Page 1: Service Manual
IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2006, 2007, 2009, 2012...
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System Safety Instructions ......1 -- 2 General Information .
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Page 5 Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Before Operating ......While Operating .
Page 6: Safety Instructions
Additional copies of the Operator’s Manual are available on the internet at www.Toro.com. B. Do not remove machine fuel tank cap while en- gine is hot or running.
Page 7: Maintenance And Service
Toro replacement parts and other parts of the body away from the cutting units and accessories. Replacement parts and accessories made other moving parts.
Page 8: Jacking Instructions
Reelmaster. If any decal becomes illegible or damaged, install a new decal. Part numbers for decals are listed in your Part Catalogs. Order replacement decals from your Autho- rized Toro Distributor. Rev. B Safety Page 1 - - 4...
Page 9: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .
Page 10: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Reelmaster 5010 Series...
Page 11: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 12 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 13 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 14 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...
Page 15: General Information
Service and repair parts for Kubota diesel engines are troubleshooting, testing and repair of the Kubota diesel supplied through your local Toro Distributor. If a parts list engine used in the Reelmaster 5010 Series of ma- is not available, be sure to provide your distributor with chines.
Page 16 Specifications: Reelmaster 5210 Item Description Make / Designation Kubota D1105, 4- -stroke, Liquid Cooled, OHV Diesel Number of Cylinders Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.53 in (1123 cc) Compression Ratio 22.0:1 Firing Order...
Page 17 Specifications: Reelmaster 5410 and 5510 Item Description Make / Designation Kubota V1505, 4- -stroke, Liquid Cooled, OHV Diesel Number of Cylinders Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 91.4 in (1498 cc) Compression Ratio 21.0:1 Firing Order 1 (fan end) - - 3 - - 4 (flywheel end) - - 2...
Page 18 Specifications: Reelmaster 5610 Item Description Make / Designation Kubota V1505, 4- -stroke, Liquid Cooled, OHV, Turbocharged Diesel Number of Cylinders Bore x Stroke 3.07” x 3.09“ (78 mm x 78.4 mm) Total Displacement 91.4 in (1498 cc) Compression Ratio 21.0:1 Firing Order 1 (fan end) - - 3 - - 4 (flywheel end) - - 2 Dry Weight (approximate)
Page 19 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 in the speed control lever. 1.
Page 20: Fuel System
Service and Repairs Fuel System RIGHT FRONT Figure 2 1. Fuel cap 7. Suction fitting 12. Fuel gauge 13. Hose clamp 2. Bushing 8. Hose clamp 3. Washer head screw (3 used) 9. Hose clamp 14. Draincock 4. Flange nut (3 used) 10.
Page 21 Fuel Tank Removal (Fig. 2) DANGER 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Because diesel fuel is highly flammable, use caution when storing or handling it. Do not 2.
Page 22: Air Cleaner
Air Cleaner REELMASTER 5410- -D/5510- -D SHOWN THREAD SEALANT RIGHT FRONT Figure 3 1. Air cleaner assembly 7. Hose 12. Flange nut 2. Hex nut 8. Hose 13. Cap screw (2 used) 3. Bolt 9. Mount bracket 14. Flange head screw (4 used) 4.
Page 23 Removal (Fig. 3) REELMASTER 5610- -D 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Raise hood. 2. Remove air cleaner components as needed using Figures 3, 4 and 5 as guides. 3.
Page 24: Exhaust System
Exhaust System REELMASTER 5410- -D/5510- -D SHOWN RIGHT FRONT Figure 6 1. Gasket 8. Cap screw 15. Rubber hanger 2. Lock washer (4 used) 9. Isolator plate 16. Spacer (2 used) 3. Flange nut (4 used) 10. Hex nut (2 used) 17.
Page 25 Removal (Fig. 6) Installation (Fig. 6) 1. Park machine on a level surface, lower cutting units, NOTE: Make sure muffler flange and exhaust manifold stop engine, engage parking brake and remove key sealing surfaces are free of debris or damage that may from the ignition switch.
Page 26 5010 series machines. Reelmaster 5410 and 5510 ma- 1. Park machine on a level surface, lower cutting units, chines use the same radiator. Reelmaster 5210 and stop engine, engage parking brake and remove key 5610 machines use different radiators. All models use from the ignition switch.
Page 27 3. Secure fan shroud and radiator to radiator frame with CAUTION removed flange head screws and flange nuts. Make sure that at least .250” (6.4 mm) clearance exists at all points between shroud opening and fan. Do not open radiator cap or drain coolant if the radiator or engine is hot.
Page 28 Engine 34 to 42 ft- -lb (47 to 56 N- -m) RIGHT FRONT Figure 9 1. Engine assembly 10. Fan spacer 19. Spring washer 2. Cap screw (12 used) 11. Cap screw (4 used) 20. Hex nut 3. Temperature sender 12.
Page 29 Removal (Fig. 9) 1. Park machine on a level surface, lower cutting units, stop engine and remove key from the ignition switch. Chock wheels to keep the machine from moving. 2. Open hood. 3. Disconnect negative (--) and then positive (+) battery cables from the battery.
Page 30 9. Disconnect hydraulic transmission drive shaft from Installation (Fig. 9) engine (see Hydraulic Transmission Drive Shaft Re- 1. Locate machine on a level surface with cutting units moval in the Service and Repairs section of Chapter 4 lowered and key removed from the ignition switch. -- Hydraulic System).
Page 31 7. Remove plugs installed in hoses during disassem- 9. Install air cleaner (see Air Cleaner Installation in this bly. Connect hoses to the engine: section). A. Connect fuel supply and fuel return hoses to en- 10.Install exhaust system to machine (see Exhaust gine fittings (Fig.
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Page 33 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .
Page 34: Specifications
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 pump Section P1/P2 Displacement (per revolution) (RM 5210 & 5410) 0.50 Cubic Inches (8.3 cc) Section P1/P2 Displacement (per revolution) (RM 5510 &...
Page 35: General Information
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 information when servicing the machine. Check Hydraulic Fluid The hydraulic system on Reelmaster 5010 series ma- chines is designed to operate on high quality hydraulic fluid.
Page 36: Hydraulic Hoses
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such WARNING as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi- tions or mishandling during operation and maintenance. These conditions can cause damage or premature dete- Before disconnecting or performing any work rioration.
Page 37 SAE Straight Thread O- -Ring Port - - Non- -adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches or any foreign material. 2. Always replace the O--ring seal when this type of fit- ting shows signs of leakage. O- -Ring 3.
Page 38: Relieving Hydraulic System Pressure
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- To relieve hydraulic pressure in lift circuit, start engine draulic system, all pressure in the hydraulic system and fully lower the cutting units. Turn key switch to OFF must be relieved.
Page 39: Hydraulic Schematics
Hydraulic Schematics The hydraulic schematics for Reelmaster 5010 series machines are located in Chapter 9 -- Foldout Drawings. Reelmaster 5010 Series Page 4 - - 7 Hydraulic System (Rev. C)
Page 40: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams SVRV Figure 8 Hydraulic System (Rev. C) Page 4 - - 8 Reelmaster 5010 Series...
Page 41: Traction Circuit
Traction Circuit The hydraulic traction circuit consists of a variable dis- Reverse Direction placement piston pump (P5) connected in a closed loop, The traction circuit operates essentially the same in re- parallel circuit to two (2) orbital roller vane wheel motors. verse as it does in the forward direction.
Page 42 SVRV Figure 10 Hydraulic System (Rev. C) Page 4 - - 10 Reelmaster 5010 Series...
Page 43: Mow Circuit
Mow Circuit A four section gear pump is coupled to the piston (trac- P1 and is directed to reel speed control valve (FC1). tion) pump. Gear pump sections (P1) and (P2) supply Flow through the speed control valve is pressure com- hydraulic flow for the mow circuit.
Page 44: Lift Circuit: Raise Cutting Units
TO STEERING & CHARGE TO FRONT CIRCUIT MOW CIRCUIT C4 L C1 L SVRV TO REAR MOW CIRCUIT C5 L 100 MESH PUMP (P5) CV23 SUCTION INTERNAL STRAINER CASE DRAIN C2/3 L C2/3 LIFT CONTROL MANIFOLD RIGHT FRONT LEFT FRONT FRONT CENTER FROM MOW...
Page 45 Lift Circuit: Raise Cutting Units A four section gear pump is coupled to the piston (trac- Raise Cutting Units (Fig. 11) tion) pump. Gear pump section (P4) supplies hydraulic When the joystick is moved to the raise position, sole- flow to the lift control manifold and ultimately for the lift noid valve (SVRV) energizes along with solenoid valves cylinders.
Page 46: Lift Circuit: Lower Cutting Units
TO STEERING & CHARGE TO FRONT CIRCUIT MOW CIRCUIT C4 L C1 L SVRV TO REAR MOW CIRCUIT C5 L 100 MESH PUMP (P5) CV23 SUCTION INTERNAL STRAINER CASE DRAIN C2/3 LIFT C2/3 L CONTROL MANIFOLD RIGHT FRONT LEFT FRONT FRONT CENTER FROM MOW...
Page 47 Lift Circuit: Lower Cutting Units A four section gear pump is coupled to the piston (trac- Lower Cutting Units (Fig. 12) tion) pump. Gear pump section (P4) supplies hydraulic When the joystick is moved to the lower position, sole- flow to the lift control manifold and ultimately for the lift noid valve (SVRV) energizes along with solenoid valves cylinders.
