Toro 5010-H - Manual

Reelmaster 5010- H 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 dependent upon the ...

Reelmaster 5010- H Page 1 - 3 Safety While Operating 1. Sit on the seat when starting and operating the ma- chine. 2. Before starting the engine: A. Apply the parking brake. B. Make sure the traction pedal is in NEUTRAL, the Enable/Disable switch is in the disabled position and the engine speed swit...

Reelmaster 5010- H Page 1 - 4 Safety Maintenance and Service 1. Before servicing or making adjustments, lower cut- ting units, apply parking brake, stop engine and remove key from the ignition switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3....

Reelmaster 5010- H Page 1 - 6 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and the cutting units of your Reelmaster. If any decal becomes illegible or damaged, install a new decal. Part numbers for decals are listed in your Part Catalog...

Reelmaster 5010- H Page 2 - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 . . . ...

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

Reelmaster 5010- H Page 2 - 3 Product Records 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 clearly identifi...

Reelmaster 5010- H Page 2 - 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque 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 + 3 ft...

Reelmaster 5010- H Page 3 - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Traction Unit Operator’s Manual 3 . . . . . . . . . . . . . . ....

Reelmaster 5010- H Page 3 - 2 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota Model D1105- E4B: 4- Cycle, 3 Cylinder, Water Cooled, Tier 4 Diesel Engine Number of Cylinders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.5 in 3 (1123 cc) Firing Or...

Reelmaster 5010- H Page 3 - 3 Kubota Diesel Engine General Information This Chapter gives information about specifications, troubleshooting, testing and repair of the Kubota diesel engine used in Reelmaster 5010- H machines. Most repairs and adjustments require tools which are commonly available in ...

Reelmaster 5010- H Page 3 - 4 Kubota Diesel Engine Service and Repairs Air Cleaner Assembly Figure 2 1. Diesel engine 2. Air cleaner assembly 3. Hose clamp (4 used) 4. Air intake hose 5. Air intake hose 6. Service indicator 7. Indicator adapter 8. Shoulder bolt 9. Nut 10. Compression spring 11. Air ...

Reelmaster 5010- H Page 3 - 6 Kubota Diesel Engine Exhaust System Figure 4 1. Diesel engine 2. Exhaust muffler 3. Clamp 4. Hex nut (2 used) 5. Flange nut (4 used) 6. Carriage bolt (4 used) 7. Bellhousing 8. Tailpipe bracket 9. Flange head screw 10. Flange nut 11. Exhaust header 12. Flange nut (4 use...

Reelmaster 5010- H Page 3 - 8 Kubota Diesel Engine Fuel System Figure 6 1. Fuel tank 2. Fuel tank cap 3. Screw (7 used) 4. Strap 5. Sender cover 6. Hose clamp 7. Fuel supply hose 8. Hose clamp 9. Fuel return hose 10. Clamp (2 used) 11. Flange head screw (2 used) 12. Flange nut (3 used) 13. Draincock...

Reelmaster 5010- H Page 3 - 10 Kubota Diesel Engine Radiator Assembly Figure 8 1. Coolant reservoir 2. Hose clamp (3 used) 3. Hose 4. Foam seal (2 used) 5. Oil cooler 6. Hose 7. Hose clamp (4 used) 8. Foam seal (2 used) 9. Radiator cap 10. Flange nut (14 used) 11. Rear screen 12. Foam seal 13. Space...

Reelmaster 5010- H Page 3 - 14 Kubota Diesel Engine Engine Figure 10 FRONT RIGHT 1. Diesel engine 2. Cap screw (12 used) 3. Flange head screw (4 used) 4. Snubbing washer (4 used) 5. Cap screw (4 used) 6. Flange nut (8 used) 7. Flange nut (8 used) 8. Spacer (4 used) 9. Lock washer (12 used) 10. Engin...

Reelmaster 5010- H Page 3 - 17 Kubota Diesel Engine CAUTION One person should operate lift or hoist while a second person guides the engine into the ma- chine. IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness, ra- diator or other parts while installing t...

Reelmaster 5010- H Page 3 - 18 Kubota Diesel Engine Engine Bellhousing Assembly Figure 14 1. Diesel engine 2. Motor/generator assembly 3. Flange head screw 4. Collar 5. Coupler hub 6. Woodruff key 7. Bellhousing 8. Cap screw (2 used) 9. Flat washer (2 used) 10. Flange head screw (7 used) 11. Flange ...

Reelmaster 5010- H Hydraulic System Page 4 - 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Traction Unit Operator’s Manual 3 . . . . . . . . . . . . . . 48 VDC Ba...

Reelmaster 5010- H Hydraulic System 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 for additional i...

Reelmaster 5010- H Hydraulic System Page 4 - 4 Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston (traction) pump may occur. If it becomes necessary to tow or push the machine, tow or push at a speed below 3 mph (4.8 kph), and for a very short distance. If the...

Reelmaster 5010- H Hydraulic System Page 4 - 5 Hydraulic Hose and Tube Installation (O- Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is...

Reelmaster 5010- H Hydraulic System Page 4 - 8 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 ...

Reelmaster 5010- H Hydraulic System Page 4 - 10 Hydraulic Schematic NOT E :A la rg er hy dr au lic sc he m at ic is in clud ed in Ch ap te r 9 - F old out Dra w ing s LIFT CONTROL MANIFOLD

Reelmaster 5010- H Hydraulic System Page 4 - 12 Hydraulic Flow Diagrams Figure 11 W orkin g P re ssu re Lo w P ressur e (Cha rge ) Return or Suction Flow Tr ac tion Ci rc uit (Forwa rd S hown) Reelmaster 5010 -H LIFT CONTROL MANIFOLD

Reelmaster 5010- H Hydraulic System Page 4 - 13 Traction Circuit The hydraulic traction circuit consists of a variable dis- placement piston pump (P3) connected in a closed loop, parallel circuit to two (2) orbital roller vane wheel motors. The piston (traction) pump input shaft is rotated by a driv...

