Form No. 3398-553 Rev A Reelmaster® 5010-H Traction Unit Model No. 03674—Serial No. 316000001 and Up Register at www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 1), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Contents Electrical System Maintenance ....................................45 Servicing the Battery...............................................45 Replacing the Fuses ................................................45 Drive System Maintenance .........................................47 Adjusting the Traction Drive for Neutral....................47 Adjusting the Rear Wheel Toe-in ..............................47 Cooling System Maintenance ......................................
Safe Handling of Fuels Safety • To avoid personal injury or property damage, use extreme This machine is designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2012 specifications in effect at time of production. care in handling fuel. Fuel is extremely flammable and the vapors are explosive. • Extinguish all cigarettes, cigars, pipes, and other sources of ignition. Improper use or maintenance by the operator or owner can result in injury.
• Be certain that the seat belt can be released quickly in • Do not change the engine governor settings or over-speed • • • • • • • • • • • the engine. Operating the engine at excessive speed may increase the hazard of personal injury. Before leaving the operator's position, do the following: – Stop on level ground. – Disengage the power take-off and lower the attachments. – Change into neutral and set the parking brake. – Stop the engine and remove the key.
• Handle fuel carefully. Wipe up any spills. • Check the safety interlock switches daily for proper • On multi-cylinder/multi-reel machines, take care as • • • • • • • • rotating 1 cylinder/reel can cause other cylinders/reels to rotate. Disengage drives, lower the cutting units, set parking brake, stop engine and remove key from ignition. Wait for all movement to stop before adjusting, cleaning, or repairing.
Safety and Instructional Decals • For major repairs, warranty work, updates to systems, or assistance, contact your Toro Distributor. • To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.
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 93-6689 1. Warning—do not carry passengers. 110-8921 117–2718 1. Traction unit speed 2. Slow 3.
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. 120–4158 1. Read the Operator’s Manual. 2.
110-8973 (Affix over Part Number 110–8869 for CE*) 110-8869 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN ISO 5395:2013. The conservative 2. Thrown object hazard—keep bystanders a safe distance from the machine. 3.
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: No Parts Required 5 Procedure Cutting units Procedure The control-arm position can be adjusted for your comfort. CAUTION 1. Loosen the 2 bolts securing the control arm to the retaining bracket (Figure 2). 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.
4. Mount the turf-compensation spring to the same side of the cutting unit as the reel-drive motor. Position the turf compensation as follows: Note: All cutting units are shipped with the turf-compensation spring mounted to the right side of the cutting unit. A. Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting-unit tabs (Figure 4). Figure 6 1. Snapper pin 7.
B. Insert the lift-arm yoke onto the carrier-frame shaft (Figure 7). C. Insert the lift-arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 8). 9. Insert the cap over the carrier-frame shaft and lift-arm yoke. 10. Secure the cap and the carrier-frame shaft to the lift-arm yoke with the snapper pin (Figure 6). Note: Use the slot if a steering cutting unit is desired or use the hole if the cutting unit is to be locked in position. 11.
2 3. Insert the connector plate onto the bulkhead-mounting bolts with the connectors positioned as shown in Figure 11. 4. Secure the connector plate to 1 of the mounting bolts with the flange nut previously removed. 1 5. Locate the wire harness on the machine and plug the wire connectors into the wire connectors of the finishing kit. 3 g027129 Figure 12 #1 Cutting Unit Location, Center Front (As viewed from under the machine) 3 g027210 1 1. Connector plate 2 3. Bulkhead bracket 2.
5 Adjusting the Turf-Compensation Spring No Parts Required Procedure The turf-compensation spring (Figure 16) 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. Figure 14 #3 Cutting Unit Location, Right Rear 1. Extra flange-head nut Important: Make spring adjustments with the cutting unit mounted to the traction unit, pointing straight ahead and lowered to the ground. 3. Connector plate 1.
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. 6 Installing the CE Hood Latch 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.
