Form No.
Revision History Revision Date -- 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.
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 servicemanuals@toro.
NOTES _
Part No. 15212SL Rev. E Service Manual ReelmasterR 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 INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
This page is intentionally blank.
Chapter 5 -- Electrical System Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 5 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 6 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Electrical System Operation . . . . . . . . . . . . . . . . . 5 -- 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 6 InfoCenter Display . . . . .
This page is intentionally blank.
Chapter 8 -- Belt Driver Groomer (Optional) 8 -8 -8 -8 -8 -8 -- 2 3 4 5 6 7 Grooming Performance . . . . . . . . . . . . . . . . . . . . . 9 -- 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 4 Chapter 10 -- Foldout Drawings Electrical Drawing Designations . . . . . . . . . . . . . 10 -Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 -Electrical Schematic . . . . . . . . . . . . .
This page is intentionally blank.
Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Safety Instructions Reelmaster machines meet or exceed safety standard specifications when weights are installed according to information in the Traction Unit Operator’s Manual. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
1. Sit on the seat when starting and operating the machine. 2. Before starting the engine: A. Apply the parking brake. 4. Do not touch engine, radiator, exhaust system or hydraulic 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: 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 position. A.
Maintenance and Service 1. Before servicing or making adjustments, lower cutting 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 heater or furnace. 4.
Jacking Instructions Safety CAUTION When changing tires, attachments or performing 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 attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or other appropriate load holding devices to support the raised machine.
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 Authorized Toro Distributor.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
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 specified 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 Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in- lb in- lb N- cm 10 + 2 13 + 2 147 + 23 # 6 - 40 UNF # 8 - 32 UNC 13 + 2 25 + 5 282 + 30 # 8 - 36 UNF # 10 - 24 UNC 18 + 2 30 + 5 339 + 56 # 10 - 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in- lb 644 + 68 N- cm 78 + 8 in- lb 881 + 90 N- cm M6 X 1.0 96 + 10 in- lb 1085 + 113 N- cm 133 + 14 in- lb 1503 + 158 N- cm M8 X 1.25 19 + 2 ft- lb 26 + 3 N- m 28 + 3 ft- lb 38 + 4 N- m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 + 20 in- lb 73 + 12 in- lb 5/16 - 18 UNC 215 + 35 in- lb 145 + 20 in- lb 3/8 - 16 UNC 35 + 10 ft- lb 18 + 3 ft- lb 1/2 - 13 UNC 75 + 15 ft- lb 50 + 10 ft- lb 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.
Chapter 3 Kubota Diesel Engine Table of Contents Reelmaster 5010- H Page 3 - 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Traction Unit Operator’s Manual . . . . . . . . . . . . . . . 3 Kubota Workshop Manual . . . . . . . . . . . . . . . . . . . . 3 48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kubota Model D1105- E4B: 4- Cycle, 3 Cylinder, Water Cooled, Tier 4 Diesel Engine Number of Cylinders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) 68.
General Information This Chapter gives information about specifications, troubleshooting, testing and repair of the Kubota diesel engine used in Reelmaster 5010- H machines. Most repairs and adjustments require tools which are commonly available in many service shops. The use of some specialized test equipment is explained in the engine Kubota Workshop Manual included at the end of this chapter.
Service and Repairs Air Cleaner Assembly 3 30 to 40 in- lb (3.4 to 4.5 N- m) 5 3 6 Thread Sealant 7 1 3 10 8 2 4 9 3 11 12 12 13 14 30 to 40 in- lb (3.4 to 4.5 N- m) 16 17 15 RIGHT 12 FRONT Figure 2 1. 2. 3. 4. 5. 6. Diesel engine Air cleaner assembly Hose clamp (4 used) Air intake hose Air intake hose Service indicator Kubota Diesel Engine 7. 8. 9. 10. 11. 12. Indicator adapter Shoulder bolt Nut Compression spring Air cleaner mounting band Flange nut (6 used) Page 3 - 4 13. 14. 15.
Removal (Fig. 2) 12 to 15 in- lb (1.4 to 1.6 N- m) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Raise and support hood. 2. Remove air cleaner components as needed using Figure 2 as a guide. 2 3. See Traction Unit Operator’s Manual for air cleaner service and maintenance procedures. 3 IMPORTANT: Any leaks in the air filter system will allow dirt into engine and will cause serious engine damage.
Exhaust System 11 12 13 14 17 5 3 4 9 14 15 16 2 1 8 6 RIGHT 7 10 FRONT Figure 4 1. 2. 3. 4. 5. 6. Diesel engine Exhaust muffler Clamp Hex nut (2 used) Flange nut (4 used) Carriage bolt (4 used) Kubota Diesel Engine 7. 8. 9. 10. 11. 12. Bellhousing Tailpipe bracket Flange head screw Flange nut Exhaust header Flange nut (4 used) Page 3 - 6 13. 14. 15. 16. 17.
3. Adjust muffler guard (item 15) on frame so there is ⅜” (9.5 mm) clearance between exhaust tailpipe and guard in all directions. Removal (Fig. 4) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. 4. After all exhaust components have been installed, lower and secure hood. D C 1. Raise and support hood to gain access to exhaust system.
Fuel System RIGHT 18 FRONT 7 6 8 9 2 19 12 3 4 20 5 1 17 3 16 15 11 12 10 14 13 Figure 6 1. 2. 3. 4. 5. 6. 7. Fuel tank Fuel tank cap Screw (7 used) Strap Sender cover Hose clamp Fuel supply hose 8. 9. 10. 11. 12. 13. 14. Hose clamp Fuel return hose Clamp (2 used) Flange head screw (2 used) Flange nut (3 used) Draincock Hose clamp 15. 16. 17. 18. 19. 20.
To clean fuel tank, flush tank out with clean diesel fuel. Make sure tank is free of all contaminates and debris. Fuel Tank Installation (Fig. 6) 1. Install fuel tank to frame using Figure 6 as a guide. Secure fuel hoses with cable ties as noted during fuel tank removal. A. If fuel sender was removed from fuel tank, make sure that fuel fittings on sender are orientated at 90o from right side of tank as shown in Figure 7.
Radiator Assembly 11 6 1 13 2 10 28 21 2 8 14 15 12 9 18 3 2 26 20 25 4 10 23 5 27 30 7 7 22 17 10 16 24 29 19 31 RIGHT FRONT 30 to 40 in- lb (3.4 to 4.5 N- m) Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Coolant reservoir Hose clamp (3 used) Hose Foam seal (2 used) Oil cooler Hose Hose clamp (4 used) Foam seal (2 used) Radiator cap Flange nut (14 used) Rear screen Kubota Diesel Engine 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 8) 30 to 40 in- lb (3.4 to 4.5 N- m) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Unlatch rear screen, lift screen from hinges and remove screen from machine. 1 RIGHT 3 FRONT 3. Remove 12 volt battery from rear of machine to ease oil cooler removal (see 12 VDC Battery Service in the Service and Repairs section of Chapter 5 - Electrical System). 4.
8. Connect air cleaner and motor/generator intake hoses to fan shroud and secure with hose clamps (Fig. 9). Torque hose clamps from 30 to 40 in- lb (3.4 to 4.5 N- m). 12.Carefully position and install oil cooler to radiator frame. Rotate clamps to secure oil cooler to radiator frame. 9. Make sure radiator draincock is closed (threaded out fully). 13.Install 12 volt battery (see 12 VDC Battery Service in the Service and Repairs section of Chapter 5 - Electrical System). 10.
Kubota Diesel Engine This page is intentionally blank.
Engine 30 to 40 in- lb (3.4 to 4.5 N- m) 22 18 25 11 Thread Sealant 16 35 22 23 14 22 19 32 46 12 44 27 26 3 24 17 1 6 44 29 22 30 33 43 7 34 37 15 42 41 45 7 36 9 13 34 to 42 ft- lb (47 to 56 N- m) 20 7 21 39 31 2 40 28 3 5 10 38 RIGHT 7 8 FRONT 4 6 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Engine Removal (Fig. 10) 2 FRONT 1. Park machine on a level surface, lower cutting units, stop engine and remove key from the ignition switch. Chock wheels to keep the machine from moving. 2. Disconnect negative (- ) and then positive (+) battery cables from the 12 volt battery at the rear of the machine (see 12 VDC Battery Service in the Service and Repairs section of Chapter 5 - Electrical System). 2 1 4 3. Open and support hood. 3 5.
9. Disconnect hydraulic pump drive shaft from 48 VDC motor/generator (see Hydraulic Pump Drive Shaft in the Service and Repairs section of Chapter 4 - Hydraulic System). Position and support drive shaft away from motor/generator and engine. IMPORTANT: To prevent damage to electrical wire harness, numerous cable ties are used to secure harness to machine components. Take note of all cable ties that are removed from machine during engine removal so they can be properly replaced during engine installation. 10.
12.Install air cleaner (see Air Cleaner Assembly in this section). One person should operate lift or hoist while a second person guides the engine into the machine. IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness, radiator or other parts while installing the engine. 13.Install exhaust muffler to machine (see Exhaust System in this section). Make sure that exhaust tube has ⅜” (9.5 mm) clearance with guard in all directions after assembly. 14.
Engine Bellhousing Assembly 50 to 60 ft- lb (68 to 81 N- m) 1 20 16 19 18 Antiseize Lubricant 7 9 8 11 2 5 4 17 15 Antiseize Lubricant 14 3 12 10 6 RIGHT 13 25 to 31 ft- lb (34 to 42 N- m) FRONT Figure 14 1. 2. 3. 4. 5. 6. 7. Diesel engine Motor/generator assembly Flange head screw Collar Coupler hub Woodruff key Bellhousing 8. 9. 10. 11. 12. 13. 14.
Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Traction Unit Operator’s Manual . . . . . . . . . . . . . . 3 48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Maximum Pump Displacement (per revolution) Closed Circuit Axial Piston Design 2.14 Cubic Inches (35 cc) Gear Pump Section P1 Displacement (per revolution) (all models) Section P2 Displacement (per revolution) (all models) 2 Section, Positive Displacement Gear Type Pump 0.24 Cubic Inches (3.96 cc) 0.40 Cubic Inches (6.
General Information Traction Unit Operator’s Manual The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publication for additional information when servicing the machine. 48 VDC Battery Disconnect CAUTION FRONT 1 2 Hydraulic System Before installing, removing or servicing components in the 48 VDC system (e.g.
Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston (traction) pump may occur. 1 If it becomes necessary to tow or push the machine, tow or push at a speed below 3 mph (4.8 kph), and for a very short distance. If the machine needs to be moved a considerable distance, machine should be transported on a trailer. The piston (traction) pump is equipped with a bypass valve that needs to be loosened for towing or pushing (Fig. 3).
Hydraulic Hose and Tube Installation (O- Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
Hydraulic Fitting Installation (SAE Straight Thread O- Ring Fitting into Component Port) Non- Adjustable Fitting (Fig. 7) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
Adjustable Fitting (Fig. 9) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O- ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O- ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back- up Washer 4. Turn back the lock nut as far as possible.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting units fully, stop engine and engage parking brake. To relieve hydraulic pressure in lift circuit, start engine and fully lower the cutting units. Turn key switch to OFF and remove key from the ignition switch.
Hydraulic System This page is intentionally blank.
Hydraulic Schematic NOTE: A larger hydraulic schematic is included in Chapter 9 - Foldout Drawings LIFT CONTROL MANIFOLD Hydraulic System Page 4 - 10 Reelmaster 5010- H
Hydraulic System This page is intentionally blank.
Hydraulic System Figure 11 Page 4 - 12 Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 5010- H Traction Circuit (Forward Shown) Hydraulic Flow Diagrams LIFT CONTROL MANIFOLD Reelmaster 5010- H
Traction Circuit Traction circuit pressure (forward and reverse) can be measured at test ports located in the hydraulic tubes that connect the front wheel motors. NOTE: In high load traction situations, the 48 VDC motor/generator may automatically assist the engine to maintain piston (traction) pump input speed. Forward Direction (Fig. 11) Pushing the top of the traction pedal angles the piston (traction) pump swash plate to create a flow of oil.
TO STEERING & CHARGE CIRCUIT G4 C4 L SV1 SV2 P4 CV4 C4 C1 L SVRV P1 C1 P2 CV1 T PUMP (P3) INTERNAL CASE DRAIN R7 CV5 C5 C5 L 100 MESH SUCTION STRAINER SV3 CV23 C2/3 L LIFT CONTROL MANIFOLD C2/3 RIGHT FRONT FRONT LEFT FRONT CENTER LEFT REAR RIGHT REAR Reelmaster 5010- H Lift Circuit: Raise Cutting Units Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 13 Hydraulic System Page 4 - 14 Reelmaster 5010- H
Lift Circuit: Raise Cutting Units A two section gear pump is coupled to the piston (traction) pump. Gear pump section (P1) supplies hydraulic flow to the lift control manifold and ultimately for the lift cylinders. The hydraulic reservoir provides fluid for the gear pump through the suction hose. Lift circuit pressure is limited to 2000 PSI (138 bar) by a solenoid relief valve (SVRV) located in the lift control manifold. The lift control manifold includes four (4) electrically operated solenoid valves.
TO STEERING & CHARGE CIRCUIT G4 C4 L SV1 SV2 P4 C4 CV4 C1 L SVRV P1 C1 P2 CV1 T PISTON PUMP (P3) INTERNAL CASE DRAIN R7 CV5 C5 C5 L 100 MESH SUCTION STRAINER SV3 CV23 LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT FRONT CENTER LEFT FRONT LEFT RIGHT REAR REAR Reelmaster 5010- H Lift Circuit: Lower Cutting Units Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 14 Hydraulic System Page 4 - 16 Reelmaster 5010- H
Lift Circuit: Lower Cutting Units The lift control manifold includes four (4) electrically operated solenoid valves. Valve (SVRV) is used to direct gear pump flow to the lift cylinders when energized or bypass pump flow back to the reservoir when de- energized. Valve (SV2) is used to direct oil flow to retract the lift cylinders when energized or extend them when deenergized. Valve (SV1) allows hydraulic flow to the front lift cylinders when energized.
Figure 15 Hydraulic System Page 4 - 18 Reelmaster 5010- H STEERING CYLINDER STEERING CONTROL VALVE TO TRACTION CHARGE CIRCUIT R10 FROM PUMP (P2) RIGHT TURN PISTON MOVEMENT STEERING CONTROL VALVE STEERING CYLINDER TO TRACTION CHARGE CIRCUIT PISTON MOVEMENT Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 5010- H Steering Circuit R10 FROM PUMP (P2) LEFT TURN
Steering Circuit With the steering wheel in the neutral position and the engine running, flow enters the steering control valve at the P port and goes through the steering control spool valve, by- passing the rotary meter (V1) and steering cylinder. Flow leaves the control valve through the T port to the hydraulic oil filter and traction charge circuit. Left Turn (Fig.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 bar), 5000 PSI (350 bar) and 10000 PSI (700 bar) gauges. Use gauges as recommended in the Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Toro Part Number: AT40002 Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi- directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
Hydraulic Test Fitting Kit Toro Part Number: TOR4079 TORO TEST FITTING KIT (TOR4079) This kit includes a variety of O- ring face seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Figure 22 Measuring Container Toro Part Number: TOR4077 Hydraulic System Use this graduated container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft.
