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Toro Reelmaster 5210, Service Manual

The Toro Reelmaster 5210 is a superior lawn maintenance machine that guarantees precision and efficiency. For complete understanding of its operation and maintenance, download the comprehensive Service Manual for free from our website. This invaluable manual will equip you with all the necessary knowledge to optimize the performance of your Toro Reelmaster 5210.

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Reelmaster 5010 Series

Page 5 -- 11

Electrical System

Starting Problems (Continued)

Problem

Possible Causes

Engine cranks, but should not, when the traction pedal

is depressed.

Traction neutral switch is out of adjustment.

Traction neutral switch or circuit wiring is faulty.

Nothing happens when start attempt is made. Control

panel lights and gauges operate with the ignition

switch in RUN.

Traction pedal is not in neutral position.

Operator seat is unoccupied OR the parking brake is

not applied.

Cutting units are engaged (PTO switch is ON).

Traction neutral switch is out of adjustment.

Traction neutral switch or circuit wiring is faulty.

Seat switch or circuit wiring is faulty.

Parking brake switch or circuit wiring is faulty.

Joystick switch (raise or lower position) is faulty.

Ignition switch or circuit wiring is faulty.

Start relay or circuit wiring is faulty.

Main power relay or circuit wiring is faulty (headlights

and powerpoint inoperative as well).

ECM fuses are faulty.

Fusible link at battery is open.

Wiring to start circuit components is loose, corroded or

damaged (see Wiring Schematic and Circuit Drawings

in Chapter 9 -- Electrical Diagrams).

High temperature shutdown switch or circuit wiring is

faulty.

Starter solenoid or starter motor is faulty.

Electronic Control Module is faulty.

Electrical System

Summary of Contents for Reelmaster 5210

Page 1: ...tional copies of the Operator s Manual and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result ...

Page 2: ...Reelmaster 5010 Series This page is intentionally blank ...

Page 3: ...F TG TH AND TL SERIES EATON DELTA MOTORS PARTS AND REPAIR MANUAL SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Chapter 5 Electrical System General Information 5 1 Electrical Diagrams 5 1 Special Tools 5 2 Troubleshooting 5 4 Electrical System Quick Checks 5 18 Adjustments 5 20 Component Testing 5 23 Service and Repairs 5 46 Chapter 6 Chassis Specifications 6 2 General Information 6 2 Servic...

Page 4: ...Reelmaster 5010 Series This page is intentionally blank ...

Page 5: ...ster 5010 Series Page 1 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SAFETY AND INSTRUCTION DECALS 4 Safety ...

Page 6: ...nd PTO switch is OFF disengaged 4 Since diesel fuel is highly flammable handle it care fully A Store fuel in containers specifically designed for this purpose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Replace fuel tank and ...

Page 7: ...ake an adjustment keep hands feet clothing and other parts of the body away from the cutting units and other moving parts Keep bystanders away 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed with a tachometer 11 Shut engine off before checking or adding oil to the crankcase 12 Disconnect battery before servicing the machine Disco...

Page 8: ...curely under the frame axle tube just to the inside of the front wheel 3 Jack front of machine off the ground 4 Position jack stands under the frame as close to the wheel as possible to support the machine Rear End Jacking Fig 2 1 Apply parking brake and chock both front tires to pre vent the machine from moving 2 Place jack securely at the center of the rear axle un der the axle pivot bracket Jac...

Page 9: ...teel Fasteners Metric Series 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manuals and Parts Catalogs for your Reelmaster at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instructions Op erator s Manuals and Parts Catalogs for those options at the end of this chapter...

Page 10: ...0 09375 Reelmaster 5010 Series Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 11: ...ner head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench ...

Page 12: ...6 2 16 2 22 3 30 3 41 4 43 5 58 7 3 8 24 UNF 17 2 18 2 24 3 35 4 47 5 50 6 68 8 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 ...

Page 13: ...lb 90 10 N m 93 10 ft lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced wh...

Page 14: ...in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Size Type A Type B Baseline Torque N...

Page 15: ...the end of this chapter However the cost of the test equipment and the special ized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Kubota diesel engines are supplied through your local Toro Distributor If a parts list is not available be sure to provide your distributor with the Toro model and serial number Traction Unit Operator ...

Page 16: ...el ASTM D975 Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle DNOPD Fuel Tank Capacity 14 U S Gallons 53 Liters Governor Centrifugal Mechanical Low Idle Speed no load 1200 to 1300 RPM High Idle Speed no load 3050 to 3250 RPM Engine Oil API Classification CH 4 CI 4 or Higher see Traction Unit Operator s Manual for viscosity recommendations Oil Pump Gear Driven Trochoid Type C...

Page 17: ... ASTM D975 Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle DNOPD Fuel Tank Capacity 14 U S Gallons 53 Liters Governor Centrifugal Mechanical Low Idle Speed no load 1200 to 1300 RPM High Idle Speed no load 3050 to 3250 RPM Engine Oil API Classification CH 4 CI 4 or Higher see Traction Unit Operator s Manual for viscosity recommendations Oil Pump Gear Driven Trochoid Type Cra...

Page 18: ... Diesel Fuel ASTM D975 Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle DNOPD Fuel Tank Capacity 14 U S Gallons 53 Liters Governor Centrifugal Mechanical Low Idle Speed no load 1200 to 1300 RPM High Idle Speed no load 3050 to 3250 RPM Engine Oil API Classification CH 4 CI 4 or Higher see Traction Unit Operator s Manual for viscosity recommendations Oil Pump Gear Driven Troch...

Page 19: ...k position of the engine speed control lever on fuel injection pump The speed control lever should be contacting the high speed screw when the throttle con trol lever is in the FAST position 3 If necessary throttle control can be adjusted by loos ening cable clamp screw and repositioning control cable until speed control lever contacts high speed screw when the throttle control lever is in the FAS...

Page 20: ...uel cap 2 Bushing 3 Washer head screw 3 used 4 Flange nut 3 used 5 Clamp 3 used 6 Return fitting 7 Suction fitting 8 Hose clamp 9 Hose clamp 10 Fuel tank 11 Grommet 12 Fuel gauge 13 Hose clamp 14 Draincock 15 Fuel hose 16 Return fuel hose FRONT RIGHT 12 11 10 5 2 6 2 7 14 5 3 9 8 1 13 4 4 3 3 15 16 ...

Page 21: ...f the fuel system becomes contaminated or if the machine is to be stored for an ex tended period To clean fuel tank flush tank out with clean diesel fuel Make sure tank is free of all contaminates and debris Fuel Tank Removal Fig 2 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Place drain pan under fuel tank Make su...

Page 22: ...se clamp 12 Flange nut 13 Cap screw 2 used 14 Flange head screw 4 used 15 Flange head screw 2 used 16 Air cleaner mounting band FRONT RIGHT REELMASTER 5410 D 5510 D SHOWN 15 2 4 3 1 7 11 12 6 11 8 5 12 9 10 12 11 11 14 13 16 THREAD SEALANT NOTE The models in the Reelmaster 5010 Series have a very similar air cleaner system The air cleaner removal and installation procedure is the same for all mode...

Page 23: ...ge Make sure that all air cleaner components are in good condition and are properly secured dur ing assembly 1 Assemble air cleaner system using Figures 3 4 and 5 as guides A If indicator and adapter were removed from air cleaner housing apply thread sealant to adapter be fore installing adapter and indicator to housing B Make sure that vacuator valve is pointed down af ter assembly Figure 4 1 Air...

Page 24: ... 11 Clamp 12 Flange nut 2 used 13 Flat washer 2 used 14 Cap screw 2 used 15 Rubber hanger 16 Spacer 2 used 17 Exhaust header 18 Support bracket 19 Tail pipe bracket 20 Muffler FRONT RIGHT REELMASTER 5410 D 5510 D SHOWN 20 12 15 4 2 12 19 2 4 18 16 13 14 3 1 17 7 6 11 8 5 9 10 14 13 16 5 6 NOTE The models in the Reelmaster 5010 Series have a very similar exhaust system The exhaust sys tem removal a...

Page 25: ... 6 NOTE Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Place new muffler gasket on the exhaust manifold Install exhaust pipe to manifold and secure with four 4 flange nuts IMPORTANT Finger tighten all exhaust system fas teners before tightening so that there is no preload on the exhaust system due to exhaust system as sem...

Page 26: ...h 32 Washer head screw 6 used 33 Flange head screw 34 Lock nut 35 Cap screw 4 used 36 Screen 37 Intake screen 38 Hose 39 Oil cooler bracket 40 Foam seal 41 Draincock 42 Radiator cap 43 Spacer 5 used 44 Flange head screw 5 used FRONT RIGHT 1 2 3 2 38 8 6 22 12 8 21 37 5 27 6 30 5 13 13 26 25 33 24 23 34 13 32 30 17 9 14 15 13 7 15 13 15 39 9 35 11 4 36 31 29 19 20 12 18 20 19 4 11 28 10 16 16 16 41...

Page 27: ...or frame Position fan shroud away from the radiator 10 Carefully pull radiator assembly from the machine Plug radiator and hose openings to prevent contamina tion 11 Inspect all foam seals placed between radiator fan shroud and radiator frame Replace damaged foam seals Installation Fig 7 1 Remove plugs placed in radiator and hose openings during the removal procedure 2 Carefully position radiator ...

Page 28: ...washer 13 Lock washer 14 Pulley 15 V belt 16 Flat washer 4 used 17 Cooling fan 18 Flat washer 19 Spring washer 20 Hex nut 21 Cap screw 22 Spacer 4 used 23 Engine bracket 4 used 24 Diode assembly 25 Lock washer 12 used 26 Engine wire harness 27 Negative battery cable FRONT RIGHT 34 to 42 ft lb 47 to 56 N m 12 6 22 4 5 23 7 25 2 13 21 9 5 9 3 1 18 19 20 8 7 11 16 17 10 14 4 25 2 15 24 23 23 4 26 26 ...

Page 29: ... see Ex haust System Removal in this section 7 Remove throttle cable from injector pump Fig 10 A Remove cap screw that secures throttle cable end to swivel in speed control lever B Loosen throttle cable clamp and remove cable from clamp Slide throttle cable end from swivel C Position throttle cable away from the engine 8 Disconnect hoses from engine A Loosen clamps and remove upper and lower ra di...

Page 30: ... gine D Raise engine and remove toward front of machin e 12 If necessary remove engine brackets from engine Installation Fig 9 1 Locate machine on a level surface with cutting units lowered and key removed from the ignition switch Chock wheels to keep the machine from moving 2 Make sure that all parts removed from the engine during maintenance or rebuilding are installed to the en gine 3 If engine...

Page 31: ...p on engine B Install the throttle cable end into the swivel in speed control lever Secure cable end with cap screw C Position cable under cable clamp D Adjust throttle control see Adjust Throttle Con trol in the Adjustments section of this chapter 9 Install air cleaner see Air Cleaner Installation in this section 10 Install exhaust system to machine see Exhaust System Installation in this section...

Page 32: ...Reelmaster 5010 Series Page 3 18 Kubota Diesel Engine This page is intentionally blank ...

Page 33: ... P4 Flow Test 50 Lift Cylinder Internal Leakage Test 52 Steering Relief Valve R10 Pressure Test 54 Steering Cylinder Internal Leakage Test 56 SERVICE AND REPAIRS 58 General Precautions for Removing and Installing Hydraulic System Components 58 Check Hydraulic Lines and Hoses 59 Flush Hydraulic System 60 Filtering Closed Loop Traction Circuit 61 Hydraulic System Start up 62 Hydraulic Reservoir 64 H...

Page 34: ... Circuit R2 3500 PSI 241 bar Cutting Unit Motor RM 5210 RM 5410 Sauer Danfoss gear motor Displacement per revolution 0 73 Cubic Inches 12 cc Cutting Unit Motor RM 5510 RM 5610 Bosch gear motor Displacement per revolution 1 18 Cubic Inches 19 3 cc Cross Over Relief Valve Pressure 1500 PSI 103 bar Steering Valve Sauer Danfoss Steering Unit Type OSPMS Steering Circuit Relief R10 Pressure 1000 PSI 69 ...

Page 35: ...c fluid Check lev el of hydraulic fluid daily See Traction Unit Operator s Manual for fluid level checking procedure and hydraulic oil recommendations 1 Hydraulic reservoir cap Figure 1 1 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 f...

Page 36: ...id escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury WARNING Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scr...

Page 37: ...es are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer...

Page 38: ...raction circuit be disas sembled drained and thoroughly cleaned to ensure that all contamination is removed from the circuit If any de bris remains in the traction circuit and the machine is op erated the debris can cause additional component failure An alternative method of removing traction circuit con tamination would be to temporarily install a high pres surehydraulicoilfilter seeSpecialTools ...

Page 39: ...Reelmaster 5010 Series Hydraulic System Rev C Page 4 7 Hydraulic Schematics The hydraulic schematics for Reelmaster 5010 series machines are located in Chapter 9 Foldout Drawings Hydraulic System ...

