Form No. 3424-321 Rev A Reelmaster® 5010-H Traction Unit Model No. 03674—Serial No. 403300001 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. This product complies with all relevant European directives. For details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Fuel System Maintenance ................................... 43 Draining the Fuel Tank ...................................... 43 Checking the Fuel Lines and Connections.................................................. 43 Servicing the Water Separator .......................... 43 Servicing the Fuel-Pickup Tube ........................ 44 Bleeding Air from the Fuel Injectors................... 44 Electrical System Maintenance ........................... 45 Electrical System Safety .................
Safety • Do not operate the machine without all guards This machine has been designed in accordance with EN ISO 5395:2013. • Keep children, bystanders, and pets out of the General Safety • Always shut off the engine, remove the key (if and other safety protective devices in place and functioning properly on the machine. operating area. Never allow children to operate the machine.
decal110-0986 decal106-6755 110-0986 106-6755 1. Press the brake pedal and parking brake pedal to set the parking brake. 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Press the brake pedal to apply the brake. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 3. Press the traction pedal to move the machine forward. 4. Reel enabled mode 5. Transport mode decal93-6689 93-6689 1. Warning—do not carry passengers.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10.
decal127-2470 127-2470 decal133-8062 133-8062 r:\decal117-0169 117–0169 1. Read the Operator's Manual. 2. Power point—10 A 3. Headlights—10 A 4. Power—10 A 5. Engine start—15 A 6. Optional air ride seat suspension—10 A 7. Engine computer management C—10 A 8. Engine computer management B—10 A 9. Engine computer management A—10 A decal133-2930 133-2930 1. Warning—read the Operator's Manual; do not operate this machine unless you are trained. 4.
decal133-2931 133-2931 (Affix over Part No. 133-2930) Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 Use Qty. No parts required – Adjust the tire pressure. No parts required – Adjust the control-arm position. Cutting units 5 Install the cutting units. Finishing kit 1 Mount the finishing kits (finishing kits are sold separately). No parts required – Adjust the turf-compensation spring. Hood-latch assembly Washer 1 1 Install the CE hood latch.
2 3 Adjusting the Control-Arm Position Installing the Cutting Units Parts needed for this procedure: 5 No Parts Required Procedure Procedure The control-arm position can be adjusted for your comfort. 1. Cutting units CAUTION If you do not disconnect the power to the cutting units, someone could accidentally start the cutting unit, causing serious injury to hands and feet. Loosen the 2 bolts securing the control arm to the retaining bracket (Figure 3).
g003967 Figure 6 1. Opposite carrier-frame tab D. Mount the rod bracket to the cutting-unit tabs with the carriage bolts and nuts (Figure 6). Note: When installing or removing the cutting units, make sure that the hairpin cotter is installed in the spring rod hole next to the rod bracket. Otherwise, install the hairpin cotter in the hole in the end of the rod. g027133 Figure 4 1. Counter weight 4. 2. Rod bracket 5. Lower all lift arms completely. 6.
Note: Use the number of chain links described in the cutting unit Operator's Manual. g003948 Figure 10 1. Lift-arm chain 2. Chain bracket g003977 3. Pin Figure 8 1. Lift arm 3. Lift-arm-pivot yoke 12. Coat the spline shaft of the reel motor with clean grease. 13. Oil the reel motor O-ring and install it onto the motor flange. 14. Install the motor by rotating it clockwise so that the motor flanges clear the bolts (Figure 11). 2. Carrier-frame shaft 8.
Note: When tightening the nuts, use a back up wrench to prevent the hose from twisting or kinking. 3. Insert the connector plate onto the bulkhead-mounting bolts with the connectors positioned as shown in Figure 12. 4. Secure the connector plate to 1 of the mounting bolts with the flange nut previously removed. 5. Locate the wire harness on the machine and plug the wire connectors into the wire connectors of the finishing kit. g027140 Figure 11 1. Reel-drive motor 2.
g032153 Figure 15 No. 3 Cutting Unit Location, Right Rear g027129 Figure 13 No. 1 Cutting Unit Location, Center Front (As viewed from under the machine) 1. Connector plate 1. Extra flange nut 3. Connector plate 2. Bulkhead bracket 3. Bulkhead bracket 2. Extra flange nut g027209 Figure 16 No. 2 Cutting Unit Location, Left Rear g027211 Figure 14 No. 5 Cutting Unit Location, Right Front 1. Bulkhead bracket 1. Bulkhead bracket 3. Extra flange nut 2. Extra flange nut 2. Connector plate 14 3.
