 9. Flange nut 10. Flange head screw (2 used) Figure 58 FRONT RIGHT 34 to 42 ft [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 67 Removal (Fig. 58) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Remove two (2) flange head screws and flange nuts that secure drive shaft guard hoop to machine frame. Remove guard. 3. Remove tw[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 68 Hydraulic Pump Assembly 1. Drive shaft assembly 2. Cap screw (2 used) 3. Flange head screw (2 used) 4. T raction pump assembly 5. O - - ring 6. Hydraulic fitting (2 used) 7. Hydraulic hose (2 used) 8. Lever damper 9. Flange nut 10. Plate 1 1. Flange head screw (2 used) 12. Flange nut ([...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 69 Removal (Fig. 60) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repair[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 70 4. Carefully lower pump assembly to machine frame. 5. Secure pump assembly to machine frame with two (2) flange screws and flange nuts. 6. Secure pump support bracket t o inside of frame bracket with two (2) carriage screws (item 38) and flange nuts (item 36). 7. Install hydraulic hose[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 71 This page is intentionally blank. Hydraulic System[...]

Rev . A Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 72 Piston (T raction) Pump Service 1. T raction pump housing 2. Auxiliary shaft 3. Retaining ring 4. Ball bearing 5. Retaining ring 6. Seal 7. Backup washer 8. Bearing 9. O - - ring 10. Trunnion cover 1 1. Screw (4 used) 12. Plug 13. O - - ring 14. Seal 15. Trunnion cover 16. Neut[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 73 This page is intentionally blank. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 74 Gear Pump Service 1. Front cover 2. Dowel pin (16 used) 3. Square section seal (8 used) 4. Back - - up ring (8 used) 5. Pressure seal (8 used) 6. Thrust plate (8 used) 7. Drive shaft 8. Driven gear (2 used) 9. Body 10. Flange (3 used) 1 1. Splined connecting shaft (3 used) 12. Drive ge[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 75 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 corrosive to gear finish. 7. Remove the thrust plates and seals from each pump section. Before[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 76 Front Wheel Motor 1. LH wheel motor (Parker) 2. Lug nut (5 used per wheel) 3. Hub 4. Tire and wheel assembly 5. Hydraulic fitting (4 used) 6. Hydraulic tube 7. Hydraulic tube 8. Cap screw (2 used per wheel shield) 9. R - - clamp (4 used) 10. Diagnostic fitting (2 used) 1 1. Dust cap (2[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 77 NOTE: Machines produced with serial number below 31 1000600 were produced with Parker brand front wheel motors. Figure 65 shows the front axle assembly with Parker wheel motors. Machines with serial number above 31 1000600 were produced with Eaton brand front wheel motors. Figure 66 sh[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 78 1 1. Disconnect hydraulic lines from fittings on wheel mo- tor . Allow lines to drain into a s uitable container . 12. Put caps or plugs on disconnected lines and fittings to prevent contamination. 13. Support w heel motor to prevent it from falling. Re- move four (4) lock nuts from ca[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 79 This page is intentionally blank. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 80 Wheel Motor Service (Parker) 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. V ane (7 used) 10. Rotor 1 1. Wear plate 12. Drive link 13. Thrust bearing 14. Coupling shaft 15. Woodruff key 16. Thrust b[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 81 Front Wheel Motor Service (Eaton) 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 alve 9. Dowel pin (4 used) 10. Balancing ring 1 1. V alve spring 12. Back - - up ring 13. O - - ring 14. Drive 15. Output shaf[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 82 Mow Control Manifold 1. Mow control manifold 2. O - - ring 3. Diagnostic fitting 4. Dust cap 5. Hydraulic tube 6. O - - ring 7. Hydraulic fitting (4 used) 8. O - - ring 9. Hydraulic tube 10. O - - ring 1 1. Hydraulic fitting 12. O - - ring 13. O - - ring 14. Hydraulic fitting 15. O - -[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 83 Removal (Fig. 70) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repair[...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 84 Mow Control Manifold Service 1. Mow control manifold 2. O - - ring 3. Plug (zero leak #6) 4. Orifice (0.020) 5. O - - ring 6. Plug (SAE #4) 7. Seal kit 8. Solenoid relief valve cartridge (MSV1) 9. Solenoid coil 10. Nut 1 1. Solenoid relief valve cartridge (MSV2) 12. Seal kit 13[...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 85 Mow Control Manifold Service 1. Make sure the manifold is thoroughly cleaned before removing any cartridge valve. 2. If solenoid cartridge valve is being serviced, remove nut securing solenoid coil to the cartridge valve. Careful- ly slide solenoid coil off the valve. 3. If flo[...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 86 6. V isually inspect the manifold port for damage to the sealing surfaces, damaged threads and contamination. 7. Visually inspect cartridge valve for damaged sealing surfaces and contamination. A. Contamination may cause valves to stick or hang up. Contamination can become lodg[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 87 1 1. If solenoid coil was removed: A. Carefully install coil onto the cartridge valve. B. Install nut and torque nut to 48 to 60 in - - lb (5.4 to 6.7 N - - m) . 12. If flow control cartridge valve was removed, install rotary handle to valve stem (Fig. 72): A. Place handle base on flow[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 88 Lift Control Manifold 1. Lift control manifold 2. Flange head screw 3. O - - ring 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. Hydraulic fitting 15. O[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 89 Removal (Fig. 75) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repair[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 90 Lift Control Manifold Service 1. Lift control manifold 2. Check valve (4 used) 3. Solenoid valve (SV3) 4. Solenoid coil 5. Solenoid coil spacer 6. Nut 7. Solenoid valve (SV2) 8. Solenoid coil 9. Nut 10. Solenoid relief valve (SVRV) 1 1. Solenoid valve (SV1) 12. Relief valve (R7) 13. O [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 91 For lift control manifold service procedures, see Mow Control Manifold Service in this section. Refer to F igure 77 for cartridge valve installation torque. Refer to Fig- ures 77 and 78 for hydraulic fitting installation torque val- ues. NOTE: Solenoid valves SV1 and SV2 on the lift co[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 92 CrossT rax TM A WD (Optional Kit) Manifold 1. A WD manifold 2. Hydraulic tube 3. Hydraulic tube 4. Hydraulic tube 5. O - - ring 6. Hydraulic fitting (7 used) 7. O - - ring 8. Dust cap (2 used) 9. Diagnostic fitting (2 used) 10. O - - ring 1 1. Cap screw (3 used) 12. Lock washer (3 used[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 93 6. Put caps or plugs on disconnected lines and fittings to prevent contamination. 7. Support manifold to prevent it from falling. Remove three (3) cap screws and lock washers that secure man- ifold to machine frame. Locate and retrieve three (3) spacers from between bracket and manifol[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 94 CrossT rax TM A WD (Optional Kit) Manifold Service 1. A WD manifold 2. O - - ring 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 80 4 3 1 2 9 10 11 8 5[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 95 This page is intentionally blank. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 96 Cutting Reel Motor 1. Hydraulic reel motor (#4) 2. O - - ring 3. 90 o hydraulic fitting 4. O - - ring 5. Hydraulic hose 6. O - - ring 7. Hydraulic fitting 8. O - - ring 9. Hydraulic hose 10. Hydraulic fitting 1 1. Hydraulic hose 12. Hydraulic hose 13. 90 o hydraulic fitting 14. Hydraul[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 97 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . 4. Disconnect hydraulic hoses from fitti[...]