Page 40: ...NT CENTER REAR R10 R8 C4 L C5 L C1 L REAR LEFT RIGHT T P REAR MOW CIRCUIT FRONT MOW CIRCUIT R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 G2 EP2 MSV2 MSV1 OR2 OR4 MR2 FC2 CV EP1 G1 OR3 FC1 OR1 MR1 G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 P2 T P1 M1 BKLP1 M2 BKLP2 B R2 R1 R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN CYLINDER A R11 C U 5 C U 1 C U 4 R11 R11 R1...

Page 41: ... internal leakage in the traction circuit Gear pump P3 takes its suction from the hydraulic res ervoir Charge pump flow is directed to the low pressure side of the closed loop traction circuit Charge pressure is limited by the charge relief valve R5 located in the traction pump The charge relief pressure is 200 PSI 14 bar The piston pump P5 includes a flushing valve R10 that bleeds off a small amo...

Page 42: ...L C5 L C1 L REAR LEFT RIGHT T P REAR MOW CIRCUIT FRONT MOW CIRCUIT R9 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TRACTION WHEEL MOTORS P1 P2 P3 P4 G5 G6 G2 EP2 MSV2 MSV1 OR2 OR4 MR2 FC2 CV EP1 G1 OR3 FC1 OR1 MR1 G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 P2 T P1 M1 BKLP1 M2 BKLP2 B R2 R1 R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN CYLINDER A R11 C U 5 C U 1 C U 4 R11 R11 R11 C U 3 C U 2 R11 M4 M1 M...

Page 43: ...anifold port T and returns to the hydraulic reservoir by passing the reel motors Mow Fig 10 When solenoid valve MSV1 is energized by the ECM pump section P1 flow enters mow control manifold port P1 and is directed to reel speed control valve FC1 Flow through the speed control valve is pressure com pensated by logic cartridge valve EP1 The logic car tridge valve maintains a pressure of 75 PSI 5 2 b...

Page 44: ...ting Units Reelmaster 5010 T C4 P4 C5 C1 C2 3 C2 3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 100 MESH SUCTION STRAINER CASE DRAIN P1 P2 P3 P4 INTERNAL PUMP P5 R8 FROM MOW CONTROL MANIFOLD TO REAR MOW CIRCUIT TO FRONT MOW CIRCUIT TO STEERING CHARGE CIRCUIT LIFT CONTROL MANIFOLD ...

Page 45: ...olenoid valves SV1 SV2 SV3 and SVRV are to be energized The ECM also provides a partial raise position of the front outside cutting units During conditions of not raising or lowering the cutting units joystick in the neutral center position all four 4 lift manifold solenoid valves SV1 SV2 SV3 and SVRV are de energized Hydraulic flow from gear pump sec tion P4 by passes the lift cylinders to the oi...

Page 46: ...ting Units Reelmaster 5010 T C4 P4 C5 C1 C2 3 C2 3 L LEFT FRONT RIGHT FRONT FRONT CENTER REAR C4 L C5 L C1 L REAR LEFT RIGHT G4 SV3 SV1 SV2 R7 SVRV CV4 CV1 CV5 CV23 100 MESH SUCTION STRAINER CASE DRAIN P1 P2 P3 P4 INTERNAL PUMP P5 R8 FROM MOW CONTROL MANIFOLD TO REAR MOW CIRCUIT TO FRONT MOW CIRCUIT TO STEERING CHARGE CIRCUIT LIFT CONTROL MANIFOLD ...

Page 47: ... joystick in the neutral center position all four 4 lift manifold solenoid valves SV1 SV2 SV3 and SVRV are de energized Hydraulic flow from gear pump sec tion P4 by passes the lift cylinders to the oil cooler and then to the hydraulic reservoir Lower Cutting Units Fig 12 When the joystick is moved to the lower position sole noid valve SVRV energizes along with solenoid valves SV1 and SV3 Solenoid ...

Page 48: ...ssure Charge Return or Suction Flow Steering Circuit Reelmaster 5010 STEERING CYLINDER PISTON MOVEMENT STEERING CYLINDER STEERING VALVE PISTON MOVEMENT STEERING VALVE R10 R10 FROM PUMP P3 FROM PUMP P3 TO TRACTION CHARGE CIRCUIT TO TRACTION CHARGE CIRCUIT LEFT TURN CONTROL RIGHT TURN CONTROL ...

Page 49: ... meter V1 and out the L port Pressure contracts the steering cylinder piston for a left turn The rotary meter ensures that the oil flow to the steering cylinder is proportional to the amount of turning on the steering wheel Fluid leaving the steering cylinder flows back through the steering control spool valve and then out of the steering control valve through the T port The steering control valve...

Page 50: ...rt Number TOR214678 Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section ofthis chapter This tester includes the following 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE...

Page 51: ... 3 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM 20 to 150 LPM NOTE This tester does notincludehoses seeHydrau lic Hose Kit TOR6007 below Figure 16 Hydraulic Hose Kit Toro Part Number TOR6007 This kitincludes fittings and hoses needed to connect40 GPM hydraulic tester AT40002 or high flow hydraulic filter kit TOR6011 to machinehydraulic...

Page 52: ...placing a failed traction circuit component e g hydrostat or wheel motor the high flow hydraulic filter can be installed in the traction circuit The filter will en sure that contaminates are removed from the closed loop and thus do not cause additional component dam age Toro Part Number TOR6011 NOTE Use of Hydraulic Hose Kit TOR6007 is recom mended when using the high flow hydraulic filter kit NOT...

Page 53: ... Use this graduated container for doing hydraulic motor efficiency testing motors with case drain lines only Measureefficiencyofahydraulicmotorby restrictingthe outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system The table in Figure 23 provides gallons per minute GPM conversion for measured milliliter or ounce leak age Fi...

Page 54: ...for precau tions and specific hydraulic test procedures General Hydraulic System Problems Problem Possible Cause Hydraulic oil leaks from machine Fitting s hose s or tube s is are loose or damaged O ring s or seal s is are missing or damaged Foaming hydraulic fluid Oil level in hydraulic reservoir is low Hydraulic system has wrong kind of oil Pump suction line has an air leak Hydraulic system oper...

Page 55: ...g or is dam aged NOTE Check relief valves for forward and reverse are iden tical and can be reversed for testing purposes Piston traction pump is worn or damaged No traction in either direction Parking brake is dragging or binding Traction control linkage is misadjusted disconnected binding or damaged Oil level in hydraulic reservoir is low other hydraulic systems af fected as well Traction pump b...

Page 56: ... be reversed for testing purposes Mow backlap lever for front cutting units MR2 not rotated fully An electrical problem exists that prevents MSV2 solenoid coil on mow control manifold from being energized see Troubleshooting in Chapter 5 Electrical System Front cutting reel s is binding Gear pump section P2 is worn or damaged Rear cutting unit motors will not op erate but front cutting unit motors...

Page 57: ... as well MR1 and or MR2 in lift control manifold are in the backlap position Solenoid valve SVRV on lift control manifold is faulty An electrical problem exists that prevents SVRV solenoid coil on the lift control manifold from being energized see Troubleshooting in Chapter 5 Electrical System Gear pump section P4 is worn or damaged None of the front cutting units will raise or lower but the rear ...

Page 58: ...nd CV23 is stuck or damaged Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components e g tie rods steering cylinder ends are worn or binding Steering cylinder is binding Oil level in hydraulic reservoir is low other hydraulic systems af fected as well Steering relief valve R12 in steering control valve is stuck or dam aged Steering cylinder leaks intern...

Page 59: ...Reelmaster 5010 Series Hydraulic System Rev C Page 4 27 This page is intentionally blank Hydraulic System ...

Page 60: ...Contamination can cause excessive wear or binding of hydraulic components 2 Review all test steps before starting the test proce dure 3 Before testing check all control linkages for improp er adjustment binding or broken parts 4 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Operate the ma chine under load for at least ten 10 minutes before per forming hy...

Page 61: ...or Efficiency and or Piston Traction Pump Flow Tests 2 If a cutting mow circuit problem exists consider performing one or more of the following tests Relief Valve R1 and R2 Pressure Gear Pump P1 and P2 Flow Reel Drive Motor Efficiency and or Reel Drive Mo tor Cross Over Relief Pressure Reelmaster 5510 and 5610 Tests 3 If a lift circuit problem exists consider performing one or more of the followin...

Page 62: ...NITS TO MOW CONTROL PRESSURE GAUGE FORWARD R3 RELIEF VALVE TEST SHOWN The traction circuit relief pressure test should be per formed to make sure that forward and reverse traction circuit relief pressures are correct Procedure for Traction Circuit Relief Valve R3 and R4 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately...

Page 63: ...pproximately 3825 PSI 264 bar in both forward R3 and reverse R4 NOTE If traction pedal continues to be pressed after the relief valve has opened system pressure can in crease higher than relief pressure 8 Release traction pedal stop engine and record test results NOTE Forward R3 and reverse R4 relief valves are identical Relief valves can be switched in traction pump to help in identifying a fault...

Page 64: ...S TO MOW CONTROL PRESSURE GAUGE OIL FILTER REMOVED The traction circuit charge pressure test should be per formed to make sure that the traction charge circuit is functioning correctly ProcedureforTractionCircuit ChargePressure 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 wi...

Page 65: ...n the forward direction and then to reverse while monitoring the pressure gauge Stop engine and record test results GAUGE READING TO BE approximately 150 to 250 PSI 13 8 to 17 2 bar 11 Compare measured charge pressure from step 9 with pressure from step 10 A If charge pressure is good under no load step 9 but drops below specification when under traction load step 10 the piston pump should be susp...

Page 66: ...O MOW CONTROL REAR CUTTING UNITS FRONT CUTTING UNITS TO MOW CONTROL TESTER OIL FILTER REMOVED AND TUBE The gear pump P3 flow test should be performed to make sure that the traction charge circuit and steering circuit have adequate hydraulic flow Procedure for Gear Pump P3 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately t...

Page 67: ...aulic leakage from test connections and correct be fore proceeding with test 9 Move throttle to full speed 3200 RPM Use a tachometer to verify that engine speed is correct IMPORTANT The gear pump is a positive displace ment type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 10 While watching pressure gauges slowly close the tester flow ...

Page 68: ... heavy load condi tions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and af fect overall machine performance IMPORTANT Refer to Traction Circuit Component Failure in the General Information section for infor mation regarding the importance of removing con tamination from the traction circuit NOTE Th...

Page 69: ...fferent wheel positions will provide the most accurate test results Record measured front wheel motor internal leakage for all three 3 wheel posi tions 13 If total leakage for the front wheel motors is more than 1 5 GPM 5 7 LPM one or both of the motors may be faulty Individual front wheel motor testing is neces sary 14 To test individual front wheel motors A Remove front wheel from wheel motor th...

Page 70: ...load valve on the tester IMPORTANT Traction circuit flow for your Reel master isapproximately 30GPM 113 5LPM Use40 GPMHydraulic Tester AT40002 pressure andflow for this test see Special Tools in this chapter 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes Make sure the hydrau lic tank is full 2 Park machine on a lev...

Page 71: ...uring anyone near the machine 8 Start engine and run at idle speed Check for any hy draulic leakage from tester and hose connections Cor rect any leaks before proceeding 9 Move throttle so engine is running at high idle speed 3200 RPM 10 Slowly push traction pedal to fully forward position Keep pedal fully depressed in the forward position 11 Have second person watch pressure gauge on test er care...

Page 72: ...NTROL VALVE RELIEF VALVE R1 TEST SHOWN MOW CONTROL MANIFOLD The relief valve R1 and R2 pressure test should be performed to make sure that the cutting unit circuit relief pressures are correct NOTE The front cutting unit circuit is protected by relief valve R2 The rear cutting unitcircuit is protected by re lief valve R1 see Hydraulic Flow Diagrams in this chapter Procedure for Relief Valve R1 and...

Page 73: ... speed 3200 RPM CAUTION Keep away from reels during test to prevent per sonal injury from rotating reel blades 10 Have a second person occupy seat press PTO switch to ON and then move Lower Mow Raise lever forward to engage cutting units IMPORTANT When performing this test do not hold over relief any longer than necessary to obtain pressure reading 11 Watch pressure gauge carefully while slowly cl...

Page 74: ...NG CONTROL VALVE GEAR PUMP P1 FLOW TEST SHOWN MOW CONTROL MANIFOLD Over a period of time the gears and wear plates in the gear pump can wear A worn pump will by pass oil and make the pump less efficient Eventually enough oil can by pass to cause the reels to stall in heavy cutting condi tions Continued operation with a worn inefficient pump can generate excessive heat and cause damage to seals and...

Page 75: ...e speed is correct IMPORTANT The gear pump is a positive displace ment type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 9 While watching pressure gauges slowly close the tester flow control valve until 2000 PSI 138 bar is ob tained on gauge FLOW TESTER READING TO BE For RM5210 and 5410 machines a pump in good condition should have a f...

Page 76: ...s will cause the reel motor to stall under heavy cutting conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hy draulic system and affect quality of cut NOTE One way to find a faulty reel motor is to have another person observe the machine while mowing in dense turf A faulty motor will run slower than other mo t...

Page 77: ...hen performing the motor efficiency test Keep away from cutting units during test to prevent personal injury from rotating reel blades Do not stand in front of the machine 9 Sit on seat and move throttle to full speed 3200 RPM Press PTO switch to ON Move Lower Mow Raise lever forward to engage cutting units 10 While watching pressure gauges slowly close flow control valve on tester until a pressur...

