Toro 5210/5410/5510/5610 - Manuals

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Reelmaster 5010 Series This page is intentionally blank.

Page 3 - Table Of Contents; Chapter 2 -- Product Records and Maintenance

Rev. C Reelmaster 5010 Series Table Of Contents Chapter 1 -- Safety Safety Instructions 1 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Jacking Instructions 1 -- 4 . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 4 . . . . . . . . . . . . . . . . Chapte...

Page 5 - Chapter 1; Safety; Table of Contents; Sa

Rev. B Reelmaster 5010 Series Page 1 -- 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 6 - Safety Instructions; To reduce the potential for injury or death,; WARNING; Before Operating

Rev. B Reelmaster 5010 Series Page 1 -- 2 Safety Safety Instructions Reelmaster machines meet or exceed safety standard specifications when weights are installed according to information in the Traction Unit Operator’s Manual. Al- though hazard control and accident prevention are par- tially depende...

Page 7 - Maintenance and Service

Reelmaster 5010 Series Page 1 -- 3 Safety 6. Anytime the machine is parked (short or long term), the cutting units should be lowered to the ground. This relieves pressure from the hydraulic lift circuit and elimi- nates the risk of the cutting units unexpectedly lowering to the ground. 7. Do not par...

Page 8 - Safety and Instruction Decals

Rev. B Reelmaster 5010 Series Page 1 -- 4 Safety Jacking Instructions When changing attachments, tires or perform- ing other service, use correct blocks, hoists and jacks. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attach-ment...

Page 9 - Chapter 2; Product Records and Maintenance

Rev. B Reelmaster 5010 Series Page 2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVER...

Page 10 - Equivalents and Conversions

0.09375 Reelmaster 5010 Series Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions

Page 11 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification

Rev. B Reelmaster 5010 Series Page 2 -- 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clea...

Page 14 - Other Torque Specifications; Grade 5; Conversion Factors

Reelmaster 5010 Series Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 +...

Page 15 - Chapter 3; Kubota Diesel Engine; Traction Unit Operator’s Manual; ubot

Reelmaster 5010 Series Page 3 -- 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . Traction Unit Operator’s Manual 1 . . . . . . . . . . . . . . . Stopping the Engine (Reelmaster 5610) 1 . . . . . . . . SPECIFICATI...

Page 16 - Specifications: Reelmaster 5210

Reelmaster 5010 Series Page 3 -- 2 Kubota Diesel Engine Specifications: Reelmaster 5210 Item Description Make / Designation Kubota D1105, 4-- stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.53 in 3 (1123 cc) Compression Rati...

Page 18 - Specifications: Reelmaster 5610

Reelmaster 5010 Series Page 3 -- 4 Kubota Diesel Engine Specifications: Reelmaster 5610 Item Description Make / Designation Kubota V1505, 4-- stroke, Liquid Cooled, OHV, Turbocharged Diesel Number of Cylinders 4 Bore x Stroke 3.07” x 3.09“ (78 mm x 78.4 mm) Total Displacement 91.4 in 3 (1498 cc) Com...

Page 19 - Adjustments; Adjust Throttle Control; FAST

Reelmaster 5010 Series Page 3 -- 5 Kubota Diesel Engine Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper ad- justment of throttle control. Make sure throttle control is operating properly. NOTE: The throttle cable swivel should be positioned in the lowest hole i...

Page 20 - Service and Repairs; Fuel System; Figure 2

Reelmaster 5010 Series Page 3 -- 6 Kubota Diesel Engine Service and Repairs Fuel System Figure 2 1. Fuel cap 2. Bushing 3. Washer head screw (3 used) 4. Flange nut (3 used) 5. Clamp (3 used) 6. Return fitting 7. Suction fitting 8. Hose clamp 9. Hose clamp 10. Fuel tank 11. Grommet 12. Fuel gauge 13....

Page 21 - DANGER

Reelmaster 5010 Series Page 3 -- 7 Kubota Diesel Engine DANGER Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, when engine is hot or when machine is in an enclosed area. Always ...

Page 22 - Air Cleaner

Reelmaster 5010 Series Page 3 -- 8 Kubota Diesel Engine Air Cleaner Figure 3 1. Air cleaner assembly 2. Hex nut 3. Bolt 4. Spring 5. Indicator 6. Adapter 7. Hose 8. Hose 9. Mount bracket 10. Air cleaner stand 11. Hose clamp 12. Flange nut 13. Cap screw (2 used) 14. Flange head screw (4 used) 15. Fla...