Reelmaster 5010- H Hydraulic System Page 4 - 14 Figure 13 Working PressureLow Pressure (Charge)Return or SuctionFlow Lift Circuit: Raise Cutting Units Reelmaster 5010- H T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 C...

Reelmaster 5010- H Hydraulic System Page 4 - 16 Figure 14 Working PressureLow Pressure (Charge)Return or SuctionFlow Lift Circuit: Lower Cutting Units Reelmaster 5010- H 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 CV4 CV1 CV...

Reelmaster 5010- H Hydraulic System Page 4 - 18 Figure 15 W ork in g P re ssu re Lo w P ressur e (C har ge ) Return or Suction Flow Steering Circuit Reel master 5010 -H STEERING CYLINDER PI ST O N MOV E M E NT STEERING CYLINDER PIS TO N MO VE ME N T STEERI NG VA LV E R10 R10 FRO M PUM P (P2) FROM PU...

Reelmaster 5010- H Hydraulic System Page 4 - 19 Steering Circuit A two section gear pump is coupled to the piston (trac- tion) pump. Gear pump section P2 supplies hydraulic flow to the steering control valve and for the traction charge circuit. The hydraulic reservoir provides fluid for the gear pum...

Reelmaster 5010- H Hydraulic System Page 4 - 20 Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings...

Reelmaster 5010- H Hydraulic System Page 4 - 21 40 GPM Hydraulic Tester (Pressure and Flow) Toro Part Number: AT40002 Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALV...

Reelmaster 5010- H Hydraulic System Page 4 - 22 High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 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 prevent...

Reelmaster 5010- H Hydraulic System Page 4 - 23 Hydraulic Test Fitting Kit Toro Part Number: TOR4079 This kit includes a variety of O- ring face seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Figur...

Reelmaster 5010- H Hydraulic System Page 4 - 24 Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft. Toro Part Number: TOR6004 Figure 25

Reelmaster 5010- H Hydraulic System Page 4 - 25 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 increase in heat ...

Reelmaster 5010- H Hydraulic System Page 4 - 26 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 not seating o...

Reelmaster 5010- H Hydraulic System Page 4 - 27 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 traction componen...

Reelmaster 5010- H Hydraulic System Page 4 - 28 Lift Circuit Problems (Continued) Problem Possible Cause None of the front cutting units will raise or lower but the rear cutting units will raise and lower Solenoid valve SV1 on lift control manifold is faulty. An electrical problem exists that preven...

Reelmaster 5010- H Hydraulic System Page 4 - 33 NOTE: If machine is equipped with optional CrossTrax TM AWD, reverse relief pressure test ports are located on CrossTrax TM hydraulic manifold. 3. Thoroughly clean traction circuit test port on hydrau- lic tube for direction to be checked (Fig. 27). Co...

Reelmaster 5010- H Hydraulic System Page 4 - 34 Traction Circuit Charge Pressure Test Figure 29 FORWARD M7 M6 FROM STEERING CONTROL VALVE R9 INTERNAL CASE DRAIN TRACTION WHEEL MOTORS G5 G6 B R5 R4 R3 A B A B LH RH A P3 TO LIFT CONTROL MANIFOLD TO STEERING CONTROL VALVE AND CHARGE CIRCUIT PRESSURE GA...

Reelmaster 5010- H Hydraulic System Page 4 - 36 Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) Figure 32 FORWARD M7 M6 FROM STEERING CONTROL VALVE R9 INTERNAL CASE DRAIN TRACTION WHEEL MOTORS G5 G6 B R5 R4 R3 A B A B LH RH A P3 TESTER OIL FILTER REMOVED AND TUBE TO LIFT ...

Reelmaster 5010- H Hydraulic System Page 4 - 38 Front Wheel Motor Efficiency Test Figure 35 FORWARD M7 M6 FROM STEERING CONTROL VALVE R9 INTERNAL CASE DRAIN TRACTION WHEEL MOTORS G5 G6 B R5 R4 R3 A B A B LH RH A P3 TESTER CAP CAP RH FRONT WHEEL MOTOR EFFICIENCY TEST SHOWN TO LIFT CONTROL MANIFOLD TO...

Reelmaster 5010- H Hydraulic System Page 4 - 46 Lift Cylinder Internal Leakage Test Figure 43 T C4 P4 C5 C1 C2/3 C2/3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVR V CV4 CV1 CV5 CV23 CHECK FOR CYLINDER (PARTIALLY RAISED) LEFT FRONT (#5) LIFT CYLINDER...

Reelmaster 5010- H Hydraulic System Page 4 - 48 Steering Relief Valve (R10) Pressure Test Figure 47 STEERING WHEEL TURNED FOR RIGHT TURN OUT IN V1 R L STEERING R10 T P CYLINDER CONTROL STEERING VALVE PRESSURE GAUGE MANIFOLD TO LIFT CONTROL TO TRACTIONCHARGE CIRCUIT 100 MESH SUCTION STRAINER P1 P2 IN...

Reelmaster 5010- H Hydraulic System Page 4 - 50 Steering Cylinder Internal Leakage Test Figure 49 STEERING CYLINDER STEERING CONTROL VALVE (FULLY EXTENDED) LOOK FOR LEAKAGE PLUG STEERING WHEEL TURNED FOR RIGHT TURN R10

Reelmaster 5010- H Hydraulic System Page 4 - 53 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 ...

Reelmaster 5010- H Hydraulic System Page 4 - 54 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 surface. Lower cutt...

Reelmaster 5010- H Hydraulic System Page 4 - 55 Filtering Closed- Loop Traction 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-...

Reelmaster 5010- H Hydraulic System Page 4 - 56 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 ...