Page 78: ...IRCUIT SHOWN Figure 43 NOTE One way to find a faulty reel motor is to have another person observe the machine while mowing in dense turf A faulty motor will run slower produce fewer clippings and may cause clip marks a choppy appear ance on the turf IMPORTANT DO NOT perform the Reel Drive Motor Cross Over Relief Pressure Test on Reelmaster 5210 and 5410 machines The reel motors on these machines d...

Page 79: ...ed Check for any hydraulic leakage from test connections and correct be fore proceeding with test CAUTION Adjacent cutting unit reels will rotate when per forming the cross over relief test Keep away from cutting units during test to prevent person al injury from rotating reel blades Do not standin front of the machine 9 One person should sit on the seat and operate the machine while another perso...

Page 80: ...ure that the lift circuit relief pressure is correct Procedure for Lift Relief Valve SVRV Pressure 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 Make sure engine is off Ap ply the parking brake 3 Read Precautions For Hydraulic...

Page 81: ...it While holding lever in the raise rearward position watch pressure gauge carefully As the cutting units fully raise and the lift relief valve lifts system pressure should be Approximately 2000 PSI 138 bar 9 Return the Lower Mow Raise lever to the neutral position and stop the engine 10 If measured pressure is incorrect remove solenoid relief valve SVRV on lift control manifold and clean or repla...

Page 82: ...ear pump P4 flow test should be performed to make sure that the cutting unit lift circuit has adequate hydraulic flow Procedure for Gear Pump P4 Flow 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 Make sure engine is off Ap ply...

Page 83: ... is correct IMPORTANT The gear pump is a positive displace ment type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 10 While carefully watching pressure gauges slowly close the tester flow control valve until 1000 PSI 69 bar is obtained on gauge FLOW TESTER READING TO BE A pump in good condition should have a flow of approximately 3 GPM ...

Page 84: ...e affected by lift cylinder binding extra weight on the cut ting units and or binding of lift components Make sure that these items are checked before proceeding with lift cylinder internal leakage test Procedure for Lift Cylinder Internal Leakage Test 1 Park machine on a level surface with the PTO switch OFF Position the cutting units in the turn around posi tion and turn the engine off Apply the...

Page 85: ...nded after two 2 hours and liftcylin der rod movement is less than 1 250 31 7 mm consider that the lift cylinder is in good condition A cylinder in good usable condition will show minimal movement B Rod movement in excess of 1 250 31 7 mm af ter two 2 hours indicates that the lift cylinder may have internal seal damage or excessive wear Re move and inspect the lift cylinder see Lift Cylinder and L...

Page 86: ...SH SUCTION STRAINER INTERNAL CASE DRAIN P1 P2 P3 P4 CYLINDER CONTROL STEERING VALVE DRAIN PUMP P5 PRESSURE GAUGE TO MOW CONTROL MANIFOLD REAR CUTTING UNITS FRONT CUTTING UNITS TO MOW CONTROL MANIFOLD MANIFOLD TO LIFT CONTROL TO TRACTION CHARGE CIRCUIT The steering relief valve R10 pressure test should be performed to make sure that the steering circuit relief pressure is correct ...

Page 87: ...fter installing pressure gauge start engine and run at idle speed Check for any hydraulic leakage from test connections and correct before proceeding with test 8 Move throttle to full speed 3200 RPM IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period may damage the steering control valve 9 W...

Page 88: ... steering cylinder internal leakage test should be performed if a steering problem is identified This test will determine if the steering cylinder is faulty NOTE Steering circuit operation will be affected by rear tire pressure steering cylinder binding extra weighton the vehicle and or binding ofrear axle steering components Make sure that these items are checked before proceeding with steering c...

Page 89: ...e steering cylinder Plug the end of the hose 7 Remove all hydraulic oil from drain pan Make sure that empty drain pan remains under the open fitting of the steering cylinder 8 With the engine off continue turning the steering wheel for a right turn clockwise with the steering cylin der fully extended Observe the open fitting on the steer ing cylinder as the wheel is turned If oil comes out of the ...

Page 90: ...exposed to prevent contamination 5 Before disconnecting hydraulic lines and hoses place labels to ensure proper installation after repairs are completed 6 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure that fittings will be aligned properly when reinstalling hydraulic hoses and tubes After Repair or Rep...

Page 91: ...re can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury CAUTION Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical dete...

Page 92: ...y clean hydraulic oil to gasket on new filters Screw filters on until gasket contacts mounting plate then tighten filter 3 4 turn IMPORTANT Use only hydraulic fluids specified in Traction Unit Operator s Manual Other fluids could cause system damage 6 Fill hydraulic reservoir with new hydraulic oil 7 Disconnect electrical connector to the fuel stop sole noid to prevent the engine from starting 8 M...

Page 93: ...eels will be off the ground and rotating dur ing this procedure Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone around machine IMPORTANT While engaging the traction circuit monitor the indicator on the high flow hydraulic fil ter If the indicator should show red either reduce pressure on the traction pedal or reduce engine speed to decrease ...

Page 94: ...ck control linkage for proper adjustment binding or broken parts 6 Disconnect electrical connector to the engine fuel stop solenoid to prevent the engine from starting 7 Make sure traction pedal is in neutral and the PTO switch is OFF Turn ignition key switch to start engage starter for ten 10 seconds to prime hydraulic pumps Repeat this step again 8 Connect fuel stop solenoid to allow engine to s...

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Page 96: ...ut 8 used 19 O ring 20 Flat washer 6 used 21 Hydraulic fitting 22 Tank cap 23 O ring 24 O ring 25 Dipstick 26 Washer head screw 2 used 27 Flange nut 3 used 28 Cap screw 29 Flat washer 30 Hydraulic hose 31 Filter screen 32 Hinge bracket 33 Hinge plate 34 Hinge 2 used 35 O ring 36 Pin assembly 37 O ring 38 Rubber receptacle 39 Holding post 40 Screw 41 Rivet 42 Flat washer 43 Plug grommet 44 Manifold...

Page 97: ...ge Installation Fig 57 1 If fittings were removed from reservoir lubricate and place new O rings onto fittings Install fittings into reser voir openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter 2 Lubricate new suction strainer O ring and install onto strainer Th...

Page 98: ...ston traction pump 2 Flange nut 2 used 3 Flange head screw 2 used 4 Guard hoop 5 Cap screw 2 used 6 Engine flywheel 7 Cap screw 6 used 8 Drive shaft assembly 9 Flange nut 10 Flange head screw 2 used Figure 58 FRONT RIGHT 34 to 42 ft lb 46 to 56 N m 4 3 1 2 9 10 8 5 6 7 Antiseize Lubricant ...

Page 99: ...to yoke and bearing D Hold cross in alignment and press bearing in until it hits the yoke E Install snap ring into yoke groove to secure installed bearing F Place second bearing into yoke bore and onto cross shaft Press bearing into yoke and secure with snap ring G Repeat procedure for other yoke H Grease cross untilgrease comes out ofall four 4 cups 4 Make sure that assembled joint moves without ...

Page 100: ...draulic hose 30 O ring 31 Flat washer 2 used 32 Lock washer 2 used 33 O ring 34 Flat washer 2 used 35 Lock nut 2 used 36 Flange nut 2 used 37 Pump support bracket 38 Carriage screw 2 used 39 O ring 40 Hydraulic fitting 2 used 41 O ring 42 Hydraulic tube 43 Hydraulic tube 44 Socket head screw 45 Gear pump assembly 46 Hydraulic fitting 47 Hose clamp 48 Hydraulic hose 49 Tube manifold 50 O ring 51 Tr...

Page 101: ...ely 67 pounds 30 5 kg 8 Connect a lift or hoist to hole in traction cable bracket on traction pump to support pump assembly and for pump removal 9 Loosen and remove two 2 carriage screws item 38 and flange nuts item 36 that secure pump support bracket to frame 1 Piston traction pump 2 Gear pump 3 Traction cable bracket Figure 61 2 1 3 10 Remove two 2 flange screws and flange nuts that secure tract...

Page 102: ...e harness electrical connector to traction neutral switch 9 Position traction control cable to traction pump lever and secure plate item 10 to pump lever with cap screw and lock nut Secure cable bracket to traction pump with two 2 flange head screws 10 Install hydraulic pump drive shaft see Hydraulic Pump Drive Shaft Installation in this section 11 Check oil level in hydraulic reservoir and add co...

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Page 104: ...0 End cap gasket 41 Seal kit 42 Relief valve reverse 43 Needle bearing 44 Loop flushing spool 45 Spring 46 Plug 47 O ring 48 Bypass valve 49 Seal kit 50 End cap 51 Coupling 52 Screw 4 used 53 Relief valve forward 54 Seal kit 55 Charge relief poppet 56 Spring Figure 62 9 6 7 3 4 1 5 2 8 10 12 11 14 13 17 15 18 16 19 20 21 22 23 24 25 26 27 28 26 5 8 9 32 33 34 35 37 38 36 39 40 41 42 43 44 45 47 48...

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Page 106: ...and thrust plates are not available separately Disassemble gear pump for cleaning inspection and seal replacement only IMPORTANT Keep bodies gears flanges and thrust plates for each pump section together do not mix parts between pump sections 1 Plug pump ports and thoroughly clean exterior of pump with cleaning solvent Make sure work area is clean 2 Use a marker to make a diagonal line across the ...

Page 107: ... all parts Check all components for burrs scoring nicks and other damage 9 Replace the entire pump assembly if parts are ex cessively worn or scored Disassembly Fig 63 1 Apply clean hydraulic oil to all parts before assem bling NOTE Pressure seals and back up rings fit in grooves machined into thrust plates Body seals fit in grooves machined in body faces 2 Assemble pump sections starting at front...

Page 108: ...H wheel motor 17 Lock nut 2 used 18 Flange head screw 4 used 19 Brake drum 2 used 20 Front wheel shield LH shown 21 Rear wheel shield LH shown 22 Wheel stud 5 used per wheel 23 Clevis pin 2 used 24 LH brake assembly 25 RH brake assembly 26 Cap screw 4 used per brake assy 27 Lock nut 4 used per brake assy 28 Cotter pin 2 used 29 O ring 30 O ring 31 Hydraulic hose 32 O ring Figure 65 339 to 474 N m ...

Page 109: ...and Repairs section of Chapter 6 Chassis NOTE Clevis pin that secures brake cable to brake ac tuator lever is secured with cotter pin shown in Fig 65 or extension spring shown in Figs 66 and 67 4 Remove cotter pin or spring from clevis pin that se cures brake cable to brake actuator lever Remove cle vis pin and position brake cable away from brake actuator lever 5 Remove brake drum 6 Loosen butdon...

Page 110: ...e Torque lock nuts from 80 to 100 ft lb 109 to 135 N m 4 Thoroughly clean wheel motor shaft and wheel hub taper 5 Install key into the wheel motor shaft keyslot Align wheel hub with key and slide wheel hub onto motor shaft Secure hub with lock nut A On machines with Parker wheel motors torque lock nut from 250 to 350 ft lb 339 to 474 N m B On machines with Eaton wheel motors torque lock nut from 4...

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Page 112: ... 15 16 17 18 19 20 21 22 23 24 25 NOTE The front wheel motors on Reelmaster 5010 machines with serial number below 311000600 are Parker Torqmotor TM TG Series Wheel motors have an identification tag on them which identifies the brand Right and left motors are the same basic design but the right side motors have a reverse timed manifold to allow correct rotation direction for forward and reverse Th...

Page 113: ... the re placement wheel motors may have been Eaton brand Wheel motors have an identification tag on them which identifies the brand Right and left motors are the same basic design but the right side motors have a reverse timed manifold to allow correct rotation direction for for ward and reverse The left side wheel motors are identi fied with either a machined groove or a painted yellow mark on th...

Page 114: ... 6 O ring 7 Hydraulic fitting 4 used 8 O ring 9 Hydraulic tube 10 O ring 11 Hydraulic fitting 12 O ring 13 O ring 14 Hydraulic fitting 15 O ring 16 Hydraulic hose 17 Hydraulic hose 18 Hydraulic tube 19 Flange head screw 3 used 20 Hydraulic tube 21 Hydraulic tube Figure 70 FRONT RIGHT 4 3 1 2 9 10 11 8 5 6 7 12 2 3 4 6 7 8 13 14 17 18 15 16 19 10 11 12 21 20 ...

Page 115: ...ttings to prevent contamination 8 Unplug wire harness leads from solenoid coils and switches on manifold 9 Remove three 3 flange head screws that secure manifold to machine frame 10 Remove manifold block from machine 11 Ifnecessary remove hydraulic fittings frommanifold Discard any removed O rings Installation Fig 70 1 If fittings were removed from mow control manifold lubricate and place new O ri...

Page 116: ...18 19 3 2 3 2 6 5 4 9 14 13 15 16 17 NOTE The ports on the control manifolds are marked for easy identification of components Example P1 on is the pump P1 connection port and MSV2 is the location for the solenoid relief valve MSV2 See Hydraulic Sche matics to identify the function of the hydraulic lines and cartridge valves at each port NOTE The mow control manifold uses several zero leak plugs Th...