Page 48 Figure 13 Hydraulic System (Rev. C) Page 4 - - 16 Reelmaster 5010 Series...
Page 49: Steering Circuit
Steering Circuit A four section gear pump is coupled to the piston (trac- cylinder flows back through the steering control spool tion) pump. Gear pump section P3 supplies hydraulic valve and then out of the steering control valve through flow to the steering control valve and for the traction the T port.
Page 50: Special Tools
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 on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 51 (TOR6011) to machine hydraulic traction system components. Figure 17 O- -Ring Kit Toro Part Number: 16- -3799 The kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connec- tion is loosened.
Page 52: Hydraulic Test Fitting Kit
Toro Part Number: TOR6011 NOTE: Use of Hydraulic Hose Kit TOR6007 is recom- mended when using the high flow hydraulic filter kit. NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft- -lb (34 N- -m).
Page 53: Measuring Container
Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft. Toro Part Number: TOR6004 Figure 21 Measuring Container Part Number: TOR4077 Use this graduated container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Page 54: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys- Continued use of an improperly functioning hydraulic tem is best diagnosed with the use of proper testing system could lead to extensive hydraulic component equipment and a thorough understanding of the com- damage.
Page 55: Traction Circuit Problems
Traction Circuit Problems Problem Possible Cause Neutral is difficult to find or unit oper- Traction control linkage is misadjusted, disconnected, binding or ates in one direction only damaged. Piston (traction) pump check relief valve is not seating or is dam- aged (NOTE: Piston (traction) pump check relief valves for forward and reverse are identical and can be reversed for testing pur- poses).
Page 56: Mow Circuit Problems
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 components are also dam- aged) Wheel motors will not hold load Charge pressure is low.
Page 57: Lift Circuit Problems
Lift Circuit Problems Problem Possible Cause Single cutting unit lifts slowly or not Cutting unit has excessive debris buildup. at all Lift arm or lift cylinder is binding. Pilot piston in lift control manifold is stuck or damaged. Lift cylinder leaks internally. Flow control orifice in lift control manifold for the affected cutting unit is plugged or damaged.
Page 58: Steering Circuit Problems
Lift Circuit Problems (Continued) Problem Possible Cause Single cutting unit lowers very slowly Lift arm or lift cylinder is binding. or not at all Lift cylinder is damaged. Flow control orifice in lift control manifold for the affected cutting unit is plugged or damaged. Check valve in lift control manifold (CV1, CV4, CV5 and CV23) is stuck or damaged.
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Page 60: Testing
Testing The most effective method for isolating problems in the 2. Review all test steps before starting the test proce- hydraulic system is by using hydraulic test equipment dure. such as pressure gauges and flow meters in the circuits 3. Before testing, check all control linkages for improp- during various operational checks (see the Special er adjustment, binding or broken parts.
Page 61 Which Hydraulic Tests Are Necessary? 3. If a lift circuit problem exists, consider performing one or more of the following tests: Lift Relief Valve (R6) Before beginning any hydraulic test, identify if the prob- Pressure, Gear Pump (P4) Flow and/or Lift Cylinder In- lem is related to the traction circuit, cutting (mow) circuit, ternal Leakage Tests.
Page 62: Traction Circuit Relief Valve (R3) And (R4) Pressure Test
Traction Circuit Relief Valve (R3) and (R4) Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) FORWARD (R3) RELIEF VALVE TEST SHOWN EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION INTERNAL...
Page 63 2WD MACHINE SHOWN CAUTION Before opening hydraulic system, operate all hy- draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information section of this chapter. NOTE: If machine is equipped with optional CrossTrax- RIGHT AWD, reverse relief pressure test ports are located on FRONT...
Page 64: Traction Circuit Charge Pressure Test
Traction Circuit Charge Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION INTERNAL STRAINER CASE DRAIN FORWARD TRACTION WHEEL...
Page 65 charge relief valve and valve seat in the traction CAUTION pump (see Traction Pump Service in the Service and Repairs section of this chapter). Also, consider a worn or damaged gear pump (P3) (see Gear Pump (P3) Flow Test in this section). Before opening hydraulic system, operate all hy- draulic controls to relieve system pressure and NOTE: If gear pump (P3) is worn or damaged, both...
Page 66: Gear Pump (P3) Flow Test
Gear Pump (P3) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH INTERNAL SUCTION...
Page 67 10.While watching pressure gauges, slowly close the CAUTION tester flow control valve until 800 PSI (55 bar) is ob- tained on gauge. FLOW TESTER READING TO BE: A pump in good Before opening hydraulic system, operate all hy- condition should have a flow of approximately 4.7 draulic controls to relieve system pressure and GPM (17.8 LPM) at 800 PSI (55 bar).
Page 68: Front Wheel Motor Efficiency Test
Front Wheel Motor Efficiency Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION INTERNAL STRAINER CASE DRAIN TESTER FORWARD TRACTION...
Page 69 13.If total leakage for the front wheel motors is more CAUTION than 1.5 GPM (5.7 LPM), one or both of the motors may be faulty. Individual front wheel motor testing is neces- sary. Before opening hydraulic system, operate all hy- 14.To test individual front wheel motors: draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
Page 70: Piston (Traction) Pump Flow Test
Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION INTERNAL...
Page 71 4. Make sure that traction pedal is adjusted to the neu- 12.Observe flow gauge. Flow indication should be tral position. Also, ensure that traction pump is at full approximately 28 GPM (106 LPM). stroke when traction pedal is pushed into fully forward 13.Release traction pedal to the neutral position, open position.
Page 72: Relief Valve (R1) And (R2) Pressure Test
Relief Valve (R1) and (R2) Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD P1 P2 EXTERNAL CASE DRAIN 100 MESH SUCTION INTERNAL STRAINER CASE DRAIN FORWARD TRACTION WHEEL MOTORS FROM STEERING CONTROL VALVE REAR MOW CIRCUIT C.U.
Page 73 IMPORTANT: When performing this test, do not CAUTION hold over relief any longer than necessary to obtain pressure reading. 11. Watch pressure gauge carefully while slowly closing Before opening hydraulic system, operate all hy- the tester flow control valve. draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
Page 74: Gear Pump (P1) And (P2) Flow Test
Gear Pump (P1) and (P2) Flow Test (Using Tester with Pressure and Flow Capabilities) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT GEAR PUMP (P1) TO LIFT CONTROL MANIFOLD FLOW TEST SHOWN TESTER P1 P2 EXTERNAL CASE DRAIN 100 MESH SUCTION INTERNAL STRAINER CASE...
Page 75 10.Open the tester flow control valve and stop the en- CAUTION gine. Record test results. 11. If flow is less than 5.4 GPM (20.6 LPM) on a RM5210/5410 machine, less than 7.1 GPM (27 LPM) on Before opening hydraulic system, operate all hy- a RM5510/5610 machine or a pressure of 2000 PSI draulic controls to relieve system pressure and (138 bar) cannot be obtained, consider that a pump...
Page 76: Reel Drive Motor Efficiency Test
Reel Drive Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) Case Drain Hose Outlet Hose FRONT OF MACHINE High Pressure RM5510/5610 FRONT MOW CIRCUIT SHOWN Low Pressure Install tester in series Case Drain between fitting and hose at Flow motor outlet.
Page 77 Before opening hydraulic system, operate all hy- nected motor case drain hose into a container gra- draulic controls to relieve system pressure and duated in ounces or milliliters (e.g. Toro #TOR4077) and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- collect hydraulic fluid for 15 seconds.
Page 78: Reel Drive Motor Cross--Over Relief Pressure Test (Reelmaster 5510 And 5610)
Reel Drive Motor Cross- -Over Relief Pressure Test (Reelmaster 5510 and 5610) Use a tee fitting to install pressure gauge in both inlet and outlet lines of motor being tested. NOTE: Inlet is front hose. Outlet is rear hose. Front Front Front Hose...
Page 79 Procedure for Reel Drive Motor Cross- -Over Relief 9. One person should sit on the seat and operate the Pressure Test machine while another person closely monitors both pressure gauges connected to the reel motor. Make 1. Make sure hydraulic oil is at normal operating tem- sure that engine speed is at low idle position (1200 perature by operating the machine under load for RPM) and press PTO switch to ON.
Page 80: Lift Relief Valve (R6) Pressure Test
Lift Relief Valve (SVRV) Pressure Test TO STEERING PRESSURE CONTROL VALVE GAUGE TO MOW CONTROL (FRONT CUTTING UNITS) C4 L TO MOW CONTROL C1 L (REAR CUTTING UNITS) PUMP (P5) C5 L INTERNAL 100 MESH CASE SUCTION DRAIN CV23 STRAINER LIFT C2/3 L CONTROL...
Page 81 5. Thoroughly clean test port (G4) on lift control man- 10.If measured pressure is incorrect, remove solenoid ifold. Access to test port can be obtained from below the relief valve (SVRV) on lift control manifold and clean or front of the machine. Connect a 5000 PSI (350 bar) pres- replace valve (see Lift Control Manifold Service in the sure gauge to test port.