Reelmaster 5010- H Hydraulic System Page 4 - 58 Hydraulic Reservoir 1. Suction strainer 2. Hydraulic reservoir 3. Recess bumper 4. Clamp (2 used) 5. Suction hose 6. Hose clamp (2 used) 7. Reservoir cap 8. Washer head screw (2 used) 9. Flange nut (3 used) 10. Cap screw 11. Flat washer 12. Filter scre...

Reelmaster 5010- H Hydraulic System Page 4 - 62 Hydraulic Pump Assembly 1. Gear pump assembly 2. O- ring 3. O- ring 4. Flat washer (4 used) 5. O- ring 6. Hydraulic fitting 7. Piston (traction) pump assembly 8. Socket head screw (2 used) 9. Lock washer (2 used) 10. Lock nut (2 used) 11. Flange nut (2...

Reelmaster 5010- H Hydraulic System Page 4 - 66 Piston (Traction) Pump Service 1. Piston (traction) pump housing 2. Auxiliary shaft 3. Retaining ring 4. Ball bearing 5. Retaining ring 6. Seal 7. Backup washer 8. Bearing (2 used) 9. O- ring 10. Trunnion cover 11. Screw (4 used) 12. Plug (2 used) 13. ...

Reelmaster 5010- H Hydraulic System Page 4 - 68 Gear Pump Service 1. Front cover 2. Dowel pin (4 used) 3. Square section seal (4 used) 4. Back- up seal (4 used) 5. Pressure seal (4 used) 6. Thrust plate (4 used) 7. Drive shaft 8. Driven gear 9. Body 10. Flange 11. Splined connecting shaft 12. Drive ...

Reelmaster 5010- H Hydraulic System Page 4 - 70 Hydraulic Pump Drive Shaft 1. Hood saddle 2. Air intake hose 3. Hose clamp (2 used) 4. Flange head screw (4 used) 5. Flange nut (4 used) 6. Upper intake shroud 7. Lower intake shroud 8. Brush seal (2 used) 9. 48 VDC motor/generator assembly 10. Engine ...

Reelmaster 5010- H Hydraulic System Page 4 - 72 Hydraulic Pump Drive Shaft Cross and Bearing Service 1. End yoke (motor/generator) 2. Grease fitting (2 used) 3. Snap ring (4 per cross and bearing) 4. Cross and bearing assembly 5. Shaft yoke (male) 6. Grease fitting 7. Telescoping yoke (female) 8. En...

Reelmaster 5010- H Hydraulic System Page 4 - 74 Front Wheel Motors 1. Wheel motor (LH shown) 2. Lug nut (5 used per wheel) 3. Hub 4. Wheel stud (5 used per wheel) 5. Wheel assembly 6. Brake drum 7. Front wheel shield (2 used) 8. Cap screw (2 used per shield) 9. Flat washer (2 used per shield) 10. Lo...

Reelmaster 5010- H Hydraulic System Page 4 - 76 Front Wheel Motor Service 1. Cap screw (7 used) 2. End cap 3. O- ring (3 used) 4. Geroler assembly 5. 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. O- ring 14. Drive 15...

Reelmaster 5010- H Hydraulic System Page 4 - 78 Rear Wheel Motors (Machines with Optional CrossTrax TM Kit) 1. Lug nut (5 used per wheel) 2. Rear wheel assembly 3. Wheel hub assembly 4. Lock nut 5. Woodruff key 6. 45 o hydraulic fitting (2 per motor) 7. O- ring 8. O- ring 9. Hydraulic hose (4 used) ...

Reelmaster 5010- H Hydraulic System Page 4 - 80 Rear Wheel Motor Service (Machines with Optional CrossTrax TM Kit) 1. Cap screw (7 used) 2. End cover 3. Body seal (5 used) 4. Commutator ring 5. Commutator 6. Commutator ring 7. Manifold 8. Stator 9. Vane (7 used) 10. Rotor 11. Wear plate 12. Drive li...

Reelmaster 5010- H Hydraulic System Page 4 - 81 Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- moving the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. C...

Reelmaster 5010- H Hydraulic System Page 4 - 82 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 13. O- ring 14....

Reelmaster 5010- H Hydraulic System Page 4 - 84 Lift Control Manifold Service 1. Lift control manifold 2. Check valve (4 used) 3. Solenoid valve (SV3) 4. Solenoid coil (2 used) 5. Solenoid coil spacer (2 used) 6. Nut (3 used) 7. Solenoid valve (SV2) 8. Solenoid coil (2 used) 9. Nut 10. Solenoid reli...

Reelmaster 5010- H Hydraulic System Page 4 - 88 CrossTrax TM AWD Manifold Service (Machines with Optional CrossTrax TM Kit) 1. CrossTrax 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-...

Reelmaster 5010- H Hydraulic System Page 4 - 90 Lift Cylinders 1. Lift cylinder 2. Cylinder pin 3. Flange head screw 4. Lift arm (#4 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. Cylinder slide pi...

Reelmaster 5010- H Hydraulic System Page 4 - 92 Lift Cylinder Service 1. Grease fitting 2. Shaft 3. Dust seal 4. Head 5. BS seal 6. Retaining ring 7. Back up washer 8. O - ring 9. Piston 10. Wear ring 11. BP seal 12. O - ring 13. Lock nut 14. Barrel 15. Grease fitting Figure 76 2 3 4 5 6 9 8 7 1 10 ...

Reelmaster 5010- H Hydraulic System Page 4 - 94 Steering Control Valve 1. Steering control valve 2. Flange head screw (2 used) 3. Socket head screw (4 used) 4. Steering wheel 5. Flat washer 6. Lock nut 7. Steering wheel cover 8. Steering column 9. Socket head screw (4 used) 10. O- ring 11. Hydraulic...

Reelmaster 5010- H Hydraulic System Page 4 - 96 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 15. Thrust was...