Rev . A Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 98 Cutting Reel Motor Service 1. Rear cover 2. Drive gear 3. Seal 4. T ab washer 5. Pressure seal 6. Back - - up ring 7. O - - ring 8. Body 9. Idler gear 10. Cap screw (4 used) 1 1. Front flange 12. Dowel pin 13. Rear bearing block 14. Front bearing block 15. O - - ring 16. O - - [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 99 2. Use a marker to m ake a diagonal line across the front flange, body and rear cover for assembly purposes (Fig. 84). IMPORT ANT : A void using excessive clamping pressure on the motor flange to prevent damage. 3. Clamp front flange of motor in a vise with the shaft end down. Use of a[...]

Rev . A Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 100 2. Clean all motor components with solvent. Dry all parts with compressed air . 3. Inspect drive gear , idler gear and bearing blocks (Fig. 87) for the following: A. Gear shafts should be free of r ough surfaces and excessive wear at bushing points and sealing areas. Scoring, [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 101 This page is intentionally blank. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 102 Lift Cylinder 1. Lift cylinder 2. Pivot shaft 3. Flange head screw 4. Lift arm (RH front shown) 5. Flat washer 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. Cylinder slide pin Figure 88 FRONT RIGHT [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 103 Removal (Fig. 88) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the en- gine. Remove the key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 104 Lift Cylinder Service 1. Grease fitting 2. Shaft 3. Wiper 4. Head 5. U - - Cup 6. Retaining ring 7. Back up washer 8. O - - ring 9. Piston 10. Cap seal 11 . O - - r i n g 12. O - - ring 13. Lock nut 14. Barrel Figure 89 2 3 4 5 6 1 9 8 7 1 10 11 14 12 13 2 3 4 5 6 1 9 8 7 1 10 11 14 1[...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 105 3. Using a spanner wrench, rotate head clockwise until the edge of the retaining ring appears in the barrel open- ing. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the open- ing. Rotate the head counter - - clockwise to [...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 106 Steering Control V alve 1. Steering control valve 2. Flange head screw 3. Foam collar 4. Steering wheel 5. Flat washer 6. Lock nut 7. Steering wheel cover 8. Steering column 9. Socket head screw (4 used) 10. O - - ring 1 1. Hydraulic fitting (4 used) 12. O - - ring 13. Steerin[...]

Rev . B Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 107 CAUTION Before opening hydraulic system, operate all hy - draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter . 7. Disconnect hydraulic lines f[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 108 Steering Control V alve Service 1. Screw (5 used) 2. O - - ring (5 used) 3. End cover 4. O - - ring 5. Outer gearwheel 6. Inner gearwheel 7. Distributor plate 8. O - - ring 9. Cardan shaft 10. Spool 1 1. Sleeve 12. Cross pin 13. Spring set 14. Ring 15. Thrust washer 16. Bearing 17. Sh[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 109 This page is intentionally blank. Hydraulic System[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 10 Steering Cylinder 1. Steering cylinder 2. Retaining ring 3. Grease fitting 4. Hydraulic hose 5. O - - ring 6. 90 o hydraulic fitting 7. O - - ring 8. Hydraulic hose 9. Grease fitting 10. Ball joint 1 1. Jam nut 12. Cotter pin 13. Slotted hex nut 14. Ball joint Figure 94 FRONT RIGHT 4[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) P a g e 4 - - 111 Removal (Fig. 94) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the en- gine. Remove the key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 12 Steering Cylinder Service 1. Shaft 2. Wiper 3. U - - Cup 4. Head 5. Retaining ring 6. Back - - up ring 7. O - - ring 8. O - - ring 9. Piston 10. O - - ring 1 1. Cap seal 12. Wear ring 13. Lock nut 14. Barrel Figure 96 2 4 6 1 9 8 7 10 11 13 3 5 12 14 4 6 9 8 7 14 11 3 5 2 1 12 13 10 [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 13 Inspection CAUTION Use eye protection such as goggles when using compressed air . 1. W ash all cylinder components in solvent. Dry parts with compressed air . 2. Inspect internal surface of barrel for deep scratches, out - - of - - roundness and bending. Replace if worn or damaged. 3[...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 14 Oil Cooler 1. Screen assembly 2. Oil cooler bracket 3. Cap screw (4 used) 4. Foam seal (2 used) 5. Draw latch 6. Rivet (2 used) 7. Oil cooler 8. Hydraulic hose (2 used) 9. Flat washer (8 used) 10. Hose clamp (4 used) 1 1. Foam seal (2 used) 12. Washer (4 used) 13. Cap screw (2 used) [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 15 Inspection 1. Back flush oil cooler with cleaning solvent. After cool- er is clean, make sure all solvent is drained from the cooler . CAUTION Use eye protection such as goggles when using compressed air . 2. Dry inside of oil cooler using compressed air in the opposite direction of [...]

Reelmaster 5010 Series Hydraulic System (Rev . C) Page 4 - - 1 16 This page is intentionally blank.[...]

Reelmaster 5010 Series Page 5 - - 1 Electrical System Chapter 5 Electrical System T able of Contents GENERAL INFORMA TION 1 ..................... ELECTRICAL DIAGRAMS 1 ...................... SPECIAL TOOLS 2 ............................. TROUBLESHOOTING 4 ......................... Diagnostic Light 4 ............................. Retrieving Fault Cod[...]

Rev . A Reelmaster 5010 Series Page 5 - - 2 Electrical System Special T ools Order Special T ools from your T oro Distributor . Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. Obtain this tool locally . NOTE: T oro recommends the use of a DIGIT AL V olt - - Ohm - - Amp multimeter when test[...]

Reelmaster 5010 Series Page 5 - - 3 Electrical System Diagnostic Display The Diagnostic Display (Fig. 4) is connected to the wiring harness connector located inside the control arm to verify correct electrical functions of the machine. Electronic Control Module (ECM) inputs and outputs can be checked using the Diagnostic Display . T oro Part Number[...]

Reelmaster 5010 Series Page 5 - - 4 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, there must be a good understanding of the elect[...]

Rev . C Reelmaster 5010 Series Page 5 - - 5 Electrical System Fault Code (Lamp Flashes) Fault Description 1- -1 High engine temp warning occurred (PTO was shutdown by ECM) 1- -2 High engine temp shutdown occurred (engine was shutdown by ECM) 1- -3 Low engine oil pressure occurred 1- -4 Engine alternator fault occurred 1- -5 Charging system voltage [...]

Rev . A Reelmaster 5010 Series Page 5 - - 6 Electrical System Diagnostic Display Reelmaster 5010 machines are equipped with an Elec- tronic Control Module (ECM) which controls machine electrical functions. The ECM monitors various input switches (e.g. ignition switch, seat switch, etc.) and en- ergizes outputs to actuate solenoids or relays for the[...]

Reelmaster 5010 Series Page 5 - - 7 Electrical System Diagnostic Display ECM Inputs Fault Description TEMP W ARN Excessive engine temperature: LED ON Normal engine temperature: LED OFF JOYSTICK LOWER Joystick moved forward: LED ON Joystick in neutral: LED OFF PTO ENABLE PTO switch ON: LED ON PTO switch OFF: LED OFF FR REELS DN Cutting units lowered[...]