Page 82: Gear Pump (P4) Flow Test
Gear Pump (P4) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE TO MOW CONTROL TESTER (FRONT CUTTING UNITS) C4 L TO MOW CONTROL C1 L (REAR CUTTING UNITS) C5 L PUMP (P5) 100 MESH INTERNAL CASE SUCTION...
Page 83 4. Raise and prop operator seat to allow access to hy- 13.After testing is completed, make sure that engine is draulic pump. stopped, then relieve hydraulic system pressure (See Relieving Hydraulic System Pressure in the General In- 5. Thoroughly clean both ends of the hydraulic tube formation section of this chapter).
Page 84: Lift Cylinder Internal Leakage Test
Lift Cylinder Internal Leakage Test TO STEERING CONTROL VALVE TO MOW CONTROL (FRONT CUTTING UNITS) C4 L TO MOW CONTROL C1 L (REAR CUTTING UNITS) C5 L PUMP (P5) 100 MESH INTERNAL CASE SUCTION CV23 DRAIN STRAINER LIFT CONTROL C2/3 L C2/3 MANIFOLD RIGHT...
Page 85 IMPORTANT: When capping lift cylinder fitting and hydraulic hose end, use a steel cap and plug to en- sure that fluid leakage will not occur. Plastic plugs will not hold hydraulic pressure that will be devel- oped during this test procedure. 4.
Page 86: Steering Relief Valve (R10) Pressure Test
Steering Relief Valve (R10) Pressure Test TO MOW CONTROL MANIFOLD (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL MANIFOLD (REAR CUTTING UNITS) PUMP (P5) 100 MESH DRAIN SUCTION INTERNAL STRAINER CASE DRAIN TO TRACTION CHARGE CIRCUIT STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL...
Page 87 Procedure for Steering Relief Valve Pressure Test: 12.If specification is not met, repair or replace steering control valve (relief valve in steering control valve is not 1. Make sure hydraulic oil is at normal operating tem- replaceable). perature by operating the machine under load for approximately ten (10) minutes.
Page 88: Steering Cylinder Internal Leakage Test
Steering Cylinder Internal Leakage Test STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE PLUG LOOK FOR LEAKAGE STEERING CYLINDER (FULLY EXTENDED) Figure 54 The steering cylinder internal leakage test should be NOTE: Steering circuit operation will be affected by performed if a steering problem is identified.
Page 89 Procedure for Steering Cylinder Internal Leakage Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine under load for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered and PTO switch off.
Page 90: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. If component failure is severe or hydraulic system is tem, park machine on a level surface, engage parking contaminated, flush hydraulic system (see Flush Hy- brake, lower cutting units and stop engine.
Page 91: Check Hydraulic Lines And Hoses
Check Hydraulic Lines and Hoses Check hydraulic lines and hoses daily for leaks, kinked CAUTION lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating the machine. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
Page 92: Flush Hydraulic System
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 8. Make sure traction pedal is in neutral and the PTO there is a severe component failure or the system is switch is OFF. Turn ignition key switch to start; engage contaminated.
Page 93: Filtering Closed--Loop Traction Circuit
(5) minutes. and key removed from ignition switch. IMPORTANT: If using a filter that is not the Toro high 2. Raise and support machine so all wheels are off the flow filter that is bi- -directional, do not press the ground (see Jacking Instructions in Chapter 1 -- Safety).
Page 94: Hydraulic System Start--Up
Hydraulic System Start- -up NOTE: When initially starting the hydraulic system with 7. Make sure traction pedal is in neutral and the PTO new or rebuilt components such as pumps, wheel mo- switch is OFF. Turn ignition key switch to start; engage tors or lift cylinders, it is important that this start--up pro- starter for ten (10) seconds to prime hydraulic pumps.
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Page 96: Hydraulic Reservoir
Hydraulic Reservoir 18 33 RIGHT FRONT Figure 57 1. Suction strainer 16. Hydraulic hose 31. Filter screen 2. Breather adapter 17. Screw (8 used) 32. Hinge bracket 3. Breather 18. Lock nut (8 used) 33. Hinge plate 4. Plastic plug 19.
Page 97 Removal (Fig. 57) Installation (Fig. 57) 1. Tilt hydraulic reservoir cover up to access reservoir. 1. If fittings were removed from reservoir, lubricate and place new O--rings onto fittings. Install fittings into reser- 2. Thoroughly clean hydraulic hose ends and fittings on voir openings using marks made during the removal hydraulic reservoir to prevent hydraulic system contami- process to properly orientate fittings.
Page 98: Hydraulic Pump Drive Shaft
Hydraulic Pump Drive Shaft 34 to 42 ft- -lb (46 to 56 N- -m) Antiseize RIGHT Lubricant FRONT Figure 58 1. Piston (traction) pump 5. Cap screw (2 used) 8. Drive shaft assembly 2. Flange nut (2 used) 6. Engine flywheel 9.
Page 99 Removal (Fig. 58) Installation (Fig. 58) 1. Park the machine on a level surface, engage parking 1. Apply antiseize lubricant to traction pump input shaft. brake, lower cutting units and stop engine. Remove key 2. Position drive shaft assembly to engine and pump in- from the ignition switch.
Page 100: Hydraulic Pump Assembly
Hydraulic Pump Assembly RIGHT FRONT Antiseize Lubricant Figure 60 1. Drive shaft assembly 19. Cap screw 36. Flange nut (2 used) 2. Cap screw (2 used) 20. Bracket 37. Pump support bracket 3. Flange head screw (2 used) 21. Traction cable ball joint 38.
Page 101 Removal (Fig. 60) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.
Page 102 4. Carefully lower pump assembly to machine frame. 9. Position traction control cable to traction pump lever and secure plate (item 10) to pump lever with cap screw 5. Secure pump assembly to machine frame with two and lock nut. Secure cable bracket to traction pump with (2) flange screws and flange nuts.
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Page 104: Piston (Traction) Pump Service
Piston (Traction) Pump Service 32 33 Figure 62 1. Traction pump housing 20. Screw 39. Slotted pin 2. Auxiliary shaft 21. Screw 40. End cap gasket 3. Retaining ring 22. Jam nut 41. Seal kit 4. Ball bearing 23. Bracket 42.
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Page 106: Gear Pump Service
Gear Pump Service 33 ft- -lb (45 N- -m) 33 ft- -lb (45 N- -m) Figure 63 1. Front cover 9. Body 17. Drive gear 2. Dowel pin (16 used) 10. Flange (3 used) 18. Driven gear 3. Square section seal (8 used) 11.
Page 107 IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassem- bled in the same position. Do not touch the gear sur- faces as residue on hands may be corrosive to gear DIAGONAL LINE finish.
Page 108: Front Wheel Motor
Front Wheel Motor STANDARD 2WD MACHINE WITH PARKER WHEEL MOTORS SHOWN 80 to 100 ft- -lb (109 to 135 N- -m) 250 to 350 ft- -lb (339 to 474 N- -m) RIGHT 70 to 90 ft- -lb (95 to 122 N- -m) FRONT Figure 65 1.
Page 109 NOTE: Machines produced with serial number below STANDARD 2WD MACHINE WITH 311000600 were produced with Parker brand front EATON WHEEL MOTORS SHOWN wheel motors. Figure 65 shows the front axle assembly with Parker wheel motors. Machines with serial number above 311000600 were produced with Eaton brand front wheel motors.
Page 110 11. Disconnect hydraulic lines from fittings on wheel mo- 5. Install key into the wheel motor shaft keyslot. Align tor. Allow lines to drain into a suitable container. wheel hub with key and slide wheel hub onto motor shaft. Secure hub with lock nut. 12.Put caps or plugs on disconnected lines and fittings to prevent contamination.
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Page 112: Wheel Motor Service (Parker)
Wheel Motor Service (Parker) 45 to 55 ft- -lb (61 to 75 N- -m) Figure 68 1. Cap screw (7 used) 10. Rotor 18. Inner bearing 2. End cover 11. Wear plate 19. Shaft seal 3. Body seal (5 used) 12.
Page 113 Front Wheel Motor Service (Eaton) 45 to 55 ft- -lb (61 to 75 N- -m) Figure 69 1. Cap screw (7 used) 8. Valve 15. Output shaft 2. End cap 9. Dowel pin (4 used) 16. Bearing race (2 used) 3.
Page 114: Mow Control Manifold
Mow Control Manifold RIGHT FRONT Figure 70 1. Mow control manifold 8. O- -ring 15. O- -ring 2. O- -ring 9. Hydraulic tube 16. Hydraulic hose 3. Diagnostic fitting 10. O- -ring 17. Hydraulic hose 4. Dust cap 11. Hydraulic fitting 18.
Page 115 Removal (Fig. 70) 9. Remove three (3) flange head screws that secure manifold to machine frame. 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key 10.Remove manifold block from machine. from the ignition switch.
Page 116: Mow Control Manifold Service
Mow Control Manifold Service 41 ft- -lb (55 N- -m) 40 ft- -lb (54 N- -m) 40 ft- -lb (54 N- -m) 198 in- -lb (22 N- -m) 30 ft- -lb (40 N- -m) 41 ft- -lb (55 N- -m) 165 in- -lb (18.6 N- -m) 25 ft- -lb...
Page 117 Mow Control Manifold Service C. Push spool down until O--ring and back--up ring are exposed on bottom of mow manifold. Remove 1. Make sure the manifold is thoroughly cleaned before lower O--ring and back--up ring from spool. removing any cartridge valve. D.
Page 118 6. Visually inspect the manifold port for damage to the E. If handle was removed from spool, position spool sealing surfaces, damaged threads and contamination. so handle location of spool is between stop pins. Ap- ply Loctite 603 Retaining Compound (or equivalent) 7.
Page 119 11. If solenoid coil was removed: D. Place compression spring and detent pin into handle cap. Use a small amount of grease to hold A. Carefully install coil onto the cartridge valve. detent pin in place. B. Install nut and torque nut to 48 to 60 in- -lb (5.4 to E.