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble and correct it before allowing the machine to be used again.
Traction Circuit Problems Problem Possible Cause Neutral is difficult to find or unit operates in one direction only Traction control linkage is misadjusted, disconnected, binding or damaged. Piston (traction) pump check relief valve is not seating or is damaged (NOTE: Piston (traction) pump check relief valves for forward and reverse are identical and can be reversed for testing purposes). Piston (traction) pump is worn or damaged. Traction response is sluggish Charge pressure is low.
Traction Circuit Problems (Continued) Problem Possible Cause Wheel motor will not turn Brakes are binding. Wheel motor is worn or damaged. (NOTE: If a traction circuit component has internal wear or damage, it is possible that other traction components are also damaged) Lift Circuit Problems Problem Possible Cause Single cutting unit lifts slowly or not at all Affected cutting unit has excessive debris buildup. Pilot piston in lift control manifold for the affected cutting unit is stuck or damaged.
Lift Circuit Problems (Continued) Problem Possible Cause None of the front cutting units will raise or lower but the rear cutting units will raise and lower Solenoid valve SV1 on lift control manifold is faulty. Neither of the rear cutting units will raise or lower but the front cutting units will raise and lower Solenoid valve SV3 on lift control manifold is faulty.
Hydraulic System This page is intentionally blank.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this chapter). 2. Review all test steps before starting the test procedure. Before Performing Hydraulic Tests 4. All hydraulic tests should be made with the hydraulic oil at normal operating temperature.
Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, lift circuit or steering circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 3. If a steering circuit problem exists, consider performing one or more of the following tests: Steering Relief Valve (R10) Pressure, Steering Cylinder Internal Leakage and/or Gear Pump (P2) Flow Tests. Hydraulic System 1.
Traction Circuit Relief Valve (R3) and (R4) Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD P1 P2 FORWARD (R3) RELIEF VALVE TEST SHOWN 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN PRESSURE GAUGE G5 A FORWARD R3 A TRACTION WHEEL MOTORS P3 LH M6 B R5 R4 B R9 A M7 RH B G6 FROM STEERING CONTROL VALVE Figure 26 The traction circuit relief pressure test should be performed to make sure that forward and reverse traction circuit relief pressures are correc
NOTE: If machine is equipped with optional CrossTraxTM AWD, reverse relief pressure test ports are located on CrossTraxTM hydraulic manifold. 2WD MACHINE SHOWN 3. Thoroughly clean traction circuit test port on hydraulic tube for direction to be checked (Fig. 27). Connect a 5000 PSI (350 bar) pressure gauge to test port. 4 1 4. After installing tester, start engine and run at low idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 3 RIGHT FRONT 5.
Traction Circuit Charge Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD P1 P2 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN G5 A FORWARD R3 A TRACTION WHEEL MOTORS P3 M6 B R5 R4 B PRESSURE GAUGE LH R9 A M7 RH B G6 FROM STEERING CONTROL VALVE Figure 29 The traction circuit charge pressure test should be performed to make sure that the traction charge circuit is functioning correctly. Procedure for Traction Circuit Charge Pressure Test 1.
5. Start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 3 1 6. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. 7. Make sure that traction pedal is in neutral, the steering wheel is stationary and parking brake is engaged. 8. Increase engine speed to high idle speed (3000 RPM) and monitor pressure gauge to determine no load charge pressure.
Gear Pump (P2) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD P1 P2 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN G5 A FORWARD R3 A TRACTION WHEEL MOTORS P3 LH M6 B R5 R4 B A M7 RH B G6 TESTER FROM STEERING CONTROL VALVE R9 OIL FILTER AND TUBE REMOVED Figure 32 The gear pump (P2) flow test should be performed to make sure that the traction charge circuit and steering circuit have adequate hydraulic flo
3. Raise and prop operator seat to allow access to hydraulic pump assembly. 4. Thoroughly clean the ends of the hydraulic tubes connected to the oil filter and piston pump inlets (Fig. 33). Disconnect hydraulic tubes from oil filter inlet and piston pump inlet. Remove two (2) flange head screws that secure oil filter adapter to frame. Remove oil filter assembly and hydraulic tube from machine.
Front Wheel Motor Efficiency Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD P1 P2 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TESTER A G5 FORWARD CAP R3 A A TRACTION WHEEL MOTORS P3 LH M6 B R5 M7 RH B R4 CAP B R9 FROM STEERING CONTROL VALVE G6 RH FRONT WHEEL MOTOR EFFICIENCY TEST SHOWN Figure 35 Procedure for Front Wheel Motor Efficiency Test NOTE: Over a period of time, a wheel motor can wear internally.
6. Thoroughly clean junction of hydraulic hose and right side elbow fitting on bottom of piston (traction) pump (Fig. 36). Disconnect hose from piston (traction) pump fitting. IMPORTANT: Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the pump, through the tester and into the hydraulic hose. 7. Install tester with pressure gauges and flow meter in series with the piston (traction) pump and the disconnected hose.
Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD P1 P2 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TESTER A G5 FORWARD R3 A TRACTION WHEEL MOTORS P3 LH M6 B R5 R4 B R9 A RH M7 B G6 FROM STEERING CONTROL VALVE Figure 37 Procedure for Piston (Traction) Pump Flow Test This test measures piston (traction) pump output (flow).
5. Thoroughly clean junction of hydraulic hose and right side fitting on bottom of piston (traction) pump (Fig. 38). Disconnect hose from right side pump fitting. 11. Observe flow gauge. For a piston pump in good condition, flow indication should be approximately 26 GPM (98 LPM). IMPORTANT: Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the pump, through the tester and into the disconnected hydraulic hose. 12.
Lift Relief Valve (SVRV) Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT G4 SV2 P4 C4 L SV1 CV4 C4 SVRV C1 L C1 P1 P2 PRESSURE GAUGE CV1 T R7 CV5 C5 C5 L PISTON PUMP (P3) INTERNAL CASE DRAIN 100 MESH SUCTION STRAINER SV3 CV23 LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT LEFT FRONT FRONT CENTER LEFT REAR RIGHT REAR Figure 39 Hydraulic System Page 4 - 42 Reelmaster 5010- H
The lift relief valve (SVRV) pressure test should be performed to make sure that the lift circuit relief pressure is correct. 8. Once relief pressure has been determined, return the lower mow/raise lever to the neutral position and stop the engine. Procedure for Lift Relief Valve (SVRV) Pressure Test 9.
Gear Pump (P1) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT G4 TESTER SV1 P2 T CV4 SVRV (NOT ENERGIZED) P1 C4 L SV2 P4 C4 C1 L C1 CV1 R7 CV5 C5 C5 L PISTON PUMP (P3) INTERNAL CASE DRAIN 100 MESH SUCTION STRAINER SV3 CV23 LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT LEFT FRONT FRONT CENTER LEFT REAR RIGHT REAR Figure 41 Hydraulic System Page 4 - 44 Reelmaster 5010- H
Procedure for Gear Pump (P1) Flow Test 1. Park machine on a level surface with the cutting units lowered and disengaged. Make sure engine is off. Apply the parking brake. 2. Read Precautions For Hydraulic Testing in this section. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 3.
Lift Cylinder Internal Leakage Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT G4 SV2 P4 C4 L SV1 CV4 C4 SVRV P1 C1 L C1 P2 CV1 T R7 CV5 C5 C5 L PISTON PUMP (P3) INTERNAL CASE DRAIN SV3 100 MESH SUCTION STRAINER CV23 LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT LEFT FRONT (PARTIALLY RAISED) PLUG FRONT CENTER CAP CHECK FOR CYLINDER EXTENDING LEFT REAR RIGHT REAR LEFT FRONT (#5) LIFT CYLINDER TEST SHOWN Figure 43 The lift cylinder internal leakage test should be performed if a c
IMPORTANT: When capping lift cylinder fitting and hydraulic hose end, use a steel cap and plug to ensure that fluid leakage will not occur. Plastic plugs will not hold hydraulic pressure that will be developed during this test procedure. 11. If needed, repeat steps 3 through 9 for other lift cylinders. 12.After lift cylinder testing is completed, check oil level in hydraulic reservoir and adjust as necessary. 3 2 5. Place a steel cap on the open lift cylinder fitting to seal the lift cylinder.
Steering Relief Valve (R10) Pressure Test TO LIFT CONTROL MANIFOLD P1 PISTON PUMP (P3) INTERNAL CASE DRAIN P2 100 MESH SUCTION STRAINER TO TRACTION CHARGE CIRCUIT OUT T P IN R10 V1 STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE R L PRESSURE GAUGE STEERING CYLINDER Figure 47 Hydraulic System Page 4 - 48 Reelmaster 5010- H
The steering relief valve (R10) pressure test should be performed to make sure that the steering circuit relief pressure is correct. IMPORTANT: As steering wheel is turned, make sure that pressure gauge is not contacted by any machine parts. Procedure for Steering Relief Valve (R10) Pressure Test: 9. Watch pressure gauge carefully while turning the steering wheel for a left hand turn (counter- clockwise) and holding. 2. Read Precautions For Hydraulic Testing in this section.
Steering Cylinder Internal Leakage Test R10 STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE PLUG LOOK FOR LEAKAGE STEERING CYLINDER (FULLY EXTENDED) Figure 49 Hydraulic System Page 4 - 50 Reelmaster 5010- H
The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty. 8. Remove all hydraulic oil from drain pan. Make sure that empty drain pan remains under the open fitting of the steering cylinder. NOTE: Steering circuit operation will be affected by rear tire pressure, steering cylinder binding, extra weight on the vehicle and/or binding of rear axle steering components.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, lower cutting units, engage parking brake and stop engine. Remove key from the ignition switch. 1. If component failure is severe or hydraulic system is contaminated, flush hydraulic system (see Flush Hydraulic System in this section). 2.
Check Hydraulic Lines and Hoses Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating the machine. CAUTION Hydraulic System Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil appears milky or black or contains metal particles. 1. Park machine on a level surface. Lower cutting units, stop engine, engage parking brake and remove key from ignition switch. 2. Drain hydraulic reservoir. 3. Clean area around the mounting area of the hydraulic filter. Remove and discard hydraulic filter. 4. Drain entire hydraulic system.
Filtering Closed- Loop Traction Circuit 1. Park machine on a level surface with engine stopped and key removed from ignition switch. 2. Raise and support machine so all wheels are off the ground (see Jacking Instructions in Chapter 1 - Safety). NOTE: If wheel motor was replaced, install high flow filter to the inlet of the new motor instead of to the piston pump fitting. This will prevent system contamination from entering and damaging the new wheel motor. 3.
Hydraulic System Start- up NOTE: When initially starting the hydraulic system with new or rebuilt components such as pumps, wheel motors or lift cylinders, it is important that this start- up procedure be used. This procedure reduces the chance of damaging the system or its components from not purging the system of air. 1.
Hydraulic System This page is intentionally blank.
Hydraulic Reservoir 7 12 20 6 1 8 5 6 16 10 11 19 13 3 4 2 18 14 17 15 RIGHT 16 9 9 FRONT Figure 52 1. 2. 3. 4. 5. 6. 7. Suction strainer Hydraulic reservoir Recess bumper Clamp (2 used) Suction hose Hose clamp (2 used) Reservoir cap Hydraulic System 8. 9. 10. 11. 12. 13. 14. Washer head screw (2 used) Flange nut (3 used) Cap screw Flat washer Filter screen Hydraulic tube O- ring Page 4 - 58 15. 16. 17. 18. 19. 20.
Removal (Fig. 52) Installation (Fig. 52) 1. Thoroughly clean hydraulic hose ends and fittings on hydraulic reservoir to prevent hydraulic system contamination. 1. If fitting (item 15) was removed from reservoir, lubricate and place new O- ring onto fitting. Install fitting into reservoir opening using marks made during the removal process to properly orientate fitting. Tighten fitting (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Piston (Traction) Pump Control Assembly 8 9 12 6 5 7 13 19 16 20 3 10 14 21 22 21 17 11 1 4 2 15 1 TO TRACTION PEDAL RIGHT 18 FRONT Figure 53 1. 2. 3. 4. 5. 6. 7. 8. Flange head screw (2 used) Piston (traction) pump Lever damper Flange nut Pump plate Cap screw (3 used) Carriage screw Lock nut Hydraulic System 9. 10. 11. 12. 13. 14. 15. Pump lever Flat washer Flange nut Lock nut Cap screw Cap screw Traction cable bracket Page 4 - 60 16. 17. 18. 19. 20. 21. 22.
Disassembly (Fig. 53) 5 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Remove components from piston (traction) pump control assembly as needed using Figures 53 and 54 as guides. 1 Assembly (Fig. 53) IMPORTANT: To prevent traction neutral switch (item 17) damage, make sure that no pump control components contact switch through entire piston (traction) pump control arm movement. 3 1.
Hydraulic Pump Assembly 33 38 RIGHT FRONT 29 30 31 27 36 32 28 7 37 35 34 22 21 9 4 1 8 3 15 19 26 23 6 16 18 5 10 3 4 26 2 17 25 Antiseize Lubricant 24 14 11 2 12 13 20 Figure 56 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Gear pump assembly O- ring O- ring Flat washer (4 used) O- ring Hydraulic fitting Piston (traction) pump assembly Socket head screw (2 used) Lock washer (2 used) Lock nut (2 used) Flange nut (2 used) Carriage screw (2 used) Hydraulic tube 14. 15. 16. 17.
Removal (Fig. 56) 3 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Raise and support hood and operator seat. Lift hood saddle from frame brackets and remove from machine. 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1 2 CAUTION Figure 57 3.
13.Remove two (2) socket head screws, lock washers and flat washers that secure gear pump to piston (traction) pump. Remove gear pump from piston (traction) pump. Locate and discard O- ring (item 15) from between pumps. 14.If necessary, remove hydraulic fittings from pumps. Note orientation of fittings for assembly purposes. 15.Remove and discard all O- rings from removed hydraulic lines and fittings. 16.
Hydraulic System This page is intentionally blank.
Piston (Traction) Pump Service 7 16 5 4 15 14 12 9 8 27 2 13 1 6 25 26 9 10 11 13 32 33 26 36 12 34 30 29 20 3 8 28 31 5 17 18 19 35 40 43 21 41 22 44 23 24 47 42 37 45 46 39 38 48 Figure 59 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Hydraulic System This page is intentionally blank.