Rev . A Reelmaster 5010 Series Page 5 - - 8 Electrical System V erify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are turned on by the ECM. This is a quick way to determine if a machine mal- function is electrical or hydraulic. NOTE: An open output (e.g. an unplugged con[...]

Reelmaster 5010 Series Page 5 - - 9 Electrical System Electronic Control Module Logic Chart Each line of the following chart identifies the necessary component position (INPUTS) in order for the Electronic Control Module (ECM) to energize the appropriate OUTPUTS for machine operation. Example: T o start the engine with no operator in the seat, when[...]

Reelmaster 5010 Series Page 5 - - 10 Electrical System Starting Problems Problem Possible Causes All electrical power is dead, including gauges. Battery is discharged. Ignition switch or circuit wiring is faulty . Fusible link harness at the engine starter motor is faulty . Battery cables are loose or corroded. Main fuse (15 amp) to the ignition sw[...]

Reelmaster 5010 Series Page 5 - - 1 1 Electrical System Starting Problems (Continued) Problem Possible Causes Engine cranks, but should not, when the traction pedal is depressed. T raction neutral switch is out of adjustment. T raction neutral switch or circuit wiring is faulty . Nothing happens when start attempt is made. Control panel lights and [...]

Reelmaster 5010 Series Page 5 - - 12 Electrical System General Run and T ransport Problems Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. Engine fuel stop solenoid is faulty . Ignition switch or circuit wiring is faulty . Main power relay or circuit wiring is faulty . Engine continues to run[...]

Reelmaster 5010 Series Page 5 - - 13 Electrical System Cutting Unit Operating Problems Problem Possible Causes The cutting units remain engaged, but should not, with no operator in the seat. Seat switch or circuit wiring is faulty . Electronic Control Module is faulty . Cutting units run, but should not, when raised. Cutting units shut off with PT [...]

Reelmaster 5010 Series Page 5 - - 14 Electrical System Cutting Unit Operating Problems (Continued) Problem Possible Causes The cutting units do not run when placed in the backlap direction. Cutting units are not fully lowered to ground. Front or rear backlap switch or circuit wiring is faulty . Up limit switch or circuit wiring is faulty . A hydrau[...]

Reelmaster 5010 Series Page 5 - - 15 Electrical System T urfDefender TM Leak Detector (Optional) The optional T urfDefender TM is an electronic hydraulic fluid leak detection device that fits inside the hydraulic reservoir of your machine (Fig. 12). It is a pressure based system which requires a sealed hydraulic reser- voir to function properly . V[...]

Reelmaster 5010 Series Page 5 - - 16 Electrical System If T urfDefender TM is functioning normally : 1. When the “Inputs Displayed ” LED is lit (Fig. 15): A. The actual float position should be identified by 1 or 2 LED’s in the left column. The correct reservoir level is some combination of Float Levels 3 and/or 4. B. The “T ank Level OK”[...]

Reelmaster 5010 Series Page 5 - - 17 Electrical System TURFDEFENDER V1.0 DIAGNOSTIC ACE 94 - -5386  OUTPUT / INPUT FLOA T LEVEL (TOP) FLOA T LEVEL 2 FLOA T LEVEL 3 FLOA T LEVEL 4 FLOA T LEVEL 5 FLOA T LEVEL 6 FLOA T LEVEL 7 FLOA T LEVEL 8 FLOA T LEVEL 9 VA LV E O N / V ALVE OPEN CIRCUIT / V ALVE SHORT CIRCUIT/ ALARM ON / ALARM OPEN CIRCUIT / ALA[...]

Reelmaster 5010 Series Page 5 - - 18 Electrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a digital multimeter to measure the battery voltage. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F( 1 6 o to 38 o C). The ignition switch should be in the OFF position a[...]

Rev . A Reelmaster 5010 Series Page 5 - - 19 Electrical System 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 operation of the interlock switches daily for proper operation. R[...]

Rev . B Reelmaster 5010 Series Page 5 - - 20 Electrical System Adjustments T raction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neu- tral position. The switch mounts to a bracket on the trac- tion pump. On machines with serial numbers below 310000000 (Fig. 17), the se[...]

Rev . B Reelmaster 5010 Series Page 5 - - 21 Electrical System Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bot- tom of the brake pedal (Fig. 19). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake sw[...]

Rev . B Reelmaster 5010 Series Page 5 - - 22 Electrical System Up Limit Switch The up limit switch is a normally open proximity switch that closes when the cutting units are in the lowered position. A bracket on the front, right lift arm acts as the sensing plate for the up limit switch (Fig. 21). Adjustment The up limit switch should be secured to[...]

Rev . B Reelmaster 5010 Series Page 5 - - 23 Electrical System Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check of the switch). NOTE: Electrical troubleshooting of any 12 volt power con[...]

Reelmaster 5010 Series Page 5 - - 24 Electrical System Indicator Lights Glow Plug Indicator Light The glow plug indicator light should come on when the ignition switch is placed in the RUN position prior to plac- ing the ignition switch in ST ART . The light should stay lit for approximately 6 seconds while the ignition switch is left in the RUN po[...]

Reelmaster 5010 Series Page 5 - - 25 Electrical System Hour Meter The hour meter is located on the outside of the control arm. 1. Remove control arm covers to gain access to hour meter and meter terminals (see Control Arm Disassem- bly in the Service and Repairs section of this chapter). 2. Make sure ignition switch is in the OFF position. Lo- cate[...]

Reelmaster 5010 Series Page 5 - - 26 Electrical System PT O Switch The PTO switch is mounted on the control panel and is pressed to allow the cutting units to operate. An indicator light on the switch identifies when the PTO switch is en- gaged. T esting 1. Before disconnecting the switch for testing, the switch and its circuit wiring should be tes[...]

Rev . B Reelmaster 5010 Series Page 5 - - 27 Electrical System T raction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neu- tral position. The switch mounts to a bracket on the trac- tion pump. On machines with serial numbers below 310000000 (Fig. 31), the sensing elemen[...]

Reelmaster 5010 Series Page 5 - - 28 Electrical System Seat Switch The seat switch is normally open and closes when the operator seat is occupied. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch is located di- rectly under the operator seat. T esting 1. Before disconnec[...]

Reelmaster 5010 Series Page 5 - - 29 Electrical System Headlight Switch The headlight switch is located on the operator side of the control arm. This rocker switch allows the headlights to be turned on and off. T esting 1. Remove inside control arm cover t o gain access to headlight switch (see Control Arm Disassembly in the Service and Repairs sec[...]

Rev . B Reelmaster 5010 Series Page 5 - - 30 Electrical System Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bot- tom of the brake pedal. The switch on machines with a serial number below 310000000 is dif ferent than the switch on machines with serial numbers above 310[...]

Rev . B Reelmaster 5010 Series Page 5 - - 31 Electrical System Up Limit Switch The up limit switch is a normally open proximity switch that closes when the cutting units are in the lowered position. A bracket on the front, right lift arm acts as the sensing plate for the up limit switch (Fig. 37). The switch on machines with a serial number below 3[...]

Rev . B Reelmaster 5010 Series Page 5 - - 32 Electrical System Joystick Raise and Lower Switches T wo micro switches for the joystick are located on the lift control that is attached to the control arm. The rear switch on the control is used to lower (and engage) the cutting units and the front switch to raise (and disen- gage) them. A normally ope[...]