Page 120: Lift Control Manifold
Lift Control Manifold 36 to 40 ft- -lb (48 to 54 N- -m) RIGHT 36 to 40 ft- -lb FRONT (48 to 54 N- -m) Figure 75 1. Lift control manifold 9. Hydraulic hose 17. Hydraulic tube 2. Flange head screw 10.
Page 121 Removal (Fig. 75) IMPORTANT: When installing orifice in manifold (Fig. 76), make sure that orifice is flat in the base 1. Park the machine on a level surface, engage parking of the fitting cavity. Manifold damage is possible brake, lower cutting units and stop engine. Remove key if the orifice is cocked in the cavity.
Page 122: Lift Control Manifold Service
Lift Control Manifold Service 48 to 60 in- -lb (5.4 to 6.7 N- -m) 25 ft- -lb 25 ft- -lb (33 N- -m) (33 N- -m) 48 to 60 in- -lb 48 to 60 in- -lb (5.4 to 6.7 N- -m) (5.4 to 6.7 N- -m) 20 ft- -lb 20 ft- -lb...
Page 123 For lift control manifold service procedures, see Mow 10 ft- -lb Control Manifold Service in this section. Refer to Figure 10 ft- -lb (17 N- -m) 77 for cartridge valve installation torque. Refer to Fig- (17 N- -m) ures 77 and 78 for hydraulic fitting installation torque val- ues.
Page 124: Crosstrax
CrossTrax AWD (Optional Kit) Manifold RIGHT FRONT Figure 79 1. AWD manifold 6. Hydraulic fitting (7 used) 11. Cap screw (3 used) 2. Hydraulic tube 7. O- -ring 12. Lock washer (3 used) 3. Hydraulic tube 8. Dust cap (2 used) 13.
Page 125 6. Put caps or plugs on disconnected lines and fittings 2. Position manifold and three (3) spacers to frame to prevent contamination. bracket. Install three (3) lock washers and cap screws but do not fully tighten. 7. Support manifold to prevent it from falling. Remove three (3) cap screws and lock washers that secure man- 3.
Page 126: Crosstrax Tm Awd (Optional Kit) Manifold Service
CrossTrax AWD (Optional Kit) Manifold Service 220 in- -lb 25 ft- -lb (24.8 N- -m) (33 N- -m) 220 in- -lb (24.8 N- -m) 25 ft- -lb (33 N- -m) 220 in- -lb (24.8 N- -m) 46 ft- -lb (62 N- -m) 120 in- -lb (13.5 N- -m) Figure 80...
Page 127 This page is intentionally blank. Reelmaster 5010 Series Page 4 - - 95 Hydraulic System (Rev. C)
Page 128: Cutting Reel Motor
Cutting Reel Motor RIGHT FRONT Figure 81 1. Hydraulic reel motor (#4) 8. O- -ring 15. Hydraulic reel motor (#1) 2. O- -ring 9. Hydraulic hose 16. Hydraulic reel motor (#5) 3. 90 hydraulic fitting 10. Hydraulic fitting 17. Hydraulic hose 4.
Page 129 Installation (Fig. 81) CAUTION 1. If hydraulic fittings were removed from motor, lubri- cate new O--rings, position O--rings to fittings and install fittings into motor ports (see Hydraulic Fitting Installation Before opening hydraulic system, operate all hy- in the General Information section of this chapter). Make draulic controls to relieve system pressure and sure that fittings are orientated correctly.
Page 130: Cutting Reel Motor Service
7. O- -ring 14. Front bearing block NOTE: Sauer--Danfoss cutting reel motors are used on Reelmaster 5210 and 5410 machines. Bosch reel mo- DIAGONAL LINE tors are used on Reelmaster 5510 and 5610 machines. Reel motors are not interchangeable. Service proce- dures for both types of motors are the same.
Page 131 2. Use a marker to make a diagonal line across the front flange, body and rear cover for assembly purposes (Fig. 84). IMPORTANT: Avoid using excessive clamping pressure on the motor flange to prevent damage. 3. Clamp front flange of motor in a vise with the shaft end down.
Page 132 2. Clean all motor components with solvent. Dry all 4. Install lubricated O--rings to the body. parts with compressed air. 5. Lubricate gear faces and bearing surfaces of drive 3. Inspect drive gear, idler gear and bearing blocks gear, idler gear and bearing blocks with clean hydraulic (Fig.
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Page 134: Lift Cylinder
Lift Cylinder 67 to 83 ft- -lb (91 to 112 N- -m) RIGHT 67 to 83 ft- -lb (91 to 112 N- -m) FRONT Figure 88 1. Lift cylinder 6. Hydraulic hose 10. Hydraulic hose 2. Pivot shaft 7. O- -ring 11.
Page 135 Removal (Fig. 88) Installation (Fig. 88) 1. Park the machine on a level surface, engage the 1. If hydraulic fittings were removed from lift cylinder, lu- parking brake, lower the cutting units and stop the en- bricate new O--rings, position O--rings to fittings and gine.
Page 136: Lift Cylinder Service
Lift Cylinder Service 30 to 35 ft- -lb (41 to 47 N- -m) Figure 89 1. Grease fitting 6. Retaining ring 11. O- -ring 2. Shaft 7. Back up washer 12. O- -ring 3. Wiper 8. O- -ring 13. Lock nut 4.
Page 137 3. Using a spanner wrench, rotate head clockwise until 2. Coat new O--rings, back--up washer and other seals the edge of the retaining ring appears in the barrel open- with clean hydraulic oil. ing. Insert a screwdriver under the beveled edge of the A.
Page 138: Steering Control Valve
Steering Control Valve ANTISEIZE LUBRICANT RIGHT FRONT 7 to 10 ft- -lb (9.5 to 13.5 N- -m) ANTISEIZE LUBRICANT 20 to 26 ft lb (28 to 35 N- -m) Figure 90 1. Steering control valve 6. Lock nut 11. Hydraulic fitting (4 used) 2.
Page 139 7. Position steering column brace (item 13) to machine CAUTION and secure with four (4) flange head screws and flange nuts. 8. Slide rubber bellows to bottom of steering column. Before opening hydraulic system, operate all hy- draulic controls to relieve system pressure and 9.
Page 140: Steering Control Valve Service
Steering Control Valve Service 20 to 24 ft- -lb (27 to 33 N- -m) Figure 93 1. Screw (5 used) 10. Spool 19. Check ball 2. O- -ring (5 used) 11. Sleeve 20. Housing 3. End cover 12. Cross pin 21.
Page 141 This page is intentionally blank. Reelmaster 5010 Series Page 4 - - 109 Hydraulic System (Rev. C)
Page 142: Steering Cylinder
Steering Cylinder RIGHT FRONT Figure 94 1. Steering cylinder 6. 90 hydraulic fitting 11. Jam nut 2. Retaining ring 7. O- -ring 12. Cotter pin 3. Grease fitting 8. Hydraulic hose 13. Slotted hex nut 4. Hydraulic hose 9. Grease fitting 14.
Page 143 Removal (Fig. 94) 2. If removed, press ball joint into barrel and secure with retaining ring. 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the en- 3. If ball joint was removed from cylinder shaft, fully re- gine.
Page 144: Steering Cylinder Service
Steering Cylinder Service 30 to 35 ft- -lb (41 to 47 N- -m) Figure 96 1. Shaft 6. Back- -up ring 11. Cap seal 2. Wiper 7. O- -ring 12. Wear ring 3. U- -Cup 8. O- -ring 13. Lock nut 4.
Page 145 Inspection 3. Coat shaft with clean hydraulic oil. Slide head and piston onto the shaft. 4. Using a wrench on shaft flats to prevent shaft from CAUTION rotating, install lock nut. Torque lock nut from 30 to 35 ft- -lb (41 to 47 N- -m). Use eye protection such as goggles when using IMPORTANT: Prevent damage when clamping the compressed air.
Page 146: Oil Cooler
Oil Cooler REELMASTER 5410/5510 SHOWN RIGHT FRONT Figure 97 1. Screen assembly 7. Oil cooler 13. Cap screw (2 used) 2. Oil cooler bracket 8. Hydraulic hose (2 used) 14. Mount plate (2 used) 3. Cap screw (4 used) 9. Flat washer (8 used) 15.
Page 147 RIGHT FRONT 1. If removed, install hydraulic fittings, clamps and brackets to oil cooler using Figures 97 and 98 as guides. On Reelmaster 5210 machines (not shown), apply hy- Figure 98 draulic thread sealant on hydraulic fitting threads before installation.
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Page 149 Chapter 5 Electrical System Table of Contents GENERAL INFORMATION ..... PTO Switch ....... ELECTRICAL DIAGRAMS .
Page 150: Special Tools
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-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 151 Electronic Control Module (ECM) inputs and outputs can be checked using the Diagnostic Display. Toro Part Number for Diagnostic Display: 85- -4750 Toro Part Number for Overlay (English): 110- -0666 NOTE: Diagnostic Display overlays are available in several languages for your Reelmaster.
Page 152: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, there must be CAUTION a good understanding of the electrical circuits and com- ponents used on this machine (see Chapter 9 -- Electri- cal Diagrams). Remove all jewelry, especially rings and If the machine has any interlock switches by--passed, watches, before doing any electrical trouble- shooting or testing.
Page 153: Clearing Fault Codes
Fault Code (Lamp Flashes) Fault Description 1 -- 1 High engine temp warning occurred (PTO was shutdown by ECM) 1 -- 2 High engine temp shutdown occurred (engine was shutdown by ECM) 1 -- 3 Low engine oil pressure occurred 1 -- 4 Engine alternator fault occurred 1 -- 5...
Page 154: Diagnostic Display
Diagnostic Display Reelmaster 5010 machines are equipped with an Elec- 5. The “inputs displayed” LED, on lower right column of tronic Control Module (ECM) which controls machine the Diagnostic Display, should be illuminated. If “outputs electrical functions. The ECM monitors various input displayed”...
Page 155 Diagnostic Display ECM Inputs Fault Description TEMP WARN Excessive engine temperature: LED ON Normal engine temperature: LED OFF JOYSTICK LOWER Joystick moved forward: LED ON Joystick in neutral: LED OFF PTO ENABLE PTO switch ON: LED ON PTO switch OFF: LED OFF FR REELS DN Cutting units lowered: LED ON Cutting units raised: LED OFF...
Page 156: Verify Diagnostic Display Output Functions
NOTE: An open output (e.g. an unplugged connector or correctly illuminated, this indicates an ECM problem. a broken wire) cannot be detected with the Diagnostic If this occurs, contact your Toro Distributor for assis- Display. tance. 1. Park machine on a level surface, lower the cutting 7.