Page 117: ...ell socket fully engages the valve base 4 Using a deep well socket remove cartridge valve from manifold Note correct location of O rings sealing rings and backup rings Remove and discard seal kit from valve IMPORTANT Before removing mow backlap spool from mow manifold remove backlap switch dowel pin and ball 5 If necessary remove mow backlap spool from mow manifold Fig 73 A Remove backlap switch f...

Page 118: ...ool Apply a light coating of grease to O ring C Carefully raise mow backlap spool until upper re taining ring groove on spool is exposed on top of manifold Install upper retaining ring D Push mow backlap spool down and install lower retaining ring to spool E If handle was removed from spool position spool so handle location of spool is between stop pins Ap ply Loctite 603 Retaining Compound or equ...

Page 119: ...rease to keep bushing toward the top of the valve stem D Place compression spring and detent pin into handle cap Use a small amount of grease to hold detent pin in place E Make sure that flow control cartridge is closed by rotating valve stem fully clockwise During handle installation DO NOT rotate valve stem or speed ad justment will be incorrect F Press handle cap onto valve stem with arrow on c...

Page 120: ...hose 8 Hydraulic hose 9 Hydraulic hose 10 Hydraulic tube 11 Hydraulic tube 12 O ring 13 O ring 14 Hydraulic fitting 15 O ring 16 Hydraulic tube 17 Hydraulic tube 18 O ring 19 Hydraulic fitting 20 O ring 21 Dust cap 22 Diagnostic fitting 23 O ring Figure 75 FRONT RIGHT 48 to 54 N m 36 to 40 ft lb 48 to 54 N m 36 to 40 ft lb 4 3 1 2 9 10 11 8 5 6 7 12 2 3 3 3 12 13 14 17 18 15 16 19 20 23 22 21 ...

Page 121: ...and an orifice is in the manifold port make sure to remove orifice and label its position for as sembly purposes 10 Ifnecessary remove hydraulic fittings frommanifold Discard any removed O rings Locate retrieve and la bel orifice from manifold ports if equipped Installation Fig 75 1 If fittings were removed from manifold A Lubricate new O rings with clean hydraulic oil Install lubricated O rings o...

Page 122: ...4 used Figure 77 FRONT RIGHT 4 3 1 2 9 10 11 8 5 6 7 12 4 5 6 6 13 14 15 16 33 N m 25 ft lb 27 N m 20 ft lb 27 N m 20 ft lb 101 N m 75 ft lb 27 N m 20 ft lb 33 N m 25 ft lb 48 to 60 in lb 5 4 to 6 7 N m 48 to 60 in lb 5 4 to 6 7 N m 48 to 60 in lb 5 4 to 6 7 N m NOTE The ports on the lift control manifold are marked for easy identification of components Example P4 is the gear pump P4 connection po...

Page 123: ...is placed be neath several of the hydraulic fittings on the lift con trol manifold Fig 78 The lift manifold uses three 3 different orifice sizes If a fitting is removed from the lift control manifold and an orifice is in the man ifold port make sure to remove orifice and label its position for assembly purposes IMPORTANT When installing orifice in manifold Fig 78 make sure that orifice is flat in ...

Page 124: ...tion 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 3 Locate CrossTraxTM AWD manifold that is attached to bracket at rear of frame 4 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic connections prior to loosening hydraulic lines CAUTION Before opening...

Page 125: ...all fittings into manifold see Hydraulic Fitting Installation in the Gener al Information section of this chapter 2 Position manifold and three 3 spacers to frame bracket Install three 3 lock washers and cap screws but do not fully tighten 3 Remove caps and plugs from disconnected lines and fittings 4 Lubricate and install new O ring s on manifold fit tings Connect hydraulic lines to hydraulic man...

Page 126: ...l kit 12 Bi Directional relief valve Figure 80 4 3 1 2 9 10 11 8 5 6 7 12 2 2 3 3 4 5 6 7 33 N m 25 ft lb 33 N m 25 ft lb 120 in lb 13 5 N m 62 N m 46 ft lb 220 in lb 24 8 N m 220 in lb 24 8 N m 220 in lb 24 8 N m For AWD control manifold service procedures see Mow Control Manifold Service in this section Refer to Figure 80 for cartridge valve installation torque NOTE Adjustment of Bi Directional ...

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Page 128: ...otor 2 Figure 81 4 3 20 2 8 6 7 4 3 19 2 8 6 7 4 3 16 2 9 8 5 6 7 4 3 15 2 10 11 8 6 12 4 3 1 2 9 8 5 6 7 2 3 4 5 4 2 13 14 4 3 2 5 4 3 2 17 18 17 17 18 17 2 3 4 FRONT RIGHT Removal Fig 81 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 Comp...

Page 129: ... discard O rings Installation Fig 81 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 in the General Information section of this chapter Make sure that fittings are orientated correctly 2 Install reel motor to cutting unit see Hydraulic Reel Motor Installation in the Service ...

Page 130: ... 5 6 7 12 1 2 10 12 7 3 5 6 9 11 8 5 6 7 12 15 15 16 17 19 18 13 14 16 13 14 47 to 55 N m 35 to 40 ft lb BOSCH MOTOR DANFOSS MOTOR SAUER RM5510 5610 RM5210 5410 17 18 20 15 to 20 N m 11 to 15 ft lb 15 to 20 N m 11 to 15 ft lb NOTE Sauer Danfoss cutting reel motors are used on Reelmaster 5210 and 5410 machines Bosch reel mo tors are used on Reelmaster 5510 and 5610 machines Reel motors are not inte...

Page 131: ...sh on the rear bearing block to remove bearing block and gear set Fig 85 NOTE Pressure seals and back up rings in Sauer Danfoss motors fit in grooves machined into front and rear cover Fig 86 Pressure seals and back up rings in Bosch motors fit in grooves machined into bearing blocks 8 Carefully remove and discard O rings pressure seals and back up rings from motor Do not cause any damage to the m...

Page 132: ...w by carefully placing the back up rings into the grooves 4 Install lubricated O rings to the body 5 Lubricate gear faces and bearing surfaces of drive gear idler gear and bearing blocks with clean hydraulic oil Carefully assemble bearing blocks and gears noting identification marks made during disassembly 6 Position the motor body on its side Carefully slide bearing block and gear assembly into t...

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Page 134: ... 90o hydraulic fitting 9 O ring 10 Hydraulic hose 11 Retaining ring 12 Thrust washer 13 Cylinder slide pin Figure 88 FRONT RIGHT 4 3 1 2 10 11 5 12 3 11 9 12 13 67 to 83 ft lb 91 to 112 N m 67 to 83 ft lb 91 to 112 N m 9 8 6 7 7 8 NOTE The procedure for lift cylinder removal and installation is the same for all Reelmaster 5010 lift cylin ders Figure 88 shows the right front lift cylinder ...

Page 135: ...etain lift cylinder to pivot shaft 8 Remove lift cylinder from pivot shaft and frame 9 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Remove fittings from lift cylinder and discard O rings Installation Fig 88 1 Ifhydraulic fittings were removed fromlift cylinder lu bricate new O rings position O rings to fittings and install fittings ...

Page 136: ...cylinder is shorter with less stroke than the other lift cylinders which are identical Service procedures for all lift cylinders used on Reel master 5010 machines are the same Disassembly Fig 89 1 Remove oilfromliftcylinder into a drainpan byslowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise c...

Page 137: ... damaged Assembly Fig 89 1 Make sure all lift cylinder parts are clean before as sembly 2 Coat new O rings back up washer and other seals with clean hydraulic oil A Carefully install cap seal and O rings to the pis ton B Carefully install back up washer O ring u cup and wiper to the head IMPORTANT Do not clamp vise jaws against the shaft surface Clamp on the clevis ONLY 3 Mount shaft securely in a...

Page 138: ...n gine Remove the key from the ignition switch 2 Remove fasteners that secure shroud to front of ma chine Fig 91 Remove shroud from machine to allow access to steering control valve Locate and retrieve two 2 rubber bushings and spacers 3 Slide rubber bellows up from bottom of steering col umn Support steering column to prevent it from falling 4 Loosen and remove four 4 flange head screws and flang...

Page 139: ... 2 Apply antiseize lubricant to splines of steering con trol valve shaft 3 Slide steering control valve shaft into steering col umn universal joint Position control valve with ports to ward front of machine Secure steering control valve to steering column with four 4 socket head screws Hand tighten screws in a crossing pattern and then torque screws again in a crossing pattern from 7 to 10 ft lb 9...

Page 140: ...Sleeve 12 Cross pin 13 Spring set 14 Ring 15 Thrust washer 16 Bearing 17 Shaft seal 18 Ball stop 19 Check ball 20 Housing 21 Dust seal ring 22 Relief valve 23 Spring 24 O ring 25 Plug 26 Plug Figure 93 2 3 4 5 6 1 9 8 7 10 11 14 12 13 4 15 16 17 18 19 20 21 24 25 22 23 26 20 to 24 ft lb 27 to 33 N m NOTE For repair of the steering control valve see the Sauer Danfoss Steering Unit Type OSPM Service...

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Page 142: ... Steering cylinder 2 Retaining ring 3 Grease fitting 4 Hydraulic hose 5 O ring 6 90o 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 Ball joint Figure 94 FRONT RIGHT 4 3 1 2 9 10 11 8 5 6 7 12 6 5 7 13 14 ...

Page 143: ...er and discard O rings Installation Fig 94 1 If hydraulic fittings were removed from steering cylin der lubricate new O rings with clean hydraulic oil posi tion O rings to fittings and install fittings into steering cylinder ports see Hydraulic Fitting Installation in the General Information section of this chapter Make sure that fittings are orientated correctly 2 Ifremoved pressballjointinto bar...

Page 144: ... end of the barrel Use of a vise with soft jaws is recommended 3 Using a spanner wrench rotate head clockwise until the edge of the retaining ring appears in the barrel open ing Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the open ing Rotate the head counter clockwise to remove re taining ring from barrel and head 4 Remove plugs from ports ...

Page 145: ...oil Slide head and piston onto the shaft 4 Using a wrench on shaft flats to prevent shaft from rotating install lock nut Torque lock nut from 30 to 35 ft lb 41 to 47 N m IMPORTANT Prevent damage when clamping the steering cylinder into a vise clamp on the clevis end of the barrel ONLY 5 Mount barrel securely in a vise by clamping on the clevis end of the barrel IMPORTANT When installing the head i...

Page 146: ... the oil cooler used on other Reelmaster 5010 machines Figure 98 illustrates the oil cooler used on the Reelmaster 5610 Removal Fig 97 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 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic connections prior t...

Page 147: ...ydraulic fittings clamps and brackets to oil cooler using Figures 97 and 98 as guides On Reelmaster 5210 machines not shown apply hy draulic thread sealant on hydraulic fitting threads before installation 2 Position oil cooler to radiator and secure with clamps 3 Install hydraulic hoses to oil cooler fittings and se cure with hose clamps 4 Install radiator screen to machine Close hood 5 Check oil ...

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Page 149: ...utral Switch 27 Seat Switch 28 Headlight Switch 29 Parking Brake Switch 30 Up Limit Switch 31 Joystick Raise and Lower Switches 32 Mow Transport Switch 33 Backlap Switches 34 Start Relay 35 Main Power and Glow Relays 36 Electronic Control Module ECM 37 Diode Assembly 38 Fusible Link Harness 38 Fuses 39 Hydraulic Solenoid Valve Coil 40 Temperature Sender 41 High Temperature Shutdown Switch 42 Oil P...

Page 150: ...gitalme ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current could cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro Part Number 505 165 Figure 2 Battery Terminal Protector Aerosol spray tha...

Page 151: ... Refer to your Parts Catalog for overlay language options and part numbers IMPORTANT The Diagnostic Display must not be left connected to the machine It is not designed to withstand the environment of the machine s every day use When use of Diagnostic Display is com pleted disconnect it from the machine and recon nect loopback connector to harness connector Machine will not operate without loopbac...

Page 152: ...n be retrieved at a future time If the diagnostic light does not illuminate when the igni tion switch is turned to the RUN position possible causes are 1 Loopback harness is not connected to the wire harness 2 The diagnostic light or circuit wiring is faulty 3 ECM fuses are faulty 4 The ECM is faulty Check electrical connections ECM fuses and the diag nostic light to determine malfunction Make sur...

Page 153: ...unit lift electrical circuit 4 2 SV3 current was too high check cutting unit lift electrical circuit 4 3 SV2 current was too high check cutting unit lift electrical circuit 4 4 SVRV current was too high check cutting unit lift electrical circuit 4 5 MSV1 current was too high check rear mow electrical circuit 5 1 Signal from optional leak detector was lost 5 4 Internal ECM fault Clearing Fault Code...

Page 154: ...g switches before oper ating the machine 1 Park machine on a level surface lower the cutting units stop the engine and engage the parking brake 2 Open control panel cover Locate wire harness and connectors near ECM Carefully unplug loop back con nector from harness connector Fig 8 3 Connectthe DiagnosticDisplay connectorto thehar ness connector Make sure correct overlay decal is posi tioned on the...