Gear Pump Service 15 9 2 4 11 3 7 6 1 10 5 18 8 19 12 17 20 16 14 33 ft- lb (45 N- m) 13 Figure 60 1. 2. 3. 4. 5. 6. 7. Front cover Dowel pin (4 used) Square section seal (4 used) Back- up seal (4 used) Pressure seal (4 used) Thrust plate (4 used) Drive shaft 8. 9. 10. 11. 12. 13. 14. Driven gear Body Flange Splined connecting shaft Drive gear Driven gear Body Disassembly (Fig. 60) NOTE: The gear pump must be replaced as a complete assembly.
IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. DIAGONAL LINE 7. Remove the thrust plates and seals from each pump section. Before removing each gear set, apply marking dye to mating teeth to retain ”timing”. Pump efficiency may be affected if the teeth are not installed in the same position during assembly.
Hydraulic Pump Drive Shaft RIGHT FRONT 3 2 1 3 6 8 7 13 10 4 14 9 11 5 Antiseize Lubricant 12 Antiseize Lubricant Figure 62 1. 2. 3. 4. 5. Hood saddle Air intake hose Hose clamp (2 used) Flange head screw (4 used) Flange nut (4 used) Hydraulic System 6. 7. 8. 9. 10. Upper intake shroud Lower intake shroud Brush seal (2 used) 48 VDC motor/generator assembly Engine bellhousing Page 4 - 70 11. 12. 13. 14.
1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Raise and support hood and operator seat. Lift hood saddle (item 1) from frame brackets and remove from machine. 3. Loosen hose clamp that secures air intake hose (item 2) to upper intake shroud. Carefully slide intake hose from upper shroud. 4. Remove intake shrouds (items 6 and 7) and brush seals (item 8) from machine. A.
Hydraulic Pump Drive Shaft Cross and Bearing Service 2 3 5 6 1 3 3 4 2 8 7 3 4 Figure 64 1. End yoke (motor/generator) 2. Grease fitting (2 used) 3. Snap ring (4 per cross and bearing) Hydraulic System 4. Cross and bearing assembly 5. Shaft yoke (male) 6. Grease fitting Page 4 - 72 7. Telescoping yoke (female) 8.
Disassembly (Fig. 64) Assembly (Fig. 64) 1. Remove hydraulic pump drive shaft from vehicle (see Hydraulic Pump Drive Shaft in this section). 1. To install new cross and bearings: 2. Lightly clamp drive shaft yoke in vise. Use two screwdrivers to remove snap rings that secure bearings at the inside of each yoke. Remove yoke from vise. IMPORTANT: Yokes must be supported when removing and installing bearings to prevent damage. 3. Use a press to remove cross and bearings from yokes: A.
Front Wheel Motors 24 26 27 25 10 26 22 21 20 23 11 13 15 8 4 9 7 18 5 1 19 17 16 14 3 12 80 to 100 ft- lb (109 to 135 N- m) 6 315 to 385 ft- lb (428 to 522 N- m) RIGHT 2 FRONT 70 to 90 ft- lb (95 to 122 N- m) Figure 65 1. 2. 3. 4. 5. 6. 7. 8. 9. Wheel motor (LH shown) Lug nut (5 used per wheel) Hub Wheel stud (5 used per wheel) Wheel assembly Brake drum Front wheel shield (2 used) Cap screw (2 used per shield) Flat washer (2 used per shield) Hydraulic System 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 65) Installation (Fig. 65) 1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the ignition switch. 1. If fittings were removed from wheel motor, lubricate and place new O- rings to fittings. Install fittings into motor ports using marks made during the removal process to properly orientate fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
Front Wheel Motor Service 11 12 13 12 14 15 16 17 18 16 3 19 1 2 4 20 3 21 6 10 9 8 5 3 45 to 55 ft- lb (61 to 75 N- m) 7 Figure 66 1. 2. 3. 4. 5. 6. 7. Cap screw (7 used) End cap O- ring (3 used) Geroler assembly Valve plate Thrust bearing Bearing 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Valve Dowel pin (4 used) Balancing ring Valve spring Back- up ring O- ring Drive NOTE: The front wheel motors are Eaton Delta motors of the same basic design with minor differences.
Hydraulic System This page is intentionally blank.
Rear Wheel Motors (Machines with Optional CrossTraxTM Kit) 7 6 8 9 13 12 14 7 6 8 5 2 3 11 10 4 RIGHT 270 to 330 ft- lb (367 to 447 N- m) FRONT 70 to 90 ft- lb (95 to 122 N- m) 70 to 80 ft- lb (95 to 108 N- m) 1 Figure 67 1. 2. 3. 4. 5. Lug nut (5 used per wheel) Rear wheel assembly Wheel hub assembly Lock nut Woodruff key 6. 7. 8. 9. 10. 45o hydraulic fitting (2 per motor) O- ring O- ring Hydraulic hose (4 used) Cap screw (4 per motor) Removal (Fig. 67) 1.
6. Remove wheel hub from rear wheel motor: Installation (Fig. 67) IMPORTANT: DO NOT hit wheel hub, puller or wheel motor with a hammer during wheel hub removal or installation. Hammering may cause damage to the wheel motor. 1. If fittings were removed from wheel motor, lubricate and place new O- rings to fittings.
Rear Wheel Motor Service (Machines with Optional CrossTraxTM Kit) 14 17 21 20 19 16 15 12 18 13 22 23 4 1 10 3 5 3 45 to 55 ft- lb (61 to 75 N- m) 7 3 9 6 2 8 3 3 11 Figure 68 1. 2. 3. 4. 5. 6. 7. 8. Cap screw (7 used) End cover Body seal (5 used) Commutator ring Commutator Commutator ring Manifold Stator 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Control Manifold Cartridge Valve Service 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing cartridge valve from manifold, make sure that deep well socket fully engages the valve base. 3. Remove cartridge valve from manifold using a deep socket wrench.
Lift Control Manifold 16 10 17 11 12 1 15 3 14 19 5 13 18 6 4 9 8 7 2 RIGHT FRONT Figure 69 1. 2. 3. 4. 5. 6. 7. Lift control manifold Flange head screw O- ring Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic System 8. 9. 10. 11. 12. 13. Hydraulic hose Hydraulic hose Hydraulic tube Hydraulic tube O- ring O- ring Page 4 - 82 14. 15. 16. 17. 18. 19.
Removal (Fig. 69) IMPORTANT: When installing orifice in manifold (Fig. 70), make sure that orifice is flat in the base of the fitting cavity. Manifold damage is possible if the orifice is cocked in the cavity. 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. B. For manifold ports with orifice, place correct orifice in port with the orifice slot facing out. 2.
Lift Control Manifold Service 60 in- lb (6.7 N- m) 25 ft- lb (33 N- m) 9 7 6 60 in- lb (6.7 N- m) 25 ft- lb (33 N- m) 10 8 6 6 5 60 in- lb (6.7 N- m) 5 4 4 11 20 ft- lb (27 N- m) 20 ft- lb (27 N- m) 3 12 20 ft- lb (27 N- m) 2 1 13 RIGHT 75 ft- lb (101 N- m) 14 FRONT 15 16 Figure 71 1. 2. 3. 4. 5. 6. Lift control manifold Check valve (4 used) Solenoid valve (SV3) Solenoid coil (2 used) Solenoid coil spacer (2 used) Nut (3 used) 7. 8. 9. 10. 11.
For lift control manifold service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 71 for cartridge valve installation torque. Refer to Figures 71 and 72 for hydraulic fitting installation torque values. NOTE: Solenoid valves SV1 and SV2 on the lift control manifold use a coil spacer between the solenoid coil and nut. 10 ft- lb (14 N- m) 10 ft- lb (14 N- m) 3 2 4 1 NOTE: Adjustment of Relief Valve (R7) is NOT recommended.
CrossTraxTM AWD Manifold (Machines with Optional CrossTraxTM Kit) 11 15 12 14 8 9 13 10 7 1 6 5 RIGHT 2 4 FRONT 3 Figure 73 1. 2. 3. 4. 5. CrossTrax AWD manifold Hydraulic tube Hydraulic tube Hydraulic tube O- ring 6. 7. 8. 9. 10. Hydraulic fitting (7 used) O- ring Dust cap (2 used) Diagnostic fitting (2 used) O- ring Removal (Fig. 73) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2.
6. Put caps or plugs on disconnected lines and fittings to prevent contamination. 3. Remove caps and plugs from disconnected hydraulic lines and fittings. 7. Support manifold to prevent it from falling. Remove three (3) cap screws and lock washers that secure manifold to machine frame. Locate and retrieve three (3) spacers from between frame bracket and manifold. 4. Lubricate and install new O- ring(s) on manifold fittings. Connect hydraulic lines to hydraulic manifold fittings.
CrossTraxTM AWD Manifold Service (Machines with Optional CrossTraxTM Kit) 220 in- lb (24.8 N- m) 25 ft- lb (33 N- m) 12 3 2 5 11 4 220 in- lb (24.8 N- m) 1 25 ft- lb (33 N- m) 2 2 220 in- lb (24.8 N- m) 3 3 10 4 5 9 8 7 7 6 6 46 ft- lb (62 N- m) 120 in- lb (13.5 N- m) Figure 74 1. 2. 3. 4. CrossTrax AWD manifold O- ring Plug (NWD #6) Seal kit 5. 6. 7. 8. Check valve Plug (NWD #4) O- ring Orifice (.040) 9. 10. 11. 12.
Hydraulic System This page is intentionally blank.
Lift Cylinders Medium strength Threadlocker 77 to 93 ft- lb (105 to 126 N- m) 18 2 17 5 15 2 1 3 16 14 9 11 12 13 8 7 4 8 6 10 RIGHT FRONT 11 12 Figure 75 1. 2. 3. 4. 5. 6. Lift cylinder Cylinder pin Flange head screw Lift arm (#4 shown) Flat washer Hydraulic hose 7. 8. 9. 10. 11. 12. O- ring 90o hydraulic fitting O- ring Hydraulic hose Retaining ring Thrust washer 13. 14. 15. 16. 17. 18.
1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 9. Remove flange head screw (item 3) and flat washer (item 5) that retain lift cylinder to cylinder pin. 10.Slide lift cylinder from cylinder pin and remove from machine. 2.
Lift Cylinder Service 1 9 14 4 7 13 3 10 6 11 12 40 ft- lb (54 N- m) 2 8 9 13 10 12 14 4 15 5 5 11 8 7 3 2 6 Figure 76 1. 2. 3. 4. 5. Grease fitting Shaft Dust seal Head BS seal 6. 7. 8. 9. 10. Retaining ring Back up washer O- ring Piston Wear ring NOTE: The front, outside lift cylinders are longer with more stroke than the other lift cylinders which are identical. Service procedures for all lift cylinders used on Reelmaster 5010- H machines are the same. Disassembly (Fig. 76) 1.
4. Remove plugs from ports. Extract shaft, head and piston by carefully twisting and pulling on the shaft. IMPORTANT: Do not clamp vise jaws against the shaft surface. Clamp on the clevis ONLY. 5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the shaft. Carefully slide head off the shaft. 6. Taking care to not scratch or damage the piston, remove wear ring, BP seal and O- ring from the piston. 7.
Steering Control Valve Antiseize Lubricant 7 5 RIGHT 6 FRONT 8 4 9 20 to 26 ft lb (28 to 35 N- m) 10 11 3 2nd 12 7 to 10 ft- lb (9.5 to 13.5 N- m) Antiseize Lubricant FRONT 3rd 1 4th Tightening Sequence (Item 9) 2 13 1st 14 Figure 77 1. 2. 3. 4. 5. Steering control valve Flange head screw (2 used) Socket head screw (4 used) Steering wheel Flat washer 6. 7. 8. 9. 10. Lock nut Steering wheel cover Steering column Socket head screw (4 used) O- ring Removal (Fig. 77) 1.
7. Position steering column brace (item 13) to machine and secure with four (4) flange head screws and flange nuts. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 7. Disconnect hydraulic lines from steering control valve. Allow lines to drain into a suitable container. 8.
Steering Control Valve Service 26 25 24 23 21 22 20 19 18 16 14 12 11 9 17 8 10 15 7 4 13 6 5 4 3 20 to 24 ft- lb (27 to 33 N- m) 2 1 Figure 80 1. 2. 3. 4. 5. 6. 7. 8. 9. Screw (5 used) O- ring (5 used) End cover O- ring Outer gearwheel Inner gearwheel Distributor plate O- ring Cardan shaft 10. 11. 12. 13. 14. 15. 16. 17. 18. Spool Sleeve Cross pin Spring set Ring Thrust washer Bearing Shaft seal Ball stop 19. 20. 21. 22. 23. 24. 25. 26.
Hydraulic System This page is intentionally blank.
Steering Cylinder 5 9 10 6 6 7 7 4 8 5 3 2 15 1 14 13 12 11 RIGHT FRONT Figure 81 1. 2. 3. 4. 5. Steering cylinder Retaining ring Grease fitting Hydraulic hose O- ring 6. 7. 8. 9. 10. 90o hydraulic fitting O- ring Hydraulic hose Grease fitting Ball joint 11. 12. 13. 14. 15. Removal (Fig. 81) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 2.
4. Disconnect hydraulic hoses from fittings in steering cylinder. 5. Put caps or plugs on disconnected hoses and fittings to prevent contamination. 6. Remove two (2) jam nuts (item 11) that secure steering cylinder to axle. Remove cotter pin (item 12), washer (item 14) and slotted hex nut (item 13) that secure steering cylinder to RH drag link. 7. Separate ball joints from axle assembly and remove steering cylinder from machine. 8.
Steering Cylinder Service 40 ft- lb (54 N- m) 12 9 11 3 8 7 2 6 13 1 10 9 13 8 12 11 4 5 4 7 3 2 10 6 1 5 Figure 84 1. 2. 3. 4. 5. Shaft Dust seal BP seal Head Retaining ring 6. 7. 8. 9. Disassembly (Fig. 84) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. IMPORTANT: Prevent damage when clamping the steering cylinder into a vise; clamp on the clevis end of the barrel ONLY. 2.
Inspection IMPORTANT: To prevent shaft damage, do not clamp shaft surface in a vise. Use eye protection such as goggles when using compressed air to clean steering cylinder components. 1. Wash all cylinder components in solvent. Dry parts with compressed air. 2. Inspect internal surface of barrel for deep scratches, out- of- roundness and bending. Replace if worn or damaged. 3. Inspect head, shaft and piston for excessive pitting, scoring and wear. Replace any worn or damaged parts. 4.