Page 157: Electronic Control Module Logic Chart
Electronic Control Module Logic Chart Each line of the following chart identifies the necessary Example: To start the engine with no operator in the component position (INPUTS) in order for the Electronic seat, when the ignition key is in start, the traction pedal Control Module (ECM) to energize the appropriate is in neutral and the parking brake is applied, the glow OUTPUTS for machine operation.
Page 158: Starting Problems
Starting Problems Problem Possible Causes All electrical power is dead, including gauges. Battery is discharged. Ignition switch or circuit wiring is faulty. Fusible link harness at the engine starter motor is faulty. Battery cables are loose or corroded. Main fuse (15 amp) to the ignition switch is faulty. Starter solenoid clicks, but starter will not crank.
Page 159 Starting Problems (Continued) Problem Possible Causes Engine cranks, but should not, when the traction pedal Traction neutral switch is out of adjustment. is depressed. Traction neutral switch or circuit wiring is faulty. Nothing happens when start attempt is made. Control Traction pedal is not in neutral position.
Page 160: General Run And Transport Problems
General Run and Transport Problems Problem Possible Causes Engine continues to run, but should not, when the Engine fuel stop solenoid is faulty. ignition switch is turned off. Ignition switch or circuit wiring is faulty. Main power relay or circuit wiring is faulty. Engine continues to run, but should not, when the Seat switch or circuit wiring is faulty.
Page 161: Cutting Unit Operating Problems
Cutting Unit Operating Problems Problem Possible Causes The cutting units remain engaged, but should not, with Seat switch or circuit wiring is faulty. no operator in the seat. Electronic Control Module is faulty. Cutting units run, but should not, when raised. Cutting Up limit switch or circuit wiring is faulty.
Page 162 Cutting Unit Operating Problems (Continued) Problem Possible Causes The cutting units do not run when placed in the Cutting units are not fully lowered to ground. backlap direction. Front or rear backlap switch or circuit wiring is faulty. Up limit switch or circuit wiring is faulty. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System).
Page 163: Turfdefender Tm Leak Detector (Optional)
TurfDefender Leak Detector (Optional) The optional TurfDefender is an electronic hydraulic 4. Turn the ignition switch to the RUN position, but do fluid leak detection device that fits inside the hydraulic not start machine. reservoir of your machine (Fig. 12). It is a pressure NOTE: Red text on the overlay decal refers to inputs based system which requires a sealed hydraulic reser- and green text refers to outputs.
Page 164 (raised or lowered), it is best to check oil level when hy- 5. Your Authorized Toro Distributor has additional draulic oil is cool and cutting units are raised. equipment to analyze TurfDefender system prob- 1.
Page 165 TURFDEFENDER V1.0 DIAGNOSTIC OUTPUT / INPUT INPUT / OUTPUT VALVE ON / TANK LEVEL HIGH / FLOAT LEVEL (TOP) FLOAT LOW VALVE OPEN CIRCUIT / TANK LEVEL OK / FLOAT LEVEL 2 RESET TOO OFTEN VALVE SHORT CIRCUIT/ TANK LEVEL LOW / FLOAT LEVEL 3 (UNUSED) Diagnostic Display Functions...
Page 166: Electrical System Quick Checks
9 Amps per glow plug (27 amps to- to the digital multimeter (refer to manufacturers’ instruc- tal on Reelmaster 5210 and 36 amps total on models tions) and set the multimeter to the correct scale. With with four cylinder engine). If low current reading is ob- the ignition switch in the OFF position, place the served, one (or more) glow plugs is faulty.
Page 167: Check Operation Of Interlock Switches
Check Operation of Interlock Switches The interlock system used on your Reelmaster includes CAUTION the seat switch, the traction neutral switch, the parking brake switch, the cutting unit up limit switch, the mow/ transport switch, the PTO switch and two (2) cutting unit The interlock switches are for the protection of backlap switches.
Page 168: Adjustments
Adjustments Traction Neutral Switch The traction neutral switch is a normally open proximity 4. After adjustment to the traction neutral switch, use switch that closes when the traction pedal is in the neu- the Diagnostic Display (see Special Tools in this chap- tral position.
Page 169: Parking Brake Switch
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bot- SERIAL NUMBER tom of the brake pedal (Fig. 19). BELOW 310000000 When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed.
Page 170: Up Limit Switch
Up Limit Switch The up limit switch is a normally open proximity switch that closes when the cutting units are in the lowered position. A bracket on the front, right lift arm acts as the sensing plate for the up limit switch (Fig. 21). Adjustment The up limit switch should be secured to the switch bracket at the midpoint of the bracket mounting slots.
Page 171: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- NOTE: See the Kubota Workshop Manual: 05 Series trically disconnect the component being tested from the Engine for additional electrical component repair in- circuit (e.g. unplug the ignition switch connector before formation.
Page 172: Indicator Lights
Indicator Lights Glow Plug Indicator Light 4. Ground terminals 1B and 2B (Fig. 24). The glow plug indicator light should come on when the 5. Both indicator lights should illuminate. ignition switch is placed in the RUN position prior to plac- 6.
Page 173: Hour Meter
Hour Meter The hour meter is located on the outside of the control arm. Hobbs 1. Remove control arm covers to gain access to hour QUARTZ meter and meter terminals (see Control Arm Disassem- 0 0 0 0 bly in the Service and Repairs section of this chapter). HOURS 2.
Page 174: Pto Switch
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, the switch and its circuit wiring should be tested as an ECM input with the Diagnostic Display (see Diagnostic Dis- play in the Troubleshooting section of this chapter).
Page 175: Traction Neutral Switch
Traction Neutral Switch The traction neutral switch is a normally open proximity 6. If the neutral switch tests correctly and a circuit prob- switch that closes when the traction pedal is in the neu- lem still exists, check wire harness (see Wiring Sche- tral position.
Page 176: Seat Switch
Seat Switch The seat switch is normally open and closes when the operator seat is occupied. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch is located di- rectly under the operator seat.
Page 177: Headlight Switch
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 Arm Disassembly in the Service and Repairs section of this chapter).
Page 178: Parking Brake Switch
Parking Brake Switch The parking brake switch is a normally open proximity 4. If parking brake switch is faulty, replace switch. Ad- switch. The parking brake switch is attached to the bot- just switch after installation (see Parking Brake Switch tom of the brake pedal.
Page 179: Up Limit Switch
Up Limit Switch The up limit switch is a normally open proximity switch 5. If the up limit switch tests correctly and a circuit prob- that closes when the cutting units are in the lowered lem still exists, check wire harness (see Wiring Sche- position.
Page 180: Joystick Raise And Lower Switches
Joystick Raise and Lower Switches Two micro switches for the joystick are located on the lift H. If the joystick switch tests correctly and a circuit control that is attached to the control arm. The rear problem still exists, check wire harness (see Wiring switch on the control is used to lower (and engage) the Schematic and Circuit Drawings in Chapter 9 -- Elec- cutting units and the front switch to raise (and disen-...
Page 181: Mow/Transport Switch
Mow/Transport Switch The mow/transport switch is a normally closed proximity NOTE: When installing the mow/transport switch on switch that opens when the mow stop lever is placed in machines with serial numbers below 310000000, place the transport position. The sensing plate for the mow/ switch plate tab into switch mounting hole that is closest transport switch is the mow stop lever.
Page 182: Backlap Switches
Backlap Switches The front and rear backlap switches are normally closed ball switches that are in the normal, closed state when the backlap lever is in the backlap position. When the backlap lever is in the mow position, the switch opens. The backlap switches are attached to the hydraulic mow control manifold located under the seat (Fig.
Page 183: Start Relay
Start Relay The start relay is used in the engine starting circuit. 6. Disconnect voltage from terminal 85 and multimeter When energized by the Electronic Control Module lead from terminal 87. (ECM), the start relay provides a current path to ener- 7.
Page 184: Main Power And Glow Relays
Main Power and Glow Relays The Reelmaster electrical system includes two identical 6. Disconnect voltage and test leads from the relay ter- relays for current control. The main power and glow re- minals. lays are attached to a frame bracket under the hood next 7.
Page 185: Electronic Control Module (Ecm)
Electronic Control Module (ECM) The Toro Electronic Control Module (ECM) senses the condition of various switches (inputs) and directs power output to allow certain machine functions. The ECM is located behind the control arm access cover next to the fuse block (Fig. 44). The handheld Diagnostic Display...
Page 186: Diode Assembly