Rev . B Reelmaster 5010 Series Page 5 - - 33 Electrical System Mow/T ransport Switch The mow/transport switch is a normally closed proximity switch that opens when the mow stop lever is placed in the transport position. The sensing plate for the mow/ transport switch is the mow stop lever . The switch on machines with a serial number below 31000000[...]

Reelmaster 5010 Series Page 5 - - 34 Electrical System Backlap Switches The front and rear backlap switches are normally closed ball switches that are in the normal, closed state when the backlap lever is in the backlap position. When the backlap lever is in the mow position, the switch opens. The backlap switches are attached to the hydraulic mow [...]

Rev . C Reelmaster 5010 Series Page 5 - - 35 Electrical System Start Relay The start relay is used in the engine starting circuit. When energized by the Electronic Control Module (ECM), the start relay provides a current path to ener- gize the engine starter solenoid. The start relay is at- tached to a frame bracket under the hood next to the hydra[...]

Reelmaster 5010 Series Page 5 - - 36 Electrical System Main Power and Glow Relays The Reelmaster electrical system includes two identical relays for current control. The main power and glow re- lays are attached to a frame bracket under the hood next to the hydraulic pump drive shaft (Fig. 42). Relays can be identified by a tag on the wire harness.[...]

Reelmaster 5010 Series Page 5 - - 37 Electrical System Electronic Control Module (ECM) The T oro Electronic Control Module (ECM) senses the condition of various switches (inputs) and directs power output to allow certain machine functions. The ECM is located behind the control arm access cover next to the fuse block (Fig. 44). The handheld Diagnost[...]

Reelmaster 5010 Series Page 5 - - 38 Electrical System Diode Assembly A diode assembly (Fig. 45) is used in the Reelmaster en- gine wire harness (see wire harness drawings in Chap- ter 9 - - Electrical Diagrams). The diode is used for circuit protection from voltage spikes that occur when the start- er solenoid is de - - energized. T esting Locate [...]

Reelmaster 5010 Series Page 5 - - 39 Electrical System Fuses The fuse block is located behind the control arm access cover (Fig. 49). Identification and Function The fuses are held in the fuse block. Use Figure 50 to identify each individual fuse and its correct amperage. Fuses for your Reelmaster have the following function: Left Fuse 1 (15 Amp): [...]

Reelmaster 5010 Series Page 5 - - 40 Electrical System Hydraulic Solenoid V alve Coil The Reelmaster hydraulic system uses several hydrau- lic solenoid valve coils for system control. The cutting deck manifold includes two (2) solenoid valves (Fig. 52) and the lift control manifold includes four (4) solenoid valves (Fig. 51). When the solenoid coil[...]

Reelmaster 5010 Series Page 5 - - 41 Electrical System T emperature Sender The temperature sender is attached to the water pump housing on the engine and has a gray wire attached to it (Fig. 53). The resistance of the temperature sender re- duces as the engine coolant temperature increases. The changing resistance of the temperature sender sig- nal[...]

Reelmaster 5010 Series Page 5 - - 42 Electrical System High T emperature Shutdown Switch The high temperature shutdown switch is located on the water pump housing (Fig. 55). The high temperature shutdown switch is normally open and closes when en- gine coolant temperature reaches approximately 239 o F (1 15 o C). When excessive coolant temperature [...]

Reelmaster 5010 Series Page 5 - - 43 Electrical System Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter (Fig.57). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm 2 ). The Electronic Control Module (ECM)[...]

Reelmaster 5010 Series Page 5 - - 44 Electrical System Fuel Stop Solenoid The fuel stop solenoid used on your Reelmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 58). The Electronic Control Module (ECM) monitors the op- eration of the fuel stop solenoid. The solenoid and its c[...]

Rev . B Reelmaster 5010 Series Page 5 - - 45 Electrical System Fuel Pump The Reelmaster fuel pump is attached to the inside of the left side frame rail near the fuel tank (Fig. 65). IMPORT ANT : When testing fuel pump, make sure that pump is not operated without fuel. DANGER Because diesel fuel is highly flammable, use cau - tion when handling it. [...]

Reelmaster 5010 Series Page 5 - - 46 Electrical System Service and Repairs NOTE: See the Kubota Workshop Manual: 05 Series Engine for engine electrical component repair informa- tion. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery from the machine and charge it fully (see Battery Service). 2. Either store[...]

Reelmaster 5010 Series Page 5 - - 47 Electrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally , battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling e[...]

Reelmaster 5010 Series Page 5 - - 48 Electrical System A. Measure the specific gravity of each cell with a hydrometer . Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm - - up the hydrometer . At the same time take the tem- perature of the cell. B. T emperature correct each cell reading. For each 10 o F( 5 . 5 [...]

Reelmaster 5010 Series Page 5 - - 49 Electrical System Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- complished with a constant current battery charger which is commonly available. CAUTION Follow the battery charger manufa[...]

Reelmaster 5010 Series Page 5 - - 50 Electrical System Control Arm 1. Arm rest 2. Headlight switch 3. LH control arm cover 4. Screw (2 used) 5. Lock nut 6. Screw 7. RH control arm cover 8. Bushing 9. Control arm 10. Seat wire harness 1 1. Clevis pin 12. Screw 13. Latch 14. Swell latch (2 used) 15. Access cover 16. Washer head screw (10 used) 17. Fl[...]

Reelmaster 5010 Series Page 5 - - 51 Electrical System Disassembly (Fig. 63) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Loosen latches and remove access cover from out- side of control arm. 3. At front of control arm, remove screw (item 6) and lock nut (item 5) [...]

Reelmaster 5010 Series Page 5 - - 52 Electrical System Hydraulic Solenoid V alve Coil A hydraulic solenoid valve coil on the mow control man- ifold (Fig. 66) or lift control manifold (Fig. 67) can be re- placed without opening the hydraulic system. Removal 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake[...]

Reelmaster 5010 Series Page 5 - - 53 Electrical System Backlap Switches Removal (Figs. 68 and 69) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. T ilt operator seat up to gain access to hydraulic mow control manifold. 3. Locate the backlap switch on the mow control [...]

Reelmaster 5010 Series Page 5 - - 54 Electrical System T urfDefender TM Leak Detector (Optional) 1. Cap 2. O - - ring 3. Filter screen 4. Solenoid valve 5. O - - ring 6. O - - ring 7. Leak detector assembly 8. Float 9. Gasket 10. Bottom cover 1 1. Cap screw (3 used) 12. Alarm 13. Plastic nut 14. Gasket 15. Hydraulic reservoir 16. Socket head screw [...]

Reelmaster 5010 Series Page 5 - - 55 Electrical System V ery small changes to the oil level in the sealed hydrau- lic reservoir result in movement of the leak detector ’s in- ternal float. The internal microprocessor of the T urfDefender TM analyzes the float movement and deter- mines if there is a leak in the hydraulic system or if the change is[...]

Reelmaster 5010 Series Page 5 - - 56 Electrical System This page is intentionally blank.[...]

Reelmaster 5010 Series Page 6 - - 1 Chassis (Rev . C) Chapter 6 Chassis T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 2 ..................... T raction Unit Operator ’s Manual 2 ............... SERVICE AND REP AIRS 4 ...................... Wheels 4 .................................... Steering Column 6 ..[...]