Hydraulic Oil Cooler 16 RIGHT 30 to 40 in- lb (3.4 to 4.5 N- m) FRONT 13 11 12 11 10 2 9 5 1 13 7 6 5 14 15 8 5 6 3 8 4 17 2 30 to 40 in- lb (3.4 to 4.5 N- m) Figure 85 1. 2. 3. 4. 5. 6. Oil cooler Hose clamp (4 used) Hydraulic hose (2 used) Radiator Cooler clamp (16 used) Flat washer (8 used) Hydraulic System 7. 8. 9. 10. 11. 12. Cap screw (4 used) Flange nut (10 used) Top cooler bracket Cap screw (2 used) Washer (4 used) Clamp (2 used) Page 4 - 102 13. 14. 15. 16. 17.
Removal (Fig. 85) 2. Unlatch and open the rear screen. 3. Remove battery to ease oil cooler removal (see 12 Volt Battery Service in the Service and Repairs section of Chapter 5 - Electrical System). 4. Label all oil cooler hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to loosening hydraulic hoses at oil cooler. 5. Loosen hose clamps that secure hydraulic hoses to oil cooler fittings. Remove hoses from oil cooler. Allow hoses to drain into a suitable container. 6.
This page is intentionally blank.
Chapter 5 Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2 48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 2 Toro Electronic Controller (TEC) . . . . . . . . . . . . . . 3 CAN--bus Communications . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SYSTEM OPERATION . . . . . . . . . . . . 4 12 VDC System Operation . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to that publication for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for Reelmaster 5010--H machines are located in Chapter 9 -- Foldout Drawings.
Toro Electronic Controller (TEC) Reelmaster 5010--H machines use a Toro Electronic Controller (TEC) to manage machine electrical functions. The controller is microprocessor controlled that senses the condition of various switches and sensors (inputs). The controller then directs electrical power to control appropriate machine functions (outputs) based on the input state.
Electrical System Operation Reelmaster 5010--H machines use two (2) separate electrical systems. Most machine functions operate on a typical 12 VDC system. The second system exists to operate the electric cutting reels and is a 48 VDC electrical system. Basic information about the two systems is included below.
48 VDC System Operation The Reelmaster 5010--H 48 VDC system includes a 48 VDC battery pack, an engine driven motor/generator assembly, five (5) cutting reel motors, a main contactor used to energize the system and additional circuit control components. Circuit protection for the 48 VDC system includes five (5) fuses in a single fuse block, an inline system logic fuse and a system Maxi--fuse. The 48 VDC system is an isolated system so the vehicle frame is not used for any ground connections in this system.
Special Tools Order Special Tools from your Toro Distributor. Digital Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Cutting Reel Motor Rotor Tool Set The rotor tool set for the cutting reel motor is required to remove and install the rotor from the reel motor housing. Tool set includes puller hub, threaded shaft, handle and four (4) screws (Fig. 6). NOTE: For cutting reel motor service procedures, see Cutting Reel Motor Service in the Service and Repairs section of this chapter. IMPORTANT: The rotor magnets are very powerful and can cause the rotor to shift position very rapidly during installation.
Generator Rotor Tool Set Toro Part Number: TOR6029 The generator rotor tool set is required to remove and install the rotor from the motor/generator housing. Tool set includes base plate, threaded shaft and handle (Fig. 8). NOTE: For motor/generator service procedures, see Motor/Generator Assembly Service in the Service and Repairs section of this chapter. IMPORTANT: When working on the motor/generator, use a clean work space with a non--metal surface.
Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte in the machine 12 VDC battery. Obtain this tool locally. NOTE: A battery hydrometer is not usable for the batteries in the Reelmaster 5010--H 48 VDC battery system. These batteries are valve regulated, sealed lead acid batteries that are maintenance free with no provision for checking or adjusting electrolyte level.
InfoCenter Display The InfoCenter Display used on your Reelmaster is a LCD device that is located on the console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings. Power for the InfoCenter is available when energized by the main power relay (ignition switch in the ON/PREHEAT or START position).
KEY SWITCHED MAIN MENU SCREEN ON Main Menu Faults Service Diagnostics Settings About SPLASH SCREEN Main Menu AFTER 5 SECONDS Faults Service Diagnostics Settings About AFTER 5 SECONDS MAIN INFORMATION SCREENS *ACCESS PROTECTED MAIN INFORMATION SCREENS eReel Info n 1600 min 13A n N 100 P 170 1400 240 RPM 120 190 n 1600 min 13A n 1600 min 13A Main Menu Faults Service Diagnostics Settings About SERVICE SCREEN Hours Hours Key On Hours Engine Run Hours PTO On Front CU Backlap Hours Hours
Main Information Screens The two (2) InfoCenter main information screens (Figs. 14 and 15) are displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screens provide machine information for the operator. Toggling between the main information screens is done by pressing the right button on the InfoCenter.
Access Protected Display Screens The protected display screens are available on the InfoCenter to view the electrical status of the 48 VDC power circuit. The protected display screens can be viewed after the Protected Menus are available by entering the machine PIN (see Settings Screen in this section). Toggling between the protected display screens is done by pressing the middle button on the InfoCenter when they are active.
Main Menu Screen The main menu screen can be accessed from the InfoCenter main information by pressing and releasing the menu/back button (left button) on the display twice. Once at the main menu screen (Fig. 19), navigation to the five (5) different menu items can occur. Pressing the move to menu item button (middle button) allows a different menu item to be highlighted. Selection of the highlighted item is completed by pressing the choose menu item button (right button).
Service Screen The service screen (Fig. 21) contains machine operational information including hours, counts, reset defaults and cutting unit backlap engage. Values listed for these service menu items cannot be changed. If the machine PIN has been entered to allow access to protected menu items in the settings screen, the protected service menu items will be listed and available in the service screen.
Diagnostics Screen For each of the diagnostics screen items, inputs, qualifiers and outputs are identified. The diagnostics screen includes the following: D Cutting Units identifies machine requirements to allow the cutting units to raise and lower. Inputs indicate the state of the joystick raise and lower switches and the position of the ignition switch.
Settings Screen The settings screen identifies the InfoCenter units (English or Metric) and language. The settings screen also allows the operator to customize the backlight (brightness) and contrast settings for the InfoCenter display. 1 2 If either the backlight (brightness) or contrast items are selected, the middle button (--) or right button (+) can be used to change the display settings.
Height of Cut (HOC) identifies the setting for cutting unit height of cut. This information is used by machine controllers to determine cutting unit reel speed. F Reel RPM displays the front reel speed that has been determined by the machine controllers based on entered information for blade count, mow speed and HOC. Front reel speed can also be manually adjusted.
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see Chapter 9 -- Foldout Drawings). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by--passed, they must be reconnected for proper troubleshooting and safety.
Advisory Description Advisory Number 160 Start Denied Possible Reason for Advisory Neither seat occupied nor parking brake applied Traction pedal is NOT in neutral position Wait to start until system functions have been initialized Joystick is in RAISE position Joystick is in LOWER position Reel engage/disengage switch is in engaged position 161 Mow Denied No operator in seat Engine coolant temperature is excessive Low voltage in 48 VDC battery pack 162 Lowered Denied Mow stop lever is in TRANSPORT
Fault Codes The InfoCenter Display will identify electrical system malfunctions (faults) if they occur. Should a fault occur during machine operation, the InfoCenter indicator light will illuminate and the fault will be displayed on the InfoCenter Display (Fig. 27). The InfoCenter display faults screen will list all machine electrical faults that have occurred since the faults were last cleared from the InfoCenter. The faults will be identified by a fault number and when the fault occurred.
Fault Code Fault Description Service Suggestions 1 Excessive engine coolant temperature (above 105oC) caused PTO to disengage Check radiator and screen for debris buildup Check engine cooling fan and drive belt Check engine coolant level 2 Excessive engine coolant temperature (above 115oC) caused engine to stop Check radiator and screen for debris buildup Check engine cooling fan and drive belt Check engine coolant level 3 One of the TEC output fuses (7.
Fault Description Fault Code 28 Service Suggestions 48 VDC devices (motor/generator and all cutting reel motors) are all off--line Make sure that 48 VDC battery disconnect is securely plugged in Check 48 VDC enable fuse (10A) Check 48 VDC master fuse (250A maxi fuse) Check 48 VDC battery system voltage Check 48 VDC logic relay and circuit wiring Check isolation module and circuit wiring Check CAN--bus termination resistors and circuit wiring 29 48 VDC system (motor/generator and all cutting reel motor
Fault Description Fault Code 43 Service Suggestions CAN--bus fault for motor/generator Check CAN--bus connection to motor/generator Verify battery power exists at motor/generator Check CAN--bus termination resistors 44 CAN--bus fault for InfoCenter Check CAN--bus connection to InfoCenter Display Verify battery power exists at InfoCenter Display 45 Software version incompatible with #1 cutting reel motor Contact Toro distributor to update software 46 Software version incompatible with #2 cutting
Fault Description Fault Code 63 Service Suggestions 48 VDC pre--charge fault Disconnect one cutting reel motor at a time until the fault is no longer active to identify faulty motor NOTE: If cutting reel motor is faulty, additional fault codes will likely be displayed 64 Motor/generator temperature sensor fault If this fault continues to occur, consider that motor/generator may be faulty 65 Motor stalled on #1 cutting unit Check #1 cutting unit for excessive rotating resistance Check #1 cutting un
Fault Description Fault Code 68 Service Suggestions Motor stalled on #4 cutting unit Check #4 cutting unit for excessive rotating resistance Check #4 cutting unit bedknife adjustment and reel condition Check #4 cutting unit motor for excessive rotating resistance Check that #4 cutting unit motor can rotate without load Replace #4 cutting unit motor if above items do not identify problem and issue is not resolved 69 Motor stalled on #5 cutting unit Check #5 cutting unit for excessive rotating resistan
Fault Description Fault Code 72 Service Suggestions High temperature warning for #3 cutting unit Let machine cool to lower cutting unit motor temperature Open the rear discharge of the cutting unit Reduce reel speed if possible Reduce mow speed if possible If fault does not seem to be related to cutting load conditions, check 48 VDC ground for #3 cutting unit motor Consider replacement of #3 cutting unit motor if this fault continues to occur NOTE: A faulty sensor will not cause this fault 73 High tem
Fault Code Fault Description Service Suggestions 75 High temperature warning for motor/generator Make sure that hood screen is clean Check that air intake to motor/generator is not restricted or blocked and that air is moving through intake when engine is running Check for motor/generator cooling fin debris obstruction Let machine cool to lower motor/generator temperature Reduce cutting system load by reducing reel speed, reducing mow speed or by opening the rear discharge of the cutting unit If this f
Fault Description Fault Code 79 Service Suggestions System voltage under 32 VDC has disabled #4 Check logic power connection to #4 cutting cutting unit unit If this fault is displayed for more than one cutting unit, check 48 VDC battery voltage when engine is OFF and also check 48 VDC logic relay and circuit wiring If 48 VDC battery voltage is correct when engine is OFF but drops when engine is ON, consider that motor/generator is faulty 80 System voltage under 32 VDC has disabled #5 Check logic power
Fault Description Fault Code 83 Service Suggestions Logic voltage over 67.
Fault Description Fault Code 86 Service Suggestions Logic voltage over 67.
Fault Description Fault Code 93 Service Suggestions System bus voltage under 36 VDC has disabled motor/generator (main contactor is engaged) Check to see if a pre--charge fault (fault 63) has occurred Check that main contactor is functional Check the motor/generator connections NOTE: If all 48 VDC components (motor/generator and cutting unit motors) have this fault, system fault 29 will be displayed on the InfoCenter 94 System bus voltage over 67.
Fault Description Fault Code 97 Service Suggestions System bus voltage over 67.
Fault Description Fault Code Service Suggestions 108 Excessive voltage occurred at internal motor regulator for #3 cutting unit #3 cutting unit motor is likely faulty if this fault continues to occur 109 Excessive voltage occurred at internal motor regulator for #4 cutting unit #4 cutting unit motor is likely faulty if this fault continues to occur 110 Excessive voltage occurred at internal motor regulator for #5 cutting unit #5 cutting unit motor is likely faulty if this fault continues to occur
Fault Code Fault Description Service Suggestions 117 Insufficient voltage occurred at internal motor/ generator regulator and disabled motor/ generator Check electrical connections to motor/generator If fault occurs for multiple cutting unit motors and motor/generator, check 48 VDC logic relay and circuit wiring Check 48 VDC battery system cables for proper connections Consider that motor/generator is faulty 123 Excessive motor/generator speed Engine speed is incorrect which causes the motor/generat
Starting Problems Problem Possible Causes All electrical power is dead, including InfoCenter Display. 12 VDC battery is discharged. Ignition switch or circuit wiring is faulty. Fusible link harness at the engine starter motor is faulty. 12 VDC battery cables are loose or corroded. Main fuse (15 amp) to the ignition switch is faulty. Starter solenoid clicks, but starter will not crank. 12 VDC battery is discharged.
Starting Problems (Continued) Problem Possible Causes Nothing happens when start attempt is made. InfoCenter Display operates with the ignition switch in RUN. Traction pedal is not in neutral position. Operator seat is unoccupied OR the parking brake is not applied. NOTE: If machine controls are not in the correct position to start the engine (e.g. the traction pedal is pressed), an Cutting units are engaged (reel engage/disengage advisory message may be displayed on the InfoCenter switch is ON).
General Run and Transport Problems Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. Engine fuel actuator or circuit wiring is faulty. Ignition switch or circuit wiring is faulty. Main power relay or circuit wiring is faulty. Engine continues to run, but should not, when the traction pedal is engaged with no operator in the seat. Seat switch or circuit wiring is faulty. TEC controller fuses are faulty. Traction neutral switch is out of adjustment.
Cutting Unit Operating Problems Problem Possible Causes The cutting units remain engaged, but should not, with no operator in the seat. Seat switch or circuit wiring is faulty. Cutting units run, but should not, when raised. Cutting units shut off with reel engage/disengage switch. Cutting unit down limit switch or circuit wiring is faulty. Cutting units run, but should not, when raised. Cutting units do not shut off with reel engage/disengage switch.
Cutting Unit Operating Problems (Continued) Problem Possible Causes The cutting units do not run when placed in the backlap direction. The parking brake is not applied. Reel engage/disengage switch is in the OFF position. High engine coolant temperature has disabled cutting unit operation. The joystick is not in the center position. Cutting units are not fully lowered to ground. Cutting unit down limit switch or circuit wiring is faulty. None of the cutting units will lower.
Electrical System Quick Checks 12 VDC Battery Test (Open Circuit Test) Use a digital multimeter to measure the battery voltage. Voltage Measured Battery Charge Level Remove battery cover to access the battery at the rear of the machine. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F (16o to 38o C). The ignition switch should be in the OFF position and all accessories turned off.
Check Operation of Interlock Switches CAUTION The interlock switches are for the protection of the operator and bystanders and to ensure correct operation of the machine. Do not bypass or disconnect switches. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. NOTE: Use the InfoCenter Display to test TEC controller inputs and outputs before further troubleshooting of an electrical problem on your Reelmaster.