Product Overview Figure 21 Figure 20 1. Chain bracket 3. Cutting-unit kickstand 2. Snapper pin 1. Engine hood 5. Seat adjustments 2. Operator's seat 6. Front cutting units 3. Control arm 7. Rear cutting units 4. Steering wheel Controls Seat-Adjusting Knobs The seat-adjusting lever (Figure 22) allows you to adjust the seat fore and aft. The weight-adjusting knob adjusts the seat for your weight. The weight gauge indicates when the seat is adjusted to your weight.
Traction Pedal Tilt-Steering Pedal The traction pedal (Figure 23) 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.
Power Point CAUTION The power point is a 12 V power supply for electronic devices (Figure 25). 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. Always separate the cutting-unit-power-disconnect connectors before working on the cutting units.
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 Engine Run 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: Indicates the inputs, qualifiers, and outputs for starting the engine. Backlap Indicates the inputs, qualifiers and outputs for operating the backlap function.
Note: If the passcode has been forgotten or misplaced, please contact your distributor for assistance. 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.
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 1,259 kg (2,776 lb) Engine Kubota 24.
Operation Note: Determine the left and right sides of the machine from the normal operating position. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Lower the cutting units to the ground, set the parking brake and remove the key from the ignition switch before servicing or making adjustments to the machine. Figure 28 1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas. 2.
Checking the Engine-Oil Level Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Crankcase capacity is approximately 3.3 L (3.5 US qt) with the filter.
WARNING DANGER Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening.
Checking the Cooling System Checking the Hydraulic Fluid Service Interval: Before each use or daily 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 machines reservoir is filled at the factory with approximately 41.6 L (11 US gallons) of high-quality hydraulic fluid.
Checking the Torque of the Wheel Nuts the hydraulic system oil is available in 20 ml (2/3 oz) bottles. 1 bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic oil. Order Part Number 44-2500 from your Toro Distributor. Service Interval: After the first hour 1. Position machine on a level surface, lower the cutting decks, and stop the engine. After the first 10 hours Every 250 hours 2. Clean the area around filler neck and cap of the hydraulic tank (Figure 34).
Note: Normally, the engine should start after the above bleeding procedures are followed. However, if engine does not start, air may be trapped between injection pump and injectors; refer to Bleeding Air from the Fuel Injectors (page 44). DANGER Under certain conditions, diesel 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.
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 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).
2. Close the bypass valve before starting the engine. However, do not exceed 7 to 11 N-m (5 to 8 ft-lb) torque to close the valve. Important: Running the engine with the bypass valve open causes the transmission to overheat. Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions.
Loading the Machine Use extreme caution when loading the machine onto a trailer or a truck. Use a full-width ramp that is wide enough to extend beyond the front tires of the machine instead of individual ramps for each tire (Figure 43). If it is not possible to use a full-width ramp, use enough individual ramps to simulate a full-width continuous ramp. The ramp should be long enough so that the angles do not exceed 15 (Figure 43).
The Diagnostic Light Verifying the Function of the Interlock Switch The machine is equipped with a diagnostic light which indicates if the electronic controller senses an electronic malfunction. The diagnostic light is located on the control arm (Figure 45). 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.
Hydraulic-Valve Solenoid Functions Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow the function to occur. Function Solenoid SVRV Lift/lower cutting units SV1 Lift/lower front cutting unit SV3 Lift/lower rear cutting unit SV2 Raise any cutting units Operating Tips Familiarization Before mowing grass, practice operating the machine in an open area. Start and stop the engine.
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. For the week of: Mon. Maintenance Check Item Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the hydraulic system oil level. Check hydraulic hoses for damage.
Service Interval Chart Figure 46 CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you perform any maintenance. Lubrication • Cutting-unit lift-arm cylinders (2 each) (Figure 48) 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.
• Cutting-unit carrier-frame and pivot (2 each) (Figure 49) • Axle-steering pivot (1) (Figure 52) Figure 52 • Steering-cylinder ball joints (2) (Figure 53) Figure 49 • Lift-arm-pivot shaft (1 each) (Figure 50) Figure 50 Figure 53 • Rear axle tie rod (2) (Figure 51) • Brake pedal (1) (Figure 54) G011615 Figure 54 Figure 51 41
Engine Maintenance Servicing the Air Cleaner Service Interval: Every 400 hours (Service the air cleaner earlier if the air cleaner indicator shows red. Service it more frequently in extremely dirty or dusty conditions.) Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage, or loose hose clamps. g027080 Figure 56 Service the air cleaner filter only when the service indicator (Figure 55) requires it.
Fuel System Maintenance DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can damage property. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. Figure 57 1. Oil drain plug • Do not fill the fuel tank completely full.
Servicing the Water Separator Bleeding Air from the Fuel Injectors Service Interval: Before each use or daily—Drain water or other contaminants from the water separator. 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 30). Every 400 hours 1. Place a clean container under the fuel filter. 1. Loosen the pipe connection to the No. 1 nozzle and holder assembly (Figure 60).
Replacing the Fuses Electrical System Maintenance There are 8 fuses in the 12 V electrical system. The fuse block (Figure 61) 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.
1 2 Figure 65 g027135 Figure 63 1. Fuse-block cover 2. Fuse block g027136 1 Figure 64 1.
Drive System Maintenance 5. Tighten the locknut to secure the adjustment. 6. Stop the engine, remove the jack stands, and lower the machine to the ground. 7. Test drive the machine to make sure that it does not creep. Adjusting the Traction Drive for Neutral Adjusting the Rear Wheel Toe-in The machine must not creep when you release the traction pedal. If it does creep, adjust it as follows: 1. Park the machine on a level surface, stop the engine, and lower the cutting units to the ground.
Cooling System Maintenance Removing Debris from the Cooling System Service Interval: Before each use or daily (More frequently in dirty operating conditions). Every 100 hours—Inspect the cooling system hoses. Every 2 years—Flush and replace the cooling system fluid. 1. Shut off the engine and remove the key from the ignition switch. 2. Thoroughly clean all debris out of the engine area. Figure 69 3. Unlatch the clamp and pivot open the rear screen (Figure 68). 1. Oil cooler 2. Oil-cooler latches 6.
Brake Maintenance Adjusting the Parking-Brake Latch Adjusting the Parking Brakes If the parking brake fails to engage and latch, an adjustment to the brake pawl is required. Adjust the brakes when there is more than 25 cm (1 inch) of free travel (Figure 71) 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. 1. Loosen the 2 screws securing the parking-brake pawl to the frame (Figure 73).
Belt Maintenance Hydraulic System Maintenance Tensioning the Alternator Belt Changing the Hydraulic Fluid Service Interval: After the first 8 hours Every 100 hours Service Interval: Every 800 hours 1. Open the hood. Every 2 years—Drain and flush the hydraulic tank. 2. Check the tension of the alternator belt by depressing it (Figure 74) midway between the alternator and the crankshaft pulleys with 10 kg (22 lb) of force.
Replacing the Hydraulic Filter Checking the Hydraulic Lines and Hoses Service Interval: Every 800 hours Important: Use of any other filters may void the warranty on some components. Service Interval: Before each use or daily 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. 1.
Testing the Pressure in the Hydraulic System Use the test port on the hydraulic tube (Figure 78) to assist in troubleshooting the charge-pressure circuit. Use the hydraulic system test ports to test the pressure in the hydraulic circuits. Contact your Toro Distributor for assistance. Use the test ports on the front hydraulic tubes (Figure 77) to assist in troubleshooting the traction circuit. Figure 77 1.
Cutting Unit System Maintenance 6. Apply lapping compound with a long-handled brush. Important: Never use a short-handled brush. 7. If the reels stall or become erratic while backlapping, select a higher reel speed setting until the speed stabilizes, then return the reel speed to your desired speed. This can be done using the buttons on the InfoCenter. Backlapping the Cutting Units WARNING • Keep fingers, hands, and clothing away from the reels or other moving parts. 8.
Storage Preparing the Traction Unit 1. Thoroughly clean the traction unit, cutting units, and engine. 2. Check the tire pressure. Inflate all traction unit tires to 83 to 103 kPa (12 to 15 psi). 3. Check all fasteners for looseness and tighten them as necessary. 4. Grease all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6.
International Distributor List Distributor: Agrolanc Kft Asian American Industrial (AAI) B-Ray Corporation Brisa Goods LLC Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Fat Dragon Femco S.A. FIVEMANS New-Tech Co., Ltd ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd.
Toro General Commercial Product 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).
