Toro Reelmaster 5010-H Traction Unit User manual

Category
Lawnmowers
Type
User manual
Form No. 15212SL Rev E
Reelmaster
®
5010-H
Original Instructions (EN)
Revision History
Revision
Date
Description
--
2015
Initial Issue.
A
2015
Updated Hydraulic chapter.
B
02/2018
Updated Electrical chapter. Added revision history.
C
04/2018
Revised bedknife installation procedure, added Universal Groomer
chapter.
D
03/2019
Updated Chassis chapter.
E
06/2020
Updated Electrical, Cutting Unit, Universal Groomer and Foldout
Drawing chapters.
©
THE TORO COMPANY 2020
This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No
intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
reproduced by a third party without the express written consent of The Toro Company (and/or the appropriate affiliated company).
Reader Comments
The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we encourage user feedback.
Please comment on the completeness, accuracy, organization, usability, and readability of this manual
by an e-mail to [email protected]
or Mail to:
Technical Publication Manager, Commercial
The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Phone: +1 952-887-8495
NOTES _
Part No. 15212SL Rev. E
Service Manual
Reelmaster
R
5010--H
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Reelmaster 5010--H (Hybrid).
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Additional 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, W ARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im -
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company -- 2015, 2018, 2019, 2020
Reelmaster 5010--H
This page is intentionally blank.
Reelmaster 5010--H
Table Of Contents
Chapter 1 -- Safety
Safety Instructions 1 -- 2..........................
Jacking Instructions 1 -- 5.........................
Safety and Instruction Decals 1 -- 6................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- Kubota Diesel Engine
Specifications 3 -- 2..............................
General Information 3 -- 3........................
Service and Repairs 3 -- 4........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05--E4B SERIES
Chapter 4 -- Hydraulic System
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Hydraulic Schematic 4 -- 10.......................
Hydraulic Flow Diagrams 4 -- 12...................
Special Tools 4 -- 20.............................
T roubleshooting 4 -- 25...........................
Testi ng 4 -- 30...................................
Service and Repairs 4 -- 52.......................
DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON
PUMPS REPAIR INSTRUCTIONS
DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON
PUMPS SERVICE MANUAL
EATON DELTA MOTORS PARTS AND REPAIR
MANUAL
PARKER TORQMOTOR
TM
SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
DANFOSS STEERING UNIT TYPE OSPM SERVICE
MANUAL
Chapter 5 -- Electrical System
General Information 5 -- 2........................
Electrical System Operation 5 -- 4.................
Special Tools 5 -- 6..............................
InfoCenter Display 5 -- 10.........................
T roubleshooting 5 -- 19...........................
Electrical System Quick Checks 5 -- 41.............
Adjustments 5 -- 43..............................
Component Testing 5 -- 47........................
Service and Repairs 5 -- 78.......................
Chapter 6 -- Chassis
Specifications 6 -- 2..............................
General Information 6 -- 2........................
Special Tools 6 -- 3..............................
Service and Repairs 6 -- 4........................
Chapter 7 -- Cutting Units
Specifications 7 -- 2..............................
General Information 7 -- 3........................
Special Tools 7 -- 4..............................
Factors That Can Affect Cutting Performance 7 -- 9..
Set--Up and Adjustments 7 -- 12...................
Service and Repairs 7 -- 14.......................
SafetyProduct Records
and Maintenance
DPA Cutting Electrical
System
Hydraulic
System
Kubota Diesel
Engine
Chassis
Units
Reelmaster 5010--H
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Reelmaster 5010--H
Table Of Contents (Continued)
Chapter 8 -- Belt Driver Groomer (Optional)
General Information 8 -- 2........................
Special Tools 8 -- 3..............................
Grooming Performance 8 -- 4.....................
T roubleshooting 8 -- 5............................
Adjustments 8 -- 6...............................
Service and Repairs 8 -- 7........................
Chapter 9 -- Universal Groomer (Optional)
Grooming Performance 9 -- 2.....................
T roubleshooting 9 -- 3............................
Service and Repairs 9 -- 4........................
Chapter 10 -- Foldout Drawings
Electrical Drawing Designations 10 -- 2.............
Hydraulic Schematic 10 -- 3.......................
Electrical Schematic 10 -- 4.......................
Wire Harness Drawings 10 -- 6....................
UniversalFoldout
Drawings
Groomer (Opt.)
Belt Driven
Groomer (Opt.)
Reelmaster 5010--H
This page is intentionally blank.
Reelmaster 5010- H Page 1 - 1 Safety
Chapter 1
Safety
Table o f Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 3.............................
Maintenance and Service 4....................
JACKING INSTRUCTIONS 5.....................
SAFETY AND INSTRUCTION DECALS 6..........