5 6 Adjusting the Turf-Compensation Spring Installing the CE Hood Latch No Parts Required Parts needed for this procedure: Procedure The turf-compensation spring (Figure 17) transfers the weight from the front to the rear roller. This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing. Hood-latch assembly 1 Washer Procedure Important: Make spring adjustments with the 1. Unlatch and raise the hood. 2.
4. Outside the hood, insert the hook end of the latch through the hole in the hood. Make sure that the rubber sealing washer remains on the outside of the hood. 5. Inside the hood, insert the metal washer onto the latch and secure with the nut. Make sure that the latch engages the frame catch when it is locked. Use the enclosed hood-latch key to operate the hood latch. 7 Using the Cutting-Unit Kickstand g004144 Figure 21 Parts needed for this procedure: 1 1. Chain bracket Cutting-unit kickstand 2.
Traction Pedal Product Overview The traction pedal (Figure 24) controls the forward and reverse operation. Press the top of the pedal to move forward and the bottom to move rearward. The ground speed depends on how far you press the pedal. For no load, maximum ground speed, fully press the pedal while the throttle is in the FAST position. To stop the machine, reduce foot pressure on the traction pedal and allow it to return to the center position.
Key Switch The key switch (Figure 25) has 3 positions: OFF, ON/PREHEAT , and START . Lower Mow/Raise Control Lever This lever (Figure 25) raises and lowers the cutting units and also starts and stops the cutting units when the cutting units are enabled in the MOW mode. You cannot lower the cutting units when the mow/transport lever is in the TRANSPORT position. Headlight Switch Pivot the switch downward to turn on the headlights (Figure 25). g003955 Figure 24 1. Traction pedal 4. Brake pedal 2.
g020650 Figure 28 1. Indicator light 3. Middle button 2. Right button 4. Left button • Left Button, Menu Access/Back Button— Press this button to access the InfoCenter menus. You can use it to back out of any menu you are currently using. g027134 • Middle Button— Press this button to scroll down Figure 27 menus. 1. Power-disconnect connector • Right Button— Press this button to open a menu where a right arrow indicates additional content.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.) Indicates when scheduled service should be performed Battery Hour meter Motor/Generator (not charging) Info icon Motor/Generator (charging) Fast E-Reel Slow Front Backlap Rear Backlap Fuel level The cutting units are lowering. The cutting units are raising. The glow plugs are active. PIN passcode Raise the cutting units. CAN bus Lower the cutting units. InfoCenter Sit in the seat.
Using the Menus To access the InfoCenter menu system, press the menu access button while at the main screen. This brings you to the main menu. Refer to the following tables for a synopsis of the options available from the menus: Engine Run Indicates the inputs, qualifiers, and outputs for starting the engine. Backlap Indicates the inputs, qualifiers and outputs for operating the backlap function.
About Menu Item Description Model Lists the model number of the machine. SN Lists the serial number of the machine. Machine Controller Revision Lists the software revision of the master controller. CU CU CU CU CU 1 2 3 4 5 Lists the software revision of each cutting unit. Generator Lists the software revision of the motor/generator. InfoCenter Revision Lists the software revision of the InfoCenter. CAN Bus Lists the machine communication bus status. 7.
Setting the Front and Rear Reel Speeds Although the front and rear reel speeds are calculated by inputting the number of blades, mow speed and HOC into the InfoCenter, the setting can be manually changed to accommodate for different mowing conditions. 1. To change the Reel Speed Settings, scroll down to the F Reel RPM, R Reel RPM, or both. 2. Press the right button to change the reel speed value.
Specifications Note: Specifications and design are subject to change without notice. Transport Width 228 cm (90 inches) Width of cut 254 cm (100 inches) Length 282 cm (111 inches) Height w/ ROPS 160 cm (63 inches) Weight 1259 kg (2,776 lb) Engine Kubota 24.
Checking the Engine-Oil Level Operation Note: Determine the left and right sides of the machine from the normal operating position. Service Interval: Before each use or daily Before Operation The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Before Operation Safety Crankcase capacity is approximately 3.3 L (3.5 US qt) with the filter.
5. Use of summer grade fuel above -7°C (20°F) contributes toward longer fuel pump life and increased power compared to winter grade fuel. If the oil level is below the FULL mark, remove the fill cap (Figure 30), and add oil until level reaches the FULL mark on the dipstick. Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution damages the engine. Biodiesel Ready This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel).
Note: If possible, fill the fuel tank after each use. This minimizes possible buildup of condensation inside the fuel tank. Checking the Cooling System Service Interval: Before each use or daily Clean debris off the screen, oil cooler, and front of the radiator daily and more often if conditions are extremely dusty and dirty. Refer to Removing Debris from the Cooling System (page 48). The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze.