Page 24 - Exhaust System

Reelmaster 5010 Series Page 3 -- 10 Kubota Diesel Engine Exhaust System Figure 6 1. Gasket 2. Lock washer (4 used) 3. Flange nut (4 used) 4. Cap screw (4 used) 5. Carriage screw (4 used) 6. Flange nut (4 used) 7. Lock washer 8. Cap screw 9. Isolator plate 10. Hex nut (2 used) 11. Clamp 12. Flange nu...

Page 25 - CAUTION

Reelmaster 5010 Series Page 3 -- 11 Kubota Diesel Engine Removal (Fig. 6) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Raise hood. CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow th...

Page 26 - Radiator

Reelmaster 5010 Series Page 3 -- 12 Kubota Diesel Engine Radiator Figure 7 1. Overflow bottle 2. Hose clamp (3 used) 3. Hose 4. Foam seal (2 used) 5. Foam seal (2 used) 6. Foam seal (2 used) 7. Oil cooler 8. Foam seal (2 used) 9. Flat washer (8 used) 10. Hose clamp (4 used) 11. Foam seal (2 used) 12...

Page 27 - Do not open radiator cap or drain coolant if the

Reelmaster 5010 Series Page 3 -- 13 Kubota Diesel Engine CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot cool- ant can escape and cause burns. Ethylene--glycol antifreeze is poisonous. Dis- pose of coolant properly, or store it in a properly label...

Page 28 - Engine; Figure 9; FRONT

Reelmaster 5010 Series Page 3 -- 14 Kubota Diesel Engine Engine Figure 9 1. Engine assembly 2. Cap screw (12 used) 3. Temperature sender 4. Engine mount (4 used) 5. Cap screw (2 used per mount) 6. Snubbing washer (4 used) 7. Cap screw (4 used) 8. Flange nut (4 used) 9. Lock nut (2 used per mount) 10...

Page 33 - Chapter 4; Hydraulic System

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Traction Unit Operator’s Manual 3 . . . . . . . . . . ....

Page 34 - Specifications; Machines produced with serial number below

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 2 Specifications Item Description Piston (Traction) 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, positive displacement gear type...

Page 35 - General Information; el of hydraulic fluid daily.; Towing Traction Unit; IMPORTANT: If towing limits are exceeded, severe

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 3 General Information Traction Unit Operator’s Manual The Traction Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publication fo...

Page 36 - Hydraulic Hoses; Hydraulic Fitting Installation

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. Thes...

Page 39 - Hydraulic Schematics; The hydraulic schematics for Reelmaster 5010 series

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

Page 40 - Hydraulic Flow Diagrams; Figure 8; Traction; Reelmaster

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 8 Hydraulic Flow Diagrams Figure 8 W orking P ressure Low Pressure (Charge) Return or Suction Flow Traction C ircuit (Forward Shown) Reelmaster 5010 (5510/5610 Shown) FOR W A R D M7 M6 OUT IN V1 R L STE E RING T C4 P4 C5 C1 C2/3 C2/3 L LEF T...

Page 41 - Traction Circuit; Reverse Direction

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 9 Traction 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 ...

Page 43 - Mow Circuit; Backlap

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 11 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...

Page 44 - Lift Circuit: Raise Cutting Units

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 12 Figure 11 Working PressureLow Pressure (Charge)Return or SuctionFlow Lift Circuit: Raise Cutting Units Reelmaster 5010 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONTCENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV...

Page 46 - Lift Circuit: Lower Cutting Units

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 14 Figure 12 Working PressureLow Pressure (Charge)Return or SuctionFlow Lift Circuit: Lower Cutting Units Reelmaster 5010 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONTCENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV...

Page 48 - LEFT

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 16 Figure 13 W orking P ressure Low Pressure (Charge) Return or Suction Flow Steering Circuit Reelmaster 5010 STEERING CYLINDER PIST ON MOVEMENT STEERING CYLINDER STEERING VA LV E PIST ON MOVEMENT STEERING VA LV E R10 R10 FROM PUMP (P3) FROM...

Page 49 - Steering Circuit

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...

Page 50 - Special Tools; Hydraulic Pressure Test Kit

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 18 Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to m...