Adjustments Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The switch mounts to a bracket on the traction pump. The sensing element for the traction neutral switch is the traction pump lever that is secured to the pump control arm (Fig. 28). 1 Adjustment 1. Before adjusting the traction neutral switch, check and adjust traction system neutral position (refer to Traction Unit Operator’s Manual).
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the brake pedal (Fig. 29). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed. The parking brake detent is moved away from the switch when the parking brake is applied causing the switch to open.
Cutting Unit Down Limit Switch The cutting unit down limit switch is a normally open proximity switch that closes when the front, outside cutting units are in the turn--around position. The down limit switch is attached to a frame bracket inside the front, right lift arm pivot tube. A bracket on the front, right lift arm acts as the sensing plate for the down limit switch (Fig. 30).
Mow/Transport Switch The mow/transport switch is a normally closed proximity switch that is attached to the bottom of the floor platform (Fig. 31). 1 4 When the mow stop lever is in the MOW position, the tab on the mow stop lever is positioned away from the target end of the mow/transport switch so the switch is closed. The tab on the mow stop lever is moved next to the mow/ transport switch when the mow stop lever is in the TRANSPORT position causing the switch to open.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check of the switch). NOTE: See the Kubota Workshop Manual, Diesel Engine, 05--E4B Series for engine electrical component repair information. CAUTION NOTE: Electrical troubleshooting of any 12 volt power connection can be performed through voltage drop tests without disconnecting the component.
12 VDC System Fuses The fuse block is located behind the control arm access cover (Fig. 33). In addition to the 12 VDC fuses in the fuse block, a 2 Amp fuse is included in the wire harness to protect the logic power circuit for the TEC controller. This fuse resides in a fuse holder near the engine starter motor and is secured to the wire harness with a cable tie (Fig. 34). 1 Identification and Function The fuses are held in the fuse block.
48 VDC System Fuses Several fuses are used in the 48 VDC system (motor/ generator and cutting unit motors) for circuit protection. Fuse Identification and Function 1 2 35 Amp Reel Motor Fuses: Protect the 48 VDC power supply circuits for the electric reel motors. The reel motor fuses are located in a fuse holder behind the hood saddle under the hood (Fig. 36).
Engine Speed Switch The engine speed switch is a momentary switch that is used as an input for the TEC controller to raise or lower the engine speed. When the switch is depressed and held in the forward position, the engine speed will increase. Conversely, when the rear of the switch is depressed, engine speed will decrease. The engine speed switch is located on the control arm (Fig. 38). 1 2 Testing 1.
Reel Engage/Disengage Switch The reel engage/disengage switch is used to allow the cutting units to operate. An indicator light on the switch identifies when the engage/disengage switch is engaged. The reel engage/disengage switch is mounted on the control panel (Fig. 40). The Toro Electronic Controller (TEC) monitors the operation of the reel engage/ disengage switch. 5. Replace reel engage/disengage switch if testing determines that it is faulty.
Headlight Switch The headlight switch allows the headlights to be turned on and off. This rocker switch is located on the operator side of the control arm (Fig. 42). 1 NOTE: The Toro Electronic Controller (TEC) does not monitor the operation of the headlight switch. Testing 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 2.
Seat Switch The seat switch is normally open and closes when the operator seat is occupied. If the traction system or reel engage/disengage switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch is located directly under the operator seat. The Toro Electronic Controller (TEC) monitors the operation of the seat switch.
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the brake pedal (Fig. 45). The Toro Electronic Controller (TEC) monitors the operation of the parking brake switch. C. Using a multimeter, verify that the machine wire harness connector terminal for black wire is closed (continuity) to ground. D.
Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The switch mounts to the pump plate on the piston (traction) pump. The sensing element for the traction neutral switch is the traction pump lever that is secured to the pump control arm (Fig. 46). The Toro Electronic Controller (TEC) monitors the operation of the traction neutral switch. C.
Cutting Unit Down Limit Switch The cutting unit down limit switch is a normally open proximity switch that closes when the front, outside cutting units are in the turn--around position. The down limit switch is attached to a frame bracket inside the front, right lift arm pivot tube. A bracket on the front, right lift arm acts as the sensing plate for the down limit switch (Fig. 47). The Toro Electronic Controller (TEC) monitors the operation of the cutting unit down limit switch. D.
Joystick Raise and Lower Switches Two (2) micro switches for the joystick are located on the lower mow/raise lever that is attached to the control arm. The rear switch on the control is used to lower (and engage) the cutting units and the front switch to raise (and disengage) them. A normally open contact in the switch closes when the joystick is positioned to either lower or raise the cutting units. Each switch has an electrical connector to make sure the normally closed contact on the switch is not used.
Mow/Transport Switch The mow/transport switch is a normally closed proximity switch that opens when the mow stop lever is placed in the transport position. The sensing plate for the mow/ transport switch is the mow stop lever (Fig. 50). The Toro Electronic Controller (TEC) monitors the operation of the mow/transport switch. C. Using a multimeter, verify that the machine wire harness connector terminal for black wire is closed (continuity) to ground. D.
Main Power, Glow and 48 VDC Logic Relays Your Reelmaster uses three (3) identical electrical relays that have four (4) terminals. The main power and glow relays are attached to a frame bracket under the hood near the engine exhaust muffler (Fig. 51). The 48 VDC logic relay is attached to a frame bracket under the hood behind the reel motor fuse block (Fig. 52). A tag near the relay harness connector identifies each relay.
6. When relay testing is complete, disconnect voltage and multimeter leads from the relay terminals. 7. Replace relay if testing determines that it is faulty. 8. Secure relay to machine and connect machine wire harness connector to relay. Install hood saddle to machine if it was removed. Lower and secure hood. Electrical System 5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85.
Start Relay The start relay is used in the engine starting circuit. When energized by the TEC controller, the start relay provides a current path to energize the engine starter solenoid. The start relay has five (5) terminals and is attached to a frame bracket under the hood near the engine exhaust muffler (Fig. 54). Relays can be identified by a tag on the wire harness.
Main Contactor The main contactor provides current to the 48 VDC system circuits (e.g. motor/generator, reel motors). When the ignition switch is ON, the 48 VDC logic relay is energized by the TEC controller which allows the main contactor to be energized if allowed by the motor/generator controller. The main contactor is attached to the right side frame rail under the operator seat (Fig. 56).
Toro Electronic Controller (TEC) Reelmaster 5010--H machines use a Toro Electronic Controller (TEC) to control electrical system operation. The TEC controller senses the condition of various switches (inputs) and directs power output to allow certain machine functions. The TEC is attached to the control arm behind the access panel on the outside of the control arm (Fig. 58). 1 2 Logic power is provided to the controller as long as the battery cables are connected to the battery.
Because of the solid state circuitry built into the TEC controller, there is no method to test it directly. The TEC may be damaged if an attempt is made to test it with an electrical test device, such as a digital multimeter.
Fusible Link Harness The Reelmaster 5010--H uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the main wire harness (Fig. 63). If any of these links should fail, current to the protected circuit will cease. Refer to wire harness drawings in Chapter 9 -- Foldout Drawings for additional fusible link information. FRONT 1 Testing 1.
Diode Assembly A diode assembly is used in the Reelmaster main wire harness (Fig. 65). The diode is used for circuit protection from voltage spikes that occur when the starter solenoid is de--energized. NOTE: The diode assembly is identified on the electrical schematic as diode D1. 2 Testing 1 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 2.
48 VDC System Protection Diode The Reelmaster 5010--H 48 VDC system includes a diode that is used for circuit protection from voltage spikes when the main contactor is de--energized. The diode plugs into the main wire harness near the 48 VDC battery disconnect and main contactor under the operator seat (Fig. 67). 1 3 Protection Diode Testing 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 2 2.
Location ID Module The location ID module exists in the 48 VDC electrical circuit to identify the location of the five (5) cutting reel motors. This module allows such machine features as starting and stopping the rear cutting units slightly later than the front cutting units. The location module plugs into the main wire harness near the 48 VDC fuse block (Fig. 69).
Cutting Reel Motor The five (5) cutting reel motors are identical 48 VDC, brushless, permanent magnet motors. Each motor has its own integral invertor and on--board controller. The InfoCenter Display can be used to monitor the speed and current draw for the five (5) cutting unit motors during machine operation. Also, if a problem exists with any cutting reel motor, a fault may have occurred that would be indicated by a fault code on the InfoCenter Display.
CAN--bus Termination Resistors The twisted pair of bus wires for the 12 VDC circuits are black/white and red/white. The twisted pair of bus wires for the 48 VDC circuits are green and yellow. The two (2) termination resistors for the 12 VDC electrical circuits have the following locations: A. In the control arm next to the operator seat. B. Near the wire harness connectors for the #3 (right rear) cutting unit motor on the right side of the machine.
Hydraulic Solenoid Valve Coil The Reelmaster hydraulic lift control manifold includes four (4) solenoid valves for system control (Fig. 74). When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic flow. Testing of the coils can be done with the coil installed on the hydraulic valve. NOTE: If electrical problems exist with a solenoid valve coil, a fault may have occurred that would be indicated by a fault code on the InfoCenter Display.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 75). The Toro Electronic Controller (TEC) monitors the operation of the temperature sender. The resistance of the temperature sender reduces as the engine coolant temperature increases. The changing resistance of the temperature sender is used as an analog input to the TEC controller to indicate engine coolant temperature during machine operation. C.
Oil Pressure Switch The engine oil pressure switch is a normally closed switch that opens with pressure during normal engine operation. The oil pressure switch is located on the engine near the oil filter (Fig.77). The Toro Electronic Controller (TEC) monitors the operation of the oil pressure switch. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2).
Fuel Actuator The fuel actuator and TEC controller work together to maintain engine speed by adjusting the fuel delivery to the engine. A sensor in the motor/generator provides the generator/engine speed to the TEC controller via the CAN--bus. If there is a change in engine speed (e.g. load conditions change, engine speed switch pressed by operator), the TEC controller modifies the electrical output to the actuator which adjusts fuel as required to maintain engine speed. 4.
Fuel Sender The fuel sender is a variable resistance device that allows the InfoCenter display to show level of the fuel tank. The fuel sender is located in the fuel tank (Fig. 81). RIGHT Testing FRONT 4 175 to 200 in--lb (20 to 22 N--m) 2 1 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 5 2. Remove screws that secure sender cover to fuel tank. Lift cover from tank. 7 8 3.
8. Use a multimeter to check resistance of the fuel sender across the two (2) sender terminals (Fig. 83). A. Resistance with the float in the full position (completely up) should be from 5 to 8 ohms. B. Resistance with the float in the empty position (completely down) should be from 89 to 95 ohms. 1 9. Replace fuel sender if testing determines that it is faulty. 10.After testing, install sender into fuel tank and secure with gasket and fuel sender cap.
Fuel Pump The Reelmaster electric fuel pump is attached to the inside of the left side frame rail near the fuel tank (Fig. 84). 10.Connect wire harness electrical connector to the engine fuel actuator. IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. 11. Bleed the fuel system. 12.Lower and secure operator seat and hood. Fuel Pump Specifications DANGER 64 fl oz/min (1.9 liters/min) Pump Capacity Because diesel fuel is flammable, use caution when handling it.
Service and Repairs NOTE: See the Kubota Workshop Manual, Diesel Engine, 05--E4B Series for engine electrical component repair information. Hydraulic Solenoid Valve Coils A hydraulic solenoid valve coil on the lift control manifold (Fig. 86) can be replaced without opening the hydraulic system. 60 in--lb (6.7 N--m) 5 Removal 7 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 7 6 5 4 8 3 2.
12 VDC Battery Service The battery is the heart of the 12 VDC electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. Battery Inspection and Maintenance 1. Check battery for cracks. Replace battery if cracked or leaking. 2. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts.
H. Using the table below, determine the minimum voltage for the battery temperature reading. If the test voltage is below the minimum voltage for the battery temperature, replace the battery. If the test voltage is at or above the minimum, return the battery to service. Battery Storage If the machine will be stored for more than thirty (30) days: 1. Charge battery fully before storing the machine (see Battery Charging in this section). 2.
Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available. CAUTION Follow the manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery electrolyte is the most accurate method of determining battery condition. 1.
Electrical System Page 5 -- 82 Electrical System This page is intentionally blank.
48 VDC Battery Pack Service (Cutting Reel and Motor/Generator Systems) 13 5 8 10 25 14 22 23 7 9 12 19 18 11 3 20 23 1 17 15 15 RIGHT 21 FRONT 16 24 15 2 6 4 Figure 88 1. 2. 3. 4. 5. 6. 7. 8. 9. Battery (4 used) Battery tray Push nut (2 used) Carriage screw (2 used) Flange nut (6 used) Carriage bolt (4 used) Flange nut (2 used) Battery cover (2 used) Hex nut (2 used) Reelmaster 5010--H 10. 11. 12. 13. 14. 15. 16. 17.
The 48 volt battery pack used in the Reelmaster 5010--H electric reel drive system is composed of four (4) 12 volt batteries that are connected in series. The batteries are absorbed glass mat (AGM), valve regulated batteries that are maintenance free with no provision for checking or adjusting electrolyte level. The batteries are equipped with a low pressure venting system designed to release excess gas pressure and then automatically reseal.
48 VDC Battery Pack Installation (Fig. 88) 48 VDC Battery Pack Service 1. Make sure that the 48 VDC battery disconnect is separated to prevent unexpected 48 VDC system component operation (see 48 VDC Battery Disconnect in the General Information section of this chapter). Clean the battery pack with clean water and a towel. Do not use solvents or chemicals to clean the battery pack. 2. Make sure the battery tray is clean and repainted if necessary.
Electrical System Page 5 -- 86 Electrical System This page is intentionally blank.
48 VDC Electrical Power Connections 12 40 to 50 in--lb (4.6 to 5.6 N--m) 18 20 10 2 7 15 19 9 to 13 ft--lb (13 to 17 N--m) 16 19 3 3 20 19 4 4 5 6 1 11 8 8 20 17 4 13 14 8 21 9 11 RIGHT 9 to 13 ft--lb (13 to 17 N--m) FRONT 22 40 to 50 in--lb (4.6 to 5.6 N--m) Figure 91 1. 2. 3. 4. 5. 6. 7. 8. Bracket Main contactor Holder bracket (3 used) Jumper strap holder (3 used) Jumper strap (positive connections) Isolator Flange head screw Flat washer (9 used) Reelmaster 5010--H 9. 10. 11.
Disassembly FRONT 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 1 5 3 2. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect. (see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation. 3. Raise and support operator seat to access 48 VDC power connections.