Diode Assembly A diode assembly (Fig. 45) is used in the Reelmaster en- gine wire harness (see wire harness drawings in Chap- ter 9 -- Electrical Diagrams). The diode is used for circuit protection from voltage spikes that occur when the start- er solenoid is de--energized.
Page 187: Fuses
Fuses The fuse block is located behind the control arm access cover (Fig. 49). Identification and Function The fuses are held in the fuse block. Use Figure 50 to identify each individual fuse and its correct amperage. Fuses for your Reelmaster have the following function: Left Fuse 1 (15 Amp): Protects starter circuit power supply.
Page 188: Hydraulic Solenoid Valve Coil
Hydraulic Solenoid Valve Coil The Reelmaster hydraulic system uses several hydrau- NOTE: The two solenoid valve coils on the mow control lic solenoid valve coils for system control. The cutting manifold (MSV1 and MSV2) are identical. Solenoid deck manifold includes two (2) solenoid valves (Fig. 52) valve coils SV2 and SVRV on the lift control manifold are and the lift control manifold includes four (4) solenoid identical and are the same as those used on the mow...
Page 189: Temperature Sender
Temperature Sender The temperature sender is attached to the water pump 4. Check resistance of the sender with a multimeter housing on the engine and has a gray wire attached to (ohms setting) as the temperature increases. Replace it (Fig. 53). The resistance of the temperature sender re- sender if specifications are not met.
Page 190: High Temperature Shutdown Switch
High Temperature Shutdown Switch The high temperature shutdown switch is located on the 5. Replace shutdown switch if specifications are not water pump housing (Fig. 55). The high temperature met. shutdown switch is normally open and closes when en- 6. After testing is complete, install shutdown switch to gine coolant temperature reaches approximately 239 the engine housing.
Page 191: Oil Pressure Switch
Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter (Fig.57). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm The Electronic Control Module (ECM) monitors the op- eration of the oil pressure switch.
Page 192: Fuel Stop Solenoid
Fuel Stop Solenoid The fuel stop solenoid used on your Reelmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 58). The Electronic Control Module (ECM) monitors the op- eration of the fuel stop solenoid.
Page 193: Fuel Pump
Fuel Pump The Reelmaster fuel pump is attached to the inside of 7. Replace fuel pump if necessary. Install fuel hose to the left side frame rail near the fuel tank (Fig. 65). the fuel/water separator. Make sure to secure fuel hose with hose clamp.
Page 194: Service And Repairs
(+) cable first. Coat battery posts and cable are explosive, keep open flames and electrical connectors with Battery Terminal Protector (Toro Part sparks away from the battery; do not smoke. No. 107--0392) or petroleum jelly to prevent corrosion.
Page 195: Battery Service
(+) cable first. Coat battery posts and Removal and Installation (Fig. 62) cable connectors with Battery Terminal Protector (Toro Part No. 107--0392) or petroleum jelly to pre- 1. Raise hood. vent corrosion. 2. Loosen and remove negative cable from battery. Af-...
Page 196 A. Measure the specific gravity of each cell with a C. Make sure battery terminals are free of corrosion. hydrometer. Draw electrolyte in and out of the D. Measure the temperature of the center battery hydrometer barrel prior to taking a reading to warm-- cell.
Page 197 Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
Page 198: Control Arm
Control Arm FRONT RIGHT Figure 63 1. Arm rest 11. Clevis pin 21. Foam seal 2. Headlight switch 12. Screw 22. Flange nut 3. LH control arm cover 13. Latch 23. Spacer 4. Screw (2 used) 14. Swell latch (2 used) 24.
Page 199 Disassembly (Fig. 63) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Loosen latches and remove access cover from out- side of control arm. 3. At front of control arm, remove screw (item 6) and lock nut (item 5) that secure control arm covers to each other.
Page 200: Hydraulic Solenoid Valve Coil
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. FRONT Removal 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake.
Page 201: Backlap Switches
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. 3.
Page 202 TurfDefender Leak Detector (Optional) 20 to 25 ft- -lb (27 to 33 N- -m) 100 to 125 in- -lb (12 to 14 N- -m) 100 to 125 in- -lb (12 to 14 N- -m) Figure 70 1. Cap 8. Float 14.
Page 203 Very small changes to the oil level in the sealed hydrau- 3. The main body of the TurfDefender is not service- lic reservoir result in movement of the leak detector’s in- able and disassembly should not be necessary. Remov- ternal float. The internal microprocessor of the al of the upper housing from the leak detector housing TurfDefender analyzes the float movement and deter-...
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Page 205 Chapter 6 Chassis Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Traction Unit Operator’s Manual .
Page 206: Specifications
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 (except RM--5210) 12 to 15 PSI (83 to 103 kPa) (20 x 12.0 -- 10, 4 ply, tubeless)
Page 207 This page is intentionally blank. Reelmaster 5010 Series Page 6 - - 3 Chassis (Rev. C)
Page 208: Service And Repairs
Service and Repairs Wheels 13 14 70 to 90 ft- -lb (95 to 122 N- -m) RIGHT FRONT Figure 1 1. Front wheel motor 6. Front wheel 11. Jam nut 2. Brake assembly 7. Lug nut (5 used per wheel) 12.
Page 209 Removal (Fig. 1) Installation (Fig. 1) 1. Park machine on a level surface, lower cutting units, 1. Install wheel and secure with five (5) lug nuts. stop engine, engage parking brake and remove key 2. Lower machine to ground. from the ignition switch. 3.
Page 210: Steering Column
Steering Column ANTISEIZE 20 to 26 ft- -lb LUBRICANT (28 to 35 N- -m) ANTISEIZE LUBRICANT RIGHT FRONT Figure 2 1. Steering column 9. Hydraulic tube 17. Flat washer (2 used) 2. Hydraulic fitting (4 used) 10. Hydraulic tube 18. Flange nut 3.
Page 211 5. Remove platform shroud from machine to allow ac- 9. Secure steering wheel to steering column with flat cess to steering column fasteners (Fig. 3). washer and lock nut. Torque hex nut from 20 to 26 ft- -lb (28 to 35 N- -m). A.
Page 212: Brake Service
Brake Service STANDARD 2WD MACHINE WITH PARKER WHEEL MOTORS SHOWN 250 to 350 ft- -lb (339 to 474 N- -m) RIGHT 70 to 90 ft- -lb (95 to 122 N- -m) FRONT Figure 5 1. LH wheel motor (Parker) 12. Lock nut (4 used per wheel motor) 23.
Page 213 Removal (Fig. 5) STANDARD 2WD MACHINE WITH 1. Park the machine on a level surface, lower the cut- EATON WHEEL MOTORS SHOWN ting units and stop the engine. Remove the key from the ignition switch. 2. Chock wheels to prevent machine from shifting. 3.
Page 214 2. If backing plate was removed from machine, secure backing plate to brake bracket with four (4) cap screws and lock nuts. 3. Lightly lubricate brake shoe pivot points with general purpose grease. 4. Position one brake shoe to the backing plate. Install brake hold down pin and secure with hold down spring and cup.
Page 215 This page is intentionally blank. Reelmaster 5010 Series Page 6 - - 11 Chassis (Rev. C)
Page 216: Rear Wheel Bearings (2 Wheel Drive)
Rear Wheel Bearings (2 Wheel Drive) See text for tightening procedure Figure 9 1. Dust cap 5. Tab washer 9. Seal 2. Cotter pin 6. Bearing cone 10. Spindle 3. Retainer 7. Bearing cup 11. Wheel stud (5 used) 4. Jam nut 8.
Page 217 Disassembly (Fig. 9) 3. Fill wheel hub cavity between bearings approximate- ly 50% full of grease. Position remaining bearing into the 1. Chock front wheels to prevent machine from shifting. outer bearing cup. 2. Remove rear wheel (see Wheel Removal in this sec- 4.
Page 218: Rear Axle
Rear Axle 90 to 120 ft- -lb (123 to 162 N- -m) RIGHT FRONT Figure 10 1. Lug nut (5 used per wheel) 12. Tab washer 22. Ball joint 2. Axle assembly 13. Wheel hub assembly 23. Ball joint 3. Dust cap 14.
Page 219 Removal (Fig. 10) Installation (Fig. 10) 1. Park machine on a level surface, lower cutting units, 1. Thoroughly clean the rear axle pivot pin. Inspect the stop engine, engage parking brake and remove key pin for wear or damage and replace if necessary. from the ignition switch.
Page 220: Rear Axle Service
Rear Axle Service 90 to 120 ft- -lb (123 to 162 N- -m) RIGHT FRONT Figure 11 1. Lug nut (5 used per wheel) 16. Jam nut 31. Hydraulic fitting 2. Axle 17. Nut retainer 32. Hydraulic hose 3. Housing 18.
Page 221 Axle Pivot Bushings (Fig. 11) 4. Remove the flange head screw, spindle cap and re- taining ring that secure the wheel spindle into the axle The rear axle must be held in place snugly by the axle tube. Slide the spindle and wheel assembly out of the pivot pin.
Page 222: Operator Seat
Operator Seat RIGHT FRONT Figure 12 1. Seat 10. Armrest 19. Cap screw (4 used) 2. Seat base 11. Cap screw 20. Housing cap 3. Seat adjuster w/latch 12. Flange nut 21. R- -clamp (2 used) 4. Flat washer (4 used) 13.
Page 223 Removal (Fig. 12) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System).
Page 224: Mechanical Seat Suspension
Mechanical Seat Suspension Figure 15 1. Upper housing 15. Lower shock bolt 29. Weight indicator assembly 2. Weight adjust knob 16. Upper shock bushing (2 used) 30. Weight adjust nut 3. Lower housing 17. Lower shock bushing (2 used) 31. Rivet 4.
Page 225 IMPORTANT: When removing the seat suspension, make sure to support the control arm to prevent damage to the throttle cable, control arm electrical FRONT components and control arm wiring harness. Removal (Figs. 15 and 16) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch.