Page 54 - Troubleshooting; General Hydraulic System Problems; Problem

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 22 Troubleshooting 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 inc...

Page 55 - Traction Circuit Problems

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 23 Traction Circuit Problems Problem Possible Cause Neutral is difficult to find or unit oper- ates in one direction only Traction control linkage is misadjusted, disconnected, binding or damaged. Piston (traction) pump check relief valve is...

Page 56 - Mow Circuit Problems

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 24 Traction 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 tra...

Page 57 - Lift Circuit Problems

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 c...

Page 58 - Steering Circuit Problems

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 c...

Page 62 - VALVE TEST SHOWN

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 30 Traction Circuit Relief Valve (R3) and (R4) Pressure Test Figure 24 FORWARD M7 M6 FROM STEERING CONTROL VALVE R9 100 MESH SUCTIONSTRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 B R5 R4 R3 A B A B LH RH EXTERNAL CASE D...

Page 64 - Traction Circuit Charge Pressure Test; Procedure for Traction Circuit Charge Pressure Test

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 32 Traction Circuit Charge Pressure Test Figure 28 FORWARD M7 M6 FROM STEERING CONTROL VALVE R9 100 MESHSUCTION 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 RESERVOIR) ...

Page 65 - Before opening hydraulic system, operate all hy-

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 cha...

Page 66 - (Using Tester with Pressure Gauges and Flow Meter)

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 34 Gear Pump (P3) Flow Test (Using Tester with Pressure Gauges and Flow Meter) Figure 31 FORWARD M7 M6 FROM STEERING CONTROL VALVE 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...

Page 68 - Front Wheel Motor Efficiency Test

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 36 Front Wheel Motor Efficiency Test Figure 33 FORWARD M7 M6 FROM STEERING CONTROL VALVE 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 RESERVOIR) A P...

Page 72 - TEST SHOWN

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 40 Relief Valve (R1) and (R2) Pressure Test Figure 37 FORWARD 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...

Page 74 - (Using Tester with Pressure and Flow Capabilities); FLOW TEST SHOWN

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 42 Gear Pump (P1) and (P2) Flow Test (Using Tester with Pressure and Flow Capabilities) Figure 39 FORWARD 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...

Page 76 - FRONT OF MACHINE

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 44 Reel Drive Motor Efficiency Test (Using Tester 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 r...

Page 84 - Lift Cylinder Internal Leakage Test; CHECK FOR; EXTENDING

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 52 Lift Cylinder Internal Leakage Test 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 MESHSUCTIONSTRAINER INTERNAL CASE DRAIN P1 P2 P3 P4 G4 SV3 SV1 SV2 R7 SVR V CV4 CV1 CV5...

Page 86 - Steering Relief Valve (R10) Pressure Test; STEERING WHEEL TURNED; The steering relief valve (R10) pressure test should be

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 54 Steering Relief Valve (R10) Pressure Test Figure 52 STEERING WHEEL TURNED FOR RIGHT TURN OUT IN V1 R L STEERING R10 T P 100 MESHSUCTIONSTRAINER INTERNAL CASE DRAIN P1 P2 P3 P4 CYLINDER CONTROL STEERING VALVE DRAIN PUMP (P5) PRESSURE GAUGE...

Page 88 - Steering Cylinder Internal Leakage Test; LOOK FOR LEAKAGE; STEERING WHEEL

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 56 Steering Cylinder Internal Leakage Test Figure 54 STEERING CYLINDER STEERING CONTROL VALVE (FULLY EXTENDED) LOOK FOR LEAKAGE PLUG STEERING WHEEL TURNED FOR RIGHT TURN R10 The steering cylinder internal leakage test should be performed if ...

Page 91 - Check Hydraulic Lines and Hoses; Check hydraulic lines and hoses daily for leaks, kinked

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 ha...

Page 92 - Flush Hydraulic System

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 60 Flush Hydraulic System IMPORTANT: 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 surfa...

Page 96 - Hydraulic Reservoir

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. Tank cover 7. Hydraulic tee fitting 8. Hydraulic tube 9. O--ring 10. Flange gasket 11. Socket head screw (6 used) 12. Bumper 13. C...

Page 98 - Hydraulic Pump Drive Shaft

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 s...