Reelmaster 5010 Series Page 6 - - 2 Chassis (Rev C) Specifications Item Description Front T ire Pressure (except RM - - 5210) 12 to 15 PSI (83 to 103 kPa) (26.5 x 14.0 - - 12, 4 ply , tubeless) Front T ire Pressure (RM - - 5210) 12 to 15 PSI (83 to 103 kPa) (24 x 13.0 - - 12, 4 ply , tubeless) Rear T ire Pressure (except RM - - 5210) 12 to 15 PSI ([...]

Reelmaster 5010 Series Page 6 - - 3 Chassis (Rev . C) This page is intentionally blank. Chassis[...]

Reelmaster 5010 Series Page 6 - - 4 Chassis (Rev C) 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. T ab washer 10. Rear wheel 1 1. Jam nut 12. Retainer 13. Cotter pin 14. Dust cap Figure 1 FRONT RIGHT 70 to 90 ft - - lb [...]

Reelmaster 5010 Series Page 6 - - 5 Chassis (Rev . C) Removal (Fig. 1) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Chock wheels to prevent machine from shifting. 3. Loosen lug nuts. When changing attachments, tires or perform- ing other service, use correct b[...]

Reelmaster 5010 Series Page 6 - - 6 Chassis (Rev C) Steering Column 1. Steering column 2. Hydraulic fitting (4 used) 3. Steering wheel 4. Steering wheel cover 5. Foam column 6. Socket head screw (4 used) 7. Flange nut 8. O - - ring 9. Hydraulic tube 10. Hydraulic tube 1 1. Hydraulic tube 12. Hydraulic tube 13. Column brace 14. Steering control valv[...]

Reelmaster 5010 Series Page 6 - - 7 Chassis (Rev . C) 5. Remove platform shroud from machine to allow ac- cess to steering column fasteners (Fig. 3). A. Remove cover plate from platform. B. Remove fasteners that secure shroud to ma- chine. C. Remove shroud from machine. D. Locate and retrieve two (2) rubber bushings and spacers. 6. Slide rubber bel[...]

Reelmaster 5010 Series Page 6 - - 8 Chassis (Rev C) Brake Service 1. LH wheel motor (Parker) 2. Lug nut (5 used per wheel) 3. Hub 4. Tire and wheel assembly 5. Hydraulic fitting (2 used per motor) 6. Hydraulic tube 7. Hydraulic tube 8. Cap screw (2 used per wheel shield) 9. R - - clamp (4 used) 10. Diagnostic fitting (2 used) 1 1. Dust cap (2 used)[...]

Reelmaster 5010 Series Page 6 - - 9 Chassis (Rev . C) Removal (Fig. 5) 1. Park the machine on a level surface, lower the cut- ting units and stop the engine. Remove the key from the ignition switch. 2. Chock wheels to prevent machine from shifting. 3. Loosen, but do not remove, lock nut (item 17) from wheel motor shaft. 4. Remove front wheel assemb[...]

Reelmaster 5010 Series Page 6 - - 10 Chassis (Rev C) 2. If backing plate was removed from machine, secure backing plate to brake bracket with four (4) cap screws and lock nuts. 3. Lightly lubricate brake shoe pivot points with general purpose grease. 4. Position one brake shoe to the backing plate. Install brake hold down pin and secure with hold d[...]

Reelmaster 5010 Series Page 6 - - 1 1 Chassis (Rev . C) This page is intentionally blank. Chassis[...]

Reelmaster 5010 Series Page 6 - - 12 Chassis (Rev C) Rear Wheel Bearings (2 Wheel Drive) 1. Dust cap 2. Cotter pin 3. Retainer 4. Jam nut 5. T ab washer 6. Bearing cone 7. Bearing cup 8. Wheel hub 9. Seal 10. Spindle 1 1. Wheel stud (5 used) Figure 9 1 3 2 8 4 5 7 6 6 10 See text for tightening procedure 9 7 11[...]

Reelmaster 5010 Series Page 6 - - 13 Chassis (Rev . C) Disassembly (Fig. 9) 1. Chock front wheels to prevent machine from shifting. 2. Remove rear wheel (see Wheel Removal in this sec- tion). 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 tab washer . Slide [...]

Reelmaster 5010 Series Page 6 - - 14 Chassis (Rev C) Rear Axle 1. Lug nut (5 used per wheel) 2. Axle assembly 3. Dust cap 4. Hydraulic fitting 5. Tie rod 6. Axle pivot pin 7. Thrust washer 8. Roll pin 9. Thrust washer 10. Jam nut 1 1. Grease fitting 12. T ab washer 13. Wheel hub assembly 14. Grease fitting 15. O - - ring 16. Jam nut 17. Nut retaine[...]

Reelmaster 5010 Series Page 6 - - 15 Chassis (Rev . C) Removal (Fig. 10) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Chock front wheels to prevent machine from shifting. 3. Thoroughly clean hydraulic hose ends and fittings on steering cylinder to prevent hydr[...]

Reelmaster 5010 Series Page 6 - - 16 Chassis (Rev C) Rear Axle Service 1. Lug nut (5 used per wheel) 2. Axle 3. Housing 4. RH drag link 5. Tie rod 6. Axle pivot pin 7. Thrust washer 8. Roll pin 9. Thrust washer 10. Jam nut 1 1. Grease fitting 12. Spindle cap 13. Retaining ring 14. Flange head screw 15. Wheel hub 16. Jam nut 17. Nut retainer 18. Hyd[...]

Reelmaster 5010 Series Page 6 - - 17 Chassis (Rev . C) Axle Pivot Bushings (Fig. 1 1) The rear axle must be held in place snugly by the axle pivot pin. Excessive movement of the axle, which is characterized by erratic steering, might indicate worn axle pivot bushings. T o c orrect the problem, replace the bushings (item 36). 1. Remove rear axle fro[...]

Reelmaster 5010 Series Page 6 - - 18 Chassis (Rev C) Operator Seat 1. Seat 2. Seat base 3. Seat adjuster w/latch 4. Flat washer (4 used) 5. Seat switch harness 6. Seat switch 7. Washer head screw (2 used) 8. Armrest bracket 9. Spacer 10. Armrest 1 1. Cap screw 12. Flange nut 13. Flat washer (4 used) 14. Flange head screw (3 used) 15. Socket head sc[...]

Reelmaster 5010 Series Page 6 - - 19 Chassis (Rev . C) Removal (Fig. 12) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 - - Electrical System). 3.[...]

Reelmaster 5010 Series Page 6 - - 20 Chassis (Rev C) 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. Extension spring (2 used) 9. Roller guide 10. Weight adjust knob 11 . C a p 12. Suspension boot 13. Pivot block (2 used) 14. Damper 15. Lower shock[...]

Reelmaster 5010 Series Page 6 - - 21 Chassis (Rev . C) IMPORT ANT : When removing the seat suspension, make sure to support the control arm to prevent damage to the throttle cable, control arm electrical components and control arm wiring harness. Removal (Figs. 15 and 16) 1. Park machine on a level surface, lower cutting units, stop engine, engage [...]

Reelmaster 5010 Series Page 6 - - 22 Chassis (Rev C) Front Lift Arms 1. #1 lift arm 2. #4 lift arm 3. #5 lift arm 4. Lift arm pivot shaft 5. Roll pin (3 used) 6. Flange nut 7. Carriage screw (2 used) 8. Lock nut (2 used) 9. Flange head screw 10. Switch bracket 1 1. Bridge plate 12. Flange screw 13. Chain hoop (3 used) 14. Washer (2 used per chain h[...]

