Toro Reelmaster 5010-H Traction Unit 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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