Viscosity, ASTM D445 cSt @ 40°C 44 to 48 cSt @ 100°C 7.9 to 8.5 Viscosity Index ASTM D2270 140 to 160 Pour Point, ASTM D97 -36.6°C (-34°F) to 9.4°C (-49°F) Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide-range of temperature conditions.
Breaking in the Machine To ensure optimum performance of the parking brake system, burnish (break in) the brakes before use. Set the forward traction speed to 6.4 km/h (4 mph) to match the reverse traction speed (all 8 spacers moved to the top of the mow-speed control). With the engine at high idle, proceed forward with the mow-speed-control stop engaged and ride the brake for 15 seconds. Proceed backward at full reverse speed and ride the brake for 15 seconds.
• • • • • • • • • • • • Slope Safety causes distractions; otherwise, injury or property damage may occur. Before you start the engine, ensure that all drives are in neutral, the parking brake is engaged, and you are in the operating position. Do not carry passengers on the machine and keep bystanders and pets away from the machine during operation. Operate the machine only in good visibility to avoid holes or hidden hazards. Avoid mowing on wet grass. Reduced traction could cause the machine to slide.
Starting the Engine Important: You must bleed the fuel system before starting the engine if you are starting the engine for the first time, the engine has shut off due to lack of fuel, or you have performed maintenance on the fuel system; refer to Bleeding the Fuel System (page 29). 1.
Setting the Reel Speed To achieve a consistent, high quality-of-cut and a uniform after cut appearance, it is important that you set the reel speed to the proper setting. Adjust the reel speed as follows: 1. In the InfoCenter, under the settings menu, enter the blade count, mow speed, and HOC to calculate the proper reel speed. 2. If further adjustments are required, in the settings menu, scroll down to the F Reel RPM, R Reel RPM, or both. 3. Press the right button to change the reel speed value.
Adjusting the Lift-Arm Counterbalance turnaround height or move the switch up to decrease the lift-arm turnaround height (Figure 38). You can adjust the counterbalance on the rear cutting-unit lift arms to compensate for different turf conditions and to maintain a uniform height of cut in the rough conditions or in areas of thatch buildup. You can adjust each counterbalance spring to 1 of 4 settings. Each increment increases or decreases counterbalance on the cutting unit by 2.3 kg (5 lb).
Understanding the Diagnostic Light Verifying the Interlock-Switch Function Service Interval: Before each use or daily The machine is equipped with a diagnostic light, which indicates if the machine detects a malfunction. The diagnostic light is located on the InfoCenter, above the display screen (Figure 39). When the machine is functioning properly and the key switch is moved to the ON/RUN position, the diagnostic light turns on briefly to indicate that the light is working properly.
Operating Tips compartment to help prevent fires. Clean up oil or fuel spills. • Shut off the fuel while storing or transporting the Becoming Familiarized with the Machine machine. • Disengage the drive to the attachment whenever you are transporting or not using the machine. Before mowing grass, practice operating the machine in an open area. Start and shut off the engine. Operate in forward and reverse. Lower and raise the cutting units and engage and disengage the reels.
Jacking Points Important: Running the engine with the bypass valve open causes the transmission to overheat. Note: Use jack stands to support the machine when required. • Front—rectangular pad, under the axle tube, Identifying the Tie-Down Points inside each front tire (Figure 43). • Front—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 41) g031850 Figure 43 1. Front jacking point g031851 Figure 41 • Rear—rectangular axle tube on the rear axle. 1.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval After the first hour Maintenance Procedure • Torque the wheel lug nuts to 94 to 122 N⋅m (70 to 90 ft-lb). After the first 8 hours • Check the condition and tension of the alternator belt. After the first 10 hours • Torque the wheel lug nuts to 94 to 122 N⋅m (70 to 90 ft-lb).
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the brake operation. Check the levels of the engine oil and fuel. Check the cooling-system fluid level. Drain the water/fuel separator. Check the air-filter service indicator. Check the radiator, oil cooler, and screen for debris. Check for unusual engine noises.1 Check for unusual operating noises.
Notation for Areas of Concern Inspection performed by: Item Date Information 1 2 3 4 5 6 7 8 Important: Refer to your engine owner’s manual and cutting unit Operator's Manual for additional maintenance procedures. Note: To obtain an electrical schematic or a hydraulic schematic for your machine, visit www.Toro.com. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours (and immediately after every washing). Lubricate all grease fittings for the bearings and bushings with No. 2 lithium grease.