Cutting Reel Motor NOTE: If electrical problems exist with a cutting reel motor, a fault may have occurred that would be indicated by a fault code on the InfoCenter Display. Before considering that reel motor service work is necessary, check for any existing fault codes that indicate problems with a reel motor (see Fault Codes in the Troubleshooting section of this chapter).
8. If cutting reel motor is to be removed from machine, disconnect reel motor cable from machine wire harness (Figs. 95 and 96): 5. If cutting reel motor was removed from machine, connect reel motor cable to machine wire harness (Fig. 96): A. Locate reel motor cable electrical connections at machine wire harness for motor that is to be removed. A. Connect two (2) reel motor cable connectors to machine wire harness. B. Position reel motor cable connector plate to machine frame and secure with flange nut.
Cutting Reel Motor Service 2 3 4 6 1 14 10 5 7 8 12 8 70 to 80 in--lb (8 to 9 N--m) 9 13 4 5 11 7 1 70 to 80 in--lb (8 to 9 N--m) Figure 98 1. 2. 3. 4. 5. Torx head screw (12 used) Motor cover O--ring Wave washer (2 used) Bearing (2 used) 6. 7. 8. 9. 10. Rotor Bearing (2 used) O--ring (2 used) Housing/controller/cable assembly O--ring NOTE: If motor housing, controller or cable damage occurs, cutting reel motor replacement is necessary. These components are not available separately.
7. Remove motor cover and wave washer (item 4) from rotor assembly. Remove and discard O--rings (items 14 and 3) from cover. 8. Remove and discard O--ring (item 8) from motor housing. IMPORTANT: Make sure to not damage the gearbox cover counter bore when removing the shaft seal from the cover. 9. Carefully remove shaft seal from gearbox cover. Discard removed seal. 10.If necessary, remove bearings from output gear (item 11) and rotor (item 6). Discard bearings if removed. 11.
Motor/Generator Assembly 1 20 50 to 60 ft--lb (68 to 81 N--m) 19 16 18 Antiseize Lubricant 7 9 8 2 11 4 17 5 15 Antiseize Lubricant 14 3 10 6 12 RIGHT 13 25 to 31 ft--lb (34 to 42 N--m) FRONT Figure 1. 2. 3. 4. 5. 6. 7. Diesel engine Motor/generator assembly Flange head screw Collar Coupler hub Woodruff key Engine bellhousing 8. 9. 10. 11. 12. 13. 14.
4. Disconnect hydraulic pump drive shaft from 48 VDC motor/generator output shaft (see Hydraulic Pump Drive Shaft in the Service and Repairs section of Chapter 4 -- Hydraulic System). Position drive shaft away from engine. 1 3 5. Remove exhaust muffler from machine (see Exhaust System in the Service and Repairs section of Chapter 3 -- Kubota Diesel Engine). 6. Disconnect wire harness connector from motor/generator assembly. CAUTION 2 7.
7. Connect wire harness connector to motor/generator assembly. CAUTION Support motor/generator and bellhousing assembly when installing it to prevent it from falling and causing personal injury. Assembly weighs approximately 69 pounds (31 kg). 8. Connect hydraulic pump drive shaft to motor/generator output shaft (see Hydraulic Pump Drive Shaft in the Service and Repairs section of Chapter 4 -- Hydraulic System).
Electrical System Page 5 -- 96 Electrical System This page is intentionally blank.
Motor/Generator Assembly Service 1 10 11 70 to 80 in--lb (8.0 to 9.0 N--m) 35 to 45 in--lb (4.0 to 5.0 N--m) 13 12 8 15 7 9 14 14 20 6 5 12 11 75 in--lb (8.5 N--m) 13 16 4 5 2 18 18 20 to 26 ft--lb (28 to 35 N--m) 17 19 95 to 105 ft--lb (129 to 142 N--m) 5 5 3 70 to 80 in--lb (8.0 to 9.0 N--m) 5 Figure 102 1. 2. 3. 4. 5. 6. 7.
Disassembly (Fig. 102) 11 35 to 45 in--lb (4.0 to 5.0 N--m) 1. Remove motor/generator cover (item 3) from motor/ generator assembly. 13 14 2. Remove access cover (item 7) and cover gasket from controller. Discard cover gasket. 15 7 5 6 9 4. Remove three (3) flange head screws (item 4) that secure motor/generator stator conductors to controller connectors. 4 5. Remove cap screws (item 11), flat washers (item 9) and flange nuts (item 10) that secure controller to motor/ generator assembly.
C. Lubricate new O--ring (item 2) with dielectric lubricant (see Special Tools in this chapter) and install into groove in housing bearing bore. 5. Install controller onto motor/generator: A. Lower controller onto motor/generator and route both controller and motor/generator harness connectors out opening in controller. IMPORTANT: The rotor magnets are very powerful and can cause the rotor to shift position very rapidly during installation.
Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Traction Unit Operator’s Manual . . . . . . . . . . . . . . 2 48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Front Tire Pressure (26.5 x 14.0 - 12, 4 ply, tubeless) 12 to 15 PSI (83 to 103 kPa) Rear Tire Pressure (20 x 12.
Special Tools Order Toro special tools from your Toro Distributor. Wheel Hub Puller The wheel hub puller allows safe removal of the front wheel hub from the wheel motor shaft. If machine is equipped with optional CrossTraxTM Kit, this wheel hub puller is needed for removing rear wheel hub from the rear wheel motor.
Service and Repairs Wheels 2 WHEEL DRIVE AXLES SHOWN 8 9 10 11 7 6 1 12 13 14 70 to 90 ft- lb (95 to 122 N- m) 2 3 7 4 RIGHT 5 FRONT Figure 3 1. 2. 3. 4. 5. Front wheel motor Brake assembly Front wheel hub Lock nut Brake drum Chassis 6. 7. 8. 9. 10. Front wheel Lug nut (5 used per wheel) Rear wheel hub Spindle washer Rear wheel Page 6 - 4 11. 12. 13. 14.
Removal (Fig. 3) Installation (Fig. 3) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. Install wheel and secure with five (5) wheel lug nuts. 2. Lower machine to ground. 2. Chock wheels to prevent machine from shifting. WARNING 3. Loosen, but do not remove, wheel lug nuts. Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury.
Steering Column 3 5 Antiseize Lubricant 4 1 2 Antiseize Lubricant 20 to 26 ft- lb (28 to 35 N- m) 6 12 11 13 14 7 9 RIGHT FRONT 10 8 9 Figure 4 1. 2. 3. 4. 5. Steering column Steering wheel Steering wheel cover Lock nut Flat washer 6. 7. 8. 9. 10. Socket head screw (4 used) Steering control valve Column brace Flange nut (6 used) Flange head screw (2 used) Removal (Fig. 4) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.
6. Slide rubber bellows up steering column to allow access to fasteners that secure steering column to machine. 3 1 2 7. Support steering control valve to prevent it from shifting during steering column removal. 4 8. Loosen and remove four (4) socket head screws (item 6) that secure steering control valve to steering column. 5 3 6 9. Loosen and remove four (4) socket head screws (item 11) and flange nuts (item 9) that secure steering column to machine. 7 8 10.
Brake Service 10 11 13 19 15 4 8 9 7 18 5 1 17 16 14 3 80 to 100 ft- lb (109 to 135 N- m) 12 6 315 to 385 ft- lb (428 to 522 N- m) RIGHT FRONT 70 to 90 ft- lb (95 to 122 N- m) 2 Figure 7 1. 2. 3. 4. 5. 6. 7. Wheel motor (LH shown) Lug nut (5 used per wheel) Wheel hub Wheel stud (5 used per wheel) Wheel assembly Brake drum Front wheel shield (2 used) Chassis 8. 9. 10. 11. 12. 13.
Removal (Fig. 7) 1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the ignition switch. RH BRAKE ASSEMBLY SHOWN 1 8 2 RIGHT FRONT 2. Chock wheels to prevent machine from shifting. 4 4. Remove front wheel assembly (see Wheels in this section). Make sure to support raised machine with appropriate jack stands. 3 5 6 5. Make sure parking brake is disengaged.
IMPORTANT: Before wheel hub is installed, thoroughly clean tapers of wheel hub and wheel motor shaft. Make sure that tapers are free of grease, oil and dirt. DO NOT use antiseize lubricant when installing wheel hub. 13.Torque wheel lug nuts evenly in a crossing pattern from 70 to 90 ft- lb (95 to 122 N- m). Torque lock nut (item 12) that secures wheel hub from 315 to 385 ft- lb (428 to 522 N- m). CAUTION 6. Mount square key in the wheel motor shaft, then install the wheel hub onto the wheel motor shaft.
Chassis This page is intentionally blank.
Rear Wheel Bearings (2 Wheel Drive) 9 6 7 8 10 7 6 5 3 2 11 See text for tightening procedure 1 4 Figure 10 1. 2. 3. 4. Dust cap Cotter pin Retainer Jam nut Chassis 5. 6. 7. 8. Spindle washer Bearing cone Bearing cup Wheel hub Page 6 - 12 9. Seal 10. Spindle 11.
Disassembly (Fig. 10) 1. Chock front wheels to prevent machine from shifting. 2. Remove rear wheel (see Wheels in this section). Make sure to support machine with jack stands. 3. Remove the dust cap from the wheel hub. 4. Remove the cotter pin, retainer, jam nut and spindle washer. Slide the wheel hub from the spindle shaft. 5. Pull the seal out of the wheel hub. Discard seal. 6. Remove the bearing cones from both sides of the wheel hub. Clean the bearings in solvent.
Rear Axle 6 90 to 120 ft- lb (123 to 162 N- m) 22 8 19 27 4 4 15 15 31 18 27 9 28 11 10 19 14 23 21 7 24 30 29 20 28 7 2 25 12 26 20 5 16 17 13 RIGHT 3 FRONT 20 1 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut (5 used per wheel) Rear axle assembly Dust cap Hydraulic fitting Tie rod Axle pivot pin Thrust washer Roll pin Thrust washer Jam nut Grease fitting Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 11) Installation (Fig. 11) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. Thoroughly clean the rear axle pivot pin. Inspect the pin for wear or damage and replace if necessary. 2. Chock front wheels to prevent machine from shifting. 3. Thoroughly clean hydraulic hose ends and fittings on steering cylinder to prevent hydraulic system contamination.
Rear Axle Service 18 17 16 1 15 13 5 12 19 3 11 20 7 6 21 8 5 7 16 14 15 9 10 4 2 RIGHT FRONT 8 Figure 12 1. 2. 3. 4. 5. 6. 7. Rear axle Housing (2 used) RH drag link Tie rod assembly Pivot bushing (2 used) Grease fitting (2 used) Flange bushing (4 used) Chassis 8. 9. 10. 11. 12. 13. 14. Flange head screw (7 used per side) LH drag link Hub and spindle assembly (2 used) Retaining ring Spindle cap Flange head screw Thrust washer Page 6 - 16 15. 16. 17. 18. 19. 20. 21.
The rear axle must be held in place snugly by the axle pivot pin. Excessive movement of the axle, which is characterized by erratic steering, might indicate worn axle pivot bushings (item 5). To correct the problem, replace the bushings. 1. Remove rear axle from machine (see Rear Axle in this section). 2. Use a bushing removal tool to extract both axle pivot bushings from the rear axle pivot tube. Take care to not damage bore of pivot tube during bushing removal.
Control Arm 33 25 3 2 26 FRONT 24 44 23 16 12 RIGHT 4 21 17 20 10 18 19 1 14 22 13 9 8 6 27 28 32 13 31 7 30 43 35 42 14 15 5 36 41 40 39 37 38 37 11 34 12 29 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Disassembly (Fig. 13) 2 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 1 2. Loosen latches and remove access cover from outside of control arm. 3. At front of control arm, remove screw (item 28) and lock nut (item 23) that secure control arm covers to each other. 4. Remove five (5) washer head screws (item 12) that secure each cover to control arm. 5. Remove control arm covers from machine.
Operator Seat 12 27 10 28 23 11 1 14 9 5 6 17 29 8 28 27 7 2 20 21 4 15 16 13 22 RIGHT 13 3 24 24 25 FRONT 26 19 18 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Operator seat Seat base Seat adjuster w/latch Flat washer (4 used) Seat switch harness Seat switch Washer head screw (2 used) Armrest bracket Spacer Armrest 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 15) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from 12 volt battery at rear of machine (see 12 Volt Battery Service in the Service and Repairs section of Chapter 5 - Electrical System). 3. Disconnect seat switch electrical connector from wire harness (Fig. 16). 4.
Mechanical Seat Suspension 40 31 18 19 37 34 20 41 1 28 29 26 38 30 6 8 23 4 24 22 7 11 10 2 27 33 16 21 12 36 14 13 25 35 17 9 32 39 3 42 5 15 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Upper housing Weight adjust knob Lower housing Scissor assembly Lock nut Weight adjuster Drive arm Extension spring (2 used) Roller guide Weight adjust knob Cap Suspension boot Pivot block (2 used) Damper Chassis 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
IMPORTANT: When removing the seat suspension, make sure to support the control arm to prevent damage to the control arm electrical components and control arm wiring harness. Removal (Figs. 18 and 19) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from 12 VDC battery (see 12 Volt Battery Service in the Service and Repairs section of Chapter 5 - Electrical System). 3.
Front Lift Arms 16 4 3 5 6 26 27 25 24 21 11 10 22 16 9 20 7 17 1 23 12 26 14 4 6 15 15 19 21 25 Antiseize Lubricant 2 13 16 9 8 18 7 Medium Strength Threadlocker 75 to 95 ft- lb (102 to 128 N- m) 20 RIGHT Medium Strength Threadlocker 135 to 165 ft- lb (184 to 223 N- m) Medium Strength Threadlocker 75 to 95 ft- lb (102 to 128 N- m) FRONT Figure 20 1. 2. 3. 4. 5. 6. 7. 8. 9.
8. Inspect bushings in lift arm and pivot yoke for wear or damage. If necessary, replace bushings (Figs. 22 and 23). 8. Check operation of lift arm up limit switch and adjust if necessary (see Up Limit Switch in Components section of Chapter 6 - Electrical System). A. Use bushing removal tool to extract bushings from the lift arm or pivot yoke. Take care to not damage the bore. 2 B. Clean the inside of the bore to remove any dirt or foreign material. C.
Rear Lift Arms 6 14 9 5 1 10 15 5 7 12 19 3 8 8 13 20 4 2 18 17 RIGHT FRONT 22 11 13 21 8 16 Figure 24 1. 2. 3. 4. 5. 6. 7. 8. Housing #2 lift arm #3 lift arm Washer (2 used per chain hoop) Washer (2 used) Flange head screw (2 used) Shoulder stud (6 used) Grease fitting 9. 10. 11. 12. 13. 14. 15. Pivot shaft (2 used) Washer head screw (1 used per shaft) Pivot yoke (2 used) Lynch pin (2 used) Thrust washer (2 used per yoke) RH torsion spring LH torsion spring Removal (Fig. 24) 1.