Page 155: ...rd LED ON Joystick in neutral LED OFF TEMP SHUTDN Very excessive engine temperature LED ON Normal engine temperature LED OFF ALT FAULT Engine not running or alternator faulty LED ON Alternator OK LED OFF OIL PRES LOW Engine not running OR low engine oil pressure LED ON Engine oil pressure OK LED OFF TR NEUTRAL Traction pedal in neutral LED ON Traction pedal in forward or reverse LED OFF KEY START ...

Page 156: ...s often as required Do not press and hold toggle but ton 6 Sit on seat and attempt to operate the desired func tion of the machine The appropriate output LED s should illuminate on the Diagnostic Display to indicate that the ECM is turning on that function The Glow Start ETR and Diag Lamp outputs can be checked with the ignition switch in the RUN position and the engine not running For testing of ...

Page 157: ...er Raise PTO Switch in ON Mow Transport Lever in Mow Up Limit Switch Closed C U Lowered Front C U in Backlap Position Rear C U in Backlap Position OUTPUTS SV1 Front Lift Cylinders Energized SV2 Energized SV3 Rear Lift Cylinders Energized SVRV Energized MSV1 Rear Reel Motors Energized MSV2 Front Reel Motors Energized Engine Run Solenoid Hold Coil Energized Engine Start Run Solenoid and Start Soleno...

Page 158: ...is discharged Battery cables are loose or corroded Ground cable is loose or corroded Wiring at the starter motor is faulty Starter solenoid or starter motor is faulty Engine starts but stops when the ignition switch is released from the START position Engine fuel stop solenoid or circuit wiring is faulty pull coil operates but hold coil is faulty Engine cranks but does not start Engine and or fuel...

Page 159: ...l switch is out of adjustment Traction neutral switch or circuit wiring is faulty Seat switch or circuit wiring is faulty Parking brake switch or circuit wiring is faulty Joystick switch raise or lower position is faulty Ignition switch or circuit wiring is faulty Start relay or circuit wiring is faulty Main power relay or circuit wiring is faulty headlights and powerpoint inoperative as well ECM ...

Page 160: ...perator can restart the engine to allow the machine to be moved a short distance After a restart in this condition the engine will run for approximately 10 seconds before the engine shuts down again Parking brake is engaged Operator is raising from the seat seat switch not fully depressed Seat switch or circuit wiring is faulty Ignition switch or circuit wiring is faulty The engine kills when the ...

Page 161: ...has occurred PTO switch is in the OFF position High coolant temperature disabled cutting units Seat switch or circuit wiring is faulty PTO switch or circuit wiring is faulty Up limit switch or circuit wiring is faulty Mow transport switch or circuit wiring is faulty Temperature sender or circuit wiring is faulty Ground circuit wiring to hydraulic solenoids may be open A hydraulic problem in cuttin...

Page 162: ...sts see Troubleshooting section of Chapter 4 Hydraulic System None of the cutting units will raise Front and or rear backlap levers are in backlap position Raise switch on joystick or circuit wiring is faulty Front and or rear backlap switch or circuit wiring is faulty Solenoid SVRV or circuit wiring is faulty Solenoid SV2 or circuit wiring is faulty A hydraulic problem exists see Troubleshooting ...

Page 163: ...ny of the following conditions occur the opera tion of the TurfDefenderTM should be checked A No beeps are heard when ignition switch is turned ON B Any time the machine gives a series of 4 short beeps C False alarms are observed 1 Park machine on a level surface lower cutting units stop engine and engage parking brake 2 Raisehydraulic reservoir cover Locate leak detector wire harness loopback con...

Page 164: ...sed by the TurfDefend erTM Fig 16 A Valve Open Circuit LED blinking check replace TurfDefenderTM electric solenoid valve or wires B Valve Short Circuit LED blinking check replace TurfDefenderTM electric solenoid valve or wires C Self Diagnostic LED blinking internal circuit fail ure in TurfDefenderTM D Data Line LED blinking problem with commu nications between ECM and TurfDefenderTM or problem wi...

Page 165: ...OUTPUT TANK LEVEL HIGH TANK LEVEL OK TANK LEVEL LOW UNUSED UNUSED UNUSED UNUSED UNUSED INPUTS DISPLAYED OUTPUTS DISPLAYED FLOAT LEVEL BOTTOM 3 2 1 1 LED lit if tank level is too high 2 LED lit if tank level is OK 3 LED lit if tank level is too low 4 One or two LED s lit displaying relative position of the TurfDefender s internal float Normal level is combin ation of levels 3 and or 4 5 Inputs Disp...

Page 166: ...n the condition of the battery charge and battery temperature the battery voltage will increase at different rates as the battery charges Start the engine and run at high idle 3200 RPM Allow the battery to charge for at least 3 minutes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be atleast0 50 volthigherthan initialbat tery voltage An example o...

Page 167: ...rol Module ECM which moni tors interlock switch operation Information on the ECM is described in the Traction Unit Operator s Manual and in the Component Testing section of this Chapter The interlock system used on your Reelmaster includes 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 ...

Page 168: ...itch body but clear ance is less than 0 125 3 2 mm C Torque jam nut from 71 to 89 in lb 8 to 10 N m to secure adjustment After jam nut is tightened make sure that clearance between cap screw head and neutral switch has not changed 3 For machines with serialnumbers above 310000000 Fig 18 adjust traction neutral switch as follows A When the traction lever is in the neutral position the clearance bet...

Page 169: ...ines with serial numbers above 310000000 Fig 20 the distance between the parking brake switch and the tab on the parking brake detent should be from 0 040 to 0 100 1 1 to 2 5 mm when the parking brake is not applied If distance is incorrect loosen jam nuts that secure brake switch to brake pedal Position switch with jam nuts to allow correct clearance between switch and brake detent tab Jam nuts s...

Page 170: ...en two 2 lock nuts that secure switch bracket to machine frame Position bracket to allow correct clearance between switch and sensing plate Tighten lock nutsto securead justment For machines with serial numbers above 310000000 Fig 22 the distance between the up limit switch and the sensing plate on lift arm should be from 0 040 to 0 100 1 1 to 2 5 mm If distance is incorrect loosen jam nuts that s...

Page 171: ...of this chapter 2 If the Diagnostic Display verifies that ignition switch and circuit wiring are functioning correctly no further switch testing is necessary 3 If the Diagnostic Display determines that ignition switch and circuit wiring are not functioning correctly test ignition switch as follows A Remove outside control arm cover to gain access to ignition switch see Control Arm Disassembly in t...

Page 172: ...e oil filter Turn ignition switch to the RUN position the engine oil pressure light should come on in dicating correct operation of the indicator light and cir cuit wiring Charge Indicator Light The charge indicator lightshould come on when the igni tion switch is in the RUN position with the engine notrun ning Also it should illuminate with an improperly operating charging circuit while the engin...

Page 173: ...eter 9 Install control arm covers to machine see Control Arm Assembly in the Service and Repairs section of this chapter Figure 25 QUARTZ Hobbs HOURS 1 0 0 0 0 1 10 BACK Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine op eration The changingresistance ofthe enginetempera ture sender signals the temperature gauge The temperature...

Page 174: ...Repairs section of this chapter B Make sure ignition switch is in the OFF position Disconnect harness electrical connector from the switch C With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position The PTO switch terminals are marked as shown in Figure 28 The circuitry of this switch i...

Page 175: ...nector from the switch and check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals B There should be continuity across the switch ter minals when the traction pedal is in the neutral posi tion There should not be continuity when the traction pedal is in either the forward or reverse direction 4 On machines with serial numbers above 310000000...

Page 176: ... and circuit wiring are not functioning correctly test seat switch as follows A Make sure ignition switch is in the OFF position B Disconnect wire harness electrical connector from the seat switch electrical lead near the manual tube under the operator seat Fig 31 C Checkthecontinuityoftheswitchby connectinga multimeter ohms setting across the switch connec tor terminals D With no pressure on the ...

Page 177: ...hms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position The switch terminals are marked as shown in Figure 32 The circuitry of the headlight switch is shown in the chart below Verify continuity between switch ter minals SWITCH POSITION NORMAL CIRCUITS OTHER CIRCUITS ON 2 3 5 6 OFF 2 1 5 4 4 Replace switch if necessary Co...

Page 178: ...ch by connecting a multimeter ohms setting across the switch connector terminals B There should be continuity closed between the switch terminals when the parking brake is released not applied There should not be continuity open between the switch terminals when the parking brake pedal is depressed applied 3 On machines with serial numbers above 310000000 Fig 36 test parking brake switch as follow...

Page 179: ... switch connector terminals B There should be continuity closed between the switch terminals when the cutting units are lowered Raise the cutting units and check the continuity ofthe switch There should not be continuity open be tween the switch terminals when the cutting units are raised 3 On machines with serial numbers above 310000000 Fig 38 test up limit switch as follows A Turn ignition switc...

Page 180: ...isplay determines that either joys tick switch and circuit wiring are not functioning correct ly test joystick switches as follows A Remove control arm covers to gain access to joystick switches see Control Arm Disassembly in the Service and Repairs section of this chapter B Make sure ignition switch is in the OFF position C Disconnect harness electrical connector from the raise or lower switch th...

Page 181: ...en between the switch terminals when the mow stop lever is in the transport position 3 On machines with serial numbers above 310000000 Fig 42 test mow transport switch as follows A Turn ignition switch to the ON position do not start engine and check LED on cable end of mow transport switch B LED should be illuminated when the mow stop lever is in the mow position LED should not be illu minated wh...

Page 182: ...g are not functioning correctly test backlap switch as follows A Make sure ignition switch is in the OFF position B Tilt operator seat to gain access to backlap switch Locate the backlap switch on hydraulic mow control manifold Disconnect the harness electrical connector from the backlap switch C Checkthecontinuityoftheswitchby connectinga multimeter ohms setting across the switch connec tor termi...

Page 183: ...en hood to gain access to relay 3 Locate start relay and disconnect the machine wire harness connector from the relay Remove relay from machine for easier testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of th...

Page 184: ...gnition switch 2 Open hood to gain access to relay 3 Locate relay and disconnect the machine wire har ness connector from the relay Remove relay from ma chine for easier testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal r...

Page 185: ...rcuit hydraulic valve sole noid coils lift circuit hydraulic valve solenoid coils diag nostic light and engine components glow plug relay start relay fuel pump and engine run solenoid are con trolled based on the inputs received by the ECM If the ECM detects a malfunction in any of the controlled circuits the Diagnostic light can be used to identify the fault see Diagnostic Light in the Troublesho...

Page 186: ...le links for circuit protection These fusible links are located in a harness that connects the starter B terminal to the main wire harness Fig 47 If any of these links should fail current to the protected circuit will cease Refer to wire harness drawings in Chapter 9 Electrical Diagrams for addi tional fusible link information Testing Make sure that ignition switch is OFF and disconnect negative b...

Page 187: ...0 Amp Protects main power supply Left Fuse 3 10 Amp Protects power supply for headlights Left Fuse 4 10 Amp Protects power supply for power point Right Fuse 1 10 Amp Protects power supply for ECM outputs Right Fuse 2 10 Amp Protects power supply for ECM outputs Right Fuse 3 10 Amp Protects power supply for ECM outputs Right Fuse 4 2 Amp Protects power supply for ECM logic Testing Remove fuses from...

Page 188: ...leads together The meter may display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 5 Using a multimeter ohms setting measure resis tance between the two connector terminals on the sole noid valve coil The resistance for the solenoid co...

Page 189: ... to gain access to engine CAUTION Make sure engine is cool before removing the temperature sender from engine 2 Lower the coolant level in the engine remove wire harness connector from temperature sender and re move the sender from the engine 3 Put the end of the sender in a container of oil with a thermometer and slowly heat the oil Fig 54 CAUTION Handle the hot oil with extreme care to prevent p...

Page 190: ...identify the fault see Diagnostic Light in the Trouble shooting section of this chapter Testing 1 Park machine on a level surface lower cutting units stop engine apply parking brake and remove key from ignition switch Open hood to gain access to engine CAUTION Make sure engine is cool before removing the temperature switch from engine 2 Lower the coolant level in the engine and remove the high tem...

Page 191: ...ht in the Troubleshooting section of this chapter Testing NOTE Refer to engine service manual for information regarding engine lubrication system and testing 1 Turn the ignition switch to the RUN position The oil pressure indicator light on the control panel should be illuminated 2 If the indicator light is not illuminated open hood to gain access to engine 3 Locate oil pressure switch on engine a...

Page 192: ... is removed from the engine make sure that the solenoid plunger moves freely and is free of dirt debris and corrosion NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from t...

Page 193: ...to START Note Machines that are equipped with a Biodiesel Conversion Kit will have the same fuel pump as ma chines with serial numbers above 280000000 6 Collect fuel in the graduated cylinder by turning igni tion switch to the RUN position Allow pump to run for time listed below then return switch to OFF A For machines with serial numbers below 280000000 the amount of fuel collected in the grad ua...

Page 194: ...rom the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts CAUTION IMPORTANT Do not remove battery fill caps while cleaning 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will disch...