Page 226: Front Lift Arms
Front Lift Arms 67 to 83 ft- -lb (91 to 112 N- -m) RIGHT 67 to 83 ft- -lb FRONT (91 to 112 N- -m) Figure 17 1. #1 lift arm 13. Chain hoop (3 used) 24. Cap screw (1 used per plate) 2.
Page 227 Removal (Fig. 17) 3. Align lift cylinder to lift arm mounting slot (Fig. 18). Slide cylinder pin (Fig. 18 item 5) with retaining ring (Fig. 1. Park machine on a level surface, lower cutting units, 18 item 3) and thrust washer (Fig. 18 item 4) through the stop engine, engage parking brake and remove key lift cylinder and lift arm.
Page 228: Rear Lift Arms
Rear Lift Arms RIGHT FRONT Figure 21 1. Spacer (2 used) 12. Lynch pin (2 used) 23. RH torsion spring 2. #2 lift arm 13. Thrust washer (2 used per yoke) 24. LH torsion spring 3. #3 lift arm 14. Spacer (2 used) 25.
Page 229 B. Push down and rearward on the spring end to un- 4. Align lift cylinder rod end to lift arm mounting slot. hook the spring from the stop on the lift arm. Slide cylinder pin (item 30) with retaining ring (item 32) and thrust washer (item 31) through the lift cylinder and 6.
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Page 231 Chapter 7 Cutting Units Table of Contents SPECIFICATIONS ......Bedbar Adjuster Service .
Page 232: Specifications
8 blades and 7 inch reels are available in both and rear rollers are used with these cutting units. All roll- 8 and 11 blade configurations. ers use the same heavy duty ball bearings with Toro’s Reel Bearings: Two double row, self--aligning ball bear- patented labyrinth seal design.
Page 233: General Information
General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the cutting units on your Reel- master machine. Additionally, if optional kits have been installed on the cutting units (e.g. groomer, rear roller brush), the installation instructions for the kit includes set--up and operation information.
Page 234: Special Tools
Figure 2 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 air or manual impact wrench with this tool.
Page 235 Figure 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 hydraulic motor is removed. Also use this tool for instal- lation of threaded inserts into cutting reel shaft.
Page 236 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL)
Page 237 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 readings (no adjustments). Figure 11 Reelmaster 5010 Series Page 7 - - 7 Cutting Units (Rev.
Page 238: Factors That Can Affect Cutting Performance
NOTE: For additional information regarding cutting unit cutting unit. It is important to remember that the lower troubleshooting, see Aftercut Appearance Trouble- the height--of--cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL). Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
Page 239 Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpen and/or remove rifling.
Page 240 Factor Possible Problem/Correction Roller condition and roller type Make sure rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options. Turf compensation spring adjustment Refer to Traction Unit Operator’s Manual for adjustment procedure.
Page 241: Set Up And Adjustments
Set Up and Adjustments Characteristics If a cutting unit is determined to be out of adjustment, CAUTION complete the following procedures in the specified order to adjust the cutting unit properly. 1. Adjust the bedknife parallel to the reel. Never install or work on the cutting units or lift arms with the engine running.
Page 242: Reel Bearing Adjustment
Reel Bearing Adjustment To insure cut quality and long life of the cutting reel bear- 4. With the cutting unit and reel in a horizontal position, ings, periodically check reel bearing adjustment. use a 1 3/8” socket and torque wrench to overtighten the bearing adjuster nut to 25 in- -lb (2.8 N- -m).
Page 243: Leveling Rear Roller
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment is possible to make sure that the cutting unit is properly aligned.
Page 244: Service And Repairs
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 a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition switch.
Page 245: Backlapping
If a reel stalls, stop engine before NOTE: Additional instructions and procedures on attempting to clear the reel. backlapping are available in the Toro General Service Reel motors are connected in series: rotating Training Book, Reel Mower Basics (part no.
Page 246: Bedbar Assembly
Bedbar Assembly 7” CUTTING REEL SHOWN 27 to 33 ft- -lb (37 to 44 N- -m) RIGHT FRONT Antiseize Lubricant Figure 19 1. Bedbar 8. Wave washer (2 used) 14. Rubber bushing (2 used) 2. Bedknife 9. Retaining ring (2 used) 15.
Page 247 6. Position a plastic washer (item 16) between bedbar CAUTION and each cutting unit side plate (Fig. 20). 7. Install the bedbar pivot bolt assemblies. Make sure that plastic washers are not caught on the threads of the Contact with the reel, bedknife or other cutting pivot bolts.
Page 248: Bedbar Adjuster Service
Bedbar Adjuster Service Antiseize Lubricant Loctite #242 14 to 16 ft- -lb (19 to 21 N- -m) RIGHT FRONT Figure 21 1. Bedbar assembly 5. Flange bushing 9. Lock nut 2. Compression spring 6. Cap screw 10. Bedbar adjuster shaft 3.
Page 249 Removal (Fig. 21) NOTE: Inside threads in bedbar adjuster shaft (item 4) are left--hand threads. 1. Remove lock nut (item 3), compression spring (item 2) and washer (item 11) from bedbar adjuster screw 4. Apply antiseize lubricant to threads of bedbar adjust- (item 10).
Page 250: Bedknife Replacement And Grinding
Also, clean and dress grinding stone often during the grinding process. Top Face Remove 1. Use Toro General Service Training Book, Reel Relief Angle Burr Mower Basics (part no. 09168SL) and grinder manufacturer’s instructions for bedknife grinding in- formation.
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Page 252: Reel Assembly Removal And Installation
Reel Assembly Removal and Installation 7” CUTTING REEL SHOWN 27 to 33 ft- -lb (37 to 44 N- -m) Grease OD surface RIGHT See text for Grease bore tightening FRONT and threads procedure Antiseize Loctite #242 Lubricant 12 to 15 in- -lb 27 to 33 ft- -lb (1.4 to 1.7 N- -m) (37 to 44 N- -m)
Page 253: Reel Assembly Removal
Reel Assembly Removal (Fig. 26) 11. Inspect and service cutting reel assembly as re- quired (see Reel Assembly Service in this section). 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.
Page 254 IMPORTANT: During cutting reel installation, keep in- 11. Make sure that set screw (item 21) is loose in LH side ner and outer bearing races aligned. If bearing races are plate to allow bearing adjuster nut movement. With the not aligned, binding will occur and reel installation may cutting unit and reel in a horizontal position, torque the cause bearing damage.
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Page 256: Reel Assembly Service
Reel Assembly Service Loctite #242 Loctite #242 85 to 95 ft- -lb (115 to 128 N- -m) (Right Hand Threads) RIGHT FRONT 85 to 95 ft- -lb (115 to 128 N- -m) (Left Hand Threads) Figure 28 1. Cutting reel 5.
Page 257 C. To install spline insert into cutting reel, clean B. Press grease seals onto reel shaft with metal side threads of insert and cutting reel shaft. Apply Loctite orientated toward bearing location. Final position of #242 (or equivalent) to threads of insert, thread in- seal should be flush to 0.060”...
Page 258: Preparing Reel For Grinding
1. Follow reel grinder manufacturer’s instructions to Blade Land Width Range 0.050 to 0.070 in (1.3 to 1.8 mm) grind cutting reel to Toro specifications (see Reel Grind- Service Limit - ing Specifications chart to the right). Additional reel 0.010 in (.25 mm) for 5” and 7” reel...
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Page 260: Front Roller
Front Roller Removal (Fig. 30) Loctite #242 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- Antiseize move key from the ignition switch. Lubricant 2. Remove the cutting unit from the machine and place on a level working surface.
Page 261: Rear Roller
Rear Roller Removal (Fig. 31) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. Remove the cutting unit from the machine and place on a level working surface.
Page 262: Roller Service (Greasable Bearings With Retaining Ring)
Roller Service (Greasable Bearings with Retaining Ring) Figure 32 1. Roller tube (front Wiehle shown) 5. Ball bearing 8. Retaining ring 2. Roller shaft 6. Inner seal 9. Outer oil seal 3. Inner oil seal 7. Outer seal 10. Roller washer 4.
Page 263 Disassembly (Figs. 32 and 33) 1. Remove retaining ring from both ends of roller. 2. Support roller assembly and press one end of roller shaft to remove seals and bearing from opposite end of roller. Press on other end of roller shaft to remove re- maining seals and bearing from roller.
Page 264: Roller Service (Greasable Bearings With Bearing Nut)
Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 34) 50 to 60 ft- -lb 1. Remove bearing lock nut from each end of roller (68 to 81 N- -m) 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 tube.
Page 265 3. From the roller tube end with only the inner seal IMPORTANT: When roller assembly is installed to installed, carefully install the roller shaft into the roller cutting deck, make sure that grease groove in each tube. Make sure that seals are not damaged as shaft is roller mount aligns with the grease hole in each end installed.
Page 266: Rear Roller Brush (Optional)
Rear Roller Brush (Optional) 20 to 25 in- -lb (2.3 to 2.8 N- -m) 17 to 21 ft- -lb (23 to 28 N- -m) Antiseize Lubricant RIGHT RIGHT FRONT FRONT 27 to 33 ft- -lb (37 to 44 N- -m) Grease Loctite #242 Grommet ID...