5. Remove lynch pin (item 12) and rear thrust washer (item 13) from rear of pivot yoke. Slide pivot yoke assembly from lift arm. Locate and retrieve front thrust washer (item 13). 2 CAUTION 3 4 Be careful when removing tension from the torsion spring on the rear lift arms. The spring is under heavy load and may cause personal injury. 1 B. Insert nut driver or small piece of pipe onto the end of the torsion spring that is secured to the shoulder stud. 5 3 6.
Installation (Fig. 24) 1 1. Position rear lift arm to frame and slide pivot shaft through frame bosses and lift arm. Secure shaft with washer head screw (item 10). 2 3 2. Place washer (item 5) over rear of each pivot shaft. 3. Place torsions springs (items 14 and 15) onto housing (item 1). Position long leg of springs forward and pointing out from top of spring. Short leg of springs should be against stop on housing (Fig. 28). 4.
Chassis This page is intentionally blank.
Hood 3 2 1 4 10 13 14 15 12 18 20 22 21 6 9 8 17 11 5 19 12 10 11 FRONT 7 RIGHT 16 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. Sealed foam Hood saddle Hood Catch (2 used) Rubber latch (2 used) Tube Bow tie pin (2 used) Deflector bracket (2 used) Chassis 9. 10. 11. 12. 13. 14. 15. Tube (2 used) Washer head screw (8 used) Flange head screw (10 used) Flange nut (10 used) Washer head screw (4 used) Flat washer (4 used) Lock nut (4 used) Page 6 - 30 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 29) Installation (Fig. 29) 1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the ignition switch. 1. Install all removed hood components using Figure 29 as a guide. 2. Unlatch hood. 2. Position hood assembly to machine and slide tube ends onto frame brackets. 3. Remove bow tie pin (item 7) and yoke pin (item 16) to allow hood removal. 3. Install yoke pin (item 16) and secure with bow tie pin (item 7). 4.
This page is intentionally blank.
Chapter 7 Cutting Units Table of Contents Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bedbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . . Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . . Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Reel Assembly Service . . . . . . . . . . . . . . Preparing Reel for Grinding . . . . . . . . . . . . . . . . . Front Roller . .
Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with bolt−on aluminum side plates. Reel Construction: Reels are 22 inches (55.9 cm.) in length and are available in 5 inch (12.7 cm) and 7 inch (17.8 cm) diameters. High strength, low alloy steel blades are thru hardened and impact resistant. Reels are available in both 8 and 11 blade configurations. Reel Bearings: Two stainless steel sealed radial ball bearings are pressed onto the reel shaft.
General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting units on your Reelmaster 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 publications for additional information when servicing the cutting units.
Special Tools Order special tools for your Reelmaster from your Toro Distributor. Some tools may have been supplied with your machine or are available as Toro parts. Gauge Bar Assembly Toro Part Number: 108−6715 Use gauge bar to verify height−of−cut adjustment. Also used for adjustment of optional groomer. Used for groomer adjustment Used for Height−of− Cut adjustment Figure 3 Cutting Reel Shim Toro Part Number: 125−5611 The cutting reel shim (0.
Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver−type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure 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 6 Handle Assembly Toro Part Number: 29−9100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel.
Spline Insert Tool Toro Part Number: TOR4112 (8 tooth for 5 inch reels) TOR4074 (9 tooth for 7 inch reels) Use spline insert tool for rotating cutting reel when motor is removed. Also use this tool for installation of threaded inserts into cutting reel shaft. Figure 9 Rear Roller Bearing and Seal Installation Tools Toro Part Number: 115−0803 Bearing Installation Washer This tool kit is used to assemble the cutting unit rollers.
Pulley Alignment Tool Toro Part Number: 114−5446 Use pulley alignment tool to verify alignment of groomer and/or rear roller brush drive and driven pulleys. Figure 12 Diameter/Circumference Measuring Tape Toro Part Number: TOR6023 Spring steel measuring 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).
Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131−6828 and 131−6829 1 Because the top grind angle on bedknives is critical for edge retention, and therefore after− cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. 2 3 Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. 1.
Factors That Can Affect Cutting Performance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the cutting unit. It is important to remember that the lower the height−of−cut, the more critical these factors are.
Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpen and/or remove rifling. NOTE: After grinding the reel and/or bedknife, check the reel to bedknife contact again after cutting two (2) fairways.
Factor Possible Problem/Correction Cutting unit alignment and carrier frame ground following Check carrier frames and lift arms for damage, binding conditions or bushing wear. Repair if necessary. Roller condition and roller type Make sure that front and rear rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options.
Set Up and Adjustments Characteristics If a cutting unit is determined to be out of adjustment, complete the following procedures in the specified order to adjust the cutting unit properly. CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first.
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjustment is possible to make sure that the cutting unit is properly aligned. Cutting Unit with 7” Reel Shown 3 2 3 1. Place the assembled cutting unit on a surface plate. 2. Make sure that bedknife is properly adjusted to cutting reel. 3.
Service and Repairs Cutting Reel Motor NOTE: If electrical problems exist with a cutting reel motor, a fault should have occurred that would be indicated by a fault code on the InfoCenter Display. Before considering that reel motor service work is necessary, check for any existing fault codes that indicate problems with a reel motor. 2 IMPORTANT: When performing service or maintenance on the cutting reel motors, take care to not damage the motors or electrical connections.
Backlapping DANGER TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running or if the 48 VDC battery pack is connected. Disconnect the cutting units from the electrical power supply by separating the 48 VDC battery disconnect (see 48 VDC Battery Disconnect in the General Information section of this chapter). D While backlapping, the reels may stall and then restart. D Do not attempt to restart reels by hand or foot.
Bedbar Assembly 7” CUTTING REEL SHOWN 2 3 4 1 27 to 33 ft−lb (37 to 44 N−m) 6 5 7 5 8 9 10 RIGHT FRONT Antiseize Lubricant Figure 23 1. 2. 3. 4. Bedbar assembly Lock nut (2 used) Compression spring (2 used) Washer (2 used) 5. Plastic washer (4 used) 6. Rubber bushing (2 used) 7. Flange bushing (2 used) Bedbar Assembly Removal (Fig. 23) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2.
Bedbar Assembly Installation (Fig. 23) 1. If rubber bushing was removed from either cutting unit side plate, install a new bushing. The bushing should be installed flush with the inside of the side plate (Fig. 24). 2. If removed, install the flange bushings with flange facing outward. Apply antiseize lubricant to inside of flange bushing. 3. Apply antiseize lubricant to the bedbar threads and the shoulder area of each bedbar pivot bolt. 9.
Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Assembly in this section). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard all removed screws. Remove bedknife from the bedbar (Fig. 25). 2 3. See bedknife grinding information on the following pages. Bedknife Installation 1. Use scraper to remove all rust, scale and corrosion from bedbar surface.
Bedknife Grinding Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. Follow the bedknife grinding specifications provided and grind only enough to make sure the top surface of the bedknife is true (Fig. 27 and 28). IMPORTANT: Do Not grind the bedknife below it’s service limit (Fig. 27 and 29).
Bedbar Adjuster Service Left Hand Threads Antiseize Lubricant Loctite #243 14 to 16 ft−lb (19 to 21 N−m) 6 7 11 2 3 4 5 Antiseize Lubricant 12 1 13 5 14 10 15 to 20 ft−lb (21 to 27 N−m) RIGHT FRONT Figure 31 1. 2. 3. 4. Bedbar assembly Compression spring Lock nut Bedbar adjuster screw Cutting Units 5. 6. 7. 8. Keyed flange bushing (2 used) Cap screw Detent Flat washer Page 7 − 20 9. 10. 11. 12.
1. Remove lock nut (item 3), compression spring and washer from bedbar adjuster screw (item 4). 2. If flange bushings (item 5) were removed, apply antiseize lubricant to bore of cutting unit frame. Align key on bushing to slot in frame and install bushings into frame. Apply antiseize lubricant to bore of each flange bushing. 2. Remove bedbar assembly (see Bedbar Assembly Removal in this section). 3.
Reel Assembly 7” CUTTING REEL SHOWN 1 17 18 8 15 2 13 4 27 to 33 ft−lb (37 to 44 N−m) 16 Antiseize Lubricant (Bearing OD) 3 4 7 5 6 14 Pack with Grease (both ends) RIGHT 9 12 FRONT Antiseize Lubricant (Bearing OD) 10 11 Antiseize Lubricant Figure 32 1. 2. 3. 4. 5. 6. Bedbar assembly Cutting unit frame Flange bushing (2 used) Plastic washer (4 used) Metal washer (2 used) Bedbar pivot bolt (2 used) 7. 8. 9. 10. 11. 12.
27 to 33 ft--lb (37 to 44 N--m) 15 to 19 ft--lb (20 to 25 N--m) 13 4 1 11 12 3 2 16 9 15 to 19 ft--lb (20 to 25 N--m) 8 12 14 9 15 10 16 7 4 11 5 27 to 33 ft--lb (37 to 44 N--m) 7 6 27 to 33 ft--lb (37 to 44 N--m) Figure 33 Frame LH side plate RH side plate Shoulder bolt (4) Carrier frame Flange head screw (2) 7. 8. 9. 10. 11. Flange bushing (2) Rear grass shield Spacer (2) Shim (0.060” -- as required) Flange nut (2) 3.
B. Insert a long--handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. 3 IMPORTANT: To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. 115 to 128 Nm (85 to 95 ft---lb) 1 C.
2. Make sure that grease seals and bearings are properly installed on cutting reel (see Reel Assembly Service in this Chapter). 3 3. Make sure the O--rings in the reel bearing boar are in good condition and properly installed in the side plates. 115 to 128 Nm (85 to 95 ft---lb) 1 4. Apply a thin coat of antiseize lubricant to the reel bearing bore of each side plate (Fig. 35). CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury.
Cutting Reel Assembly Service Loctite #243 9 10 11 1 12 2 7 6 5 85 to 95 ft−lb (115 to 128 N−m) (Right Hand Threads) 4 3 Left Hand Threads (Groove in Face) Loctite #243 85 to 95 ft−lb (115 to 128 N−m) 10 3 4 5 RIGHT 6 FRONT Flocked Surface Toward Bearing 7 8 Mobil XHP−222 Grease or equivalent Figure 35 1. 2. 3. 4. Cutting reel Threaded insert (RH thread) Plastic plug (2) Retaining ring 5. 6. 7. 8.
Reel Assembly 1. If removed, install new reel shaft plugs into cutting reel shaft. Plugs should be recessed into reel shaft from 1.370” to 1.630” (34.8 to 41.4 mm) (Fig. 36). 1 NOTE: One insert has LH threads and the other insert has RH threads. The insert with LH threads has a groove on the insert face. A groove is cut in the end of the reel shaft that has LH threads. 2 2. If previously removed, use correct spline insert tool to install threaded inserts (see Special Tools in this chapter).
Preparing Reel for Grinding Three (3) types of reel designs are used in Reelmaster cutting units: scalloped radial reel, tapered radial reel and tapered forward swept reel (Fig. 37). The radial reel designs have blades that are placed in line with the center of the reel shaft. The rear of the blades either have a scalloped relief or a tapered relief. The forward swept reel have blades that have a slight forward slant. The rear of the forward swept reel blades have a tapered relief.
DPA Cutting Units This page is intentionally blank.
Front Roller Removal (Fig. 39) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 Loctite #243 Antiseize Lubricant 2. Remove the cutting unit from the machine and place on a level working surface. Use cutting unit kickstand (see Special Tools in this chapter) to raise front roller from work surface. 2 15 to 19 ft−lb (20 to 26 N−m) 3 5 3.
Rear Roller Removal (Fig. 40) 4 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 5 1 5 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under bedbar to raise rear roller from work surface. 6 3. Loosen two (2) flange nuts that secure the rear roller shaft to each rear roller bracket. 4.
Roller Service Disassembly (Fig. 41) 2 1. Remove bearing lock nut from each end of roller shaft. 50 to 60 ft−lb (68 to 81 N−m) 3 4 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove shaft from roller tube. 5 6 7 1 2 4 3 5 3.
3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. IMPORTANT: When roller assembly is installed to cutting deck, make sure that grease groove in each roller mount aligns with the grease hole in each end of roller shaft. 4.
Rear Roller Brush (Optional) 20 9 Grease Seal Lip 1 3 22 21 20 to 25 in−lb (2.3 to 2.8 N−m) 4 15 8 Antiseize Lubricant 7 6 14 v 5 6 5 Grease Seal Lip 16 19 17 7 18 10 11 12 18 Grease Seal Lip RIGHT FRONT 2 8 27 to 33 ft−lb (37 to 44 N−m) 9 13 Figure 47 1. 2. 3. 4. 5. 6. 7. 8. Brush bearing housing (non−drive) Brush bearing housing (drive) O−ring Roller brush shaft Flange nut (4 used) Mounting bracket (2 used) Excluder seal (2 used) Flat washer (4 used) 9. 10. 11. 12. 13. 14.
4. Disassemble roller brush components as necessary using Figures 47 as a guide. If drive brush bearing housing (item 2) or driven pulley (item 12) need to be removed, brush cover and drive belt removal will be necessary (see Rear Roller Brush Drive System in this section). 6. Once all rear roller brush service is completed, plug the 48 VDC battery disconnect back in before operating the machine. 2 1 3 Rear Roller Brush Assembly (Fig. 47) 1.
Drive System Disassembly (Fig. 51) Loctite #243 15 to 19 ft−lb (20 to 25 N−m) 2 4 1 5 6 9 10 to 15 ft−lb (14 to 20 N−m) 10 6 2 Grease Grommet ID 11 3 Loctite #243 RIGHT v 13 15 5 14 6 15 to 19 ft−lb (20 to 25 N−m) 19 7 20 18 8 17 16 Loctite #243 FRONT 22 6 21 12 35 to 40 ft−lb (48 to 54 N−m) Figure 51 1. 2. 3. 4. 5. 6. 7. 8. Carriage screw (2 used) Carriage screw (3 used) Brush plate Cap screw (2 used) Flat washer (4 used) Lock nut (6 used) Idler arm Idler spacer 9. 10. 11. 12.
B. Loosen and remove drive shaft from cutting reel. 85 to 95 ft−lb (115 to 128 N−m) Drive System Assembly (Fig. 51) 1. Install drive shaft if it was removed (Fig. 52): 2 IMPORTANT: If rear roller brush drive is on left side of cutting unit, drive shaft has left hand threads and can be identified by a groove on the flange. If the rear roller brush drive is on right side of cutting unit, drive shaft has right hand threads and does not have a groove on the flange (Fig. 53). A.