Reelmaster 5010 Series Page 6 - - 23 Chassis (Rev . C) Removal (Fig. 17) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting unit from front lift arm to be removed. 3. Remove one retaining ring (Fig. 18 item 3) and thrust washer (Fig. 18 item 4) from t[...]

Reelmaster 5010 Series Page 6 - - 24 Chassis (Rev C) Rear Lift Arms 1. Spacer (2 used) 2. #2 lift arm 3. #3 lift arm 4. Washer (2 used per chain hoop) 5. Spring catch 6. Flange head screw (2 used) 7. Cap screw (2 used) 8. Flat washer (2 used) 9. Pivot pin (2 used) 10. Washer head screw (1 used per pin) 1 1. Pivot yoke (2 used) 12. Lynch pin (2 used[...]

Reelmaster 5010 Series Page 6 - - 25 Chassis (Rev . C) B. Push down and rearward on the spring end to un- hook the spring from the stop on the lift arm. 6. Disconnect hydraulic lift cylinder rod end clevis from lift arm (see Lift Cylinder Removal in the Service and Re- pairs section of Chapter 4 - - Hydraulic System). Pivot lift cylinder rod end aw[...]

Reelmaster 5010 Series Page 6 - - 26 Chassis (Rev C) This page is intentionally blank.[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 1 Chapter 7 Cutting Units T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ..................... Cutting Unit Operator ’s Manual 3 ................ SPECIAL TOOLS 4 ............................. F ACTORS THA T CAN AFFECT CUTTING PERFORMANCE 8 .......[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 2 Specifications Figure 1 Frame Construction: Precision machined die cast alu- minum cross member with two bolt - - on cast ductile iron side plates. Reel Construction: Reels are 22 inches (55.9 cm.) in length and are available in 5 inch (12.7 cm) and 7 inch (17.8 cm) diameters. High strengt[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 3 General Information Cutting Unit Operator ’s Manual The Cutting Unit Operator ’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the cutting units on your Reel- master machine. Additionally , if optional kits have been installed [...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 4 Special T ools Order Special T ools from y our T oro Distributor . Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly T oro Part Number: 108 - - 6715 Use gauge bar to verify height - - of - - cut adjustment. Also used for adjustment of op[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 5 Plastic Plug T oro Part Number: 2410 - - 30 (for 5 inch reels) 94 - - 2703 (for 7 inch reels) This cap is used for placement into the side plate bear- ing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area. Figure 5 Cut[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 6 Cutting Unit T ool Kit T oro Part Number: T OR4070 This tool kit includes special tools required for rebuilding the cutting unit and cutting unit drive motor on the Reelmaster 5010 series of machines. TOR4064 Spanner Wrench ( not used on RM 5010) TOR4065 Inner Oil Seal Installer TOR4066 Be[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 7 Diameter/Circumference Measuring T ape T oro Part Number: T OR6023 Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components. T ape calibration is in fixed inch readings (no adjustments). Figure 1 1 Cutting Un[...]

Reelmaster 5010 Series Cutting Units (Rev . C) 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” or attempting to cut off too much grass height may not always [...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 9 Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedkni[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 10 Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely . Repair roller bearings as necessary . See Roller Service in the Service and Repairs section of this chapter . Refer to Cutting Unit Operator ’s Manual for roller options. T urf compensa[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 1 1 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. The dual knob bedknife - - to - - reel adjustment system in- corporated in this cutting unit simplifies the adjustmen[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 12 Reel Bearing Adjustment T o insure cut quality and long life of the cutting reel bear- ings, periodically check reel bearing adjustment. Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in the Service and Re- pairs section of[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 13 Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment is possible to make sure that the c[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 14 Service and Repairs Hydraulic Reel Motor IMPORT ANT : When performing maintenance pro- cedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. Removal 1. Park machine on a clean and level surface, lower cutting unit[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 15 Backlapping DANGER TO A VOID PERSONAL INJUR Y OR DEA TH: D Never place hands or feet in the reel area while the engine is running. D While backlapping, the reels may stall and then restart. D Do not attempt to restart reels by hand or foot. D Do not adjust reels while the engine is runnin[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 16 Bedbar Assembly 1. Bedbar 2. Bedknife 3. Screw (8 used) 4. Bedbar adjuster shaft (2 used) 5. Flange bushing (4 used) 6. Cap screw (2 used) 7. Detent (2 used) 8. Wave washer (2 used) 9. Retaining ring (2 used) 10. Bedbar adjuster screw (2 used) 1 1. W asher (2 used) 12. Compression spring [...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 17 CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury . Use heavy gloves when handling the bedbar . 6. Remove bedbar assembly from cutting unit. 7. Inspect flange bushings (item 15) and rubber bush- ings (item 14) in side plates for wear or dama[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 18 Bedbar Adjuster Service Figure 21 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster screw 5. Flange bushing 6. Cap screw 7. Detent 8. Wave washer 9. Lock nut 10. Bedbar adjuster shaft 1 1. W asher FRONT RIGHT 14 to 16 ft - - lb ( 1 9t o2 1N - - m ) Antiseize Lubrican[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 19 Removal (Fig. 21) 1. Remove lock nut (item 3), compression spring (it em 2) and washer (item 1 1) from bedbar adjuster screw (item 10). 2. Remove bedbar (see Bedbar Removal in this sec- tion). NOTE: Inside threads in bedbar adjuster shaft ( item 4) are left - - hand threads. 3. Unscrew be[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 20 Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re- moval in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special T ools). Discard screws. Remove bedknife from the bedbar (Fig. 23). Bedknif[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 21 This page is intentionally blank. Cutting Units[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 22 Reel Assembly Removal and Installation 1. Bedbar assembly 2. Rubber bushing (2 used) 3. Flange bushing (2 used) 4. Plastic washer (4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7. Lock nut (2 used) 8. Shoulder bolt (3 used per side plate) 9. LH side plate 10. Weight 1 1. [...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 23 Reel Assembly Removal (Fig. 26) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a flat work area. 3. If cutting unit is equipped wit[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 24 IMPORT ANT : During cutting reel installation, keep in- ner and outer bearing races aligned. If bearing races are not aligned, binding will occur and reel installation may cause bearing damage. 3. Carefully slide the cutting reel with bearings and grease seals into the RH side plate. Make[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 25 This page is intentionally blank. Cutting Units[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 26 Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Retaining ring 4. Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove 8. Groove indicating LH threads 9. Bearing shoulder 10. Reel spider Figure 28 85 to 95 ft - - lb (1 15 to 128 N - - m) 8[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 27 C. T o install spline insert into cutting reel, clean threads of insert and cutting reel shaft. Apply Loctite #242 (or equivalent) to threads of insert, thread in- sert into reel shaft and torque from 85 to 95 ft -lb (1 15 to 128 N - - m) . Assembly of Cutting Reel (Fig. 28) 1. If seals a[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 28 Preparing Reel for Grinding NOTE: Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depend- ing on type of grinder used, faulty cutting unit compo- nents can affect grinding results. NOTE: When grinding, be careful to not overheat the cuttin[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 29 This page is intentionally blank. Cutting Units[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 30 Front Roller Removal (Fig. 30) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake 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 ([...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 31 Rear Roller Removal (Fig. 31) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under be[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 32 Roller Service (Greasable Bearings with Retaining Ring) 1. Roller tube (front Wiehle shown) 2. Roller shaft 3. Inner oil seal 4. Grease fitting 5. Ball bearing 6. Inner seal 7. Outer seal 8. Retaining ring 9. Outer oil seal 10. Roller washer Figure 32 v 9 10 8 7 1 2 3 4 6 5 NOTE: Numerous[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 33 Disassembly (Figs. 32 and 33) 1. Remove retaining ring from both ends of roller . 2. Support roller assembly and press one end of roller shaft to remove seals and bearing from opposite end of roller . Press on other end of roller shaft to remove re- maining seals and bearing from roller .[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 34 Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 34) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of rolle[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 35 3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: A. Position a second new bearing to r[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 36 Rear Roller Brush (Optional) 1. Roller brush shaft 2. Roller brush 3. Lock nut (2 used) 4. J - - bolt (2 used) 5. Square key 6. Excluder seal (2 used) 7. Brush bearing housing (drive) 8. Spacer 9. Flat washer (as required) 10. Driven pulley 1 1. Flange nut 12. Carriage screw (2 used) 13. [...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 37 Disassembly (Fig. 40) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. T o remove roller brush from brush shaft: A. Remove the non - - drive brush bearing housing (item 30) from cutting u[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 38 3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 43 and 44. A. Install bearing on shaft by pressing equally on the inner and outer bearing races. Install the bearing so that the bearing s eal is closest to the shoulder on t[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 39 5. Check that roller brush has light contact with rear roll- er (Fig. 47). If contact is incorrect, brush operation will be adversely affected. Also make sure that brush shaft is parallel with rear roller . 6. Lubricate grease fittings on brush housings until grease purges past inboard se[...]