Page 267 Disassembly (Fig. 40) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2. To remove roller brush from brush shaft: A. Remove the non--drive brush bearing housing 20 to 25 in- -lb (item 30) from cutting unit.
Page 268 3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 43 and 44. A. Install bearing on shaft by pressing equally on the inner and outer bearing races. Install the bearing so that the bearing seal is closest to the shoulder on the shaft.
Page 269 5. Check that roller brush has light contact with rear roll- er (Fig. 47). If contact is incorrect, brush operation will be adversely affected. Also make sure that brush shaft is parallel with rear roller. 6. Lubricate grease fittings on brush housings until grease purges past inboard seals.
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Page 271 Chapter 8 Groomer Table of Contents GROOMING PERFORMANCE ....TROUBLESHOOTING ......Groomer Reel Mechanical Problems .
Page 272: Grooming Performance
Grooming Performance There are a number of factors that can affect the perfor- mance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to in- spect the turf frequently and vary the grooming practice with turf needs.
Page 273: Troubleshooting
Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be Adjust groomer drive belt. adjusted. Seized groomer reel or idler bear- Identify and replace faulty bear- ing(s) in groomer side plate(s). ing(s).
Page 274: Adjustments
Adjustments NOTE: The Groomer Installation Instructions provide information regarding the installation, set--up and op- CAUTION eration of the optional groomer on your Reelmaster ma- chine. Refer to these instructions for additional Never work on the groomer with the engine information when servicing the groomer. running.
Page 275: Service And Repairs
Service and Repairs NOTE: The Groomer Installation Instructions provide information regarding the installation, set--up and op- CAUTION eration of the optional groomer on your Reelmaster ma- chine. Refer to these instructions for additional Never work on the groomer with the engine information when servicing the groomer.
Page 276: Groomer Plate Assembly
Groomer Plate Assembly Loctite #242 Antiseize Lubricant Loctite #242 RIGHT FRONT Antiseize 17 to 21 ft- -lb Loctite #242 Lubricant (23 to 28 N- -m) 27 to 32 ft- -lb (37 to 43 N- -m) Figure 4 1. Groomer reel 9.
Page 277 C. Remove the flange nut (item 6) that secures driv- D. Press bushings into groomer plate until the bush- en pulley (item 5) to groomer shaft. Remove driven ing contacts the shoulder in the groomer plate bore. pulley from shaft. Locate and retrieve square key E.
Page 278 2. Install groomer plate assembly to groomer non-- I. Check pulley alignment by laying a straight edge drive side of cutting unit: along the outer face of the drive pulley (Fig. 7). Drive and driven pulleys should be in line within 0.030” A.
Page 279 This page is intentionally blank. Reelmaster 5010 Series Page 8 - - 9 Groomer...
Page 280: Groomer Reel
Groomer Reel Loctite #242 Antiseize Lubricant Loctite #242 RIGHT FRONT Antiseize 17 to 21 ft- -lb Loctite #242 Lubricant (23 to 28 N- -m) 27 to 32 ft- -lb (37 to 43 N- -m) Figure 8 1. Groomer reel 9. Idler pulley assembly 17.
Page 281 Installation (Fig. 8) 1. Position cutting unit on a level surface. If cutting unit is attached to traction unit, make sure to stop engine, en- gage parking brake and remove key from the ignition switch. 2. Apply a light coating of grease to seal lips in groomer plate assemblies.
Page 282: Groomer Reel Service
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 midpoint of the blade tip must be reversed or re- placed for best groomer performance.
Page 283 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). Figure 13 1. Groomer shaft 2. Broomer strap Reelmaster 5010 Series Page 8 - - 13 Groomer...
Page 284: Groomer Pivot Hub
Groomer Pivot Hub Apply Grease to Seal Lip Figure 14 1. Groomer drive shaft 5. Pivot hub 8. Retaining ring 2. Ball bearing 6. Retaining ring 9. Idler plate 3. Grease seal 7. Extension spring 10. O- -ring (7” cutting unit only) 4.
Page 285 Disassembly (Fig. 14) Fill cavity 50 to 75% full 1. Remove pivot hub assembly (with idler plate) from with grease cutting unit (see Groomer Plate Assembly Removal in this section). 2. Remove retaining ring (item 4) that secures idler plate to pivot hub. Slide idler plate from pivot hub. 3.
Page 286: Height Adjuster Assembly
Height Adjuster Assembly Antiseize Lubricant 30 to 40 in- -lb (3.4 to 4.5 N- -m) Antiseize Lubricant 17 to 21 ft- -lb (23 to 28 N- -m) Antiseize Lubricant Figure 16 1. Groomer plate (LH drive shown) 6. Flange head screw 11.
Page 287 Foldout Drawings Table of Contents HYDRAULIC SCHEMATICS Reelmaster 5210 and 5410 ....Reelmaster 5510 and 5610 ....
Page 288 This page is intentionally blank. Foldout Drawings Page 9 - - 2 Reelmaster 5010 Series...
Page 289 M6 (RM5410) 24.7 M7 (RM5210) 22.0 MSV2 M7 (RM5410) 24.7 2500 3500 BKLP2 3625 3625 SVRV 2000 FRONT MOW CIRCUIT C.U. 4 C.U. 1 C.U. 5 CONTROL MANIFOLD 1000 Reelmaster 5210 and 5410 Hydraulic Schematic Page 9 - - 3...
Page 290: Hydraulic Schematics
C4 L GEAR PUMP C1 L C5 L CV23 EXTERNAL CASE DRAIN LIFT 100 MESH CONTROL SUCTION MANIFOLD STRAINER INTERNAL C2/3 L C2/3 CASE DRAIN RIGHT FRONT LEFT FORWARD FRONT FRONT CENTER TRACTION STEERING WHEEL CONTROL MOTORS VALVE STEERING LEFT RIGHT CYLINDER REAR...
Page 291: Reelmaster 5010 Series (Serial Number Below 310000000)
ALTERNATOR RUN SOLENOID (HOLD) HOUR R/BK R/BK METER TEMP GAUGE (PULL) (- -) OT WARNING BU/W TEMP SENDER GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP. R/BK (115 C) GN/W BU/W R/BK FUEL PUMP GLOW PLUGS GLOW RELAY (3 GLOW PLUGS USED ON RM5210) INDICATOR LIGHTS Start...
Page 292: Above 310000000)
(3 GLOW PLUGS USED ON RM5210) INDICATOR LIGHTS PARKING BRAKE SWITCH (BRAKE APPLIED) SEAT SWITCH (UNOCCUPIED) NEUTRAL SWITCH (NOT IN NEUTRAL) FRONT BACKLAP SWITCH (IN MOW) REAR BACKLAP SWITCH (IN MOW) MOW/TRANSPORT SWITCH (IN MOW) UP LIMIT SWITCH (C.U. RAISED) Reelmaster 5010 Series Electrical Schematic (Serial Number Above 310000000)
Page 293 ALTERNATOR RUN SOLENOID (HOLD) HOUR R/BK R/BK METER TEMP GAUGE (PULL) (- -) OT WARNING BU/W TEMP SENDER GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP. R/BK (115 C) GN/W BU/W R/BK FUEL PUMP GLOW PLUGS GLOW RELAY (ENERGIZED) (3 GLOW PLUGS USED ON RM5210) INDICATOR (ENERGIZED) LIGHTS...
Page 294: Crank Circuits
ALTERNATOR RUN SOLENOID (HOLD) HOUR R/BK R/BK METER TEMP GAUGE (PULL) (- -) OT WARNING BU/W TEMP SENDER GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP. R/BK (115 C) GN/W BU/W R/BK FUEL PUMP GLOW PLUGS GLOW RELAY (ENERGIZED) (3 GLOW PLUGS USED ON RM5210) INDICATOR (ENERGIZED) LIGHTS...
Page 295 ALTERNATOR RUN SOLENOID (HOLD) HOUR R/BK R/BK METER TEMP GAUGE (PULL) (- -) OT WARNING BU/W TEMP SENDER GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP. R/BK (115 C) GN/W BU/W R/BK FUEL PUMP GLOW PLUGS GLOW RELAY (NOT (3 GLOW PLUGS USED ON RM5210) INDICATOR ENERGIZED) LIGHTS...
Page 296 ALTERNATOR RUN SOLENOID (HOLD) HOUR R/BK R/BK METER TEMP GAUGE (PULL) (- -) OT WARNING BU/W TEMP SENDER GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP. R/BK (115 C) GN/W BU/W R/BK FUEL PUMP GLOW PLUGS GLOW RELAY (NOT (3 GLOW PLUGS USED ON RM5210) INDICATOR ENERGIZED) LIGHTS...
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Page 298: Main Wire Harness Drawing
Reelmaster 5010 Series Main Wire Harness Drawing Page 9 - - 12 Rev. B...
Page 299: Main Wire Harness Diagram
BROWN VIOLET BLUE BLACK PINK PINK BLACK/WHITE BLACK WHITE GREEN/WHITE BLUE YELLOW GRAY PINK GREEN YELLOW BLACK BLUE BLACK BLACK RED/BLACK RED/BLACK BLACK ORANGE BLACK GREEN Reelmaster 5010 Series Main Wire Harness Diagram Page 9 - - 13 Rev. B...
Page 300: Seat Wire Harness Drawing
Reelmaster 5010 Series Seat Wire Harness Drawing Page 9 - - 14 Rev. B...
Page 301: Seat Wire Harness Diagram
GRAY GREEN/WHITE PINK WHITE BLUE GRAY GREEN BLUE/WHITE YELLOW/BLACK BLACK/WHITE GREEN/WHITE WHITE RED/BLACK BROWN BLUE WHITE BLUE PINK PINK PINK YELLOW BLACK BLACK BLACK BLACK PINK BLACK WHITE TAN/BLACK GRAY/BLACK VIOLET BLACK BLACK BLACK Reelmaster 5010 Series Seat Wire Harness Diagram Page 9 - - 15 Rev.
Page 302: Engine Wire Harness Drawing
Reelmaster 5010 Series Engine Wire Harness Drawing Page 9 - - 16 Rev. B...
Page 303: Engine Wire Harness Diagram
ORANGE BLACK GREEN/WHITE BLUE Reelmaster 5010 Series Engine Wire Harness Diagram Page 9 - - 17 Rev. B...
Page 304: Turfdefender
TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS ALARM RED/YELLOW RED/WHITE BLACK/YELLOW BLACK/WHITE YELLOW TURF DEFENDER COMMUNICATION BLACK/ORANGE ELECTRIC PORT AND SOLENOID LOOPBACK GREEN/WHITE VALVE CONNECTOR BLACK TURF DEFENDER LOOPBACK I.D. DECAL TURF DEFENDER LEAK DETECTOR Reelmaster 5010 Series TurfDefender (Optional) Electrical Schematic Page 9 - - 18 Rev.

This manual is also suitable for:

Reelmaster 5410 Reelmaster 5510 Reelmaster 5610

Toro Reelmaster 5210 Service Manual

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Chapter 1 -- Safety

Chapter 2 -- Product Records and Maintenance

Chapter 5 -- Electrical System

Chapter 6 -- Chassis

Chapter 7 -- Cutting Units

Chapter 4 Hydraulic System

Chapter 3 -- Kubota Diesel Engine

Chapter 8 -- Groomer

Chapter 5 Electrical System

Chapter 6 Chassis

Chapter 7 Cutting Units

Chapter 8 Groomer

Chapter 9 Foldout Drawings

Quick Links

Service Manual

Chapters

Troubleshooting

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Summary of Contents for Toro Reelmaster 5210