Page 195: ...hort circuits or faulty components and repaired 6 Lower and secure hood Inspection Maintenance and Testing 1 Perform the following inspections and maintenance A Check battery case for cracks Replace battery if cracked or leaking 1 Battery 2 Battery tray 3 Retainer 4 Flange nut 5 Carriage screw 6 Negative battery cable 7 Positive battery cable 8 Fusible link Figure 62 2 7 3 4 5 1 6 8 FRONT B Checkb...

Page 196: ...y as itsimulates the cold cranking test A commercialbat tery load tester is required to perform this test CAUTION Follow the battery load tester manufacturer s instructions when using a battery load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B If the battery has recently been charged remove the batt...

Page 197: ...250 5 8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60o F 15 5o C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive kee...

Page 198: ... Clevis pin 12 Screw 13 Latch 14 Swell latch 2 used 15 Access cover 16 Washer head screw 10 used 17 Flat washer 18 Foam seal 19 Cotter pin 20 Throttle control assembly 21 Foam seal 22 Flange nut 23 Spacer 24 Cotter pin 25 Retainer bracket 26 Spring 27 Clevis pin 28 Flange head screw 2 used 29 Flat washer 2 used Figure 63 FRONT RIGHT 2 3 1 4 5 6 8 9 7 12 13 14 15 16 17 18 20 23 25 21 26 24 27 22 22...

Page 199: ...needed using Figure 65 as a guide Assembly Fig 63 1 Install all removed electrical components to control arm using Figure 65 as a guide 2 Position covers to control arm As LH cover item 3 is placed plug wire harness connector to headlight switch Also make sure that wire harness and throttle control cable are routed correctly through cover open ings Fig 64 3 Secure each cover to controlarm with fiv...

Page 200: ...ons on the lift control manifold 3 Disconnect the wire harness electrical connector from the solenoid valve coil to be replaced 4 Remove the nut from the hydraulic valve 5 Ifequipped SV1andSV3onliftcontrolmanifold re move coil spacer from hydraulic valve 6 Slide the solenoid coil from the valve 7 Clean any corrosion or dirt from the valve Installation 1 Slide new coil assembly onto the hydraulic v...

Page 201: ...ve backlap switch from hydraulic manifold Remove and discard o ring Installation Figs 68 and 69 1 Make sure that dowel pin and ball are placed in man ifold port as shown in Figure 69 2 Install backlap switch with new o ring into manifold port and torque to 15 ft lb 20 N m 3 Connect harness electrical connector to the backlap switch Use the Diagnostic Display to verify that backlap switches are fun...

Page 202: ...N m 100 to 125 in lb 12 to 14 N m 20 to 25 ft lb 27 to 33 N m 19 TurfDefenderTM Operation The optional TurfDefenderTM is an electronic hydraulic fluid leak detection device that fits inside the hydraulic reservoir of the machine It is a pressure based system which requires a sealed hydraulic reservoir to function properly The solenoid valve that is attached to the leak detector assembly allows the...

Page 203: ...to 33 N m 2 If the leak detector assembly is to be removed from the hydraulic reservoir A Tip the hydraulic reservoir cover to gain access to TurfDefenderTM Thoroughly clean the top of the hy draulic reservoir around the TurfDefenderTM upper housing B Disconnect leak detector wire harness connector from machine wire harness Disconnect wire har ness connectors from the alarm C Remove six 6 socket h...

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Page 205: ...ATIONS 2 GENERAL INFORMATION 2 Traction Unit Operator s Manual 2 SERVICE AND REPAIRS 4 Wheels 4 Steering Column 6 Brake Service 8 Rear Wheel Bearings 2 Wheel Drive 12 Rear Axle 14 Rear Axle Service 16 Operator Seat 18 Mechanical Seat Suspension 20 Front Lift Arms 22 Rear Lift Arms 24 Chassis ...

Page 206: ...M 5210 12 to 15 PSI 83 to 103 kPa 20 x 12 0 10 4 ply tubeless Rear Tire Pressure RM 5210 12 to 15 PSI 83 to 103 kPa 20 x 10 0 10 4 ply tubeless Wheel Lug Nut Torque 70 to 90 ft lb 95 to 122 N m 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 machin...

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Page 208: ...el motor 2 Brake assembly 3 Front wheel hub 4 Lock nut 5 Brake drum 6 Front wheel 7 Lug nut 5 used per wheel 8 Rear wheel hub 9 Tab washer 10 Rear wheel 11 Jam nut 12 Retainer 13 Cotter pin 14 Dust cap Figure 1 FRONT RIGHT 70 to 90 ft lb 95 to 122 N m 2 3 1 4 5 6 8 9 7 10 11 12 13 14 7 ...

Page 209: ... ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or other ap propriate load holding devices to support the raised machine If the machine is not properly supported the machine may move or fall which may result in personal injury CAUTION 4 Using a jack raise machine so wheel is off ground see Jacking Instructions in Chapter 1 Safe...

Page 210: ...0 Lock nut 21 Flat washer 22 O ring 23 Gear pump Figure 2 FRONT RIGHT 2 1 16 17 19 19 18 9 10 12 11 21 13 3 4 15 7 5 14 8 20 6 7 15 23 20 to 26 ft lb 28 to 35 N m ANTISEIZE LUBRICANT ANTISEIZE LUBRICANT 22 Removal Fig 2 1 Park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch 2 Remove cover from steering whe...

Page 211: ...teering column onto steering control valve Secure steering column in place with four 4 flange head screws item 15 and flange nuts item 7 3 Secure steering controlvalve tosteering columnwith four 4 socket head screws item 6 4 Slide rubber bellows to bottom of steering column 5 Place rubber bushings and spacers into holes of shroud Position shroud in place and secure with re moved fasteners 6 Slide ...

Page 212: ...H wheel motor Parker 17 Lock nut 2 used 18 Flange head screw 4 used 19 Brake drum 2 used 20 Front wheel shield LH shown 21 Rear wheel shield LH shown 22 Wheel stud 5 used per wheel 23 Clevis pin 2 used 24 LH brake assembly 25 RH brake assembly 26 Cap screw 4 used per brake assy 27 Lock nut 4 used per brake assy 28 Cotter pin 2 used 29 O ring 30 O ring 31 Hydraulic hose 32 O ring Figure 5 339 to 47...

Page 213: ...te puller to loosen wheel hub from wheel motor shaft 9 Remove lock nut and wheel hub from motor shaft Locate and retrieve woodruff key NOTE If desired the complete brake assembly can be removed from the machine for disassembly see step 12 10 Remove upper and lower shoe springs from brake shoes 11 Remove shoe hold down cups and hold down springs Remove brake shoes and hold down pins from backing pl...

Page 214: ...l motor shaft with lock nut item 17 8 Install brake drum 9 Position brake cable end to brake actuator lever Se cure brake cable clevis to brake actuator lever with cle vis pin and cotter pin or spring 10 Install front wheel assembly see Wheel Installation in this section 11 Check and adjust brakes 12 Lower machine to ground 13 Torque lug nuts evenly in a crossing pattern from 70 to 90 ft lb 95 to ...

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Page 216: ... C Rear Wheel Bearings 2 Wheel Drive 1 Dust cap 2 Cotter pin 3 Retainer 4 Jam nut 5 Tab washer 6 Bearing cone 7 Bearing cup 8 Wheel hub 9 Seal 10 Spindle 11 Wheel stud 5 used Figure 9 1 3 2 8 4 5 7 6 6 10 See text for tightening procedure 9 7 11 ...

Page 217: ... both bearings with grease Install one bearing into the bearing cup on inboard side of the wheel hub Lubricate the inside of a new seal and press it into the wheel hub with the seal lip toward the bearing 3 Fill wheel hub cavity between bearings approximate ly 50 full of grease Position remaining bearing into the outer bearing cup 4 Slide the wheel hub assembly onto the spindle shaft and secure it...

Page 218: ... hub assembly 14 Grease fitting 15 O ring 16 Jam nut 17 Nut retainer 18 Hydraulic hose 19 O ring 20 Cotter pin 21 Steering cylinder 22 Ball joint 23 Ball joint 24 Retaining ring 25 Jam nut 26 Wheel assembly 27 Grease fitting 28 Bushing 29 Slotted hex nut 30 Hydraulic hose 31 Slotted hex nut Figure 10 FRONT RIGHT 9 10 11 22 4 29 15 28 3 20 30 20 7 27 19 13 2 12 8 6 23 21 24 18 7 14 16 17 1 20 26 5 ...

Page 219: ...ent it from falling 8 Pull the axle pivot pin from frame and rear axle This will release the rear axle and thrust washers item 7 from the frame Carefully pull the entire axle and wheel assembly out from under the machine Installation Fig 10 1 Thoroughly clean the rear axle pivot pin Inspect the pin for wear or damage and replace if necessary 2 Position the rear axle assembly to the frame Install t...

Page 220: ...oint 23 Ball joint 24 Retaining ring 25 Jam nut 26 Wheel assembly 27 LH drag link 28 Spindle 29 Tab washer 30 Flange head screw 31 Hydraulic fitting 32 Hydraulic hose 33 Grease fitting 34 O ring 35 O ring 36 Bushing 37 Slotted hex nut 38 Grease seal 39 Bearing cup 40 Bearing cone 41 Wheel stud 5 used per wheel 42 Dust cap 43 Flange bushing 44 Grease fitting 45 Slotted hex nut Figure 11 FRONT RIGHT...

Page 221: ...ylinder from drag link 4 Remove the flange head screw spindle cap and re taining ring that secure the wheel spindle into the axle tube Slide the spindle and wheel assembly out of the axle tube to expose the spindle bushings Locate and re trieve thrust washer item 19 from wheel spindle shaft 5 Use a bushing removal tool to extract both bushings from the axle tube Take care to not damage the bore of...

Page 222: ...21 R clamp 2 used 22 Manual housing 23 Cap 4 used 24 Flange nut 4 used 25 Seat suspension 26 Flange head screw 4 used Figure 12 15 4 16 1 2 7 6 12 10 11 14 9 17 8 3 5 13 20 21 24 25 22 23 19 18 24 23 FRONT RIGHT 21 26 IMPORTANT The operator seat seat base and con trol arm assembly are attached to the machine with the same fasteners Make sure to support the seat base and control arm to prevent them...

Page 223: ...nd seat base to seat adjust ers 7 Support seat base to keep it positioned on seat ad justers 8 Remove operator seat from seat adjusters Installation Fig 12 1 Position seat and seat base to seat adjusters 2 Secure seat and seat base to seat adjusters with four 4 flat washers and socket head screws IMPORTANT Take care to not damage throttle cable or electrical harness when installing control arm as ...

Page 224: ...ed 18 Stop bumper 19 Height adjust rod 20 Lock nut 21 Stop bumper 2 used 22 Bearing tube 2 used 23 Spring shaft 24 Pivot pin 25 Roller pin 26 Spring bushing 2 used 27 Shaft block 2 used 28 Weight adjust spacer 29 Weight indicator assembly 30 Weight adjust nut 31 Rivet 32 Roller 4 used 33 Extension spring 34 Bumper 35 Hex nut 2 used 36 Retainer 3 used 37 Flat washer 38 Flat washer 39 Thread forming...

Page 225: ...cate and retrieve four 4 spacers Figure 16 item 7 from be tween seat suspension and seat frame 7 Remove seat suspension components as needed using Figures 15 and 16 as guides Installation Figs 15 and 16 1 Install all removed seat suspension components us ing Figures 15 and 16 as guides IMPORTANT Take care to not damage the throttle cable or electrical harness when installing seat sus pension to ma...

Page 226: ...fitting 2 used per lift arm 20 Bridge plate 21 Snapper pin 1 used per lift arm 22 Cap 1 used per lift arm 23 Thrust washer 1 used per plate 24 Cap screw 1 used per plate 25 Chain 3 used 26 Up limit switch 27 Carriage bolt 28 Switch plate 29 Lock nut 30 Flange nut 2 used per chain hoop 31 Flange bushing 2 used per lift arm 32 Flange bushing 2 used per lift arm 33 Grease fitting 1 used per yoke 34 B...

Page 227: ...yoke Lift arm bushings should be pressed until bushing flange is against lift arm bore The upper pivot yoke bushing should be pressed ful ly to the shoulder in the pivot yoke bore The lower pivot yoke bushing should be flush with the yoke tube Installation Fig 17 1 Slide front lift arm onto pivot shaft Secure lift arm with bridge plate Torque flange screw s item 12 that secure bridge plate to pivo...

Page 228: ... pin 32 Retaining ring 2 used per pin Figure 21 FRONT RIGHT 17 28 27 20 16 13 18 21 13 3 15 9 10 2 12 22 4 25 1 23 5 6 14 8 7 19 15 24 11 26 13 12 26 27 29 29 29 31 32 30 31 32 Removal Fig 21 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove cutting unit from rear lift arm to be removed 3 Remove one retaining rin...

Page 229: ...bushing flange is against lift arm bore The upper pivot yoke bushing should be pressed ful ly to the shoulder in the pivot yoke bore The lower pivot yoke bushing should be flush with the yoke tube Installation Fig 21 1 Position rear lift arm to frame and slide pivot pin through frame bosses and lift arm Secure pin with washer head screw 2 Place washer spacer and torsion spring over rear of each pi...