Safety
Reelmaster 5010- HPage 1 - 2Safety
Safety Instructions
Reelmaster machines meet or exceed safety standard
specifications when weights are installed according to
information in the Traction Unit Operator’s Manual. Al-
though hazard control and accident prevention are par-
tially dependent upon the design and configuration of
the machine, these factors are also dependent upon the
awareness, concern and proper training of the person-
nel involved in the operation, transport, maintenance
and storage of the machine. Improper use or mainte-
nance of the machine can result in injury or death. To re-
duce the potential for injury or death, comply with the
following safety instructions.
To reduce the potential for injury or death, com-
ply with the following safety instructions.
WARNING
Before Operating
1. Review and understand the contents of the Opera-
tor’s Manuals and Operator Training DVD before start-
ing and operating the machine. Become familiar with the
controls and know how to stop the machine and engine
quickly. Additional copies of the Operator’s Manual are
available on the internet at www.Toro.com.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and Enable/Disable switch is OFF (dis-
abled).
4. Since fuel is flammable, handle it carefully:
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 fuel container caps secure-
ly after refueling machine.
F. If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of spill-
age. Avoid creating any source of ignition until fuel
vapors have dissipated. Wipe up any spilled fuel.
Reelmaster 5010- H Page 1 - 3 Safety
While Operating
1. Sit on the seat when starting and operating the ma-
chine.
2. Before starting the engine:
A. Apply the parking brake.
B. Make sure the traction pedal is in NEUTRAL, the
Enable/Disable switch is in the disabled position and
the engine speed switch is in the mid- speed posi-
tion.
C. Turn the ignition switch to the ON/PREHEAT po-
sition to energize the glow plugs. After allowing the
glow plugs to preheat, turn the switch to the START
position. Release the switch to the ON/PREHEAT
position when the engine starts.
D. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage is
adjusted incorrectly; therefore, shut engine off and
adjust traction pedal linkage until machine does not
move when traction pedal is released (see Traction
Unit Operator’s Manual).
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
4. Do not touch engine, radiator, exhaust system or hy-
draulic components while engine is running or soon after
it is stopped. These areas could be hot enough to cause
burns.
5. Before getting off the seat:
A. Ensure that traction pedal is in NEUTRAL.
B. Lower and disengage cutting units. Wait for all
movement to stop.
C. Apply parking brake.
D. Move the engine speed switch to the low idle po-
sition and allow the engine to reach low idle speed.
E. Stop engine and remove key from ignition switch.
6. Anytime the machine is parked (short or long term),
the cutting units should be lowered to the ground. This
relieves pressure from the hydraulic lift circuit and elimi-
nates the risk of the cutting units unexpectedly lowering
to the ground.
7. Do not park on slopes unless wheels are chocked or
blocked.
Safety
Reelmaster 5010- HPage 1 - 4Safety
Maintenance and Service
1. Before servicing or making adjustments, lower cut-
ting units, apply parking brake, stop engine and remove
key from the ignition switch.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heat-
er or furnace.
4. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the hydraulic system.
5. Keep body and hands away from pin hole leaks in hy-
draulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doc-
tor familiar with this form of injury or gangrene may re-
sult.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be re-
lieved by using all of the hydraulic controls with the en-
gine not running (see Relieving Hydraulic Pressure in
the General Information section of Chapter 4 - Hydrau-
lic System).
7. Use care when checking or servicing the cutting
units. Wear appropriate gloves and use caution when
servicing them.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
9. If engine must be running to perform maintenance or
to make 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.To assure safety and accuracy, check maximum en-
gine speed.
11. Shut engine off before checking or adding oil to the
engine crankcase.
12.Disconnect 12 VDC battery located at the rear of the
machine before servicing the machine. Disconnect neg-
ative battery cable first and positive cable last. If battery
voltage is required for troubleshooting or test proce-
dures, temporarily connect the battery. Reconnect posi-
tive battery cable first and negative cable last.
13.Before installing, removing or working on 48 VDC
system components (e.g. cutting units, motor/genera-
tor), separate system components from the 48 VDC bat-
tery pack by unplugging the 48 VDC battery disconnect
(see 48 VDC Battery Disconnect in the General Infor-
mation section of Chapter 5 - Electrical System). Plug
the connector back in before operating the machine.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.When changing tires, attachments or performing
other service, use correct jacks, hoists and supports.
Make sure machine is parked on a solid level floor such
as a concrete floor . Prior to raising the machine, remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Use jack stands or appropriate load holding de-
vices to support the raised machine. If the machine is
not properly supported, the machine may move or fall,
which may result in personal injury (see Jacking Instruc-
tions in this section).