Reelmaster 5010 Series Cutting Units (Rev . C) Page 7 - - 40 This page is intentionally blank.[...]

Reelmaster 5010 Series Groomer Page 8 - - 1 Chapter 8 Groomer T able of Contents GROOMING PERFORMANCE 2 .................. TROUBLESHOOTING 3 ......................... Groomer Reel Mechanical Problems 3 ........... ADJUSTMENTS 4 .............................. Groomer Height/Depth Adjustment 4 ............ SERVICE AND REP AIRS 5 .....................[...]

Reelmaster 5010 Series Groomer Page 8 - - 2 Grooming Performance There are a number of factors that can affect the perfor- mance of grooming. These factors vary for different golf courses and from fairway to fairway . It is important to in- spect the turf frequently and vary the grooming practice with turf needs. IMPORT ANT : Improper or overaggres[...]

Reelmaster 5010 Series Groomer Page 8 - - 3 T roubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be adjusted. Seized groomer reel or idler bear- ing(s) in groomer side plate(s). Broken or damaged idler spring. The groomer drive belt is worn, bro- ken or[...]

Reelmaster 5010 Series Groomer Page 8 - - 4 Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait f or all machine movement to stop before working on the groomer . NOTE: The Groomer Installation Instructions provide information regarding the installation, set [...]

Reelmaster 5010 Series Groomer Page 8 - - 5 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 f or all machine movement to stop before working on the groomer . NOTE: The Groomer Installation Instructions provide information regarding the installati[...]

Reelmaster 5010 Series Groomer Page 8 - - 6 Groomer Plate Assembly Figure 4 1. Groomer reel 2. Pulley spacer 3. Washer (as required) 4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw 8. Idler plate 9. Idler pulley assembly 10. Lock nut 1 1. Flange head screw 12. Drive pulley 13. Retaining ring 14. Extension spring 15. Pivot hub asse[...]

Reelmaster 5010 Series Groomer Page 8 - - 7 C. Remove the flange nut (item 6) that secures driv- en pulley (item 5) to groomer shaft. Remove driven pulley from shaft. Locate and retrieve square key (item 4) that locates driven pulley on shaft. D. Slide w asher (item 3) and pulley spacer (item 2) from groomer shaft. E. Remove shoulder bolt that secu[...]

Reelmaster 5010 Series Groomer Page 8 - - 8 2. Install groomer plate assembly to groomer non- - drive side of cutting unit: A. Carefully position non - - drive side groomer plate onto groomer shaft and slide to cutting unit. B. Position pivot hub to cutting unit. C. Secure groomer components to cutting unit side plate with two (2) socket head screw[...]

Reelmaster 5010 Series Groomer Page 8 - - 9 This page is intentionally blank. Groomer[...]

Reelmaster 5010 Series Groomer Page 8 - - 10 Groomer Reel Figure 8 1. Groomer reel 2. Pulley spacer 3. W asher 4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw 8. Idler plate 9. Idler pulley assembly 10. Lock nut 1 1. Flange head screw 12. Drive pulley 13. Retaining ring 14. Extension spring 15. Pivot hub assembly (drive) 16. O - -[...]

Reelmaster 5010 Series Groomer Page 8 - - 1 1 Installation (Fig. 8) 1. Position cutting unit on a level surface. If cutting unit is attached to traction unit, make sure to stop engine, en- gage parking brake and remove key from the ignition switch. 2. Apply a light coating of grease to seal lips in groomer plate assemblies. 3. Make sure that exclud[...]

Reelmaster 5010 Series Groomer Page 8 - - 12 Groomer Reel Service Inspect groomer reel blades frequently for damage and wear . Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig. 1 1). Blades that are rounded to the midpoint of the blade tip must be reversed or re- plac[...]

Reelmaster 5010 Series Groomer Page 8 - - 13 6. Place excluder seals on groomer shaft. 7. Install o- - ring on non - - drive end of groomer shaft. 8. Install groomer reel back on cutting unit (see Groom- er Reel Installation in this section). 1. Groomer shaft 2. Broomer strap Figure 13 1 2 2 2 2 Groomer[...]

Reelmaster 5010 Series Groomer Page 8 - - 14 Groomer Pivot Hub Figure 14 1. Groomer drive shaft 2. Ball bearing 3. Grease seal 4. Retaining ring 5. Pivot hub 6. Retaining ring 7. Extension spring 8. Retaining ring 9. Idler plate 10. O - - ring (7” cutting unit only) 4 3 1 2 9 10 8 5 6 7 Apply Grease to Seal Lip NOTE: The groomer reel drive is loc[...]

Reelmaster 5010 Series Groomer Page 8 - - 15 Disassembly (Fig. 14) 1. Remove pivot hub assembly (with idler plate) from cutting unit (see Groomer Plate Assembly Removal in this section). 2. Remove retaining ring (item 4) that secures idler plate to pivot hub. Slide idler plate from pivot hub. 3. Remove retaining ring (item 8) that retains ball bear[...]

Reelmaster 5010 Series Groomer Page 8 - - 16 Height Adjuster Assembly Figure 16 1. Groomer plate (LH drive shown) 2. Shoulder bolt 3. Ball joint rod 4. Jam nut 5. Compression spring 6. Flange head screw 7. Lower ramp 8. External snap ring 9. Upper ramp 10. Bushing 1 1. Flat washer 12. Groomer adjuster 13. Detent spring 14. Washer head screw 17 to 2[...]

Rev . B Reelmaster 5010 Series Foldout Drawings Page 9 - - 1 Chapter 9 Foldout Drawings T able of Contents HYDRAULIC SCHEMA TICS Reelmaster 5210 and 5410 3 ................... Reelmaster 5510 and 5610 4 ................... ELECTRICAL SCHEMA TICS Reelmaster 5010 Series (Serial Number Below 310000000) 5 ......................... Reelmaster 5010 Serie[...]