3. After assembly (including drive belt installation), check alignment of pulleys with a straight edge placed along the outer face of the drive pulley (Fig. 54). 27 to 33 ft−lb (37 to 44 N−m) A. The outer faces of the drive and driven pulleys (not the idler pulley) should be in−line within 0.030” (0.76 mm). 4 3 B. If necessary to align pulleys, remove driven pulley from brush shaft and add or remove flat washer(s) until drive and driven pulleys are correctly aligned (Fig. 55). C.
Belt Driven Groomer (Optional) Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Groomer Kit Installation Instructions . . . . . . . . . . . 2 48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 5 Groomer Reel Mechanical Problems . . . . . . . . . . . 5 ADJUSTMENTS . .
General Information Groomer Kit Installation Instructions The groomer kit installation instructions provides information regarding the installation, set−up and operation of the optional groomer on your Reelmaster machine. Refer to this publication for additional information when servicing the groomer. 48 VDC Battery Disconnect CAUTION FRONT 1 Before installing, removing or servicing components in the 48 VDC system (e.g. cutting unit motors, motor/generator), separate the 48 VDC battery disconnect.
Special Tools Belt Driven Groomer (Opt.) Order Special Tools from your Toro Distributor. Some tools may have been supplied with your machine or are available as Toro parts. Spline Insert Tool Toro Part Number: TOR4112 (8 tooth for 5 inch reels) TOR4074 (9 tooth for 7 inch reels) Use spline insert tool for rotating cutting reel when motor is removed. Also use this tool for installation of threaded inserts into cutting reel shaft.
Grooming Performance There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT: Improper or overaggressive use of the groomer (e.g. too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be adjusted. Adjust groomer drive belt. Failed groomer idler bearing(s) in groomer side plate(s). Replace faulty bearing(s). Broken or damaged idler spring. Replace spring. The groomer drive belt is worn, bro- If the drive belt slips, it probably is out of adjustment or worn. ken or damaged. Repair or replace drive belt if necessary.
Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. Also, before installing, removing or working on the cutting units, disconnect the cutting units from the electrical power supply by separating the cutting unit power disconnect connector (see 48 VDC Battery Disconnect in the General Information section of this chapter).
CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. NOTE: The Groomer Installation Instructions provide information regarding the installation, set−up and operation of the optional groomer on your Reelmaster machine. Refer to these instructions for additional information when servicing the groomer.
Groomer Drive Assembly 22 23 7” CUTTING UNIT SHOWN Antiseize Lubricant In Key Slot 21 3 27 to 33 ft−lb (37 to 44 N−m) 6 5 4 17 1 15 10 Antiseize Lubricant 9 19 8 7 16 14 13 12 11 75 to 90 in−lb (8.5 to 10.1 N−m) 2 27 to 33 ft−lb (37 to 44 N−m) 20 Loctite #242 18 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. Flange nut (2 used) Groomer cover Groomer drive belt Flange head screw Drive pulley Square key Lock nut Retaining ring Belt Driven Groomer (Optional) 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly (Fig. 8) 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 2. To prevent unexpected reel motor operation, disconnect motors from the electrical power supply by unplugging the 48 VDC battery disconnect (see 48 VDC Battery Disconnect in the General Information section of this chapter).
Groomer Reel and Groomer Plate Assembly 23 17 7” CUTTING UNIT SHOWN Loctite #242 85 to 95 ft−lb (115 to 128 N−m) 20 24 18 Antiseize Lubricant 19 11 17 to 21 ft−lb (23 to 28 N−m) Loctite #242 13 6 15 7 21 Antiseize Lubricant 22 Antiseize Lubricant 20 12 1 Antiseize Lubricant RIGHT FRONT 11 6 14 2 3 4 27 to 33 ft−lb (37 to 44 N−m) Loctite #242 85 to 95 ft−lb (115 to 128 N−m) 9 5 13 16 8 10 Figure 10 1. 2. 3. 4. 5. 6. 7. 8.
DRIVE SIDE GROOMER PLATE F. Remove pivot hub with attached idler plate assembly from cutting unit. G. Support groomer shaft to prevent it from falling. Carefully slide drive side groomer plate from groomer shaft and cutting unit. Remove groomer shim (item 15). 14 to 18 ft−lb (19 to 24 N−m) Belt Driven Groomer (Opt.) E. Remove two (2) socket head screws (item 11) that secure pivot hub to cutting unit side plate. 1 5 3 2 4 3.
2. If removed, install groomer plate (item 18) to groomer non−drive side of cutting unit: A. Position non−drive side groomer plate to cutting unit side plate. B. Slide O−ring onto pivot hub and then apply antiseize lubricant onto pivot hub flange. Position pivot hub to groomer plate and cutting unit. C. Secure pivot hub to cutting unit side plate with two (2) socket head screws (item 11). Make sure that groomer plate rotates freely after installation. D.
8. Check groomer reel height and mower height−of−cut settings. Adjust as needed. Reelmaster 5010−H 9. Lubricate groomer bearings. 10.Install cutting unit back on machine. NOTE: After greasing groomer bearings, operate groomer for thirty (30) seconds, stop machine and wipe excess grease from groomer shaft and seals. Page 8 − 13 Belt Driven Groomer (Optional) Belt Driven Groomer (Opt.) 7. Check that excluder seals just touch groomer plate assembly (Fig. 15).
Groomer Reel Service 6 7 1 5 4 2 3 Figure 16 1. Groomer shaft 2. Lock nut (2 used) 3. Spacer (thick) (41 used) 4. Spacer (thin) (2 used) 5. Groomer blade (40 used) Inspect groomer reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig. 17). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. 6.
4. Using wrench on shaft flats to prevent shaft from turning, torque second lock nut from 375 to 425 in−lb (43 to 48 N−m). After torquing lock nut, spacers should not be free to rotate and groomer blades should be centered on shaft. 2 5. If groomer reel is equipped with broomer kit, position broomer brushes to reel blades and secure with straps. Straps should be wrapped around the groomer assembly as shown in Figure 19 and between blades 1−2, 14−15, 28−29 and 41−42.
Height Adjuster Assembly 7” CUTTING UNIT SHOWN 18 17 19 20 21 22 23 17 to 21 ft−lb (23 to 28 N−m) 24 Antiseize Lubricant 12 11 10 9 8 7 13 16 6 5 14 RIGHT FRONT 4 30 to 40 in−lb (3.4 to 4.5 N−m) 3 1 15 2 Loctite #242 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. Groomer plate (drive side) Shoulder bolt Ball joint rod Jam nut Compression spring Flange head screw LH lower ramp External snap ring 9. 10. 11. 12. 13. 14. 15. 16.
Assembly (Fig. 20) 5” CUTTING UNIT FRONT 1 NOTE: On 7” cutting units, the ball joint rod on the cutting unit motor side is longer that the ball joint rod used on the groomer drive side of the cutting unit. On 5” cutting units, the ball joint rods are identical. A. If bushing (item 10) was removed from upper ramp, press new bushing into housing fully to the shoulder in the bore. Belt Driven Groomer (Opt.) 1. Assemble height adjuster using Figure 20 as a guide noting the following items: 2 1.320” to 1.
This page is intentionally blank.
Chapter 9 Universal Groomer (Optional) Universal Groomer (Opt.) Table of Contents GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Groomer Reel Mechanical Problems . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6 Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Groomer Reel . . . . . . . . . .
Grooming Performance There are a number of factors that can affect the performance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs. IMPORTANT: Improper or overaggressive use of the groomer (e.g. too deep or too frequent grooming) may cause unnecessary stress on the turf leading to severe turf damage. Use the groomer carefully.
Troubleshooting Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive is in Neutral. Engage groomer drive to Forward or Reverse. Damaged or seized groomer drive gears. Repair groomer drive. The groomer reel blades are bent, damaged or missing. Repair or replace blades if necessary. The groomer reel shaft is bent or damaged. Replace groomer reel shaft. Grooming depth is not equal on both ends of groomer reel. Adjust depth if necessary.
Service and Repairs 5 2 6 3 1 4 RIGHT 4 FRONT Figure 1 1. Gear box assembly 2. Idler assembly 3. Groomer reel 4. Height adjuster assembly (2) CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. Universal Groomer (Optional) 5. Weight 6.
Universal Groomer (Opt.) This page is intentionally left blank.
Gear Box Assembly 90 to 100 ft--lb (122 to 135 N--m) 6 RIGHT FRONT 2 4 3 1 5 Figure 2 1. Gear box assembly 2. Rear roller brush drive shield 3. Button head screw 4. Cotter pin NOTE: The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Removal (Fig. 2) 5. Clevis pin 6.
4. If installed, remove the rear roller brush drive shield from the gear box. 3 6 5. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1--803022) in the end of the drive shaft and tighten to 13 N·m (120 in--lb); refer to Fig. 3. 2 5 1 13 Nm (120 in--lb) 4 6. Remove the cotter pin and clevis pin from the height adjustment rod at the front of the groomer gear box. Discard cotter pin. 7. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. Figure 3 1.
H. Insert a long--handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. IMPORTANT: To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. 5 I.
Disassembly (Fig. 6) 1 115 to 125 ft--lb (156 to 169 N--m) 2 3 4 13 5 12 6 7 11 8 10 9 14 40 16 15 39 38 18 37 33 36 35 32 26 31 34 41 30 19 29 42 25 17 28 20 27 43 44 18 45 44 21 43 18 46 7 in. Reel Cutting Units Only 85 to 95 in--lb (9 to 11 N--m) 24 23 22 Tighten to Specified Torque (see text) 32 to 42 in--lb (4 to 5 N--m) Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
The gear box assemblies for cutting units with 5 in. reels and 7 in. reels are very similar. The gear box for cutting units with 7 in. reels have two (2) additional idler gear assemblies (Fig. 4). 1 Use the 1--3/8” flats on the input shaft to prevent the input shaft from rotating during adapter removal. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur. 2 3 1. Remove input shaft adapter (item 1) if necessary. 2.
CAUTION Use the 1--3/8” flats on the input shaft to prevent the input shaft from rotating during adapter installation. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter installation or input shaft damage may occur. 10.If removed, install the threaded adapter in the input shaft. If reusing a previously installed threaded adapter, apply medium strength thread locker to the smaller (5/8--11) threads only. Tighten threaded adapter from 115--125 ft--lb (156--196 N--m). 5 2 4 6 11.
Idler Assembly Loctite #242 85 to 95 ft--lb (115 to 129 N--m) 5 Antiseize Lubricant 4 3 2 1 6 27 to 33 ft--lb (37 to 45 N--m) 8 9 7 12 9 11 10 13 24 to 30 ft--lb (33 to 41 N--m) Figure 9 1. 2. 3. 4. 5. Socket head screw (2) Pivot hub Idler arm Bushing Threaded insert 6. 7. 8. 9. Cotter pin Clevis pin Stub shaft and shield Bearing shield (2) NOTE: The groomer idler assembly is located on the same side of the cutting unit as the cutting unit hydraulic motor. Removal (Fig. 9) 1.
Installation (Fig. 9) 1. If shields, bearing or bushing was removed from idler arm, install new components. 1 B. Press bearing into idler arm so that bearing contact shoulder in idler arm bore and install bearing retaining ring. C. Install bearing shields with flocked side of shield toward bearing. D. Verify idler arm orientation (LH or RH cutting unit) and insert stub shaft through shields and bearing.
Groomer Reel 3 4 2 45 to 60 in--lb (5 to 7 N--m) 1 2 4 3 45 to 60 in--lb (5 to 7 N--m) Figure 11 1. Groomer reel 2. Shaft clamp (4) 3. Cap screw (4) Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. Removal (Fig. 11) 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch.
Groomer Reel Service 2 1 MIDPOINT Disassembly (Fig. 13) 3 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove groomer reel from cutting unit (see Groomer Reel Removal in this section). GROOMER ROTATION 3. If groomer reel is equipped with broomer kit, remove straps and broomer brushes from reel (Fig. 16). 4. Remove lock nut from either end of the shaft (Fig. 13). Figure 12 1.
5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 1 31 to 35 ft--lb (42 to 48 N--m) B. Slide a brush into each groove around the full length of the groomer reel (Fig. 14). Make sure brushes are seated in groomer blade slots (Fig. 15) 2 IMPORTANT: The straps must be wrapped around the groomer blade and brush assembly in the correct direction. C. Loosely wrap the straps around the groomer reel shaft and brushes as shown (Fig. 14).
Grooming Brush (Optional) Service The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (see Groomer Reel in this chapter). 3 1 3 2 Figure 17 1. Brush element 2. Shaft Reelmaster 5010--H Page 9 -- 17 3. Roll pin (2) Universal Groomer (Optional) Universal Groomer (Opt.) The grooming brush element or shaft can be serviced separately (Fig. 17).
Height Adjuster Assembly 9 Antiseize Lubricant 10 2 3 4 11 5 12 13 6 14 15 7 1 8 16 Antiseize Lubricant 17 18 16 19 Figure 18 1. 2. 3. 4. 5. 6. 7. Height of cut bracket Height adjustment bolt Washer (2) Lock nut Carriage bolt Flange nut Cotter pin 8. 9. 10. 11. 12. 13. Clevis pin Button head screw Detent spring Groomer height adjuster knob Quick up cover Quick up lever Disassembly (Fig. 18) 1.
Assembly (Fig. 18) 1. Apply antiseize lubricant to upper threads of adjustment rod and lower threads of height adjusters. Assemble height adjuster assembly as shown. Universal Groomer (Opt.) 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and secure with carriage bolt and flange nut. Do Not tighten the flange nut at this time.
This page is intentionally left blank.
Chapter 10 Foldout Drawings Table of Contents Reelmaster 5010--H Page 10 -- 1 Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATIC (Serial number below 403430000) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ELECTRICAL SCHEMATIC (Serial number above 403430001) . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WIRE HARNESS DRAWINGS Main Wire Harness Drawing (Serial number below 403430000) . . .
Electrical Drawing Designations NOTE: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g. SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
LIFT CONTROL MANIFOLD POWER STEERING VALVE Reelmaster 5010--H Hydraulic Schematic Page 10 -- 3
Reelmaster 5010--H Electrical Schematic (Serial number below 403430000) Page 10 -- 4 All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS.
122--1458 Rev A Reelmaster 5010--H Electrical Schematic (Serial numbers above 403430001) All relays and solenoids are shown as de--energized. All ground wires are black. NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS.
Reelmaster 5010--H Main Wire Harness Drawing (Serial number below 403430000) Page 10 -- 6
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122--1459 Rev B Reelmaster 5010--H Main Wire Harness Drawing (Serial numbers 403430001 to 406599999) CV Page 10 -- 8
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS.
122--1728 Rev B Reelmaster 5010--H Main Wire Harness Drawing (Serial numbers above 406600000) CV Page 10 -- 10
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS.
NOTE CLOCK POSITION Reelmaster 5010--H Seat Wire Harness Drawing Page 10 -- 12
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