Reelmaster 5010- H Hydraulic System Page 4 - 98 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 nut 14. Washer 15...

Reelmaster 5010- H Hydraulic System Page 4 - 100 Steering Cylinder Service 1. Shaft 2. Dust seal 3. BP seal 4. Head 5. Retaining ring 6. Back- up ring 7. O- ring 8. O- ring 9. Piston 10. BS seal 11. Barrel 12. Wear ring 13. Lock nut Figure 84 4 6 9 8 7 11 3 5 2 1 12 13 10 40 ft- lb (54 N- m) 2 4 6 1...

Reelmaster 5010- H Hydraulic System Page 4 - 102 Hydraulic Oil Cooler Figure 85 1. Oil cooler 2. Hose clamp (4 used) 3. Hydraulic hose (2 used) 4. Radiator 5. Cooler clamp (16 used) 6. Flat washer (8 used) 7. Cap screw (4 used) 8. Flange nut (10 used) 9. Top cooler bracket 10. Cap screw (2 used) 11....

Reelmaster 5010- H Hydraulic System Page 4 - 103 Removal (Fig. 85) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Unlatch and open the rear screen. 3. Remove battery to ease oil cooler removal (see 12 Volt Batter...

Reelmaster 5010- H Page 5 - 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Drawings 2 . . . . . . . . . . . . . . . . . . . . . . . . ...

Reelmaster 5010- H Page 5 - 2 Electrical System General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publication for additional information when servicing the...

Reelmaster 5010- H Page 5 - 3 Electrical System Toro Electronic Controller (TEC) Reelmaster 5010- H machines use a Toro Electronic Controller (TEC) to manage machine electrical func- tions. The controller is microprocessor controlled that senses the condition of various switches and sensors (inputs)...

Reelmaster 5010- H Page 5 - 4 Electrical System Electrical System Operation Reelmaster 5010- H machines use two (2) separate electrical systems. Most machine functions operate on a typical 12 VDC system. The second system exists to operate the electric cutting reels and is a 48 VDC electri- cal syst...

Reelmaster 5010- H Page 5 - 5 Electrical System 48 VDC System Operation The Reelmaster 5010- H 48 VDC system includes a 48 VDC battery pack, an engine driven motor/generator as- sembly, five (5) cutting reel motors, a main contactor used to energize the system and additional circuit con- trol compon...

Reelmaster 5010- H Page 5 - 6 Electrical System Special Tools Order Special Tools from your Toro Distributor. Digital 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 Volt-...

Reelmaster 5010- H Page 5 - 7 Electrical System Cutting Reel Motor Rotor Tool Set Toro Part Number: 127- 2574 (for both 5” and 7” cutting unit motors) The rotor tool set for the cutting reel motor is required to remove and install the rotor from the reel motor housing. Tool set includes puller hub, ...

Reelmaster 5010- H Page 5 - 8 Electrical System Generator Rotor Tool Set Toro Part Number: TOR6029 The generator rotor tool set is required to remove and install the rotor from the motor/generator housing. Tool set includes base plate, threaded shaft and handle (Fig. 8). NOTE: For motor/generator se...

Reelmaster 5010- H Page 5 - 9 Electrical System Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte in the machine 12 VDC bat- tery. Obtain this tool locally. NOTE: A battery hydrometer is not usable for the bat- teries in the Reelmaster 5010- H 48 VD...

Reelmaster 5010- H Page 5 - 10 Electrical System InfoCenter Display The InfoCenter Display used on your Reelmaster is a LCD device that is located on the console. The InfoCent- er provides information for the machine operator during machine operation, provides electrical system diagnos- tic assistan...

Reelmaster 5010- H Page 5 - 11 Electrical System Main Information Screens The two (2) InfoCenter main information screens (Figs. 13 and 14) are displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screens provide mach...

Reelmaster 5010- H Page 5 - 12 Electrical System Access Protected Display Screens The protected display screens are available on the Info- Center to view the electrical status of the 48 VDC power circuit. The protected display screens can be viewed af- ter the Protected Menus are available by enteri...

Reelmaster 5010- H Page 5 - 13 Electrical System Main Menu Screen The main menu screen can be accessed from the Info- Center main information by pressing and releasing the menu/back button (left button) on the display twice. Once at the main menu screen (Fig. 18), navigation to the five (5) differen...

Reelmaster 5010- H Page 5 - 14 Electrical System Service Screen The service screen (Fig. 20) contains machine opera- tional information including hours, counts, reset defaults and cutting unit backlap engage. Values listed for these service menu items cannot be changed. If the machine PIN has been e...

Reelmaster 5010- H Page 5 - 15 Electrical System Diagnostics Screen The diagnostics screen (Fig. 21) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine controls and to verify that switches and circuit wiring are functioning ...

Reelmaster 5010- H Page 5 - 16 Electrical System Settings Screen The settings screen identifies the InfoCenter units (En- glish or Metric) and language . The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings for the InfoCenter display. If either...

Reelmaster 5010- H Page 5 - 17 Electrical System Height of Cut (HOC) identifies the setting for cutting unit height of cut. This information is used by machine controllers to determine cutting unit reel speed. F Reel RPM displays the front reel speed that has been determined by the machine controlle...

Reelmaster 5010- H Page 5 - 18 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, ther...

Reelmaster 5010- H Page 5 - 20 Electrical System Fault Codes The InfoCenter Display will identify electrical system malfunctions (faults) if they occur. Should a fault occur during machine operation, the InfoCenter indicator light will illuminate and the fault will be displayed on the Info- Center D...

Reelmaster 5010- H Page 5 - 35 Electrical System Starting Problems Problem Possible Causes All electrical power is dead, including InfoCenter Display. 12 VDC battery is discharged. Ignition switch or circuit wiring is faulty. Fusible link harness at the engine starter motor is faulty. 12 VDC battery...