17.If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
18.When welding on machine, disconnect battery
cables to prevent damage to machine electronic equip-
ment. Disconnect negative battery cable first and posi-
tive cable last. Also, disconnect wire harness connector
from the TEC controller and disconnect the terminal
connector from the alternator. Attach welder ground
cable no more than two (2) feet (0.6 meters) from the
welding location.
19.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, batteries) in an en-
vironmentally safe manner. Follow all local codes and
regulations when recycling or disposing of waste.
20.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure op-
timum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
Reelmaster 5010- H Page 1 - 5 Safety
Jacking Instructions
When changing tires, attachments or perform-
ing other service, use correct hoists, jacks and
jack stands. Make sure machine is parked on a
solid, level surface such as a concrete floor .
Prior to raising machine, remove any attach-
ments that may interfere with thesafe and prop-
er 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
Front End Jacking (Fig. 1)
1. Apply parking brake and chock both rear tires to pre-
vent the machine from moving.
2. Position jack securely below the rectangular pad un-
der 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
raised wheel as possible to support the machine.
Rear End Jacking
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. Jack rear of machine off the
ground.
3. To support the raised machine, position jack stands
under the frame rail next to the axle support bracket.
Figure 1
1. Front wheel 2. Front jacking point
1
2
Safety
Reelmaster 5010- HPage 1 - 6Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the traction unit and the cutting units of your Reelmaster .
If any decal becomes illegible or damaged, install a new
decal. Part numbers for decals are listed in your Part
Catalogs. Order replacement decals from your Autho-
rized Toro Distributor .
Reelmaster 5010- H Page 2 - 1 Product Records and Maintenance
Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1.........................
MAINTENANCE 1..............................
EQUIVALENTS AND CONVERSIONS 2...........
Decimal and Millimeter Equivalents 2............
U.S. to Metric Conversions 2...................
TORQUE SPECIFICATIONS 3...................
Fastener Identification 3.......................
Using a Torque Wrench with an Offset Wrench 3..
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) 4...............
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Series) 5..............
Other Torque Specifications 6..................
Conversion Factors 6.........................
Product Records
Insert Operator’s Manual and Parts Catalog for your
Reelmaster at the end of this chapter. Refer to Opera-
tor’s Manual for recommended maintenance intervals.
Additionally, insert Installation Instructions, Operator’s
Manuals and Parts Catalogs for any accessories that
have been installed on your Reelmaster at the end of
this section.
Maintenance
Maintenance procedures and recommended service in-
tervals for your Reelmaster are covered in the Opera-
tor’s Manual. Refer to that publication when performing
regular equipment maintenance. Several maintenance
procedures have break- in intervals identified in the Op-
erator’s Manual. Refer to the Engine Operator ’s Manual
for additional engine specific maintenance procedures.
Product Records
and Maintenance
0.09375
Reelmaster 5010- HPage 2 - 2Product Records and Maintenance
Equivalents and Conversions
Reelmaster 5010- H Page 2 - 3 Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and spe-
cified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (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 Torq ue Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommen-
dation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommen-
dation.
Example: Themeasuredeffectivelengthofthetorque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
Themeasuredeffectivelengthofthetorquewrenchwith
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
Thecalculatedtorqueconversionfactorforthistorque
wrench with this offset wrench would be 18 / 19 = 0 .947.
If the listed torque recommendation for a fastener is
from 76 to 94 ft- lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft- lb.
Figure 3
(effective length of
torque wrench)
TORQUE CONVERSION FACTOR = A / B
A
B
(effective length of torque
Torque wrenchOffset wrench
wrench + offset wrench)
Product Records
and Maintenance
Reelmaster 5010- HPage 2 - 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel F asteners (Inch Series)
Thread Size
Grade 1, 5 &
8withThin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in- lb in- lb N-cm in- lb N-cm in- lb N-cm
#6- 32UNC
10 + 2 13 + 2 147 + 23
15 + 2 169 + 23 23 + 3 262 + 34
#6- 40UNF 17 + 2 192 + 23 25 + 3 282 + 34
#8- 32UNC
13 + 2 25 + 5 282 + 30
29 + 3 328 + 34 41 + 5 463 + 56
#8- 36UNF 31 + 4 350 + 45 43 + 5 486 + 56
# 10 - 24 UNC
18 + 2 30 + 5 339 + 56
42 + 5 475 + 56 60 + 6 678 + 68
#10- 32UNF 48 + 5 542 + 56 68 + 7 768 + 79
1/4 - 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 - 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 - 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 - 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
ft- lb ft- lb N-m ft- lb N-m ft- lb N- m
3/8 - 16 UNC 16 + 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 - 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 - 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 - 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 - 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
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 when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The n ominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
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Toro Reelmaster 5010-H Traction Unit User manual

Category
Lawnmowers
Type
User manual

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