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Page 231: ...eling Rear Roller 13 SERVICE AND REPAIRS 14 Hydraulic Reel Motor 14 Backlapping 15 Bedbar Assembly 16 Bedbar Adjuster Service 18 Bedknife Replacement and Grinding 20 Reel Assembly Removal and Installation 22 Reel Assembly Removal 23 Reel Assembly Installation 23 Reel Assembly Service 26 Preparing Reel for Grinding 28 Front Roller 30 Rear Roller 31 Roller Service Greasable Bearings with Retaining R...

Page 232: ...th spline The drive inserts for 7 inch reels have an internal nine tooth spline Height of Cut HOC Cutting height is adjusted on the front roller by two vertical screws Effective HOC may vary depending on turf conditions type of bedknife roller type and installed attachments Bedknife Replaceable high carbon steel EdgeMaxTM bedknife is fastened to a machined cast iron bedbar with 8 screws Optional b...

Page 233: ... 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 Refer to those publi cations for additional information when servicing the cutting units Cutting Units ...

Page 234: ...omer Figure 2 Used for Height of Cut adjustment Used for Groomer adjustment 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 Figure 3 Handle Assembly Toro Par...

Page 235: ...Cutting Unit Kickstand Toro Part Number 110 4088 03 The cutting unit kickstand is used to prop up the rear of the cutting unit during service Use of this tool prevents the bedbar adjusting screws from resting on the work surface 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 hydrau...

Page 236: ...ation Tools These tools are used to assemble the cutting unit roller that has greasable bearings and a bearing lock nut used to retain the bearings 115 0852 Inner Seal Tool 115 0853 Bearing Outer Seal Tool 107 8133 Bearing Installation Washer Figure 9 Inner Seal Tool Bearing Outer Seal Bearing Installation Washer Tool Turf Evaluator Tool Toro Model Number 04399 Many turf discrepancies are subtle a...

Page 237: ...ference 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 Cutting Units ...

Page 238: ... s manual and Chapter 6 Chassis in this manual Governed engine speed For best cutting performance and appearance engine should be run at maximum governed speed during machine operation Check maximum governed engine speed Adjust engine to specifications if necessary See the Traction Unit Operator s Manual and Chapter 3 Kubota Diesel Engine in this manual Reel speed All cutting reels must rotate at ...

Page 239: ...d Repairs section of this chapter Rear roller adjustment Adjust the rear roller brackets to correct position depending on the height of cut range desired See Rear Roller Adjustment in the Cutting Unit Operator s Manual Height of cut Effective or actual height of cut depends on the cutting unit weight and turf conditions Effective height of cut will be different from the bench set height of cut See...

Page 240: ...fer to Cutting Unit Operator s Manual for roller options Turf compensation spring adjustment Refer to Traction Unit Operator s Manual for adjustment procedure Rear lift arm counterbalance spring adjustment Refer to Traction Unit Operator s Manual for adjustment procedure Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance Ref...

Page 241: ...self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for various height of cut ranges and aggressiveness of cut selections If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the cu...

Page 242: ...ontact exists between bedknife and reel 2 Remove cutting unit components on LH side plate to allow access to bearing adjuster nut If cutting unit is equipped with a rear roller brush refer to Rear Roller Brush Optional in the Service and Repairs section of this chapter If cutting unit is equipped with a groomer refer to Chapter 8 Groomer 3 Loosen set screw that secures bearing adjuster nut in LH s...

Page 243: ...de plate to the frame opposite the side that is not level Fig 13 5 Adjust the position of the side plate to parallel the rear roller and cutting reel Then tighten the shoulder bolts to a torque from 27 to 33 ft lb 37 to 44 N m 6 After tightening the side plate recheck the rear roller If necessary loosen and adjust second side plate 7 If rear roller is still not level after adjusting both side plat...

Page 244: ...t splines for wear Replace if neces sary see Reel Removal and Installation in the Service and Repairs section of this chapter Installation NOTE Refer to Figure 15 for correct placement of cut ting unit reel motors and weights 1 Coat spline shaft of the reel motor with No 2 multi purpose lithium base grease 2 Install the cap screws for the reel drive motor into the cutting unit side plate and leave...

Page 245: ...Apply lapping compound to cutting reel blades with a long handled brush see Special Tools While back lapping occasionally move brush across reel to distrib ute compound CAUTION Be careful when backlapping the reel because contact with the reel or other moving parts can result in personal injury 7 To make a cutting unit adjustment while backlapping turn reels OFF shut off engine and wait for all ma...

Page 246: ...nt 27 to 33 ft lb 37 to 44 N m 6 7 8 9 10 1 11 12 13 15 16 17 18 19 14 4 5 2 5 3 16 7 CUTTING REEL SHOWN FRONT RIGHT Bedbar Removal Fig 19 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 Use the cutting unit kickstand to support the cutting unit see Special Tools...

Page 247: ...ult in personal injury Use heavy gloves when handling the bedbar 5 Position bedbar into cutting unit Make sure that the top of each bedbar arm is between washer item 11 and adjuster screw flange item 10 6 Position a plastic washer item 16 between bedbar 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...

Page 248: ...aft 11 Washer FRONT RIGHT 14 to 16 ft lb 19 to 21 N m Antiseize Lubricant Loctite 242 1 2 11 3 4 5 6 7 8 9 10 5 NOTE The bedbar adjuster system for early produc tion DPA cutting units Fig 22 used a retaining ring on the end of the bedbar adjuster shaft Current production DPA cutting units Fig 21 include a lock nut on the end of the bedbar adjuster shaft The bedbar adjuster ser vice procedures for ...

Page 249: ...e Align key on bushing to slot in frame and install bushings into frame 3 Install adjuster shaft to cutting unit frame A On early production cutting units Fig 21 slide bedbar adjuster shaft into flange bushings in cutting unit frame Secure adjuster shaft with wave washer and retaining ring B On current production cutting units Fig 22 slide wave washer onto adjuster shaft and then slide ad juster s...

Page 250: ...nce there can be variations in the mounting surface of the bedbar a new bedknife will not be perfectly flat after it is installed to the bedbar Because of this it is neces sary to grind a new bedknife after installing it to the bed bar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface of the bedknife is true Fig 25 NOTE When grinding the...

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Page 252: ...d per side plate Figure 26 Antiseize Lubricant 6 7 8 9 10 1 11 12 13 15 16 17 18 19 14 4 2 5 3 Grease OD surface See text for tightening procedure Loctite 242 Grease bore and threads 27 to 33 ft lb 37 to 44 N m 27 to 33 ft lb 37 to 44 N m 12 to 15 in lb 1 4 to 1 7 N m 21 20 22 FRONT RIGHT 12 4 23 24 7 CUTTING REEL SHOWN NOTE This section provides the procedure for remov ing and installing the cutt...

Page 253: ...ulder bolts and flange nuts Side plates on 7 cutting reel use three 3 shoulder bolts and flange nuts 9 Remove shoulder bolts item8 and flange nuts item 24 that secure the LH side plate to the cutting unit frame Remove the LH side plate from thereel shaft roll ers bedbar and cutting unit frame CAUTION Contact with the reel bedknife or other cutting unit parts can result in personal injury Use heavy...

Page 254: ...n in this section IMPORTANT Over tightening reel bearing adjuster nut may damage reel bearings 11 Make sure that set screw item 21 is loose in LH side plate to allow bearing adjuster nut movement With the cutting unit and reel in a horizontal position torque the bearing adjuster nut item 20 25 in lb 2 8 N m to re move cutting reel end play 12 Loosen the bearing adjuster nut Then torque bear ing ad...

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Page 256: ...aft as follows If reel damage is de tected replace reel A Check the reel shaft for bending and distortion by placing the shaft ends in V blocks B Check the reel blades for bending or cracking C Check the service limit of the reel diameter see Preparing a Reel for Grinding in this section 3 Check the threaded inserts in the reel shaft for ex cessive wear or distortion Replace inserts if damage is e...

Page 257: ...ith no grease or lubricant applied to ID of seal IMPORTANT The grease seal should be installed so the metal side of the seal is toward the bearing location B Press grease seals onto reel shaft with metal side orientated toward bearing location Final position of seal should be flush to 0 060 1 5 mm away fromre taining ring on reel shaft Do not force seal against retaining ring Seal must be perpendi...

Page 258: ...ons chart to the right Additional reel grinding information can be found in Toro General Ser vice Training Book Reel Mower Basics part no 09168SL 2 After completing the reel grinding process adjust cutting unit see Cutting Unit Operator s Manual Reel Grinding Specifications Reel Diameter New 5 060 in 128 5 mm for 5 reel 7 060 in 179 3 mm for 7 reel Service Limit Reel Diameter 4 500 in 114 mm for 5...

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Page 260: ...cut roller bracket C Thread cap screw into bracket NOTE When assembling height of cut roller brack ets to side plate make sure thatcap screwhead andone washer are above adjustment flange on side plate and second washer and flange lock nut are below flange 3 If both front height of cut roller brackets were re moved from cutting unit side plate position one of the brackets to side plate Secure brack...

Page 261: ...evel working surface NOTE Refer to Cutting Unit Operator s Manual for number of roller shims required for various height of cut settings NOTE A 0 010 shim part number 107 4001 is avail able to allow for leveling of the rear roller see Leveling Rear Roller in the Set up and Adjustments section of this chapter If necessary this shim would be used on one side of the rear roller and should be installe...

Page 262: ...Outer seal 8 Retaining ring 9 Outer oil seal 10 Roller washer Figure 32 v 9 10 8 7 1 2 3 4 6 5 NOTE Numerous front and rear rollers are available for the Reelmaster cutting units These rollers use one of two styles of bearing and seal configurations The first design has retaining rings that secure the bearings and seals in the roller Fig 32 The second design uses a bearing lock nut to retain beari...

Page 263: ...ings into roller tube A Use tool TOR4066 and handle TOR4073 to install bearing into one end of roller B Install roller shaft from opposite end of roller Be careful not to damage the inner oil seals when instal ling shaft C Put roller in a vertical position and support shaft and installed bearing with tool TOR4067 D Use tool TOR4067 to install second bearing 3 Use tool TOR4068 to install inner seal...

Page 264: ...ation IMPORTANT During assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing against roller...

Page 265: ...ft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nut loos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 6 Install bearing lock nut onto each end of the roller shaft Make sure that outer seals are not...

Page 266: ...racket 2 used 30 Brush bearing housing non drive 31 O ring 32 Socket head screw 2 used Figure 40 v Loctite 242 Antiseize Lubricant FRONT RIGHT 9 10 11 13 8 3 2 17 5 4 1 18 26 27 23 24 25 11 30 6 FRONT RIGHT 12 7 6 11 17 to 21 ft lb 23 to 28 N m 20 to 25 in lb 2 3 to 2 8 N m 14 15 16 29 22 19 21 20 11 26 27 28 31 27 to 33 ft lb 37 to 44 N m Grease Grommet ID 32 NOTE Drive components for the rear ro...

Page 267: ...olts and lock nuts Make sure that the J bolts are installed with the threaded portion on the outside of the brush Fig 41 Torque lock nuts from 20 to 25 in lb 2 3 to 2 8 N m 2 If seals or bearings were removed from brush bear ing housings install new components noting proper ori entation as shown in Figure 42 A Pack bearings with grease before installation B Press bearing into bearing housing so th...

Page 268: ...lange head screw item 20 that secures drive pulley to drive shaft from 27 to 33 ft lb 37 to 44 N m D Apply antiseize lubricant to square key that lo cates driven pulley onto roller brush shaft E Torque flange nut item 11 that secures driven pulley to roller brush shaft from 17 to 21 ft lb 23 to 28 N m F Check alignment of pulleys with a straight edge placed along the outer face of the driven pulle...

Page 269: ...l 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 Wipe excess grease from seals and fittings 1 Driven pulley 2 Drive pulley 3 Straight edge Figure 45 2 1 3 Figure 46 1 Rear roller brush 2 Rear roller 3 Light contact Figure 47 2 1 3 Cutting Units ...

Page 270: ...Reelmaster 5010 Series Cutting Units Rev C Page 7 40 This page is intentionally blank ...

Page 271: ...RFORMANCE 2 TROUBLESHOOTING 3 Groomer Reel Mechanical Problems 3 ADJUSTMENTS 4 Groomer Height Depth Adjustment 4 SERVICE AND REPAIRS 5 Groomer Drive Belt Replacement 5 Groomer Plate Assembly 6 Groomer Reel 10 Groomer Reel Service 12 Groomer Pivot Hub 14 Height Adjuster Assembly 16 Groomer ...

Page 272: ...AT ING OR TESTING GROOMER PERFORMANCE It is important to remember that factors affecting quality of cut also affect grooming performance Variables That Affect the Use and Performance of Groomers 1 The growing season and weather conditions 2 General turf conditions 3 The frequency of grooming cutting number of cut tings per week and how many passes per cutting 4 The height of cut 5 The grooming dep...

Page 273: ... spring If the drive belt slips it probably is out of adjustment or worn Repair or replace drive belt if nec essary A broken or worn belt could be the result of improper belt rout ing or seized bearings in groomer assembly Change grooming depth The turf is damaged or has uneven grooming The groomer reel blades are bent damaged or missing The groomer reel shaft is bent or damaged Grooming depth is ...