Reelmaster 5010 Series Foldout Drawings Page 9 - - 2 This page is intentionally blank.[...]

Page 9 - - 3 Hydr aulic S chem atic Reelmaster 5210 and 5410 FORW ARD M7 M6 OUT IN V1 R L STEERING T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRON T RIGHT FRON T FRON T CENTER REAR R10 R8 C4 L C5 L C1 L REAR LEFT RIGHT T P REAR MOW CIRCUIT FRONT MOW CIRCUIT R9 100 ME SH SUCTION STRAINER INTERNAL CASE DRAIN TRACTIO N WHEEL MOTOR S P1 P2 P3 P4 G5 G6 G2 EP2 MSV2 [...]

Page 9 - - 4 Hydr aulic S chem atic Reelmaster 5510 and 5610 FORW ARD M7 M6 OUT IN V1 R L STEERING T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRON T RIGHT FRON T FRON T CENTER REAR R10 R8 C4 L C5 L C1 L REAR LEFT RIGHT T P REAR MOW CIRCUIT FRONT MOW CIRCUIT R9 100 ME SH SUCTION STRAINER INTERNAL CASE DRAIN TRACTIO N WHEEL MOTOR S P1 P2 P3 P4 G5 G6 G2 EP2 MSV2 [...]

Rev . B Page 9 - - 5 Electr ical Schema tic Reelmaster 5010 Seri es All r elays and so lenoid s are shown as de - - ene rgiz ed. All gr ound wir es are black. R Y T T Y T Y T PK R PK W BK R BK BK R BK BK T BK GY BK BK BU OR R BU BK R/BK T GN/W W BK R/BK Y BU PK R PK R/BK BU VIO BN R GY/ BU Y/BK OR BU Y GN OR VIO PK W/BK R/BK R/W BK/W BK GN/B K OR/B[...]

Rev . B Page 9 - - 6 Electr ical Schema tic Reelmaster 5010 Seri es All r elays and so lenoid s are shown as de - - ene rgiz ed. All gr ound wir es are black. (Serial Number Above 310000000) INDICA TOR LIGHTS (3 GLOW PLU GS U SE D ON RM 52 10 ) SEA T SWI TCH (UNOCCUPI ED) PARKING BRAKE SWI TCH ( BRAKE APPLIED) FRONT BACKLAP SWITCH ( IN MO W) NEUTRA[...]

Rev . B Page 9 - - 7 Glow Plug Circuits Power C urr ent Contr ol Curr ent Indicat or/G auge Cur rent Reelmaster 5010 Seri es R Y T T Y T Y T PK R PK W BK R BK BK R BK BK T BK GY BK BK BU OR R BU BK R/BK T GN/W W BK R/BK Y BU PK R PK R/BK BU VIO BN R GY/ BU Y/BK OR BU Y GN OR VIO PK W/BK R/BK R/W BK/W BK GN/B K OR/B K GN VIO Y/BK W W/BU BN BN T/W BU[...]

Rev . B Page 9 - - 8 Crank Cir cuits Power C urr ent Contr ol Curr ent Indicat or/G auge Cur rent Reelmaster 5010 Seri es R Y T T Y T Y T PK R PK W BK R BK BK R BK BK T BK GY BK BK BU OR R BU BK R/BK T GN/W W BK R/BK Y BU PK R PK R/BK BU VIO BN R GY/ BU Y/BK OR BU Y GN OR VIO PK W/BK R/BK R/W BK/W BK GN/B K OR/B K GN VIO Y/BK W W/BU BN BN T/W BU R/[...]

Rev . B Page 9 - - 9 Run (T ranspor t) Cir cuits Power C urr ent Contr ol Curr ent Indicat or/G auge Cur rent Reelmaster 5010 Seri es R Y T T Y T Y T PK R PK W BK R BK BK R BK BK T BK GY BK BK BU OR R BU BK R/BK T GN/W W BK R/BK Y BU PK R PK R/BK BU VIO BN R GY/ BU Y/BK OR BU Y GN OR VIO PK W/BK R/BK R/W BK/W BK GN/B K OR/B K GN VIO Y/BK W W/BU BN [...]

Rev . B Page 9 - - 10 Run (Mow) Cir cuits Power C urr ent Contr ol Curr ent Indicat or/G auge Cur rent Reelmaster 5010 Seri es R Y T T Y T Y T PK R PK W BK R BK BK R BK BK T BK GY BK BK BU OR R BU BK R/BK T GN/W W BK R/BK Y BU PK R PK R/BK BU VIO BN R GY/ BU Y/BK OR BU Y GN OR VIO PK W/BK R/BK R/W BK/W BK GN/B K OR/B K GN VIO Y/BK W W/BU BN BN T/W [...]

Rev . B Page 9 - - 1 1 This page is intenti onally bl ank.[...]

Rev . B Page 9 - - 12 Reelmaster 5010 Seri es Main Wire Har ness Drawing[...]

Rev . B Page 9 - - 13 Reelmaster 5010 Seri es Ma in Wi re Ha rn es s Di ag ra m ORANGE RED YELLO W BLACK GRA Y BLUE GREEN/WHITE PINK WHITE VIOLET TA N WHITE/BLUE BROWN PINK ORANGE WHITE RED YELLOW/BLACK BLACK RED BLACK BLACK BLACK RED PINK GREEN YELLO W BLACK BLACK PINK BLUE GRA Y GRA Y/B LUE VIOLET BLACK/WHITE BLACK BLACK BLACK BLACK BLACK GRA Y B[...]

Rev . B Page 9 - - 14 Reelmaster 5010 Seri es Seat Wir e Harness Dr awing[...]

Rev . B Page 9 - - 15 Reelmaster 5010 Seri es Sea t Wi re Harn e ss D ia g ram TA N BROWN/ WHITE YELLOW/BLACK RED PINK PINK WHITE TA N BLACK PINK RED/BL ACK RED RED WHITE RED WHITE/BLACK YELLO W RED ORANGE VIOLET BLACK GRA Y BLACK T AN/BLACK BLACK BLACK BLACK BLACK BLACK GRA Y BLACK PINK PINK WHITE GREEN/WHITE BLUE BLACK BLACK TA N ORANGE GRA Y/B L[...]

Rev . B Page 9 - - 16 Reelmaster 5010 Seri es Engi ne Wir e Har ness D raw ing[...]

Rev . B Page 9 - - 17 Reelmaster 5010 Seri es Engi ne Wir e Har ness D iagr am PINK GRA Y WHITE GREEN/WH ITE WHITE ORANGE RED BLACK RED/BL ACK BLACK BLUE TA N BLUE FUSIBLE LINK[...]

Rev . B Page 9 - - 18 TURF DEFENDER LEAK DETECTOR 2D 1B 3B 2C 1E 2E 1C 3C 2A 2F 1F 3F AB CD AA BB CC EE ELECTRIC SOLENOID VA LV E RED/WHI TE BLACK/WHI TE TO LEAK DETECT OR CONNECTOR OF MAIN HARNESS RED/YELLOW BLACK/YELLOW + -- RED ALARM TURF DEFENDER COMMUNICA TION PORT AND LOOPBACK CONNECTOR YELLOW BLACK/ORANGE GREEN/WHI TE BLACK BLACK/BLUE TURF D[...]