Page 100 - Hydraulic Pump Assembly; Traction pump and gear pump should be re-

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. Traction pump assembly 5. O--ring 6. Hydraulic fitting (2 used) 7. Hydraulic hose (2 used) 8. Lever damper 9. Flange nut 10. Plate 11. ...

Page 104 - curred, refer to Traction Circuit Component Failure

Rev. A Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 72 Piston (Traction) Pump Service 1. Traction 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 11. Screw (4 used) 12. Plug 13. O--rin...

Page 106 - Gear Pump Service; thrust plates for each pump section together do not

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) 11. Sp...

Page 108 - Front Wheel Motor

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....

Page 113 - IMPORTANT: If a wheel motor failure occurred, refer

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. Valve plate 6. Thrust bearing 7. Bearing 8. Valve 9. Dowel pin (4 used) 10. Balancing ring 11. Valve spring 12. Back--up ring 13...

Page 114 - Mow Control Manifold

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 11. Hydraulic fitting 12. O--ring 13. O--ring 14...

Page 116 - Mow Control Manifold Service

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 11. Solenoid relie...

Page 120 - Lift Control Manifold

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 11. Hydraulic tube 12. O--ring 1...

Page 122 - Lift Control Manifold Service

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) 11. So...

Page 126 - For AWD control manifold service procedures, see Mow

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 94 CrossTrax TM AWD (Optional Kit) Manifold Service 1. AWD 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 11. Seal kit 12. Bi--Directional relief val...

Page 128 - Cutting Reel Motor

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 11. Hydraulic hose 12. Hydraulic hose 13....

Page 130 - Cutting Reel Motor Service; DIAGONAL LINE

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. Tab washer 5. Pressure seal 6. Back--up ring 7. O--ring 8. Body 9. Idler gear 10. Cap screw (4 used) 11. Front flange 12. Dowel pin 13. Rear bearing block 14. Front ...

Page 134 - Lift Cylinder

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 11. Retaining ring 12. Thrust washer 13. ...

Page 136 - Lift Cylinder Service; IMPORTANT: Prevent damage when clamping 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--ring 12. O--ring 13. Lock nut 14. Barrel Figure 89 2 3 4 5 6 1 9 8 7 1 10 11 14 12 1...

Page 138 - Steering Control Valve

Rev. B Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 106 Steering Control Valve 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 11. Hydraulic f...

Page 140 - Steering Control Valve Service; For repair of the steering control valve, see the

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 108 Steering Control Valve 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 11. Sleeve 12. Cross pin 13. Spring set 14. Ring...

Page 142 - Steering Cylinder

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 110 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 11. Jam nut 12. Cotter pin 13. Slotted hex nu...

Page 144 - Steering Cylinder Service

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 112 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 11. 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 ...

Page 146 - Oil Cooler

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 114 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) 11. Foam seal (2 use...

Page 147 - Inspection; Use eye protection such as goggles when using

Reelmaster 5010 Series Hydraulic System (Rev. C) Page 4 -- 115 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...

Page 149 - Chapter 5; Electrical System; Electrical System

Reelmaster 5010 Series Page 5 -- 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL DIAGRAMS 1 . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 150 - Multimeter

Rev. A Reelmaster 5010 Series Page 5 -- 2 Electrical System Special Tools Order Special Tools from your Toro Distributor. Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL V...

Page 151 - Diagnostic Display; Battery Hydrometer

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...

Page 152 - Diagnostic Light

Reelmaster 5010 Series Page 5 -- 4 Electrical System Troubleshooting 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, ...

Page 157 - Electronic Control Module Logic Chart; Start

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: To sta...

Page 158 - Starting Problems

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 ...

Page 160 - General Run and Transport Problems

Reelmaster 5010 Series Page 5 -- 12 Electrical System General Run and Transport 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 circ...

Page 161 - Cutting Unit Operating Problems

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 no...

Page 162 - Cutting Unit Operating Problems (Continued)

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 lim...

Page 163 - TurfDefender; Checking TurfDefender; Operation

Reelmaster 5010 Series Page 5 -- 15 Electrical System TurfDefender TM Leak Detector (Optional) The optional TurfDefender 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...