Reelmaster 5010- H Page 5 - 37 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 actuator or circuit wiring is faulty. Ignition switch or circuit wiring is faulty. Main power relay...

Reelmaster 5010- H Page 5 - 38 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. TEC controller is faulty. Cutting units run, but should not, when raised. ...

Reelmaster 5010- H Page 5 - 39 Electrical System Cutting Unit Operating Problems (Continued) Problem Possible Causes The cutting units do not run when placed in the backlap direction. The parking brake is not applied. Reel engage/disengage switch is in the OFF position. High engine coolant temperatu...

Reelmaster 5010- H Page 5 - 40 Electrical System Electrical System Quick Checks 12 VDC Battery Test (Open Circuit Test) Use a digital multimeter to measure the battery voltage. Remove battery cover to access the battery at the rear of the machine. Set the multimeter to the DC volts set- ting. The ba...

Reelmaster 5010- H Page 5 - 41 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 swi...

Reelmaster 5010- H Page 5 - 42 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. The sensing element for the tr...

Reelmaster 5010- H Page 5 - 43 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. 28). When the parking brake is not applied, the parking brake detent is positioned near th...

Reelmaster 5010- H Page 5 - 44 Electrical System Cutting Unit Down Limit Switch The cutting unit down limit switch is a normally open proximity switch that closes when the front, outside cut- ting units are in the turn- around position. The down limit switch is attached to a frame bracket inside the...

Reelmaster 5010- H Page 5 - 46 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: Electrical troub...

Reelmaster 5010- H Page 5 - 47 Electrical System 12 VDC System Fuses The fuse block is located behind the control arm access cover (Fig. 32). In addition to the 12 VDC fuses in the fuse block, a 2 Amp fuse is included in the wire harness to protect the logic power circuit for the TEC controller. Thi...

Reelmaster 5010- H Page 5 - 48 Electrical System 48 VDC System Fuses Several fuses are used in the 48 VDC system (motor/ generator and cutting unit motors) for circuit protection. Fuse Identification and Function 35 Amp Reel Motor Fuses: Protect the 48 VDC power supply circuits for the electric reel...

Reelmaster 5010- H Page 5 - 49 Electrical System Engine Speed Switch The engine speed switch is a momentary switch that is used as an input for the TEC controller to raise or lower the engine speed. When the switch is depressed and held in the forward position, the engine speed will in- crease. Conv...

Reelmaster 5010- H Page 5 - 50 Electrical System Reel Engage/Disengage Switch The reel engage/disengage switch is used to allow the cutting units to operate. An indicator light on the switch identifies when the engage/disengage switch is en- gaged. The reel engage/disengage switch is mounted on the ...

Reelmaster 5010- H Page 5 - 51 Electrical System Headlight Switch The headlight switch allows the headlights to be turned on and off. This rocker switch is located on the operator side of the control arm (Fig. 41). NOTE: The Toro Electronic Controller (TEC) does not monitor the operation of the head...

Reelmaster 5010- H Page 5 - 52 Electrical System Seat Switch The seat switch is normally open and closes when the operator seat is occupied. If the traction system or reel engage/disengage switch is engaged when the opera- tor raises out of the seat, the engine will stop. The seat switch is located ...

Reelmaster 5010- H Page 5 - 56 Electrical System Joystick Raise and Lower Switches Two (2) micro switches for the joystick are located on the lower mow/raise lever that is attached to the control arm. The rear switch on the control is used to lower (and en- gage) the cutting units and the front swit...

Reelmaster 5010- H Page 5 - 58 Electrical System Main Power, Glow and 48 VDC Logic Relays Your Reelmaster uses three (3) identical electrical re- lays that have four (4) terminals. The main power and glow relays are attached to a frame bracket under the hood near the engine exhaust muffler (Fig. 50)...

Reelmaster 5010- H Page 5 - 60 Electrical System Start Relay The start relay is used in the engine starting circuit. When energized by the TEC controller, the start relay provides a current path to energize the engine starter solenoid. The start relay has five (5) terminals and is at- tached to a fr...

Reelmaster 5010- H Page 5 - 61 Electrical System Main Contactor The main contactor provides current to the 48 VDC sys- tem circuits (e.g. motor/generator, reel motors). When the ignition switch is ON, the 48 VDC logic relay is ener- gized by the TEC controller which allows the main con- tactor to be...

Reelmaster 5010- H Page 5 - 64 Electrical System Fusible Link Harness The Reelmaster 5010- H uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the main wire harness (Fig. 60). If any of these links should fail, ...

Reelmaster 5010- H Page 5 - 65 Electrical System Diode Assembly A diode assembly is used in the Reelmaster main wire harness (Fig. 62). The diode is used for circuit protection from voltage spikes that occur when the starter solenoid is de- energized. Testing 1. Park the machine on a level surface, ...

Reelmaster 5010- H Page 5 - 66 Electrical System 48 VDC System Protection Diode The Reelmaster 5010- H 48 VDC system includes a diode that is used for circuit protection from voltage spikes when the main contactor is de- energized. The diode plugs into the main wire harness near the 48 VDC battery d...

Reelmaster 5010- H Page 5 - 67 Electrical System Location ID Module The location ID module exists in the 48 VDC electrical circuit to identify the location of the five (5) cutting reel motors. This module allows such machine features as starting and stopping the rear cutting units slightly later tha...

Reelmaster 5010- H Page 5 - 68 Electrical System Cutting Reel Motor The five (5) cutting reel motors are identical 48 VDC, brushless, permanent magnet motors. Each motor has its own integral invertor and on- board controller. The In- foCenter Display can be used to monitor the speed and current draw...