Engine Maintenance Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. Do not change the governor speed or overspeed the engine. • g004169 Servicing the Air Cleaner Figure 49 Service Interval: Every 400 hours—Service the air cleaner. Service the air cleaner earlier if the service indicator shows red. Service it more frequently in extremely dirty or dusty conditions.
Servicing the Engine Oil and Filter remove large accumulations of debris packed between outside of the filter and the canister. Important: Avoid using high-pressure air, which could force dirt through the filter into the intake tract. Service Interval: After the first 50 hours—Change the engine oil and filter. Note: This cleaning process prevents debris Every 150 hours from migrating into the intake when you remove the filter. 5. 1.
Fuel System Maintenance rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn. Important: Do not over-tighten the filter. 6. Add oil to the crankcase; refer to Checking the Engine-Oil Level (page 25). DANGER Under certain conditions, fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Fill the fuel tank outdoors, in an open area, when the engine is off and is cold.
Bleeding Air from the Fuel Injectors Note: Perform this procedure only if the fuel system has been purged of air through normal priming procedures and the engine does not start; refer to Bleeding the Fuel System (page 29). 1. Loosen the pipe connection to the No. 1 nozzle and holder assembly (Figure 57). g007367 Figure 56 1. Water-separator-filter canister 3. Clean the area where the filter canister mounts. 4. Remove the filter canister and clean the mounting surface. 5.
Replacing the Fuses Electrical System Maintenance There are 8 fuses in the 12 V electrical system. The fuse block (Figure 58) is located behind the control-arm-access panel. Important: Before welding on the machine, disconnect all cables from the battery, both wire harness plugs from the electronic control module, and the terminal connector from the alternator to prevent damage to the electrical system. Electrical System Safety • Disconnect the battery before repairing the machine.
decal127-2470 Figure 62 g027135 Figure 60 1. Fuse-block cover 2. Fuse block g027136 Figure 61 1.
Drive System Maintenance WARNING The engine must be running while you perform the final adjustment on the traction adjustment cam. This could cause personal injury. Adjusting the Traction Drive for Neutral Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and any rotating parts. The machine must not creep when you release the traction pedal. If it does creep, adjust it as follows: 1.
Cooling System Maintenance Note: The distance at the front of the rear wheels should be less than 6 mm (1/4 inch) of the distance measured at the rear of the wheels. 5. Repeat this procedure as required. Cooling System Safety • Swallowing engine coolant can cause poisoning; • keep out of reach from children and pets. Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
4. Clean the screen thoroughly with compressed air. 5. Pivot the latches inward to release the oil cooler (Figure 66). Brake Maintenance Adjusting the Parking Brakes Adjust the brakes when there is more than 25 cm (1 inch) of free travel (Figure 68) of the brake pedal, or when more holding force is required. Free travel is the distance that the brake pedal moves before you feel braking resistance. g003974 Figure 66 g026816 1. Oil cooler 6. 2. Oil-cooler latches Figure 68 1.
Belt Maintenance Note: Ensure that the cable conduit does not rotate while you are tightening the nuts. Tensioning the Alternator Belt Adjusting the Parking-Brake Latch Service Interval: After the first 8 hours If the parking brake fails to engage and latch, an adjustment to the brake pawl is required. 1. Every 100 hours Loosen the 2 screws securing the parking-brake pawl to the frame (Figure 70). 1. Open the hood. 2.
Hydraulic System Maintenance Hydraulic System Safety • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. g027137 Figure 72 • Keep your body and hands away from pinhole 1. Hose leaks or nozzles that eject high-pressure hydraulic fluid.
Replacing the Hydraulic Filter Checking the Hydraulic Lines and Hoses Service Interval: Every 800 hours Service Interval: Before each use or daily Important: Use of any other filters may void the Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. warranty on some components. 1.
Cutting Unit System Maintenance Blade Safety • A worn or damaged blade or bedknife can break, and a piece could be thrown toward you or bystanders, resulting in serious personal injury or death. • Inspect the cutting units periodically for excessive wear or damage. • Use care when checking the cutting units. Wrap the blades or wear gloves, and use caution when servicing the reels and bedknives. Only replace or sharpen the reels and bedknives; never straighten or weld them. g027139 Figure 75 1.
Storage DANGER Changing the engine speed while backlapping may cause the reels to stall. 5. 6. Preparing the Traction Unit • Never change the engine speed while backlapping. 1. Thoroughly clean the traction unit, cutting units, and engine. • Only backlap at idle engine speed. 2. Check the tire pressure. Inflate all traction unit tires to 83 to 103 kPa (12 to 15 psi). With the Mow/Transport lever in the MOW position, move the Enable/Disable switch to the ENABLE position.
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The Toro Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