Page 165 - Diagnostic Display Functions

Reelmaster 5010 Series Page 5 -- 17 Electrical System TURFDEFENDER V1.0 DIAGNOSTIC ACE 94--5386 OUTPUT / INPUT FLOAT LEVEL (TOP) FLOAT LEVEL 2 FLOAT LEVEL 3 FLOAT LEVEL 4 FLOAT LEVEL 5 FLOAT LEVEL 6 FLOAT LEVEL 7 FLOAT LEVEL 8 FLOAT LEVEL 9 VALVE ON / VALVE OPEN CIRCUIT / VALVE SHORT CIRCUIT/ ALARM ...

Page 166 - Electrical System Quick Checks; Voltage Measured; Charging System Test; At least 0.50 volt over initial battery voltage.; Glow Plug System Test

Reelmaster 5010 Series Page 5 -- 18 Electrical System Electrical System Quick Checks Battery Test (Open Circuit Test) 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 (16 o to 38 o C). The i...

Page 167 - Check Operation of Interlock Switches

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 i...

Page 168 - Traction Neutral Switch

Rev. B Reelmaster 5010 Series Page 5 -- 20 Electrical System Adjustments Traction 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 s...

Page 169 - Parking Brake Switch; Adjustment

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 positi...

Page 170 - Up Limit Switch

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). Adj...

Page 171 - Ignition Switch

Rev. B Reelmaster 5010 Series Page 5 -- 23 Electrical System Component Testing 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: Elec...

Page 172 - Indicator Lights

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 START. The light should stay lit for approximately 6 seconds ...

Page 173 - Hour Meter; Hobbs; BACK; Temperature Gauge

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...

Page 174 - PTO Switch

Reelmaster 5010 Series Page 5 -- 26 Electrical System PTO 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. Testing 1. Before disconnecting the switch for testing, ...

Page 176 - Seat Switch; Testing

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 unde...

Page 177 - Headlight Switch

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. Testing 1. Remove inside control arm cover to gain access to headlight switch (see Control...

Page 180 - Joystick Raise and Lower Switches

Rev. B Reelmaster 5010 Series Page 5 -- 32 Electrical System Joystick Raise and Lower Switches Two 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 ...

Page 182 - Backlap Switches

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 ba...

Page 183 - Start Relay; should

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 ...

Page 184 - Main Power and Glow Relays

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). Relay...

Page 186 - Diode Assembly; Fusible Link Harness

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- e...

Page 187 - Fuses; Identification and Function

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 ha...

Page 188 - Hydraulic Solenoid Valve Coil

Reelmaster 5010 Series Page 5 -- 40 Electrical System Hydraulic Solenoid Valve 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) s...

Page 189 - Temperature Sender

Reelmaster 5010 Series Page 5 -- 41 Electrical System Temperature 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 changi...

Page 190 - High Temperature Shutdown Switch

Reelmaster 5010 Series Page 5 -- 42 Electrical System High Temperature 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...

Page 191 - Oil Pressure Switch

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....

Page 192 - Fuel Stop Solenoid

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 ...

Page 193 - Fuel Pump

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). IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. DANGER Because diesel fuel is highl...

Page 194 - Battery Storage

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 charg...

Page 195 - Battery Service

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 ex...

Page 198 - Control Arm

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 11. Clevis pin 12. Screw 13. Latch 14. Swell latch (2 used) 15. Acc...

Page 200 - Removal

Reelmaster 5010 Series Page 5 -- 52 Electrical System Hydraulic Solenoid Valve 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 cut...

Page 201 - are

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. Tilt operator seat up to gain access to hydraulic mow control manifold. ...

Page 203 - Service

Reelmaster 5010 Series Page 5 -- 55 Electrical System Very 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 TurfDefender TM analyzes the float movement and deter- mines if there is a leak...

Page 205 - Chapter 6; Chassis

Reelmaster 5010 Series Page 6 -- 1 Chassis (Rev. C) Chapter 6 Chassis Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Traction Unit Operator’s Manual 2 . . . . . . . . . . . . . . . SERVICE A...

Page 206 - The Traction Unit Operator’s Manual provides informa-

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

Page 208 - Wheels; Figure 1

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. Tab washer 10. Rear wheel 11. Jam nut 12. Retainer 13. Cotter pin 14. Du...

Page 210 - Steering Column

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 11. Hydraulic tube 12. Hydraulic tu...

Page 212 - Brake Service; Figure 5

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. Diag...

Page 218 - Rear Axle

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 11. Grease fitting 12. Tab washer 13. Wheel hub assembly 14. Grease fit...

Page 220 - Rear Axle Service

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 11. Grease fitting 12. Spindle cap 13. Retaining ring 14. Flange head screw 15...

Page 222 - Operator Seat

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 11. Cap screw 12. Flange nut 13. Flat washer (4 used) 1...

Page 224 - Mechanical Seat Suspension

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. Cap 12. Suspension boot 13. P...

Page 226 - Front Lift Arms

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 11. Bridge plate 12. Flange screw 13. Ch...

Page 228 - Rear Lift Arms; Be careful when removing tension from the tor-

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 pi...

Page 229 - Be careful when applying tension to the torsion

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 -- Hy...

Page 231 - Chapter 7; Cutting Units; Cutting

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 1 Chapter 7 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Cutting Unit Operator’s Manual 3 . . . . . . . . . . . . . . ...

Page 232 - Front and Rear Rollers:

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)...

Page 233 - Cutting Unit Operator’s Manual

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. Additional...

Page 234 - Gauge Bar Assembly; Bedknife Screw Tool; IMPORTANT: To prevent damage to the bedbar, DO; Handle Assembly

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 4 Special Tools Order Special Tools from your Toro Distributor. Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly Toro Part Number: 108--6715 Use gauge bar to verify height--of--cut adjustmen...

Page 236 - Turf Evaluator Tool

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 6 Cutting Unit Tool Kit Toro Part Number: TOR4070 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)...

Page 237 - Diameter/Circumference Measuring Tape; Spring steel measuring tape for accurately measuring

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 7 Diameter/Circumference Measuring Tape Toro Part Number: TOR6023 Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components. Tape calibration is in fixed inch read...

Page 238 - Factors That Can Affect Cutting Performance; Aftercut Appearance Trouble-

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. Turf conditions such as excessive thatch, “sponginess” or attempting to cu...

Page 241 - Set Up and Adjustments; Characteristics; Never install or work on the cutting units or lift

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 11 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 t...

Page 242 - Reel Bearing Adjustment

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 12 Reel Bearing Adjustment To 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 ...

Page 243 - Leveling Rear Roller

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 ...

Page 244 - Hydraulic Reel Motor

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 14 Service and Repairs Hydraulic Reel Motor IMPORTANT: 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...

Page 245 - Backlapping

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 15 Backlapping DANGER TO AVOID PERSONAL INJURY OR DEATH: 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 D...

Page 246 - Bedbar Assembly; ” CUTTING REEL SHOWN

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 use...

Page 248 - Bedbar Adjuster Service

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 11. Washer FRONT RIGHT 14 to 16 ft-...

Page 249 - DP

Reelmaster 5010 Series Cutting Units (Rev. C) Page 7 -- 19 Removal (Fig. 21) 1. Remove lock nut (item 3), compression spring (item 2) and washer (item 11) from bedbar adjuster screw (item 10). 2. Remove bedbar (see Bedbar Removal in this sec- tion). NOTE: Inside threads in bedbar adjuster shaft (ite...

Page 250 - Bedknife Replacement and Grinding

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 Tools). Discard screws. Rem...

Page 252 - Reel Assembly Removal and Installation

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 p...

Page 256 - Reel Assembly Service

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 Figu...

Page 258 - Preparing Reel for Grinding

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...

Page 260 - Front Roller

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 lev...

Page 261 - Rear Roller

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 leve...

Page 262 - Roller Service (Greasable Bearings with Retaining Ring); Numerous front and rear rollers are available

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...

Page 264 - Roller Service (Greasable Bearings with Bearing Nut); IMPORTANT: During assembly process, frequently

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 an...

Page 271 - Chapter 8; Groomer; Groomer

Reelmaster 5010 Series Groomer Page 8 -- 1 Chapter 8 Groomer Table of Contents GROOMING PERFORMANCE 2 . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 3 . . . . . . . . . . . . . . . . . . . . . . . . . Groomer Reel Mechanical Problems 3 . . . . . . . . . . . ADJUSTMENTS 4 . . . . . . . . . . . ....

Page 272 - Grooming Performance

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...

Page 273 - Groomer Reel Mechanical Problems

Reelmaster 5010 Series Groomer Page 8 -- 3 Troubleshooting 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 spr...

Page 274 - Never work on the groomer with the engine; Groomer Height/Depth Adjustment

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 for all machine movement to stop before working on the groomer. NOTE: The Groomer Installation Instructions provi...

Page 275 - Groomer Drive Belt Replacement

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 for all machine movement to stop before working on the groomer. NOTE: The Groomer Installation Instructio...

Page 276 - Groomer Plate Assembly

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 11. Flange head screw 12. Drive pulley 13. Retain...

Page 280 - Groomer Reel

Reelmaster 5010 Series Groomer Page 8 -- 10 Groomer Reel Figure 8 1. Groomer reel 2. Pulley spacer 3. Washer 4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw 8. Idler plate 9. Idler pulley assembly 10. Lock nut 11. Flange head screw 12. Drive pulley 13. Retaining ring 14. Extension ...

Page 282 - Groomer Reel Service; not

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. 11). Blades that are rounded to the midpoin...

Page 283 - Place excluder seals on groomer shaft.

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

Page 284 - Groomer Pivot Hub; The groomer reel drive is located on the oppo-

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 ...

Page 286 - Height Adjuster Assembly

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 11. Flat washer 12. Groomer adjuster...

Page 287 - Chapter 9; Foldout Drawings; Foldout Drawings

Rev. B Reelmaster 5010 Series Foldout Drawings Page 9 -- 1 Chapter 9 Foldout Drawings Table of Contents HYDRAULIC SCHEMATICS Reelmaster 5210 and 5410 3 . . . . . . . . . . . . . . . . . . . Reelmaster 5510 and 5610 4 . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATICS Reelmaster 5010 Series ...

Page 289 - Hydraulic Schematic

Page 9 -- 3 Hydraulic Schematic Reelmaster 5210 and 5410 FORWARD 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 CIRCUIT FRONT MOW CIRCUIT R9 100 MESHSUCTIONSTRAINER INTERNAL CASE DRAIN TRACTION WHEEL ...

Page 291 - Electrical Schematic

Rev. B Page 9 -- 5 Electrical Schematic Reelmaster 5010 Series All relays and solenoids are shown as de-- energized.All ground wires 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...

Page 293 - Glow Plug Circuits

Rev. B Page 9 -- 7 Glow Plug Circuits Power CurrentControl CurrentIndicator/Gauge Current Reelmaster 5010 Series 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/BK OR...

Page 294 - Crank Circuits

Rev. B Page 9 -- 8 Crank Circuits Power CurrentControl CurrentIndicator/Gauge Current Reelmaster 5010 Series 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/BK OR/BK ...

Page 298 - Main Wire Harness Drawing

Rev. B Page 9 -- 12 Reelmaster 5010 Series Main Wire Harness Drawing

Page 299 - Main Wire Harness Diagram

Rev. B Page 9 -- 13 Reelmaster 5010 Series Main Wire Harness Diagram ORANGE RED YELLOW BLACK GRAY BLUE GREEN/WHITE PINK WHITE VIOLET TAN W H IT E/ BL U E BR O W N PI N K OR A N GE WH ITE RE D YEL LO W /BL AC K BL AC K RE D BL AC K BL AC K BLACK RED PINK GREEN YELLOW BL AC K BLACK PINK BLUE GR AY GR ...

Page 300 - Seat Wire Harness Drawing

Rev. B Page 9 -- 14 Reelmaster 5010 Series Seat Wire Harness Drawing

Page 301 - Seat Wire Harness Diagram

Rev. B Page 9 -- 15 Reelmaster 5010 Series Seat Wire Harness Diagram TA N BR O W N / WHITE YELLOW/BLACK RE D PINK PINK WHITE TAN BLACK PINK RED/BLACK RED RED WH ITE RE D W H IT E/ BL AC K Y E LLO W RE D OR A N GE VI O LET BL AC K GR AY BLACK TAN/BLACK BL AC K BL AC K BL AC K BL AC K BL AC K GR AY BL...

Page 302 - Engine Wire Harness Drawing

Rev. B Page 9 -- 16 Reelmaster 5010 Series Engine Wire Harness Drawing

Page 303 - Engine Wire Harness Diagram

Rev. B Page 9 -- 17 Reelmaster 5010 Series Engine Wire Harness Diagram PIN K GRA Y WH ITE GREEN/WHITE WH ITE ORANGE RE D BL AC K RE D/ B LA CK BLACK BLUE TA N BL U E FU SIBL E LIN K