Reelmaster 5010- H Page 5 - 69 Electrical System CAN- bus Termination Resistors System communication between electrical components on Reelmaster 5010- H machines is accomplished on two (2) CAN- bus communication systems: one for the 12 VDC system and one for the 48 VDC system. Two (2) specially desi...

Reelmaster 5010- H Page 5 - 70 Electrical System Hydraulic Solenoid Valve Coil The Reelmaster hydraulic lift control manifold includes four (4) solenoid valves for system control (Fig. 71). When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic flow. Testing of the ...

Reelmaster 5010- H Page 5 - 71 Electrical System Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 72). The Toro Electronic Controller (TEC) monitors the operation of the temperature sender. The resistance of the t...

Reelmaster 5010- H Page 5 - 72 Electrical System Oil Pressure Switch The engine oil pressure switch is a normally closed switch that opens with pressure during normal engine operation. The oil pressure switch is located on the en- gine near the oil filter (Fig.74). The Toro Electronic Con- troller (...

Reelmaster 5010- H Page 5 - 73 Electrical System Fuel Actuator The fuel actuator used on your Reelmaster must be en- ergized by the TEC controller for the diesel engine to run. The actuator is mounted to the injection pump on the engine (Fig. 76). The fuel actuator and TEC controller work together t...

Reelmaster 5010- H Page 5 - 74 Electrical System Fuel Sender The fuel sender is a variable resistance device that al- lows the InfoCenter display to show level of the fuel tank. The fuel sender is located in the fuel tank (Fig. 78). Testing 1. Park the machine on a level surface, engage the parking ...

Reelmaster 5010- H Page 5 - 76 Electrical System Fuel Pump The Reelmaster electric fuel pump is attached to the in- side of the left side frame rail near the fuel tank (Fig. 81). IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. DANGER Because diesel fuel is flamma...

Reelmaster 5010- H Page 5 - 77 Electrical System Service and Repairs NOTE: See the Kubota Workshop Manual, Diesel En- gine, 05- E4B Series for engine electrical component re- pair information. Hydraulic Solenoid Valve Coils A hydraulic solenoid valve coil on the lift control manifold (Fig. 83) can b...

Reelmaster 5010- H Page 5 - 78 Electrical System 12 VDC Battery Service The battery is the heart of the 12 VDC electrical system. With regular and proper service, battery life can be ex- tended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batter...

Reelmaster 5010- H Page 5 - 86 Electrical System 48 VDC Electrical Power Connections 1. Bracket 2. Main contactor 3. Holder bracket (3 used) 4. Jumper strap holder (3 used) 5. Jumper strap (positive connections) 6. Isolator 7. Flange head screw 8. Flat washer (9 used) 9. Flange nut (3 used) 10. Nut ...

Reelmaster 5010- H Page 5 - 90 Electrical System Cutting Reel Motor Service 1. Torx head screw (12 used) 2. Motor cover 3. O- ring 4. Wave washer (2 used) 5. Bearing (2 used) 6. Rotor 7. Bearing (2 used) 8. O- ring (2 used) 9. Housing/controller/cable assembly 10. O- ring 11. Output gear 12. Gearbox...

Reelmaster 5010- H Page 5 - 92 Electrical System Motor/Generator Assembly Figure 97 1. Diesel engine 2. Motor/generator assembly 3. Flange head screw 4. Collar 5. Coupler hub 6. Woodruff key 7. Engine bellhousing 8. Cap screw (2 used) 9. Flat washer (2 used) 10. Flange head screw (7 used) 11. Flange...

Reelmaster 5010- H Page 5 - 96 Electrical System Motor/Generator Assembly Service 1. Controller assembly 2. Motor/generator assembly 3. Motor/generator cover 4. Flange head screw (3 used) 5. Washer head screw (6 used) 6. Washer head screw (2 used) 7. Access cover 8. Cover gasket 9. Flat washer (2 us...

Reelmaster 5010- H Page 6 - 1 Chassis Chapter 6 Chassis Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Traction Unit Operator’s Manual 2 . . . . . . . . . . . . . . 48 VDC Battery Disconnect 2...

Reelmaster 5010- H Page 6 - 4 Chassis Service and Repairs Wheels 1. Front wheel motor 2. Brake assembly 3. Front wheel hub 4. Lock nut 5. Brake drum 6. Front wheel 7. Lug nut (5 used per wheel) 8. Rear wheel hub 9. Spindle washer 10. Rear wheel 11. Jam nut 12. Retainer 13. Cotter pin 14. Dust cap Fi...

Reelmaster 5010- H Page 6 - 6 Chassis Steering Column 1. Steering column 2. Steering wheel 3. Steering wheel cover 4. Lock nut 5. Flat washer 6. Socket head screw (4 used) 7. Steering control valve 8. Column brace 9. Flange nut (6 used) 10. Flange head screw (2 used) 11. Socket head screw (4 used) 1...

Reelmaster 5010- H Page 6 - 8 Chassis Brake Service 1. Wheel motor (LH shown) 2. Lug nut (5 used per wheel) 3. Wheel hub 4. Wheel stud (5 used per wheel) 5. Wheel assembly 6. Brake drum 7. Front wheel shield (2 used) 8. Cap screw (2 used per shield) 9. Flat washer (2 used per shield) 10. Lock nut (2...

Reelmaster 5010- H Page 6 - 14 Chassis Rear Axle 1. Lug nut (5 used per wheel) 2. Rear 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 fitting 15....

Reelmaster 5010- H Page 6 - 16 Chassis Rear Axle Service 1. Rear axle 2. Housing (2 used) 3. RH drag link 4. Tie rod assembly 5. Pivot bushing (2 used) 6. Grease fitting (2 used) 7. Flange bushing (4 used) 8. Flange head screw (7 used per side) 9. LH drag link 10. Hub and spindle assembly (2 used) 1...