Page 274: ...p engine en gage parking brake and remove key from the ignition switch 2 Make sure rollers are clean and cutting unit is set to the desired height of cut see Cutting Unit Operator s Manual 3 Place the groomer reel in the grooming lowered position by rotating the raise lower lever toward the front of the cutting unit Fig 1 NOTE Improper or over aggressive use of the groom er e g too deep or too fre...

Page 275: ... equipped with powered rear roll er brush removal of roller brush components will be necessary to replace groomer drive belt see Roller Brush Optional in the Service and Repairs section of Chapter 7 Cutting Units NOTE When removing groomer cover groomer weight does not have to be removed from cover 2 Remove two 2 flange nuts that secure groomer cover then remove cover Fig 2 3 Remove groomer belt t...

Page 276: ...omponents used when the groomer reel drive is on the left side of the cutting unit Removal Fig 4 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 NOTE If cutting unit is equipped with powered rear roll er brush removal of roller brush components will be necessary to service groomer pla...

Page 277: ... secure groomer components to cutting unit side plate C Remove pivot hub from cutting unit D Support groomer shaft to prevent it from falling Carefully slide non drive side groomer plate from groomer shaft and cutting unit 4 Inspect seals bearings and bushing in groomer plates Remove and discard damaged or worn compo nents Installation Fig 4 1 If seals bearings or bushing was removed from groomer ...

Page 278: ... that locate drive and driven pulleys Position keys into shaft slots NOTE To prevent cutting reel from turning when installing drive pulley block cutting reel with piece of wood G Apply Loctite 242 to threads of flange head screw that secures drive pulley to pivot hub shaft Slide drive pulley onto shaft and secure with flange head screw Torque screw from 27 to 32 ft lb 37 to 43 N m NOTE To prevent...

Page 279: ...Reelmaster 5010 Series Groomer Page 8 9 This page is intentionally blank Groomer ...

Page 280: ...onal blade life NOTE The groomer reel drive is located on the oppo site side of the cutting unit from the reel hydraulic motor Figure 8 shows the groomer reel drive on the left side of the cutting unit Removal Fig 8 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 If desired remove cut...

Page 281: ...er reel into the non drive side groomer plate assembly taking care not to damage seals in groomer plate assembly 5 Carefully install groomer plate assembly to groomer reel and groomer drive side of cutting unit see Groomer Plate Assembly Installation in this section 6 Check that excluder seals just touch groomer plate assembly Fig 10 Reposition excluder seals on groomer shaft if necessary 7 Checkg...

Page 282: ...on drive end of groomer shaft Place first spacer and then first blade on shaft 2 Alternately install remaining spacers and blades making sure that all blades are separated by a spacer Additionally rotate location hole on each installed blade one flat of the shaft in a counterclockwise direction 3 When all blades have been installed place final spacer onshaftandthen threadsecond locknutontothe shaf...

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 1 Groomer shaft 2 Broomer strap Figure 13 1 2 2 2 2 Groomer ...

Page 284: ...aining ring 7 Extension spring 8 Retaining ring 9 Idler plate 10 O ring 7 cutting unit only 4 3 1 2 9 10 8 5 6 7 Apply Grease to Seal Lip NOTE The groomer reel drive is located on the oppo site side of the cutting unit from the cutting reel hydraulic motor Figure 14 shows components used when the groomer reel drive is on the left side of the cutting unit ...

Page 285: ...ter bearing races Install the bearing so that the bearing seal is closest to the shoulder on the shaft Install retaining ring item 7 onto shaft to retain bearing 2 Install new grease seal into housing with the lip of the seal toward the outside of the housing Apply grease to lip of seal 3 Fill cavity between bearing location and grease seal 50 to 75 full with high temperature Mobil XHP 222 grease ...

Page 286: ...spect for wear or dam age Replace all worn or damaged components Assembly Fig 16 1 Assemble height adjuster using Figure 16 as a guide noting the following items A If bushing item 10 was removed from upper ramp press new bushing into housing fully to the shoulder in the bore B If jam nuts item 4 were removed from ball joint rod apply antiseize lubricant to threads of rod where jam nuts will be pos...

Page 287: ...10000000 5 Reelmaster 5010 Series Serial Number Above 310000000 6 ELECTRICAL CIRCUIT DIAGRAMS Glow Plug Circuits 7 Crank Circuits 8 Run Transport Circuits 9 Run Mow Circuits 10 WIRE HARNESS DRAWINGS Main Wire Harness Drawing 12 Main Wire Harness Diagram 13 Seat Wire Harness Drawing 14 Seat Wire Harness Diagram 15 Engine Wire Harness Drawing 16 Engine Wire Harness Diagram 17 TURF DEFENDERTM OPTIONA...

Page 288: ...Reelmaster 5010 Series Foldout Drawings Page 9 2 This page is intentionally blank ...

Page 289: ...7 SVRV CV4 CV1 CV5 CV23 P2 T P1 M1 BKLP1 M2 BKLP2 B R2 R1 R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN P1 50 8 25 6 4 24 2 P2 50 8 25 6 4 24 2 P3 37 6 1 4 7 17 8 P4 24 3 9 3 0 11 4 P5 2 14 35 27 2 103 M1 73 12 M2 73 12 M3 73 12 M4 73 12 M5 73 12 M6 RM5210 24 7 405 M7 RM5210 24 7 405 V1 6 1 100 R1 2500 172 R2 3500 241 R3 3625 250 R4 3625 250 R5 200 14 SVRV 2000 138 R7 500 35 R8 50 3 4 R9 50 3 4 R10 1...

Page 290: ...7 SVRV CV4 CV1 CV5 CV23 P2 T P1 M1 BKLP1 M2 BKLP2 B R2 R1 R5 R4 R3 A B A B LH RH EXTERNAL CASE DRAIN P1 66 10 8 8 4 31 8 P2 66 10 8 8 4 31 8 P3 37 6 1 4 7 17 8 P4 24 3 9 3 0 11 4 P5 2 14 35 27 2 103 M1 1 18 19 3 M2 1 18 19 3 M3 1 18 19 3 M4 1 18 19 3 M5 1 18 19 3 M6 24 7 405 M7 24 7 405 V1 6 1 100 R1 2500 172 R2 3500 241 R3 3625 250 R4 3625 250 R5 200 14 SVRV 2000 138 R7 500 35 R8 50 3 4 R9 50 3 4...

Page 291: ... 3 P2 12 P2 2 P1 2 P2 9 P2 10 P1 19 P1 18 P1 17 P2 4 P2 3 P2 5 P2 15 P2 14 KEY START P2 13 KEY RUN P1 14 PWR LOGIC P1 12 P1 13 P1 11 5 2 1 3 6 4 7 4 1 6 3 8 5 2 Y A S I X B OFF RUN START IGNITION SWITCH B X 2F 4 3 4 R I S 10 A 1F 4 1F 3 10 A 15 A 1F 1 D1 G FL FL POWER POINT ENGINE GROUND FL BLOCK A 10 A 2 1 OT WARNING ALTERNATOR FL ENGINE OVER TEMP FL BATTERY GROUND Y START AIR RIDE SEAT OPTIONAL ...

Page 292: ...gized All ground wires are black Serial Number Above 310000000 INDICATOR LIGHTS 3 GLOW PLUGS USED ON RM5210 SEAT SWITCH UNOCCUPIED PARKING BRAKE SWITCH BRAKE APPLIED FRONT BACKLAP SWITCH IN MOW NEUTRAL SWITCH NOT IN NEUTRAL REAR BACKLAP SWITCH IN MOW UP LIMIT SWITCH C U RAISED MOW TRANSPORT SWITCH IN MOW ...

Page 293: ...P2 4 P2 3 P2 5 P2 15 P2 14 KEY START P2 13 KEY RUN P1 14 PWR LOGIC P1 12 P1 13 P1 11 5 2 1 3 6 4 7 4 1 6 3 8 5 2 Y A S I X B OFF RUN START IGNITION SWITCH B X 3 3 2F 4 3 4 R I S 1 1 2 2 10 A 1F 4 1F 3 10 A 15 A 1F 1 D1 G FL FL POWER POINT ENGINE GROUND FL BLOCK A 10 A 2 1 OT WARNING ALTERNATOR FL ENGINE OVER TEMP FL BATTERY GROUND Y START AIR RIDE SEAT OPTIONAL 2F 3 10 A 2F 1 10 A 2F 2 ECM COMMUNI...

Page 294: ... P2 4 P2 3 P2 5 P2 15 P2 14 KEY START P2 13 KEY RUN P1 14 PWR LOGIC P1 12 P1 13 P1 11 5 2 1 3 6 4 7 4 1 6 3 8 5 2 Y A S I X B OFF RUN START IGNITION SWITCH B X 3 3 2F 4 3 4 R I S 1 1 2 2 10 A 1F 4 1F 3 10 A 15 A 1F 1 D1 G FL FL POWER POINT ENGINE GROUND FL BLOCK A 10 A 2 1 OT WARNING ALTERNATOR FL ENGINE OVER TEMP FL BATTERY GROUND Y START AIR RIDE SEAT OPTIONAL 2F 3 10 A 2F 1 10 A 2F 2 ECM COMMUN...

Page 295: ...2 4 P2 3 P2 5 P2 15 P2 14 KEY START P2 13 KEY RUN P1 14 PWR LOGIC P1 12 P1 13 P1 11 5 2 1 3 6 4 7 4 1 6 3 8 5 2 Y A S I X B OFF RUN START IGNITION SWITCH B X 3 3 2F 4 3 4 R I S 1 1 2 2 10 A 1F 4 1F 3 10 A 15 A 1F 1 D1 G FL FL POWER POINT ENGINE GROUND FL BLOCK A 10 A 2 1 OT WARNING ALTERNATOR FL ENGINE OVER TEMP FL BATTERY GROUND Y START AIR RIDE SEAT OPTIONAL 2F 3 10 A 2F 1 10 A 2F 2 ECM COMMUNIC...

Page 296: ...P2 4 P2 3 P2 5 P2 15 P2 14 KEY START P2 13 KEY RUN P1 14 PWR LOGIC P1 12 P1 13 P1 11 5 2 1 3 6 4 7 4 1 6 3 8 5 2 Y A S I X B OFF RUN START IGNITION SWITCH B X 3 3 2F 4 3 4 R I S 1 1 2 2 10 A 1F 4 1F 3 10 A 15 A 1F 1 D1 G FL FL POWER POINT ENGINE GROUND FL BLOCK A 10 A 2 1 OT WARNING ALTERNATOR FL ENGINE OVER TEMP FL BATTERY GROUND Y START AIR RIDE SEAT OPTIONAL 2F 3 10 A 2F 1 10 A 2F 2 ECM COMMUNI...

Page 297: ...Rev B Page 9 11 This page is intentionally blank ...

Page 298: ...Rev B Page 9 12 Reelmaster 5010 Series Main Wire Harness Drawing ...

Page 299: ...AN WHITE BLUE BROWN PINK ORANGE WHITE RED YELLOW BLACK BLACK RED BLACK BLACK BLACK RED PINK GREEN YELLOW BLACK BLACK PINK BLUE GRAY GRAY BLUE VIOLET BLACK WHITE BLACK BLACK BLACK BLACK BLACK GRAY BLACK BROWN GREEN GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK RED BLACK BLACK BLACK RED BLACK BLUE RED RED RED RED WHITE ...

Page 300: ...Rev B Page 9 14 Reelmaster 5010 Series Seat Wire Harness Drawing ...

Page 301: ...LACK TAN BLACK BLACK BLACK BLACK BLACK BLACK GRAY BLACK PINK PINK WHITE GREEN WHITE BLUE BLACK BLACK TAN ORANGE GRAY BLACK BLACK VIOLET BLACK BLACK YELLOW GREEN BLACK WHITE BROWN BLUE GREEN WHITE WHITE BLUE WHITE GRAY GRAY BLUE VIOLET RED WHITE WHITE BLUE PINK PINK PINK BLUE BLUE WHITE BLACK PINK GRAY ORANGE BLACK GREEN BLACK YELLOW BLACK BROWN YELLOW ORANGE GREEN BLACK RED WHITE BLACK PINK BLUE T...

Page 302: ...Rev B Page 9 16 Reelmaster 5010 Series Engine Wire Harness Drawing ...

Page 303: ...Rev B Page 9 17 Reelmaster 5010 Series Engine Wire Harness Diagram PINK GRAY WHITE GREEN WHITE WHITE ORANGE RED BLACK RED BLACK BLACK BLUE TAN BLUE FUSIBLE LINK ...

Page 304: ...WHITE BLACK WHITE TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS RED YELLOW BLACK YELLOW RED ALARM TURF DEFENDER COMMUNICATION PORT AND LOOPBACK CONNECTOR YELLOW BLACK ORANGE GREEN WHITE BLACK BLACK BLUE TURF DEFENDER LOOPBACK I D DECAL ORANGE BLACK BLACK RED 94 6345 TM Reelmaster 5010 Series Electrical Schematic TurfDefenderTM Optional ...

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