Reelmaster 5010- H Page 6 - 18 Chassis Control Arm 1. Control arm frame 2. InfoCenter display 3. Headlight switch 4. Reel engage/disengage switch 5. Screw (4 used) 6. Carriage screw (2 used) 7. Latch 8. Joystick assembly 9. Flange nut (2 used) 10. Screw (2 used) 11. Swell latch (2 used) 12. Washer h...

Reelmaster 5010- H Page 6 - 20 Chassis Operator Seat 1. Operator seat 2. Seat base 3. Seat adjuster w/latch 4. Flat washer (4 used) 5. Seat switch harness 6. Seat switch 7. Washer head screw (2 used) 8. Armrest bracket 9. Spacer 10. Armrest 11. Cap screw 12. Flange nut 13. Flat washer (4 used) 14. F...

Reelmaster 5010- H Page 6 - 22 Chassis Mechanical Seat Suspension 1. Upper housing 2. Weight adjust knob 3. Lower housing 4. Scissor assembly 5. Lock nut 6. Weight adjuster 7. Drive arm 8. Extension spring (2 used) 9. Roller guide 10. Weight adjust knob 11. Cap 12. Suspension boot 13. Pivot block (2...

Reelmaster 5010- H Page 6 - 24 Chassis Front Lift Arms 1. #1 lift arm 2. #4 lift arm 3. #5 lift arm 4. Lift arm pivot shaft (3 used) 5. Roll pin (3 used) 6. Lock nut (4 used) 7. Cap screw (4 used) 8. Bridge plate 9. Cap screw (1 used per lift arm) 10. Chain hoop (3 used) 11. Washer (2 used per chain...

Reelmaster 5010- H Page 6 - 26 Chassis Rear Lift Arms 1. Housing 2. #2 lift arm 3. #3 lift arm 4. Washer (2 used per chain hoop) 5. Washer (2 used) 6. Flange head screw (2 used) 7. Shoulder stud (6 used) 8. Grease fitting 9. Pivot shaft (2 used) 10. Washer head screw (1 used per shaft) 11. Pivot yok...

Reelmaster 5010- H Page 6 - 27 Chassis 5. Remove lynch pin (item 12) and rear thrust washer (item 13) from rear of pivot yoke. Slide pivot yoke as- sembly from lift arm. Locate and retrieve front thrust washer (item 13). CAUTION Be careful when removing tension from the tor- sion spring on the rear ...

Reelmaster 5010- H Page 6 - 28 Chassis Installation (Fig. 24) 1. Position rear lift arm to frame and slide pivot shaft through frame bosses and lift arm. Secure shaft with washer head screw (item 10). 2. Place washer (item 5) over rear of each pivot shaft. 3. Place torsions springs (items 14 and 15)...

Reelmaster 5010- H Page 6 - 30 Chassis Hood 1. Sealed foam 2. Hood saddle 3. Hood 4. Catch (2 used) 5. Rubber latch (2 used) 6. Tube 7. Bow tie pin (2 used) 8. Deflector bracket (2 used) 9. Tube (2 used) 10. Washer head screw (8 used) 11. Flange head screw (10 used) 12. Flange nut (10 used) 13. Wash...

Reelmaster 5010- H Cutting Units Page 7 - 1 Chapter 7 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Cutting Unit Operator’s Manual 3 . . . . . . . . . . . . . . . 48 VDC Battery...

Reelmaster 5010- H Cutting Units Page 7 - 2 Specifications Figure 1 Frame Construction: Precision machined die cast alu- minum cross member with two (2) bolt- on aluminum side plates. Reel Construction: Reels are 22 inches (55.9 cm.) in length and are available in 5 inch (12.7 cm) and 7 inch (17.8 c...

Reelmaster 5010- H Cutting Units 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 optiona...

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

Reelmaster 5010- H Cutting Units Page 7 - 5 Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver- type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: To prevent damage to the bedbar, DO NOT use an ...

Reelmaster 5010- H Cutting Units Page 7 - 6 Spline Insert Tool Toro Part Number: TOR4112 (8 tooth for 5 inch reels) TOR4074 (9 tooth for 7 inch reels) Use spline insert tool for rotating cutting reel when motor is removed. Also use this tool for installation of threaded inserts into cutting reel sha...

Reelmaster 5010- H Cutting Units Page 7 - 7 Pulley Alignment Tool Toro Part Number: 114- 5446 Use pulley alignment tool to verify alignment of groomer and/or rear roller brush drive and driven pulleys. Figure 12 Diameter/Circumference Measuring Tape Toro Part Number: TOR6023 Spring steel measuring t...

Reelmaster 5010- H Cutting Units Page 7 - 8 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much...

Reelmaster 5010- H Cutting Units Page 7 - 12 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. Also, before installing, removing or working on the cutting units, disconnect the cu...

Reelmaster 5010- H Cutting Units 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 i...

Reelmaster 5010- H Cutting Units Page 7 - 14 Service and Repairs Cutting Reel Motor NOTE: If electrical problems exist with a cutting reel motor, a fault should have occurred that would be indi- cated by a fault code on the InfoCenter Display. Before considering that reel motor service work is neces...

Reelmaster 5010- H Cutting Units 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 or if the 48 VDC bat- tery pack is connected. Disconnect the cutting units from the electrical power supply by sepa- rating the ...

Reelmaster 5010- H Cutting Units Page 7 - 16 Bedbar Assembly 1. Bedbar assembly 2. Flange bushing (2 used) 3. Plastic washer (4 used) 4. Metal washer (2 used) 5. Bedbar pivot bolt (2 used) 6. Lock nut (2 used) 7. Lock nut (2 used) 8. Compression spring (2 used) 9. Washer (2 used) 10. Bedbar adjuster...

Reelmaster 5010- H Cutting Units Page 7 - 18 Bedknife Replacement and Grinding 1. Screw (8 used) 2. Bedbar 3. Bedknife Figure 23 v 1 2 3 Antiseize Lubricant 200 to 250 in- lb (23 to 28 N- m) Lightly Oil Bedbar Surface Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar As- sembly in this...

Reelmaster 5010- H Cutting Units Page 7 - 20 Bedbar Adjuster Service Figure 27 1. Bedbar assembly 2. Compression spring 3. Lock nut 4. Bedbar adjuster screw 5. Keyed flange bushing (2 used) 6. Cap screw 7. Detent 8. Flat washer 9. Lock nut 10. Bedbar adjuster shaft 11. Wave washer 12. Washer FRONT R...

Reelmaster 5010- H Cutting Units Page 7 - 22 Cutting Reel Assembly Removal and Installation 1. Bedbar assembly 2. Cutting unit frame 3. Flange bushing (2 used) 4. Plastic washer (4 used) 5. Metal washer (2 used) 6. Bedbar pivot bolt (2 used) 7. Lock nut (2 used) 8. RH side plate 9. LH side plate 10....

Reelmaster 5010- H Cutting Units Page 7 - 24 Reel Assembly Installation (Fig. 28) 1. Thoroughly clean side plates and other cutting unit components. Inspect side plates for wear or damage and replace if needed. CAUTION Contact with the reel, bedknife or other cutting unit parts can result in persona...

Reelmaster 5010- H Cutting Units Page 7 - 26 Cutting Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread) 3. Bearing 4. Flocked seal 5. Special washer 6. Retaining ring 7. Reel shaft plug 8. Threaded insert (LH thread) Figure 31 85 to 95 ft- lb (115 to 128 N- m) 85 to 95 ft- lb (115 ...

Reelmaster 5010- H Cutting Units Page 7 - 28 Preparing Reel for Grinding Three (3) types of cutting reel designs are used in cutting units for Reelmaster 5010- H machines: scalloped radi- al reel, tapered radial reel and tapered forward swept reel. The different types of individual reel blades are s...

Reelmaster 5010- H Cutting Units Page 7 - 30 Front Roller Removal (Fig. 36) 1. Position machine on a clean and level surface, lower cutting units, 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 sur...

Reelmaster 5010- H Cutting Units Page 7 - 31 Rear Roller Removal (Fig. 37) 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 surf...

Reelmaster 5010- H Cutting Units Page 7 - 32 Roller Service Disassembly (Fig. 38) 1. Remove bearing lock nut from each end of roller shaft. 2. Loosely 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 roller tu...

Reelmaster 5010- H Cutting Units Page 7 - 36 Rear Roller Brush Drive System (Optional) 1. Carriage screw (2 used) 2. Carriage screw (3 used) 3. Brush plate 4. Cap screw (2 used) 5. Flat washer (4 used) 6. Lock nut (6 used) 7. Idler arm 8. Idler spacer 9. Idler spring 10. Pivot washer 11. Drive belt ...

Reelmaster 5010- H Groomer Page 8 - 1 Chapter 8 Groomer Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Groomer Kit Installation Instructions 2 . . . . . . . . . . . 48 VDC Battery Disconnect 2 . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3 . . . . . . . . . . ...

Reelmaster 5010- H Groomer Page 8 - 2 General Information Groomer Kit Installation Instructions The groomer kit installation instructions provides infor- mation regarding the installation, set- up and operation of the optional groomer on your Reelmaster machine. Refer to this publication for additio...

Reelmaster 5010- H Groomer Page 8 - 4 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...

Reelmaster 5010- H Groomer Page 8 - 5 Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be adjusted. Failed groomer idler bearing(s) in groomer side plate(s). Broken or damaged idler spring. The groome...

Reelmaster 5010- H Groomer Page 8 - 7 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. Also, before installing, removing or working on the cu...

Reelmaster 5010- H Groomer Page 8 - 8 Service and Repairs CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. Also, before installing, removing or working o...

Reelmaster 5010- H Groomer Page 8 - 10 Groomer Reel and Groomer Plate Assembly Figure 8 1. Groomer reel 2. Pulley spacer 3. Washer (for pulley alignment) 4. Driven pulley 5. Flange nut 6. Excluder seal (2 used) 7. O- ring 8. Idler plate 9. Extension spring 10. Retaining ring 11. Socket head screw (2...

Reelmaster 5010- H Groomer Page 8 - 14 Groomer Reel Service Figure 14 1. Groomer shaft 2. Lock nut (2 used) 3. Spacer (thick) (41 used) 4. Spacer (thin) (2 used) 5. Groomer blade (40 used) 6. Broomer brush (5 used) 7. Broomer strap (4 used) 4 3 1 2 5 7 6 Inspect groomer reel blades frequently for da...

Reelmaster 5010- H Groomer Page 8 - 16 Height Adjuster Assembly Figure 18 1. Groomer plate (drive side) 2. Shoulder bolt 3. Ball joint rod 4. Jam nut 5. Compression spring 6. Flange head screw 7. LH lower ramp 8. External snap ring 9. LH upper ramp 10. Bushing 11. Flat washer 12. Groomer adjuster 13...

Reelmaster 5010- H Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS 2 . . . . . . . HYDRAULIC SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATIC 4 . . . . . . . . . . . . . . . . . . . . WIRE HARNESS DRAWINGS Main Wire H...

Reelmaster 5010- H Foldout Drawings Page 9 - 2 Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R ...

Page 9 - 4 Electrical Schematic Reelmaster 5010- H All relays and solenoids are shown as de- energized.All ground wires are black. WIRE COLOR ABBREVIATIONS. NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR

Page 9 - 6 Reelmaster 5010- H Main Wire Harness Drawing

Page 9 - 7 Reelmaster 5010- H Main Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.

Page 9 - 8 Reelmaster 5010- H Seat Wire Harness Drawing NOTE CLOCK POSITION

Page 9 - 9 Reelmaster 5010- H Seat Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION.