Form No.
Revision History Revision Date -- 2006 Initial Issue. A 2007 Updated Electrical chapter. B 2009 Updated Safety chapter and Product Records and Maintenance chapter. C 2012 Updated Hydraulic chapter and Electrical chapter. D 2015 Updated Hydraulic chapter and Electrical chapter. E 02/2018 Added revision history. F 04/2018 Revised bedknife installation procedure and painted/aluminum side plate cutting unit information. Added universal groomer chapter G 03/2019 Updated Chassis chapter.
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. 06148SL Rev. G Service Manual (Models 03660, 03670, 03680, 03690 and 03691) ReelmasterR 5210/5410/5510/5610 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 series: the 5210, 5410, 5510 and 5610 (Models 03660, 03670, 03680, 03690 and 03691). REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
This page is intentionally blank.
2−1 2−1 2−2 2−3 Chapter 3 − Kubota Diesel Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3−1 3−2 3−5 3−6 KUBOTA WORKSHOP MANUAL: 05 SERIES DIESEL ENGINE Chapter 4 − Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
7. Do not park on slopes unless wheels are chocked or blocked. Maintenance and Service 1. Before servicing or making adjustments, lower cutting units, stop engine, apply parking brake 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 CAUTION When changing attachments, tires or performing other service, use correct blocks, hoists and jacks. 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.
Product Records and Maintenance Table of Contents 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 N
Thread Size 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 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m M12 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 1 1 1 2 2 3 4 5 5 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications: Reelmaster 5210 Item Description Make / Designation Kubota D1105, 4--stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.53 in3 (1123 cc) Compression Ratio 22.0:1 Firing Order 1 (fan end) -- 2 -- 3 (flywheel end) Dry Weight (approximate) 205 lb. (93 kg) Fuel No. 2--D Diesel Fuel (ASTM D975) Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle (DNOPD) Fuel Tank Capacity 14 U.S.
Specifications: Reelmaster 5410 and 5510 Item Description Make / Designation Kubota V1505, 4--stroke, Liquid Cooled, OHV Diesel Number of Cylinders 4 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 91.4 in3 (1498 cc) Compression Ratio 21.0:1 Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2 Dry Weight (approximate) 242 lbs (110 kg) Fuel No. 2--D Diesel Fuel (ASTM D975) Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle (DNOPD) Fuel Tank Capacity 14 U.S.
Specifications: Reelmaster 5610 Item Description Make / Designation Kubota V1505, 4--stroke, Liquid Cooled, OHV, Turbocharged Diesel Number of Cylinders 4 Bore x Stroke 3.07” x 3.09“ (78 mm x 78.4 mm) Total Displacement 91.4 in3 (1498 cc) Compression Ratio 21.0:1 Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2 Dry Weight (approximate) 251 lbs (114 kg) Fuel No.
Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is operating properly. NOTE: The throttle cable swivel should be positioned in the lowest hole in the speed control lever. 5 2. Check position of the engine speed control lever on fuel injection pump. The speed control lever should be contacting the high speed screw when the throttle control lever is in the FAST position. 3.
Service and Repairs Fuel System 8 15 12 7 2 11 1 6 10 9 2 16 3 5 3 13 3 14 5 RIGHT FRONT 4 4 Figure 2 1. 2. 3. 4. 5. 6. Fuel cap Bushing Washer head screw (3 used) Flange nut (3 used) Clamp (3 used) Return fitting Kubota Diesel Engine 7. 8. 9. 10. 11. Suction fitting Hose clamp Hose clamp Fuel tank Grommet Page 3 -- 6 12. 13. 14. 15. 16.
Fuel Tank Removal (Fig. 2) Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, when engine is hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep container cap in place. Use diesel fuel for the engine only; not for any other purpose.
Air Cleaner REELMASTER 5410--D/5510--D SHOWN 7 11 3 4 6 11 5 16 THREAD SEALANT 2 1 13 11 12 9 15 10 12 14 RIGHT 11 8 FRONT 12 Figure 3 1. 2. 3. 4. 5. 6. Air cleaner assembly Hex nut Bolt Spring Indicator Adapter 7. 8. 9. 10. 11. Hose Hose Mount bracket Air cleaner stand Hose clamp 12. 13. 14. 15. 16.
Removal (Fig. 3) REELMASTER 5610--D 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Raise hood. 10 11 12 13 11 2. Remove air cleaner components as needed using Figures 3, 4 and 5 as guides. 9 8 6 3. See Traction Unit Operator’s Manual for air cleaner service and maintenance procedures. 6 1 2 3 7 4 5 Kubota Diesel Engine Installation (Fig.
Exhaust System 17 REELMASTER 5410--D/5510--D SHOWN 3 11 1 10 6 18 20 2 4 14 13 19 5 12 16 4 15 RIGHT 12 7 8 2 5 16 6 9 13 14 FRONT Figure 6 1. 2. 3. 4. 5. 6. 7. Gasket Lock washer (4 used) Flange nut (4 used) Cap screw (4 used) Carriage screw (4 used) Flange nut (4 used) Lock washer 8. 9. 10. 11. 12. 13. 14. Cap screw Isolator plate Hex nut (2 used) Clamp Flange nut (2 used) Flat washer (2 used) Cap screw (2 used) 15. 16. 17. 18. 19. 20.
Removal (Fig. 6) Installation (Fig. 6) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Raise hood. NOTE: Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal. 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.
Radiator 28 38 2 3 1 2 4 13 10 34 11 23 24 40 22 6 33 21 29 20 12 43 8 18 19 19 44 5 12 13 42 13 32 26 13 16 25 16 27 16 36 37 17 16 31 20 6 2 14 30 15 7 15 13 15 39 9 35 11 4 9 RIGHT FRONT 8 41 5 30 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly labeled container away from children and pets. 3. Drain coolant from radiator. A. Slowly remove radiator cap from the radiator. B. Place drain pan below the radiator draincock located on the bottom of the radiator.
Engine 34 to 42 ft--lb (47 to 56 N--m) 3 24 2 25 20 19 18 11 26 16 7 23 15 14 17 10 5 1 4 7 23 25 5 13 4 26 22 9 6 23 27 8 5 21 9 2 12 27 4 RIGHT 9 FRONT Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine assembly Cap screw (12 used) Temperature sender Engine mount (4 used) Cap screw (2 used per mount) Snubbing washer (4 used) Cap screw (4 used) Flange nut (4 used) Lock nut (2 used per mount) 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 9) 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. Open hood. 3 3. Disconnect negative (--) and then positive (+) battery cables from the battery. 1 2 Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Kubota Diesel Engine CAUTION Figure 10 1. Throttle cable end 2. Swivel 3.
9. Disconnect hydraulic transmission drive shaft from engine (see Hydraulic Transmission Drive Shaft Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). Support drive shaft away from engine. Installation (Fig. 9) 10.Disconnect wire harness connectors from the following engine components: 2. Make sure that all parts removed from the engine during maintenance or rebuilding are installed to the engine.
7. Remove plugs installed in hoses during disassembly. Connect hoses to the engine: 9. Install air cleaner (see Air Cleaner Installation in this section). A. Connect fuel supply and fuel return hoses to engine fittings (Fig. 11). Secure with hose clamps. 10.Install exhaust system to machine (see Exhaust System Installation in this section). B. Connect upper and lower radiator hoses to the engine. Secure with hose clamps. 11. Add coolant to radiator. A. Route throttle cable to injector pump on engine.
This page is intentionally blank.
Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Traction Unit Operator’s Manual . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Maximum Pump Displacement (per revolution) Sauer- Danfoss, LPV Closed Circuit Axial Piston Design 2.14 Cubic Inches (35 cc) Gear Pump Section P1/P2 Displacement (per revolution) (RM 5210 & 5410) Section P1/P2 Displacement (per revolution) (RM 5510 & 5610) Section P3 Displacement (per revolution) (all models) Section P4 Displacement (per revolution) (all models) Casappa 4 section, positive displacement gear type pump 0.50 Cubic Inches (8.3 cc) 0.
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. Check Hydraulic Fluid Hydraulic System The hydraulic system on Reelmaster 5010 series machines is designed to operate on high quality hydraulic fluid. The hydraulic system reservoir holds approximately 11 gallons (41.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O- Ring Port - Non- adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches or any foreign material. 2. Always replace the O- ring seal when this type of fitting shows signs of leakage. O- Ring 3. Lubricate the O- ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 5 5. Tighten the fitting to the correct Flats From Finger Tight (F.F.F.T.). 4 (1/4 in.
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 traction circuit, move traction pedal to both forward and reverse directions. To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions.
Hydraulic Schematics Hydraulic System The hydraulic schematics for Reelmaster 5010 series machines are located in Chapter 9 - Foldout Drawings.
Hydraulic System Figure 8 Page 4 - 8 R8 P2 R2 G2 MSV2 MSV1 R1 EP2 EP1 MOW CONTROL MANIFOLD MR2 MR1 M1 M2 BKLP2 BKLP1 R11 C.U. 4 M4 M2 C.U. 2 R11 M3 C.U. 3 R11 M1 C.U. 1 R11 M5 C.U.
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. Forward Direction (Fig. 8) Reverse Direction The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the flow through the circuit is reversed. Pushing the bottom of the traction pedal rotates the traction pump swash plate to create a flow of oil.
Hydraulic System Page 4 - 10 R8 P2 EP2 EP1 OR2 FC2 MR2 MR1 MOW CONTROL MANIFOLD OR4 CV OR3 FC1 OR1 R9 M1 M2 BKLP2 BKLP1 B R11 M4 R11 B A M7 RH M2 C.U. 2 R11 M3 C.U. 3 REAR MOW CIRCUIT G6 A TRACTION WHEEL LH M6 MOTORS B G5 R11 M1 C.U. 1 R11 M5 C.U. 5 FRONT MOW CIRCUIT C.U.
Mow Circuit The mow control manifold contains two independent control circuits for the front and rear cutting units. Each circuit is supplied by its own pump section. Pump section (P1) supplies hydraulic power to the rear cutting units through mow control manifold port P1, solenoid relief valve (MSV1) and direction valve (MR1). Pump section (P2) supplies the front cutting units through manifold port P2, solenoid relief valve (MSV2) and direction valve (MR2).
TO STEERING & CHARGE CIRCUIT TO FRONT MOW CIRCUIT G4 C4 L SV1 SV2 P4 CV4 C4 C1 L SVRV C1 TO REAR MOW CIRCUIT CV1 T P1 P2 P3 R7 P4 CV5 C5 C5 L SV3 100 MESH SUCTION STRAINER PUMP (P5) INTERNAL CASE DRAIN CV23 C2/3 L LIFT CONTROL MANIFOLD C2/3 RIGHT FRONT FRONT LEFT FRONT CENTER FROM MOW CONTROL MANIFOLD LEFT REAR RIGHT REAR R8 Reelmaster 5010 Lift Circuit: Raise Cutting Units Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 11 Hydraulic System Page 4 - 12
Lift Circuit: Raise 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.
TO STEERING & CHARGE CIRCUIT TO FRONT MOW CIRCUIT G4 C4 L SV1 SV2 P4 C4 CV4 C1 L SVRV C1 TO REAR MOW CIRCUIT CV1 T P1 P2 P3 R7 P4 CV5 C5 C5 L SV3 100 MESH SUCTION STRAINER PUMP (P5) INTERNAL CASE DRAIN CV23 LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT FRONT LEFT FRONT FROM MOW CONTROL MANIFOLD CENTER LEFT RIGHT REAR REAR R8 Reelmaster 5010 Lift Circuit: Lower Cutting Units Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 12 Hydraulic System Page 4 - 1
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 13 Hydraulic System Page 4 - 16 Reelmaster 5010 Series STEERING CYLINDER STEERING CONTROL VALVE TO TRACTION CHARGE CIRCUIT R10 FROM PUMP (P3) 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 Steering Circuit R10 FROM PUMP (P3) LEFT TURN
Steering Circuit A four section gear pump is coupled to the piston (traction) pump. Gear pump section P3 supplies hydraulic flow to the steering control valve and for the traction charge circuit. The gear pump takes its suction from the hydraulic reservoir. Steering circuit pressure is limited to 1000 PSI (69 bar) by a relief valve (R10) located in the steering control. cylinder flows back through the steering control spool valve and then out of the steering control valve through the T port.
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 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 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.
Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft. Toro Part Number: TOR6004 Figure 21 Measuring Container Hydraulic System Part Number: TOR4077 Use this graduated container for doing hydraulic motor efficiency testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system.
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) Wheel motors will not hold load when traction pedal is in neutral Charge pressure is low. Valve plate and/or piston shoes in piston (traction) pump are scored.
Lift Circuit Problems Problem Possible Cause Single cutting unit lifts slowly or not at all Cutting unit has excessive debris buildup. Lift arm or lift cylinder is binding. Pilot piston in lift control manifold is stuck or damaged. Lift cylinder leaks internally. Flow control orifice in lift control manifold for the affected cutting unit is plugged or damaged.
Lift Circuit Problems (Continued) Problem Possible Cause Single cutting unit lowers very slowly or not at all Lift arm or lift cylinder is binding. Lift cylinder is damaged. Flow control orifice in lift control manifold for the affected cutting unit is plugged or damaged. Check valve in lift control manifold (CV1, CV4, CV5 and CV23) is stuck or damaged. Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g.
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, cutting (mow) circuit, lift circuit or steering circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
Traction Circuit Relief Valve (R3) and (R4) Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) P1 P2 P3 FORWARD (R3) RELIEF VALVE TEST SHOWN P4 EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN PRESSURE GAUGE G5 A FORWARD R3 A TRACTION WHEEL MOTORS P5 LH M6 B R5 R4 B R9 A M7 RH B G6 FROM STEERING CONTROL VALVE Figure 24 The traction circuit relie
2WD MACHINE SHOWN CAUTION 4 1 3 NOTE: If machine is equipped with optional CrossTraxTM AWD, reverse relief pressure test ports are located on CrossTraxTM hydraulic manifold. 4. Thoroughly clean traction circuit test port on hydraulic tube for direction to be checked (Fig. 25 and 26). Connect a 5000 PSI (350 bar) pressure gauge to test port. RIGHT FRONT 2 Figure 25 1. RH wheel motor 2. LH wheel motor 3. Forward test port 4. Reverse test port 5.
Traction Circuit Charge Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) P1 P2 P3 P4 EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN G5 A FORWARD R3 A TRACTION WHEEL MOTORS P5 LH M6 B R5 R4 B PRESSURE GAUGE FROM STEERING CONTROL VALVE R9 A M7 RH B G6 TEST PORT (SERIAL NUMBER ABOVE 313000000) OIL FILTER ASSEMBLY REMOVED Figure 28 The traction
4. Connect a 1000 PSI (70 bar) pressure gauge to machine: A. On machine with serial number below 313000000, thoroughly clean ends of hydraulic tubes that connect to the oil filter (there is no test port in hydraulic tube between the oil filter and piston pump on these machines as shown in Fig. 29). Disconnect hydraulic tubes from oil filter adapter. Remove two (2) flange head screws that secure oil filter adapter to frame and remove oil filter and adapter assembly from machine.
Gear Pump (P3) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) P1 P2 P3 P4 EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN G5 A FORWARD R3 A TRACTION WHEEL MOTORS P5 LH M6 B R5 R4 B A M7 RH B G6 TESTER FROM STEERING CONTROL VALVE R9 OIL FILTER ASSEMBLY AND TUBE REMOVED Figure 31 Hydraulic System
Procedure for Gear Pump (P3) Flow Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered and PTO switch off. Make sure engine is off. Apply the parking brake. 3. Read Precautions For Hydraulic Testing in this section.
Front Wheel Motor Efficiency Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) P1 P2 P3 P4 EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TESTER A G5 FORWARD CAP R3 A TRACTION WHEEL MOTORS P5 LH M6 B R5 R4 A RH M7 B CAP B R9 FROM STEERING CONTROL VALVE G6 RH FRONT WHEEL MOTOR EFFICIENCY TEST SHOWN Figure 33 Procedure for Front Wheel Motor Efficiency
13.If total leakage for the front wheel motors is more than 1.5 GPM (5.7 LPM), one or both of the motors may be faulty. Individual front wheel motor testing is necessary. 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. 5.
Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) P1 P2 P3 P4 EXTERNAL CASE DRAIN (TO RESERVOIR) 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN TESTER A G5 FORWARD R3 A TRACTION WHEEL MOTORS P5 LH M6 B R5 R4 B R9 A RH M7 B G6 FROM STEERING CONTROL VALVE Figure 35 Procedure for Piston (Traction) Pump Flow Test Th
5. Raise and support machine so all wheels are off the ground (see Jacking Instructions in Chapter 1 - Safety). 6. Thoroughly clean junction of hydraulic hose and right side fitting on bottom of traction pump (Fig. 36). Disconnect hose from right side 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 disconnected hydraulic hose. 7.
Relief Valve (R1) and (R2) Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD P1 P2 P3 P4 EXTERNAL CASE DRAIN 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN G5 A FORWARD R3 A TRACTION WHEEL LH M6 MOTORS B P5 R4 R5 B R9 A M7 RH B G6 FROM STEERING CONTROL VALVE REAR MOW CIRCUIT G1 C.U. 2 TESTER OR1 R11 P1 M1 FC1 EP1 R1 C.U.
IMPORTANT: When performing this test, do not hold over relief any longer than necessary to obtain pressure reading. 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. 4. Raise and prop operator seat to allow access to hydraulic mow control manifold. 5. Set reel speed controls (FC1 and FC2) to full open (highest number).
Gear Pump (P1) and (P2) Flow Test (Using Tester with Pressure and Flow Capabilities) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT GEAR PUMP (P1) FLOW TEST SHOWN TO LIFT CONTROL MANIFOLD TESTER P1 P2 P3 P4 EXTERNAL CASE DRAIN 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN G5 A FORWARD R3 A TRACTION WHEEL LH M6 MOTORS B P5 R4 R5 B R9 A M7 RH B G6 FROM STEERING CONTROL VALVE REAR MOW CIRCUIT G1 C.U. 2 C.U.
10.Open the tester flow control valve and stop the engine. Record test results. 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. 4. Raise and prop operator seat to allow access to hydraulic pump. 5. Identify suspected bad pump section to be tested (Fig. 40).
Reel Drive Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) Case Drain Hose Outlet Hose FRONT OF MACHINE High Pressure Low Pressure Case Drain Flow RM5510/5610 FRONT MOW CIRCUIT SHOWN Front Hose Front Hose R11 R11 R11 R11 Front Hose R11 M4 Install tester in series between fitting and hose at motor outlet. NOTE: Outlet is rear hose.
10.While watching pressure gauges, slowly close flow control valve on tester until a pressure of 1200 PSI (83 bar) is obtained. 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. NOTE: The reel motors are connected in series.
Reel Drive Motor Cross- Over Relief Pressure Test (Reelmaster 5510 and 5610) Use a tee fitting to install pressure gauge in both inlet and outlet lines of motor being tested. NOTE: Inlet is front hose. Outlet is rear hose.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. 2. Determine which reel motor is malfunctioning. 3. Park machine on a level surface with the cutting units lowered and PTO switch off. Make sure engine is off and mow/transport lever is in mow. Apply the parking brake. 4. Read Precautions For Hydraulic Testing in this section.
Lift Relief Valve (SVRV) Pressure Test PRESSURE GAUGE TO STEERING CONTROL VALVE TO MOW CONTROL (FRONT CUTTING UNITS) G4 SV2 P4 CV4 C4 SVRV TO MOW CONTROL (REAR CUTTING UNITS) C1 L C1 P1 P2 P3 P4 CV1 T PUMP (P5) INTERNAL CASE DRAIN C4 L SV1 R7 CV5 C5 C5 L SV3 100 MESH SUCTION CV23 STRAINER LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT LEFT FRONT FRONT CENTER FROM MOW CONTROL MANIFOLD LEFT REAR RIGHT REAR R8 Figure 45 The lift relief valve (SVRV) pressure test should be perfo
5. Thoroughly clean test port (G4) on lift control manifold. Access to test port can be obtained from below the front of the machine. Connect a 5000 PSI (350 bar) pressure gauge to test port. 6. After installing pressure gauge to manifold test port, start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 7. Move throttle to full speed (3200 RPM). IMPORTANT: Do not allow pressure to exceed 2500 PSI (172 bar).
Gear Pump (P4) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE TO MOW CONTROL (FRONT CUTTING UNITS) G4 TESTER SV1 P1 P2 P3 P4 T PUMP (P5) INTERNAL CASE DRAIN SVRV (NOT ENERGIZED) TO MOW CONTROL (REAR CUTTING UNITS) C4 L SV2 P4 CV4 C4 C1 L C1 CV1 R7 CV5 C5 C5 L SV3 100 MESH SUCTION CV23 STRAINER LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT LEFT FRONT FRONT CENTER FROM MOW CONTROL MANIFOLD LEFT REAR RIGHT REAR R8 Figure 46 The gear pump
5. Thoroughly clean both ends of the hydraulic tube that connects gear pump (P4) outlet (Fig. 47) and lift control manifold P4 port. Remove hydraulic tube. Access to hydraulic tube at lift control manifold can be obtained from below the machine. 13.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (See Relieving Hydraulic System Pressure in the General Information section of this chapter).
Lift Cylinder Internal Leakage Test TO STEERING CONTROL VALVE TO MOW CONTROL (FRONT CUTTING UNITS) G4 SV2 P4 CV4 C4 SVRV TO MOW CONTROL (REAR CUTTING UNITS) P1 P2 P3 C1 L C1 P4 CV1 T PUMP (P5) INTERNAL CASE DRAIN C4 L SV1 R7 CV5 C5 C5 L SV3 100 MESH SUCTION CV23 STRAINER LIFT CONTROL MANIFOLD C2/3 L C2/3 RIGHT FRONT LEFT FRONT (PARTIALLY RAISED) FROM MOW CONTROL MANIFOLD PLUG FRONT CENTER CAP CHECK FOR CYLINDER EXTENDING LEFT REAR R8 RIGHT REAR LEFT FRONT (#5) LIFT CYLINDE
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. 3 2 4. Place a steel cap on the open lift cylinder fitting to seal the lift cylinder. Also, install a steel plug in the open end of the disconnected hose to prevent leakage or contamination. 1 5. Slowly lower the jack and remove it from under the lift arm.
Steering Relief Valve (R10) Pressure Test TO MOW CONTROL MANIFOLD (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL MANIFOLD (REAR CUTTING UNITS) P1 PUMP (P5) DRAIN INTERNAL CASE DRAIN P2 P3 P4 100 MESH SUCTION STRAINER TO TRACTION CHARGE CIRCUIT OUT T P IN R10 V1 STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE L R PRESSURE GAUGE STEERING CYLINDER Figure 52 The steering relief valve (R10) pressure test should be performed to make sure that the steering circuit rel
Procedure for Steering Relief Valve Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. 2. Park machine on a level surface with the cutting units lowered and PTO switch off. Make sure engine is off. Apply the parking brake. 3. Read Precautions For Hydraulic Testing in this section. 12.
Steering Cylinder Internal Leakage Test R10 STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE PLUG LOOK FOR LEAKAGE STEERING CYLINDER (FULLY EXTENDED) Figure 54 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.
Procedure for Steering Cylinder Internal Leakage Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. 1 2. Park machine on a level surface with the cutting units lowered and PTO switch off. Make sure engine is off. Apply the parking brake. 3. Read Precautions For Hydraulic Testing. 2 CAUTION Figure 55 1. Steering cylinder 2.
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, engage parking brake, lower cutting units 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. 8. Make sure traction pedal is in neutral and the PTO switch is OFF. Turn ignition key switch to start; engage starter for ten (10) seconds to prime hydraulic pumps. Repeat this step again. 1. Park machine on a level surface.
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 traction 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. 7. Make sure traction pedal is in neutral and the PTO switch is OFF. Turn ignition key switch to start; engage starter for ten (10) seconds to prime hydraulic pumps. Repeat this step again.
Hydraulic System This page is intentionally blank.
Hydraulic Reservoir 4 6 37 3 25 2 31 42 35 38 41 40 39 1 15 18 33 14 11 22 34 17 20 10 18 20 28 44 43 29 5 36 32 17 26 12 26 13 13 19 24 9 21 7 23 27 19 RIGHT 24 30 27 8 16 FRONT Figure 57 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 57) Installation (Fig. 57) 1. Tilt hydraulic reservoir cover up to access reservoir. 1. If fittings were removed from reservoir, lubricate and place new O- rings onto fittings. Install fittings into reservoir openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3. Drain hydraulic oil from reservoir. 4. Label hydraulic hoses to assist in installation.
Hydraulic Pump Drive Shaft 6 4 5 3 2 8 7 9 10 34 to 42 ft- lb (46 to 56 N- m) 1 Antiseize Lubricant RIGHT FRONT Figure 58 1. 2. 3. 4. Piston (traction) pump Flange nut (2 used) Flange head screw (2 used) Guard hoop Hydraulic System 5. Cap screw (2 used) 6. Engine flywheel 7. Cap screw (6 used) Page 4 - 66 8. Drive shaft assembly 9. Flange nut 10.
Removal (Fig. 58) Installation (Fig. 58) 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 1. Apply antiseize lubricant to traction pump input shaft. 2. Remove two (2) flange head screws and flange nuts that secure drive shaft guard hoop to machine frame. Remove guard. 3. Remove two (2) cap screws (item 5) and flange nuts (item 9) that secure drive shaft yoke to piston pump input shaft. 4.
Hydraulic Pump Assembly 50 23 50 19 10 RIGHT FRONT 18 21 17 16 9 24 15 22 25 19 26 12 5 18 14 2 11 17 1 9 8 13 48 47 47 32 46 44 16 51 31 30 5 33 45 9 26 49 28 52 33 34 3 27 20 28 29 4 6 28 7 Antiseize Lubricant 39 40 41 37 36 35 42 43 38 Figure 60 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 60) 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. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2 1 CAUTION Figure 61 3. To prevent contamination of the hydraulic system, thoroughly clean traction and gear pump assembly and all hydraulic connections. 4.
4. Carefully lower pump assembly to machine frame. 5. Secure pump assembly to machine frame with two (2) flange screws and flange nuts. 6. Secure pump support bracket to inside of frame bracket with two (2) carriage screws (item 38) and flange nuts (item 36). 7. Install hydraulic hoses to fittings on pump assembly in positions noted during removal. 8. Connect machine harness electrical connector to traction neutral switch. Hydraulic System 9.
Hydraulic System This page is intentionally blank.
Piston (Traction) Pump Service 18 19 16 17 7 5 4 15 20 14 12 9 8 21 2 13 5 1 6 22 23 24 27 25 26 9 28 32 33 31 10 11 13 26 12 34 36 30 29 53 3 8 56 55 54 35 40 43 52 41 51 44 50 49 47 42 37 45 46 39 38 48 Figure 62 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
NOTE: For piston (traction) pump repair information, see the Sauer- Danfoss LPV Closed Circuit Axial Piston Pumps Repair Manual and Service Instructions at the end of this chapter. 4 7 3 5 8 IMPORTANT: If a piston (traction) pump failure occurred, refer to Traction Circuit Component Failure in the General Information section for information regarding the importance of removing contamination from the traction circuit.
Gear Pump Service 33 ft- lb (45 N- m) 12 10 11 9 1 6 2 7 13 8 21 22 23 19 17 6 8 3 4 5 21 16 24 20 14 18 33 ft- lb (45 N- m) 15 Figure 65 1. 2. 3. 4. 5. 6. 7. 8. Front cover Dowel pin (16 used) Square section seal (8 used) Back- up ring (8 used) Pressure seal (8 used) Thrust plate (8 used) Drive shaft Driven gear (2 used) 9. 10. 11. 12. 13. 14. 15. 16. Body Flange (3 used) Splined connecting shaft (3 used) Drive gear Body Drive gear Driven gear Body Disassembly (Fig.
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.
Front Wheel Motor STANDARD 2WD MACHINE WITH PARKER WHEEL MOTORS SHOWN 5 32 25 29 6 9 31 18 7 23 28 9 31 18 29 16 29 15 80 to 100 ft- lb (109 to 135 N- m) 11 10 30 12 13 24 27 32 26 3 29 5 21 8 22 19 29 15 14 1 20 17 4 RIGHT 250 to 350 ft- lb (339 to 474 N- m) 2 70 to 90 ft- lb (95 to 122 N- m) FRONT Figure 67 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
NOTE: Machines produced with serial number below 311000600 were produced with Parker brand front wheel motors. Figure 67 shows the front axle assembly with Parker wheel motors. Machines with serial number above 311000600 were produced with Eaton brand front wheel motors. Figure 68 shows the front axle assembly with Eaton wheel motors. If Parker brand wheel motors were replaced for some reason, the replacement wheel motors may have been Eaton brand.
11. Disconnect hydraulic lines from fittings on wheel motor. Allow lines to drain into a suitable container. 12.Put caps or plugs on disconnected lines and fittings to prevent contamination. 5. Install key into the wheel motor shaft keyslot. Align wheel hub with key and slide wheel hub onto motor shaft. Secure hub with lock nut. A. On machines with Parker wheel motors, torque lock nut from 250 to 350 ft- lb (339 to 474 N- m). 13.Support wheel motor to prevent it from falling.
Hydraulic System This page is intentionally blank.
Wheel Motor Service (Parker) 14 18 22 21 20 17 16 12 19 13 15 23 24 25 4 1 10 3 5 3 3 6 2 45 to 55 ft- lb (61 to 75 N- m) 7 8 9 3 3 11 Figure 70 1. 2. 3. 4. 5. 6. 7. 8. 9. Cap screw (7 used) End cover Body seal (5 used) Commutator ring Commutator Commutator ring Manifold Stator Vane (7 used) 10. 11. 12. 13. 14. 15. 16. 17. NOTE: The front wheel motors on Reelmaster 5010 machines with serial number below 311000600 are Parker Torqmotor TM TG Series.
Front Wheel Motor Service (Eaton) 11 12 13 12 14 15 16 17 18 16 1 2 4 20 3 21 6 10 9 8 5 3 45 to 55 ft- lb (61 to 75 N- m) 7 Figure 71 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. NOTE: Machines with serial number above 311000600 were produced with Eaton brand front wheel motors.
Mow Control Manifold 5 4 3 2 1 3 9 8 2 6 7 10 11 4 12 21 13 17 14 15 6 7 18 19 8 11 10 20 12 16 RIGHT FRONT Figure 72 1. 2. 3. 4. 5. 6. 7. Mow control manifold O- ring Diagnostic fitting Dust cap Hydraulic tube O- ring Hydraulic fitting (4 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. O- ring Hydraulic tube O- ring Hydraulic fitting O- ring O- ring Hydraulic fitting Page 4 - 82 15. 16. 17. 18. 19. 20. 21.
1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Tilt operator seat and engage seat prop to retain seat in the raised position. 4. Locate hydraulic mow control manifold. 5. Label all hydraulic and electrical connections for assembly purposes.
Mow Control Manifold Service 41 ft- lb (55 N- m) 17 17 40 ft- lb (54 N- m) 16 15 198 in- lb (22 N- m) 40 ft- lb (54 N- m) 13 16 14 3 15 3 18 19 2 41 ft- lb (55 N- m) 20 UP 2 165 in- lb (18.6 N- m) 25 ft- lb (33 N- m) 21 14 12 6 5 30 ft- lb (40 N- m) 13 4 1 11 2 9 3 48 to 60 in- lb (5.4 to 6.7 N- m) 5 7 6 4 8 9 165 in- lb (18.6 N- m) 198 in- lb (22 N- m) 25 ft- lb (33 N- m) 10 Figure 73 1. 2. 3. 4. 5. 6. 7. Mow control manifold O- ring Plug (zero leak #6) Orifice (0.
Mow Control Manifold Service C. Push spool down until O- ring and back- up ring are exposed on bottom of mow manifold. Remove lower O- ring and back- up ring from spool. 1. Make sure the manifold is thoroughly cleaned before removing any cartridge valve. D. Pull spool up and out of mow manifold. Remove O- rings and back- up ring from spool. 2. If solenoid cartridge valve is being serviced, remove nut securing solenoid coil to the cartridge valve. Carefully slide solenoid coil off the valve. E.
6. Visually inspect the manifold port for damage to the sealing surfaces, damaged threads and contamination. E. If handle was removed from spool, position spool so handle location of spool is between stop pins. Apply Loctite 603 Retaining Compound (or equivalent) to threads on handle and install handle into spool. 7. Visually inspect cartridge valve for damaged sealing surfaces and contamination. F. Place ball and dowel pin in backlap switch manifold port (Fig. 76).
11. If solenoid coil was removed: D. Place compression spring and detent pin into handle cap. Use a small amount of grease to hold detent pin in place. B. Install nut and torque nut to 48 to 60 in- lb (5.4 to 6.7 N- m). 12.If flow control cartridge valve was removed, install rotary handle to valve stem (Fig. 74): A. Place handle base on flow control valve and position alignment mark on base with number 1 on manifold. Secure base with two (2) set screws.
Lift Control Manifold 36 to 40 ft- lb (48 to 54 N- m) 11 13 12 10 9 14 16 15 3 12 8 3 7 2 23 3 6 4 18 22 2 3 17 21 19 20 1 RIGHT FRONT 36 to 40 ft- lb (48 to 54 N- m) 5 Figure 77 1. 2. 3. 4. 5. 6. 7. 8. Lift control manifold Flange head screw O- ring Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic System 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 77) IMPORTANT: When installing orifice in manifold (Fig. 78), 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 48 to 60 in- lb (5.4 to 6.7 N- m) 25 ft- lb (33 N- m) 9 7 6 48 to 60 in- lb (5.4 to 6.7 N- m) 25 ft- lb (33 N- m) 10 8 6 6 5 48 to 60 in- lb (5.4 to 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 79 1. 2. 3. 4. 5. 6. Lift control manifold Check valve (4 used) Solenoid valve (SV3) Solenoid coil Solenoid coil spacer Nut 7. 8. 9. 10. 11.
NOTE: Solenoid valves SV1 and SV2 on the lift control manifold use a coil spacer between the solenoid coil and nut. 10 ft- lb (17 N- m) 10 ft- lb (17 N- m) 3 2 4 1 3 IMPORTANT: A flow control orifice is placed beneath several of the hydraulic fittings on the lift control manifold (Fig. 80). The lift manifold uses three (3) different orifice sizes.
CrossTraxTM AWD (Optional Kit) Manifold 11 15 12 13 8 9 14 10 7 1 6 5 RIGHT FRONT 2 4 3 Figure 81 1. 2. 3. 4. 5. 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. 81) 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. 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 bracket and manifold. 8. Remove AWD manifold from machine. 9. If necessary, remove hydraulic fittings from manifold. Discard any removed O- rings. Installation (Fig. 81) 3. Remove caps and plugs from disconnected lines and fittings. 4.
CrossTraxTM AWD (Optional Kit) Manifold Service 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 82 1. 2. 3. 4. 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.
Cutting Reel Motor 18 8 17 8 7 6 5 6 4 5 9 17 7 2 3 19 2 3 4 7 4 3 2 16 2 3 12 13 4 3 4 2 8 14 17 8 17 4 6 18 3 20 2 4 6 3 11 10 4 2 15 9 2 5 RIGHT 8 5 7 6 4 3 4 2 3 FRONT 2 1 Figure 83 1. 2. 3. 4. 5. 6. 7. Hydraulic reel motor (#4) O- ring 90o hydraulic fitting O- ring Hydraulic hose O- ring Hydraulic fitting 8. 9. 10. 11. 12. 13. 14. O- ring Hydraulic hose Hydraulic fitting Hydraulic hose Hydraulic hose 90o hydraulic fitting Hydraulic hose 15. 16.
Installation (Fig. 83) 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. 4. Disconnect hydraulic hoses from fittings in reel motor. Allow lines to drain into a suitable container. Remove and discard O- rings. 1.
Cutting Reel Motor Service (Bosch and Sauer- Danfoss) 10 35 to 40 ft- lb (47 to 55 N- m) 18 17 15 16 10 1 15 16 17 18 6 1 215 to 280 in- lb (24 to 32 N- m) 5 11 to 15 ft- lb (15 to 20 N- m) 7 6 13 5 11 to 15 ft- lb (15 to 20 N- m) 12 7 9 BOSCH MOTOR RM5510/5610 8 13 SAUERDANFOSS MOTOR RM5210/5410 8 12 12 14 9 2 14 6 5 2 5 7 6 12 3 4 7 11 11 3 20 19 Figure 85 1. 2. 3. 4. 5. 6. 7. Rear cover Drive gear Seal Tab washer Pressure seal Back- up ring O- ring 8. 9. 10. 11.
2. Use a marker to make a diagonal line across the front flange, body and rear cover for assembly purposes (Fig. 86). 1 IMPORTANT: Avoid using excessive clamping pressure on the motor flange to prevent damage. 3. Clamp front flange of motor in a vise with the shaft end down. Use of a vise with soft jaws is recommended. 4. Loosen cap screws that secure rear cover. 2 5. Remove motor from vise and remove cap screws. 6. Remove front flange from the body, then remove rear cover.
2. Clean all motor components with solvent. Dry all parts with compressed air. 3. Inspect drive gear, idler gear and bearing blocks (Fig. 89) for the following: A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces or wear on gear shafts indicates need for replacement. 4. Install lubricated O- rings to the body. 5. Lubricate gear faces and bearing surfaces of drive gear, idler gear and bearing blocks with clean hydraulic oil.
Hydraulic System This page is intentionally blank.
Cutting Reel Motor Service (Casappa) 33 ft- lb (45 N- m) MOTOR RM5510/5610 21 19 7 8 20 1 10 4 5 3 12 2 21 18 13 10 11 16 19 18 ft- lb (25 N- m) 6 15 14 17 MOTOR RM5410 11 16 5 2 17 18 8 13 9 7 1 6 3 15 14 4 10 19 18 ft- lb (25 N- m) 12 Figure 90 1. 2. 3. 4. 5. 6. 7. Body Front flange Front thrust plate Rear thrust plate Drive gear Idler gear Socket head screw (4 used) 8. 9. 10. 11. 12. 13. 14.
Disassembly (Fig. 85) MARKER LINE 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 2. Use a marker to make a diagonal line across the front flange and body for assembly purposes (Fig. 91). IMPORTANT: Prevent damage when clamping the fan motor in a vise; clamp on the front flange only. Also, use a vise with soft jaws. 3. Clamp front flange of motor in a vise with soft jaws with the shaft end down. 4.
Inspection 1. Remove any nicks and burrs from all motor parts with emery cloth. C. Install new dust seal into front flange. CAUTION 3. Place front flange, seal side down, on a flat surface. Use eye protection such as goggles when using compressed air. 2. Clean all motor parts with solvent. Dry all parts with compressed air. 3. Inspect drive gears and idler gears for the following (Fig. 93): A. Gear shafts should be free of scoring, rough surfaces and excessive wear at bushing points and sealing areas B.
14.Place front flange of the motor into a vise with soft jaws and alternately torque the socket head screws to the values identified in Figure 85. 15.On Reelmaster 5510 and 5610 reel motor, install cross- over relief valves into rear flange if they were removed. Torque relief valves 18 ft- lb (25 N- m). Reelmaster 5010 Series 16.Remove motor from vise. 17.Place a small amount of clean hydraulic oil in the inlet of the motor and rotate the drive shaft away from the inlet one revolution.
Lift Cylinder 67 to 83 ft- lb (91 to 112 N- m) 12 12 3 11 13 11 2 1 9 8 9 7 10 5 8 4 3 7 6 RIGHT 67 to 83 ft- lb (91 to 112 N- m) FRONT Figure 94 1. 2. 3. 4. 5. Lift cylinder Pivot shaft Flange head screw Lift arm (RH front shown) Flat washer 6. 7. 8. 9. Hydraulic hose O- ring 90o hydraulic fitting O- ring 10. 11. 12. 13.
Removal (Fig. 94) Installation (Fig. 94) 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. 1. If hydraulic fittings were removed from lift cylinder, lubricate new O- rings, position O- rings to fittings and install fittings into lift cylinder ports (see Hydraulic Fitting Installation in the General Information section of this chapter). Make sure that fittings are orientated correctly. 3.
Lift Cylinder Service 1 2 4 6 9 11 13 3 5 14 7 8 1 10 12 13 10 14 9 6 7 8 4 2 1 1 5 11 12 3 Figure 95 1. 2. 3. 4. 5. Grease fitting Shaft Wiper Head U- Cup 6. 7. 8. 9. 10. Retaining ring Back up washer O- ring Piston Cap seal 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 machines are very similar. Disassembly (Fig. 95) 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 seals and O- rings from the piston. 7.
Steering Control Valve ANTISEIZE LUBRICANT RIGHT 8 7 5 6 FRONT 9 10 4 11 2 12 7 to 10 ft- lb (9.5 to 13.5 N- m) 3 1 ANTISEIZE LUBRICANT 20 to 26 ft lb (28 to 35 N- m) 2 13 14 Figure 96 1. 2. 3. 4. 5. Steering control valve Flange head screw Foam collar 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. 96) 1.
7. Position steering column brace (item 13) to machine and secure with four (4) flange head screws and flange nuts. 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 6 13 5 4 3 2 20 to 24 ft- lb (27 to 33 N- m) 1 Figure 99 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 7 6 5 8 7 9 6 5 4 10 14 11 13 1 2 3 12 RIGHT FRONT Figure 1. 2. 3. 4. 5. Steering cylinder Retaining ring Grease fitting Hydraulic hose O- ring Hydraulic System 6. 7. 8. 9. 10. 90o hydraulic fitting 100 O- ring Hydraulic hose Grease fitting Ball joint Page 4 - 114 11. 12. 13. 14.
Removal (Fig. 100) 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. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. CAUTION 2. If removed, press ball joint into barrel and secure with retaining ring. 3.
Steering Cylinder Service 2 7 9 12 1 14 3 6 8 11 4 5 10 13 6 7 13 12 11 9 5 4 14 1 30 to 35 ft- lb (41 to 47 N- m) 8 1. 2. 3. 4. 5. Shaft Wiper U- Cup Head Retaining ring 6. 7. 8. 9. 10. Figure 102 Back- up ring O- ring O- ring Piston O- ring Disassembly (Fig. 102) 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.
Inspection 3. Coat shaft with clean hydraulic oil. Slide head and piston onto the shaft. Use eye protection such as goggles when using compressed air. 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. Assembly (Fig. 102) 1.
Oil Cooler 8 11 REELMASTER 5410/5510 SHOWN 4 10 6 12 17 13 16 17 5 1 4 3 17 13 14 3 15 7 2 9 11 15 9 RIGHT FRONT Figure 1. 2. 3. 4. 5. 6. Screen assembly Oil cooler bracket Cap screw (4 used) Foam seal (2 used) Draw latch Rivet (2 used) 7. 8. 9. 10. 11. 12.
Inspection 5 1. Back flush oil cooler with cleaning solvent. After cooler is clean, make sure all solvent is drained from the cooler. REELMASTER 5610 6 3 7 2 CAUTION 4 11 8 10 9 Use eye protection such as goggles when using compressed air. 2. Dry inside of oil cooler using compressed air in the opposite direction of the oil flow. 8 12 1 3. Plug both ends of oil cooler. Clean exterior of cooler. Make sure oil cooler fins are clear of dirt and debris. Installation (Fig. 103) 1.
This page is intentionally blank.
Chapter 5 Electrical System Table of Contents Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Up Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Raise and Lower Switches . . . . . . . . . . . Mow/Transport Switch . . . . . . . . . . . . . . . . . . .
Special Tools Order Special Tools from your Toro Distributor. 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 VoltOhm- 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.
Diagnostic Display The Diagnostic Display (Fig. 4) is connected to the wiring harness connector located inside the control arm to verify correct electrical functions of the machine. Electronic Control Module (ECM) inputs and outputs can be checked using the Diagnostic Display. Toro Part Number for Diagnostic Display: 85--4750 Toro Part Number for Overlay (English): 110--0666 NOTE: Diagnostic Display overlays are available in several languages for your Reelmaster.
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 -- Electrical Diagrams). 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.
Fault Description 1- 1 High engine temp warning occurred (PTO was shutdown by ECM) 1- 2 High engine temp shutdown occurred (engine was shutdown by ECM) 1- 3 Low engine oil pressure occurred 1- 4 Engine alternator fault occurred 1- 5 Charging system voltage was incorrect (check charging system) 1- 6 Internal ECM fault 2- 1 Check ECM output fuse 1 2- 2 Check ECM output fuse 2 2- 3 Check ECM output fuse 3 2- 4 No power to all ECM output fuses (check main power relay) 2- 5 Leak in hydrauli
Diagnostic Display Reelmaster 5010 machines are equipped with an Electronic Control Module (ECM) which controls machine electrical functions. The ECM monitors various input switches (e.g. ignition switch, seat switch, etc.) and energizes outputs to actuate solenoids or relays for the requested machine function. For the ECM to control the machine as desired, each of the input switches, output solenoids and relays must be connected and functioning properly.
Fault Description TEMP WARN Excessive engine temperature: LED ON Normal engine temperature: LED OFF JOYSTICK LOWER Joystick moved forward: LED ON Joystick in neutral: LED OFF PTO ENABLE PTO switch ON: LED ON PTO switch OFF: LED OFF FR REELS DN Cutting units lowered: LED ON Cutting units raised: LED OFF TRANSPORT OFF Mow/Transport lever in MOW: LED ON Mow/Transport lever in TRANSPORT: LED OFF BACKLAP RR Rear CU Backlap lever in BACKLAP: LED ON Rear CU Backlap lever in MOW: LED OFF BACKLAP FR Fr
Verify Diagnostic Display Output Functions B. If the output LED’s are on as specified, but the machine does not function properly, suspect a nonelectrical problem (e.g. hydraulic component problem). Repair as necessary. The Diagnostic Display also has the ability to detect which output solenoids or relays are turned on by the ECM. This is a quick way to determine if a machine malfunction is electrical or hydraulic. C.
Electronic Control Module Logic Chart Start (No Operator in Seat) X X Start (Operator in Seat) X X Run (No Operator in Seat) X Run (Operator in Seat) X Lower Cutting Units to Ground X Engine Start (Run Solenoid and Start Solenoid Energized) Engine Run Solenoid Hold Coil Energized Engine Glow Plugs Energized MSV2 (Front Reel Motors) Energized MSV1 (Rear Reel Motors) Energized SVRV Energized SV3 (Rear Lift Cylinders) Energized SV2 Energized SV1 (Front Lift Cylinders) Energized OUTPUTS R
Starting Problems Problem Possible Causes All electrical power is dead, including gauges. Battery is discharged. Ignition switch or circuit wiring is faulty. Fusible link harness at the engine starter motor is faulty. Battery cables are loose or corroded. Main fuse (15 amp) to the ignition switch is faulty. Starter solenoid clicks, but starter will not crank. Battery is discharged. NOTE: If the starter solenoid clicks, the problem is not Battery cables are loose or corroded. in the interlock circuit.
Starting Problems (Continued) Problem Possible Causes Engine cranks, but should not, when the traction pedal is depressed. Traction neutral switch is out of adjustment. Nothing happens when start attempt is made. Control panel lights and gauges operate with the ignition switch in RUN. Traction pedal is not in neutral position. Traction neutral switch or circuit wiring is faulty. Operator seat is unoccupied OR the parking brake is not applied. Cutting units are engaged (PTO 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 stop solenoid 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. 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 PTO switch. Up limit switch or circuit wiring is faulty. Cutting units run, but should not, when raised. Cutting units do not shut off with PTO switch. Both the up limit switch (or circuit wiring) and PTO switch (or circuit wiring) are faulty.
Cutting Unit Operating Problems (Continued) Problem Possible Causes The cutting units do not run when placed in the backlap direction. Cutting units are not fully lowered to ground. Front or rear backlap switch or circuit wiring is faulty. Up limit switch or circuit wiring is faulty. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The cutting units do not backlap, but run in the forward direction instead.
TurfDefenderTM Leak Detector (Optional) 4. Turn the ignition switch to the RUN position, but do not start machine. NOTE: Red text on the overlay decal refers to inputs and green text refers to outputs. 5. The red “Inputs Displayed” LED (Light Emitting Diode), on lower right column of the Diagnostic Display, should be illuminated (Fig. 14). If green “Outputs Displayed” LED is illuminated, press and release the toggle button, on the Diagnostic Display, to change LED to “Inputs Displayed”.
A. Valve Open Circuit LED blinking: check / replace TurfDefenderTM electric solenoid valve or wires. If TurfDefenderTM is functioning normally: 1. When the “Inputs Displayed” LED is lit (Fig. 15): B. Valve Short Circuit LED blinking: check / replace TurfDefenderTM electric solenoid valve or wires. A. The actual float position should be identified by 1 or 2 LED’s in the left column. The correct reservoir level is some combination of Float Levels 3 and/or 4. C.
TURFDEFENDER V1.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a digital multimeter to measure the battery voltage. Voltage Measured Battery Charge Level 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. Connect the positive (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post.
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.
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. On machines with serial numbers below 310000000 (Fig. 17), the sensing element for the traction neutral switch is a cap screw on the pump control arm. On machines with serial numbers above 310000000 (Fig.
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. 19). SERIAL NUMBER BELOW 310000000 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.
Up Limit Switch The up limit switch is a normally open proximity switch that closes when the cutting units are in the lowered position. A bracket on the front, right lift arm acts as the sensing plate for the up limit switch (Fig. 21). 1 4 Adjustment The up limit switch should be secured to the switch bracket at the midpoint of the bracket mounting slots.
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: 05 Series Engine for additional 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.
Indicator Lights Glow Plug Indicator Light 4. Ground terminals 1B and 2B (Fig. 24). The glow plug indicator light should come on when the ignition switch is placed in the RUN position prior to placing the ignition switch in START. The light should stay lit for approximately 6 seconds while the ignition switch is left in the RUN position. The indicator light should also be illuminated when the ignition switch is in the START position. 5. Both indicator lights should illuminate. 6.
Hour Meter The hour meter is located on the outside of the control arm. Hobbs 1. Remove control arm covers to gain access to hour meter and meter terminals (see Control Arm Disassembly in the Service and Repairs section of this chapter). QUARTZ 00001 HOURS 2. Make sure ignition switch is in the OFF position. Locate the hour meter and disconnect the wire harness electrical connector from the meter. 1 10 + 3.
PTO Switch The PTO switch is mounted on the control panel and is pressed to allow the cutting units to operate. An indicator light on the switch identifies when the PTO switch is engaged. Testing 1 1. Before disconnecting the switch for testing, the switch and its circuit wiring should be tested as an ECM input with the Diagnostic Display (see Diagnostic Display in the Troubleshooting section of this chapter). 2.
Traction Neutral Switch 6. If the neutral switch tests correctly and a circuit problem still exists, check wire harness (see Wiring Schematic and Circuit Drawings in Chapter 9 -- Electrical Diagrams). 7. Make sure that wire harness electrical connector is connected to the traction neutral switch. Lower operator seat. SERIAL NUMBER BELOW 310000000 Testing 4 1.
Seat Switch The seat switch is normally open and closes when the operator seat is occupied. If the traction system or PTO 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. 1 Testing 1. Before disconnecting the seat switch for testing, the switch and its circuit wiring should be tested as an ECM input with the Diagnostic Display (see Diagnostic Display in the Troubleshooting section of this chapter). 2 2.
Headlight Switch The headlight switch is located on the operator side of the control arm. This rocker switch allows the headlights to be turned on and off. Testing 1. Remove inside control arm cover to gain access to headlight switch (see Control Arm Disassembly in the Service and Repairs section of this chapter). BACK OF SWITCH 2. Make sure ignition switch is in the OFF position. Disconnect harness electrical connector from the 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. The switch on machines with a serial number below 310000000 is different than the switch on machines with serial numbers above 310000000 but the switch function is the same. 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.
Up Limit Switch The up limit switch is a normally open proximity switch that closes when the cutting units are in the lowered position. A bracket on the front, right lift arm acts as the sensing plate for the up limit switch (Fig. 37). The switch on machines with a serial number below 310000000 is different than the switch on machines with serial numbers above 310000000 but the switch function is the same. 5.
Joystick Raise and Lower Switches Two micro switches for the joystick are located on the lift control 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 Testing 1. Before disconnecting the mow/transport switch for testing, the switch and its circuit wiring should be tested as an ECM input with the Diagnostic Display (see Diagnostic Display in the Troubleshooting section of this chapter). If the Diagnostic Display verifies that the mow/ transport switch and circuit wiring are functioning correctly, no further switch testing is necessary.
Backlap Switches The front and rear backlap switches are normally closed ball switches that are in the normal, closed state when the backlap lever is in the backlap position. When the backlap lever is in the mow position, the switch opens. The backlap switches are attached to the hydraulic mow control manifold located under the seat (Fig. 38).
Start Relay The start relay is used in the engine starting circuit. When energized by the Electronic Control Module (ECM), the start relay provides a current path to energize the engine starter solenoid. The start relay is attached to a frame bracket under the hood next to the hydraulic pump drive shaft (Fig. 45). The ECM controls and monitors the operation of the start relay.
Main Power and Glow Relays The Reelmaster electrical system includes two identical relays for current control. The main power and glow relays are attached to a frame bracket under the hood next to the hydraulic pump drive shaft (Fig. 42). Relays can be identified by a tag on the wire harness. 6. Disconnect voltage and test leads from the relay terminals. The main power relay is used to provide current to the Electronic Control Module (ECM), headlights, power point and optional electric equipment.
Electronic Control Module (ECM) The Toro Electronic Control Module (ECM) senses the condition of various switches (inputs) and directs power output to allow certain machine functions. The ECM is located behind the control arm access cover next to the fuse block (Fig. 49). The handheld Diagnostic Display (see Special Tools in this chapter) with the correct overlay should be used when checking inputs and outputs of the ECM used on your Reelmaster (see Troubleshooting in this chapter).
Diode Assembly A diode assembly (Fig. 51) is used in the Reelmaster engine wire harness (see wire harness drawings in Chapter 9 - Electrical Diagrams). The diode is used for circuit protection from voltage spikes that occur when the starter solenoid is de- energized. 1 Testing Locate diode assembly and remove cable tie that secures diode to wire harness. Unplug the diode from the wire harness for testing. The diode (Fig.
Fuses The fuse block is located behind the control arm access cover (Fig. 49). 1 Identification and Function The fuses are held in the fuse block. Use Figure 50 to identify each individual fuse and its correct amperage. Fuses for your Reelmaster have the following function: Left Fuse 1 (15 Amp): Protects starter circuit power supply. Left Fuse 2 (10 Amp): Protects main power supply. Left Fuse 3 (10 Amp): Protects power supply for headlights. Figure 49 1.
Hydraulic Solenoid Valve Coil The Reelmaster hydraulic system uses several hydraulic solenoid valve coils for system control. The cutting deck manifold includes two (2) solenoid valves (Fig. 58) and the lift control manifold includes four (4) solenoid valves (Fig. 57). 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. Testing 1.
Temperature Sender The temperature sender is attached to the water pump housing on the engine and has a gray wire attached to it (Fig. 53). The resistance of the temperature sender reduces as the engine coolant temperature increases. The changing resistance of the temperature sender signals the console temperature gauge to indicate engine coolant temperature level during machine operation.
High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump housing (Fig. 55). The high temperature shutdown switch is normally open and closes when engine coolant temperature reaches approximately 239oF (115oC). When excessive coolant temperature causes the shutdown switch to close, the engine shuts down. There is a tan wire attached to the shutdown switch. 5. Replace shutdown switch if specifications are not met. 6.
Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter (Fig.57). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2). 2 1 The Electronic Control Module (ECM) monitors the operation of the oil pressure switch. The switch and its circuit wiring should be tested as an ECM input with the Diagnostic Display (see Special Tools and Troubleshooting in this chapter).
Fuel Stop Solenoid The fuel stop solenoid used on your Reelmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 58). 1 The Electronic Control Module (ECM) monitors the operation of the fuel stop solenoid. The solenoid and its circuit wiring should be tested as an ECM output with the Diagnostic Display (see Special Tools and Troubleshooting in this chapter).
Fuel Pump The Reelmaster fuel pump is attached to the inside of the left side frame rail near the fuel tank (Fig. 65). IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. 7. Replace fuel pump if necessary. Install fuel hose to the fuel/water separator. Make sure to secure fuel hose with hose clamp. 8. Connect harness electrical connector to the engine fuel stop solenoid. 9. Bleed the fuel system. DANGER 10.Lower and secure operator seat and hood.
Service and Repairs NOTE: See the Kubota Workshop Manual: 05 Series Engine for engine electrical component repair information. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery from the machine and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 7 6 FRONT 1 4 3 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm-up the hydrometer. At the same time take the temperature of the cell. C. Make sure battery terminals are free of corrosion. D. Measure the temperature of the center battery cell. E. Connect a battery load tester to the battery terminals following the load tester manufacturer’s instructions. Connect a digital multimeter to the battery terminals. B.
Charging CAUTION Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1. Determine the battery charge level from either its specific gravity or open circuit voltage. Battery Charge Level Specific Gravity Open Circuit Voltage 100% 1.265 12.68 75% 1.225 12.45 50% 1.190 12.24 25% 1.155 12.06 0% 1.120 11.89 2.
Control Arm 1 2 5 FRONT RIGHT 3 16 4 19 17 22 22 6 23 24 26 8 13 29 11 12 27 28 9 7 18 8 10 25 14 5 20 15 16 21 Figure 63 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Arm rest Headlight switch LH control arm cover Screw (2 used) Lock nut Screw RH control arm cover Bushing Control arm Seat wire harness Electrical System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Disassembly (Fig. 63) 4 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 3 2 2. Loosen latches and remove access cover from outside of control arm. 3. At front of control arm, remove screw (item 6) and lock nut (item 5) that secure control arm covers to each other. 1 4. Remove five (5) washer head screws (item 16) that secure each cover to control arm. Figure 64 1. Wire harness 2. Harness foam seal 3.
Hydraulic Solenoid Valve Coil A hydraulic solenoid valve coil on the mow control manifold (Fig. 66) or lift control manifold (Fig. 67) can be replaced without opening the hydraulic system. 1 FRONT Removal 3 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Locate the solenoid valve coil that is to be replaced. A. Tilt operator seat up to gain access to hydraulic mow control manifold.
Backlap Switches Removal (Figs. 68 and 69) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2 4 3 2. Tilt operator seat up to gain access to hydraulic mow control manifold. 5 3. Locate the backlap switch on the mow control manifold that is to be replaced (Fig. 68). 1 4. Disconnect the wire harness electrical connector from the backlap switch that is to be removed. Installation (Figs. 68 and 69) Figure 68 1.
TurfDefenderTM Leak Detector (Optional) 1 2 19 20 to 25 ft--lb (27 to 33 N--m) 12 13 100 to 125 in--lb (12 to 14 N--m) 3 4 18 17 5 16 6 14 7 15 8 100 to 125 in--lb (12 to 14 N--m) 9 10 11 Figure 70 1. 2. 3. 4. 5. 6. 7. Cap O--ring Filter screen Solenoid valve O--ring O--ring Leak detector assembly 8. 9. 10. 11. 12. 13.
When the ignition switch is turned to RUN, the TurfDefenderTM alarm should sound a single, short beep indicating normal operation. If there is no beep when the ignition switch is turned to RUN or if the alarm gives 4 short beeps it means a system problem has been detected that should be checked by a technician. 3. The main body of the TurfDefenderTM is not serviceable and disassembly should not be necessary. Removal of the upper housing from the leak detector housing is not recommended. 4.
This page is intentionally blank.
Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Traction Unit Operator’s Manual . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Brake Service . . . . . . . . . . . . . . . .
Specifications Item Description Front Tire Pressure (except RM- 5210) (26.5 x 14.0 - 12, 4 ply, tubeless) 12 to 15 PSI (83 to 103 kPa) Front Tire Pressure (RM- 5210) (24 x 13.0 - 12, 4 ply, tubeless) 12 to 15 PSI (83 to 103 kPa) Rear Tire Pressure (except RM- 5210) (20 x 12.0 - 10, 4 ply, tubeless) 12 to 15 PSI (83 to 103 kPa) Rear Tire Pressure (RM- 5210) (20 x 10.
Chassis This page is intentionally blank.
Service and Repairs Wheels 8 9 10 11 7 12 13 14 2 3 1 5 70 to 90 ft- lb (95 to 122 N- m) 6 RIGHT 4 7 FRONT Figure 1 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 Tab washer Rear wheel Page 6 - 4 11. 12. 13. 14.
Removal (Fig. 1) Installation (Fig. 1) 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) lug nuts. 2. Chock wheels to prevent machine from shifting. 3. Torque lug nuts evenly in a crossing pattern from 70 to 90 ft- lb (95 to 122 N- m). 3. Loosen lug nuts. 2. Lower machine to ground.
Steering Column 4 ANTISEIZE LUBRICANT 20 20 to 26 ft- lb (28 to 35 N- m) 21 1 3 ANTISEIZE LUBRICANT 5 6 16 17 8 23 11 10 15 2 12 9 22 14 7 19 19 RIGHT 15 13 7 FRONT 18 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. Steering column Hydraulic fitting (4 used) Steering wheel Steering wheel cover Foam column Socket head screw (4 used) Flange nut O- ring 9. 10. 11. 12. 13. 14. 15. 16.
5. Remove platform shroud from machine to allow access to steering column fasteners (Fig. 3). A. Remove cover plate from platform. B. Remove fasteners that secure shroud to machine. 9. Secure steering wheel to steering column with flat washer and lock nut. Torque hex nut from 20 to 26 ft- lb (28 to 35 N- m). 10.Install steering wheel cover to steering wheel. 3 C. Remove shroud from machine. 1 D. Locate and retrieve two (2) rubber bushings and spacers. 2 4 6.
Brake Service 5 32 STANDARD 2WD MACHINE WITH PARKER WHEEL MOTORS SHOWN 29 6 9 18 25 23 9 28 16 31 7 18 29 29 15 11 27 14 10 30 12 13 24 32 26 3 29 5 21 8 22 19 29 15 1 20 17 4 RIGHT 250 to 350 ft- lb (339 to 474 N- m) 2 70 to 90 ft- lb (95 to 122 N- m) FRONT Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Removal (Fig. 5) STANDARD 2WD MACHINE WITH EATON WHEEL MOTORS SHOWN 11 1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the ignition switch. 2. Chock wheels to prevent machine from shifting. 7 3. Loosen, but do not remove, lock nut (item 17) from wheel motor shaft. 6 4. Remove front wheel assembly (see Wheel Removal in this section). Make sure to support machine with jack stands. RIGHT 5. Make sure parking brake is disengaged.
2. If backing plate was removed from machine, secure backing plate to brake bracket with four (4) cap screws and lock nuts. 12 3. Lightly lubricate brake shoe pivot points with general purpose grease. 4. Position one brake shoe to the backing plate. Install brake hold down pin and secure with hold down spring and cup. Repeat for second brake shoe. 11 10 5 9 6. Mount key in the wheel motor shaft, then install the wheel hub onto the wheel motor shaft. 7.
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 9 1. 2. 3. 4. Dust cap Cotter pin Retainer Jam nut Chassis 5. 6. 7. 8. Tab washer Bearing cone Bearing cup Wheel hub Page 6 - 12 9. Seal 10. Spindle 11.
Disassembly (Fig. 9) 1. Chock front wheels to prevent machine from shifting. 2. Remove rear wheel (see Wheel Removal 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 tab 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 90 to 120 ft- lb (123 to 162 N- m) 6 8 4 19 22 15 27 30 4 15 27 18 9 31 11 10 28 19 25 7 29 23 31 20 7 21 24 14 2 28 12 26 20 5 16 RIGHT 17 3 13 FRONT 1 20 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Lug nut (5 used per wheel) 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. 10) Installation (Fig. 10) 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 90 to 120 ft- lb (123 to 162 N- m) 6 8 35 22 31 34 44 44 37 11 36 7 45 7 34 18 25 20 31 9 10 23 4 32 36 20 30 37 14 24 33 21 12 13 43 44 35 2 43 19 5 27 40 41 39 3 RIGHT 28 30 38 26 29 16 39 15 FRONT 17 42 40 1 20 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
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. To correct the problem, replace the bushings (item 36). 4. Remove the flange head screw, spindle cap and retaining ring that secure the wheel spindle into the axle tube. Slide the spindle and wheel assembly out of the axle tube to expose the spindle bushings.
Operator Seat 12 10 11 1 14 9 5 6 8 17 7 20 2 21 4 21 15 16 22 13 3 23 24 24 RIGHT 23 25 26 FRONT 19 18 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. Seat Seat base Seat adjuster w/latch Flat washer (4 used) Seat switch harness Seat switch Washer head screw (2 used) Armrest bracket Spacer 10. 11. 12. 13. 14. 15. 16. 17. 18. Armrest Cap screw Flange nut Flat washer (4 used) Flange head screw (3 used) Socket head screw (4 used) Seat adjuster Flat washer Seat bracket (2 used) 19. 20. 21. 22.
Removal (Fig. 12) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 2 2. Disconnect negative battery cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 - Electrical System). 3. Disconnect seat switch electrical connector from wire harness (Fig. 13). 4 4. Remove two (2) flange head screws and flat washers that secure control arm assembly to seat base (Figs. 13 and 14).
Mechanical Seat Suspension 31 18 40 37 34 11 41 1 19 28 29 26 20 38 30 6 8 23 4 24 10 22 7 2 27 16 21 33 36 14 12 13 25 17 35 9 32 3 39 15 42 5 Figure 15 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 throttle cable, control arm electrical components and control arm wiring harness. 13 14 FRONT 12 Removal (Figs. 15 and 16) 11 1 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 8 2 5 3 9 7 2.
Front Lift Arms 19 4 31 7 32 3 30 12 24 85 ft- lb (115 N- m) 23 20 9 25 15 28 29 10 26 17 19 4 31 18 32 1 4 16 31 2 22 32 34 18 33 RIGHT 13 14 5 8 6 27 24 34 23 12 11 17 31 18 32 21 FRONT 85 ft- lb (115 N- m) Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. #1 lift arm #4 lift arm #5 lift arm Lift arm pivot shaft Roll pin (3 used) Flange nut Carriage screw (2 used) Lock nut (2 used) Flange head screw Switch bracket Bridge plate Flange screw 13. 14. 15. 16. 17. 18.
4. Pivot lift cylinder rod end away from lift arm. 5. Remove lynch pin (item 17) and slide pivot yoke assembly from lift arm. Locate and retrieve two (2) thrust washers (item 18). 6. Remove fasteners that secure bridge plate to machine. The bridge plates on machines with serial numbers below 310000000 are secured with three (3) fasteners as shown in Fig. 17. On machines with serial numbers above 310000000, the bridge plates are secured with fasteners as shown in Fig. 19.
Rear Lift Arms 3 17 16 13 26 13 12 14 15 7 8 6 5 19 25 27 21 4 18 11 28 1 23 29 20 29 15 22 24 9 27 29 10 2 30 32 31 32 12 31 13 26 RIGHT FRONT Figure 22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Spacer (2 used) #2 lift arm #3 lift arm Washer (2 used per chain hoop) Spring catch Flange head screw (2 used) Cap screw (2 used) Flat washer (2 used) Pivot pin (2 used) Washer head screw (1 used per pin) Pivot yoke (2 used) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
6. Disconnect hydraulic lift cylinder rod end clevis from lift arm (see Lift Cylinder Removal in the Service and Repairs section of Chapter 4 - Hydraulic System). Pivot lift cylinder rod end away from lift arm. 7. Remove lynch pin (item 12) and thrust washer (item 13) from rear of pivot yoke. Slide pivot yoke assembly from lift arm. Locate and retrieve front thrust washer (item 13). 8. Remove two (2) flange head screws (item 6) that secure spring catch to machine.
This page is intentionally blank.
Chapter 7 DPA Cutting Units Table of Contents Reel Assembly Service (cutting units with painted side plates) . . . . . . Reel Assembly (cutting units with aluminum side plates) . . . . Reel Assembly Service (cutting units with aluminum side plates) . . . . Preparing Reel for Grinding . . . . . . . . . . . . . . . . . Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with bolt−on cast ductile iron or aluminum side plates. Bedknife: Replaceable, tool steel EdgeMaxTM bedknife is fastened to a machined cast iron bedbar with 8 screws. Optional bedknives are available. 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.
General Information Cutting Unit Operator’s Manual DPA Cutting Units 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.
Special Tools Order Special Tools 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 2 Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver−type bit is made to fit Toro bedknife attaching screws.
Plastic Plug Toro Part Number: 2410−30 (for 5 inch reels) 94−2703 (for 7 inch reels) This cap is used for placement into the side plate bearing housing when the hydraulic reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area. Figure 5 Cutting Unit Kickstand Toro Part Number: 119−8010−03 The cutting unit kickstand is used to prop up the front of the cutting unit during service. Use of this tool prevents the bedbar adjusting screws from resting on the work surface.
Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting unit roller that has greasable bearings and a bearing lock nut used to retain the bearings. Bearing Installation Washer 115−0852 Inner Seal Tool 115−0853 Bearing/Outer Seal Tool 107−8133 Bearing Installation Washer Bearing/Outer Seal Tool Inner Seal Tool Figure 8 Turf Evaluator Tool Toro Model Number: 04399 Many turf discrepancies are subtle and require closer examination.
Reel Bearing Installation Tool (cutting units with painted side plates) Toro Part Number: 117−0975 Use the reel bearing installation tool to keep the reel bearing aligned as the cutting unit side plate is installed on the bearing. Figure 11 Cutting Reel Shim Toro Part Number: 125−5611 The cutting reel shim (0.002”) is used to help parallel the bedknife and cutting reel.
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 Roller condition and roller type Make sure 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. Refer to Traction Unit Operator’s Manual for adjustment procedure. Rear lift arm counterbalance spring adjustment Refer to Traction Unit Operator’s Manual for adjustment procedure.
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. The dual knob bedknife−to−reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing performance.
Reel Bearing Adjustment (cutting units with painted side plates) NOTE: Cutting units that have aluminum side plates do not require reel bearing adjustment. 4 12 to 15 in−lb (1.4 to 1.7 N−m) To insure cut quality and long life of the cutting reel bearings, periodically check reel bearing adjustment. 1 Check Reel Bearing Adjustment 1. Remove hydraulic reel motor from cutting unit (see Hydraulic Reel Motor Removal in the Service and Repairs section of this chapter). 15 to 17 in−lb (1.7 to 1.
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. 3 2 4 1 Cutting Unit with 7” Reel Shown 1. Place the assembled cutting unit on a surface plate. 4 2. Make sure that bedknife is properly adjusted to cutting reel. 3.
DPA Cutting Units This page is intentionally blank.
Service and Repairs Hydraulic Reel Motor IMPORTANT: When performing maintenance procedures on the cutting units, carefully position the cutting unit reel motors to prevent damage to the motors or hydraulic hoses. 2 1 4 1 5 Removal 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. Loosen two (2) cap screws that secure the hydraulic reel motor to the cutting unit side plate.
Backlapping DANGER 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. TO BACKLAP 3. Raise seat, locate hydraulic mow control manifold and rotate directional valve lever fully to the R (backlap) position (Fig. 22). Rotate flow control valve knob to position 1. 3 TO BACKLAP 5 2 1 FRONT Figure 22 1. Mow control manifold 2. Rear directional lever 3. Rear flow control 2.
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 24 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. 24) 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. 24) 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. 25). 2. If removed, install the flange bushings with flange facing outward. Apply antiseize lubricant to inside of flange bushing. 9. Tighten the lock nut (item 2) on each bedbar adjuster assembly until the adjuster spring is fully compressed, then loosen lock nut 1/2 turn. 10.
Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Assembly in this chapter). 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar (Fig. 26). 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. 28 and 29). IMPORTANT: Do Not grind the bedknife below it’s service limit (Fig. 30).
Bedbar Adjuster Service Antiseize Lubricant Loctite #243 14 to 16 ft−lb (19 to 21 N−m) 6 Left Hand Threads 11 2 3 4 5 7 Antiseize Lubricant 8 5 9 1 10 Antiseize Lubricant A Loctite #243 14 to 16 ft−lb (19 to 21 N−m) 6 7 Left Hand Threads 5 RIGHT FRONT 12 13 5 10 2 3 4 Antiseize Lubricant B 11 1 14 15 to 20 ft−lb (21 to 27 N−m) Figure 32 1. 2. 3. 4. 5. Bedbar assembly Compression spring Lock nut Bedbar adjuster screw Flange bushing 6. 7. 8. 9. 10.
Removal (Fig. 32) 1. Remove lock nut (item 3), compression spring and washer from bedbar adjuster screw (item 4). 2. Remove bedbar assembly (see Bedbar Assembly Removal in this section). 3. Remove bedbar adjuster screw (left hand threads) from the bedbar adjuster shaft (item 10). 4. Remove adjuster shaft from cutting unit frame: A. On early production cutting units (Fig. 32 A), remove retaining ring and wave washer from adjuster shaft. Slide adjuster shaft from cutting unit frame. B.
Reel Assembly (cutting units with painted side plates) 11 7” CUTTING REEL SHOWN 21 1 23 14 Grease bore 22 15 27 to 33 ft−lb (37 to 44 N−m) Grease OD surface 8 7 3 12 2 13 16 17 FRONT See text for tightening procedure 4 5 6 18 19 RIGHT 3 20 11 Loctite #243 12 to 15 in−lb (1.4 to 1.7 N−m) Grease bore and threads 27 to 33 ft−lb (37 to 44 N−m) 10 9 Antiseize Lubricant Figure 33 1. 2. 3. 4. 5. 6. 7. 8.
Reel Assembly Removal (Fig. 33) 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. Remove the cutting unit from the machine and place on a flat work area. 8 3. If the cutting unit is equipped with a counterweight or accessory on LH side plate (as shown in Figure 33), remove the counter weight or accessory. Remove and discard the O−ring from counter weight. 5.
IMPORTANT: During cutting reel installation, keep inner and outer bearing races aligned. If bearing races are not aligned, binding will occur and reel installation may cause bearing damage. Use reel bearing installation tool (Toro part number 117−0975) to help with bearing alignment during reel installation. 3. Using reel bearing installation tool (see Special Tools in this chapter) to keep reel bearing aligned, carefully slide the cutting reel with bearings and grease seals into the RH side plate.
DPA Cutting Units This page is intentionally blank.
Reel Assembly Service (cutting units with painted side plates) 8 10 7 Loctite #243 9 5 4 3 2 Clean Threads 85 to 95 ft−lb (115 to 128 N−m) (Right Hand Threads) 1 10 RIGHT 6 3 Left Hand Threads Loctite #243 85 to 95 ft−lb (115 to 128 N−m) FRONT 4 5 Figure 35 1. 2. 3. 4. Cutting reel Threaded insert (RH thread) Retaining ring Grease seal 5. Bearing 6. Threaded insert (LH thread) 7. Retaining ring groove Inspection of Cutting Reel (Fig. 35) 1.
C. To install spline insert into cutting reel, clean threads of insert and cutting reel shaft. Apply Loctite #243 (or equivalent) to threads of insert, thread insert into reel shaft and torque from 85 to 95 ft-lb (115 to 128 N−m). Assembly of Cutting Reel (Fig. 35) 1. If seals and/or bearings were removed from reel shaft, discard removed components and replace. 2. Make sure that the two (2) retaining rings are fully seated into the grooves on the cutting reel shaft. 3.
Reel Assembly (cutting units with aluminum side plates) 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 36 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 37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Frame LH side plate RH side plate Shoulder bolt (4) Carrier frame Flange head screw (2) Flange bushing (2) Rear grass shield Spacer (2) Shim (0.060” − as required) Flange nut (2) Reel Assembly Removal 1.
6. Remove cap screw and flat washer that secure rear grass shield to LH side plate. 7. Remove flange head screw and flange nut that secures frame spacer and carrier frame to LH side plate. NOTE: The reel bearings and grease seals are press fit on the cutting reel shaft and should remain on the reel when removing the LH side plate. 1 2 Antiseize Lubricant 8. Remove two (2) shoulder bolts and flange nuts that secure the LH side plate to the cutting unit frame.
NOTE: The parallel position of the rear roller to the cutting reel is controlled by the precision machined frame and side plates of the cutting unit. If necessary, the cutting unit side plates can be loosened and a slight adjustment can be made to parallel the rear roller with the cutting reel (see Leveling Rear Roller in this Chapter). 15.If counterweight was removed from cutting unit, install new O−ring on counter weight. Secure counter weight to cutting unit side plate with two (2) flange nuts.
Reel Assembly Service (cutting units with aluminum side plates) 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 Loctite #243 Loctite #243 13* 15* 10 3 14* 4 5 RIGHT 6 7 FRONT 8 85 to 95 ft−lb (115 to 128 N−m) (Left Hand Threads − Groove in Face) Figure 39 1. 2. 3. 4. 5. Cutting reel Threaded insert (RH thread) Plastic plug (2) Retaining ring Special washer 6. 7. 8. 9. 10.
Reel Assembly Cutting Unit Serial no. 315000001 & Up 1. If removed, install new reel shaft plugs into cutting reel shaft. For cutting unit serial no. prior to 315000001, make sure plastic plug is pressed flush into end of threaded insert. For cutting unit serial no. 315000001 & Up, make sure plastic plug is pressed unto reel shaft 1.63 to 1.37 in. (41 to 35 mm) below the end of the shaft (Fig. 40) 1 2 NOTE: One insert has LH threads and the other insert has RH threads.
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. 41). 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.
Front Roller Removal (Fig. 43) 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) to raise front roller from work surface. 2 15 to 19 ft−lb (20 to 26 N−m) 3 3.
Rear Roller Removal (Fig. 44) 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. 1 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. 5 3. Loosen two (2) flange nuts that secure the rear roller shaft to each rear roller bracket. 6 4.
DPA Cutting Units This page is intentionally blank.
Roller Service (greasable bearings with retaining ring) v 2 5 7 9 1 10 8 3 4 6 Figure 45 1. 2. 3. 4. Roller tube (front Wiehle shown) Roller shaft Inner oil seal Grease fitting 5. Ball bearing 6. Inner seal 7. Outer seal 8. Retaining ring 9. Outer oil seal 10. Roller washer NOTE: Numerous front and rear rollers are available for the Reelmaster cutting units. These rollers use one of two styles of bearing and seal configurations.
Assembly (Figs. 45 and 46) 4. Use tool TOR4069 to install outer seal. NOTE: Use of a press is recommended to assemble the roller. If a press is not available, a soft face hammer can be used with the special tools to assemble the roller. 5. Install retaining ring. 1. Use installation tool TOR4065 and handle TOR4073 to install inner oil seal into each end of roller tube. Apply grease to ID of seal after installation. 7. Use tool TOR4067 to install roller washer. 2. Install bearings into roller tube: A.
Roller Service (greasable bearings with bearing nut) Disassembly (Fig. 47) 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 (cutting units with painted side plates) 30 6 31 20 to 25 in−lb (2.3 to 2.8 N−m) 26 2 27 11 3 29 17 to 21 ft−lb (23 to 28 N−m) 6 1 7 4 8 Antiseize Lubricant 9 5 27 12 26 10 v 11 13 14 25 15 16 17 11 18 RIGHT FRONT 19 28 24 32 Grease Grommet ID 27 to 33 ft−lb (37 to 44 N−m) Loctite #243 23 22 21 20 11 Figure 53 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Disassembly (Fig. 53) 10 to 15 ft−lb (14 to 20 N−m) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 11 10 9 2. To remove roller brush from brush shaft: 1 3 A. Remove the non−drive brush bearing housing (item 30) from cutting unit. 3 8 B. Slide excluder seal from roller brush shaft. 5 7 C. Remove lock nut and J−bolt from both ends of the brush. 2 3.
3. If drive bearing housing was disassembled, install new components noting proper orientation as shown in Figures 57 and 58. 8 A. Install bearing on shaft by pressing equally on the inner and outer bearing races. Install the bearing so that the bearing seal is closest to the shoulder on the shaft. Install snap ring onto shaft to retain bearing. 7 6 B. Install new grease seal into housing with the lip of the seal toward the drive shaft splines. Apply grease to lip of seal. 9 5 3 2 C.
5. To tension a roller brush drive system that includes an adjustable idler pulley (shown in Figure 53), make sure idler pulley lock nut is loose. Lift up on idler plate tab with 15 lbs of force for a new belt (10 lbs of force for a used belt) and tighten pulley lock nut. Refer to decal on brush plate (Fig. 60). 1 IMPORTANT: The roller brush shaft must nor contact the cutting unit side plate. Also, heavy brush contact on the rear roller will cause premature brush wear. 6.
Rear Roller Brush − Optional (cutting units with aluminum side plates) 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 63 1. 2. 3. 4. 5. 6. 7. 8.
3. Disassemble roller brush components as necessary using Figures 53 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. 53) 1.
Drive System Disassembly (Fig. 67) 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 67 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.
Drive System Assembly (Fig. 67) 85 to 95 ft−lb (115 to 128 N−m) 1. Install drive shaft if it was removed: 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. 69). 2 4 Loctite #243 A. Apply Loctite #243 (or equivalent) to threads of drive shaft.
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. 59). 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. 71). C.
Chapter 8 Belt Driven Groomer (Optional) Table of Contents Belt Driven Groomer (Opt.) GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Groomer Reel Mechanical Problems . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Groomer Height/Depth Adjustment . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Groomer Drive Belt Replacement . . . . .
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 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. Seized groomer reel or idler bearing(s) in groomer side plate(s). Identify and 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 ken or damaged. out of adjustment or worn.
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. 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.
Service and Repairs 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 Plate Assembly Loctite #243 7 21 20 19 16 Antiseize Lubricant 21 22 18 17 23 Loctite #243 16 24 7 4 1 14 13 12 2 RIGHT 3 4 5 6 15 23 FRONT 7 8 9 Antiseize Lubricant 17 to 21 ft−lb (23 to 28 N−m) 10 11 Loctite #243 27 to 32 ft−lb (37 to 43 N−m) Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Groomer reel Pulley spacer Washer (as required) Square key Driven pulley Flange nut Socket head screw Idler plate 9. 10. 11. 12. 13. 14. 15. 16.
C. Remove the flange nut (item 6) that secures driven pulley (item 5) to groomer shaft. Remove driven pulley from shaft. Locate and retrieve square key (item 4) that locates driven pulley on shaft. D. Press bushings into groomer plate until the bushing contacts the shoulder in the groomer plate bore. E. If groomer studs (not shown) were removed from groomer plate (item 17), install new studs into groomer plate and torque from 14 to 18 ft−lb (19 to 24 N−m). D.
I. Check pulley alignment by laying a straight edge along the outer face of the drive pulley (Fig. 7). Drive and driven pulleys should be in line within 0.030” (0.76 mm). If necessary, align pulleys by removing driven pulley and installing or removing washer(s) (item 3) between pulley and pulley spacer. 2. Install groomer plate assembly to groomer non− drive side of cutting unit: A. Carefully position non−drive side groomer plate onto groomer shaft and slide to cutting unit. B.
Belt Driven Groomer (Opt.) This page is intentionally blank.
Groomer Reel Loctite #243 7 21 20 19 16 Antiseize Lubricant 21 22 18 17 23 Loctite #243 16 24 7 4 14 13 12 1 2 3 4 5 RIGHT 6 15 7 23 FRONT 8 9 Antiseize Lubricant 17 to 21 ft−lb (23 to 28 N−m) 10 11 Loctite #243 27 to 32 ft−lb (37 to 43 N−m) Figure 8 1. 2. 3. 4. 5. 6. 7. 8. Groomer reel Pulley spacer Washer Square key Driven pulley Flange nut Socket head screw Idler plate 9. 10. 11. 12. 13. 14. 15. 16.
Installation (Fig. 8) 3 1. Position cutting unit on a level surface. If cutting unit is attached to traction unit, make sure to stop engine, engage parking brake and remove key from the ignition switch. 1 2. Apply a light coating of grease to seal lips in groomer plate assemblies. 3. Make sure that excluder seals (item 23) and O−ring (item 24) are positioned on groomer shaft. The excluder seal lips should be toward the end of the groomer shaft. Apply a film of grease onto seal lip. 4.
Groomer Reel Service 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. 11). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. 3 1 2 Groomer shafts are either hex shaped or splined so two styles of groomer blades are available.
5. If groomer reel is equipped with broomer kit (Fig. 14), position broomer brushes to reel blades and secure with straps. Straps should be positioned between blades 1−2, 14−15, 28−29 and 41−42. Pull straps tight and cut off strap extension approximately 1/4” (6 mm) beyond retainer. 2 2 2 2 1 6. Place excluder seals on groomer shaft. 7. Install O−ring on non−drive end of groomer shaft. 8. Install groomer reel back on cutting unit (see Groomer Reel Installation in this section). Figure 14 2.
Groomer Pivot Hub 6 2 10 5 3 4 7 8 Apply Grease to Seal Lip 1 9 Figure 15 1. 2. 3. 4. Groomer drive shaft Ball bearing Grease seal Retaining ring 5. Pivot hub 6. Retaining ring 7. Extension spring 8. Retaining ring 9. Idler plate 10. O−ring (7” cutting unit only) NOTE: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic motor. Figure 15 shows components used when the groomer reel drive is on the left side of the cutting unit.
Disassembly (Fig. 15) Fill cavity 50 to 75% full with grease 1. Remove pivot hub assembly (with idler plate) from cutting unit (see Groomer Plate Assembly Removal in this section). 4 2. Remove retaining ring (item 4) that secures idler plate to pivot hub. Slide idler plate from pivot hub. 3 3. Remove retaining ring (item 8) that retains ball bearing into pivot hub. Slide drive shaft and bearing out of hub. 4. Remove retaining ring (item 7) that retains bearing on drive shaft.
Height Adjuster Assembly 11 12 10 9 8 Antiseize Lubricant 7 13 30 to 40 in−lb (3.4 to 4.5 N−m) 6 14 Antiseize Lubricant 5 4 17 to 21 ft−lb (23 to 28 N−m) 3 2 1 Antiseize Lubricant Figure 17 1. 2. 3. 4. 5. Groomer plate (LH drive shown) Shoulder bolt Ball joint rod Jam nut Compression spring 6. 7. 8. 9. 10.
Chapter 9 Universal Groomer (Optional) Table of Contents Universal Groomer (Opt.) 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 Groomer Reel Mechanical Problems 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.
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. 5. To detach the gear box from the cutting unit: A. Turn the input shaft in the correct direction to loosen it from the reel. B. Remove the cotter pin and clevis pin from the height adjustment rod at the front of the groomer gear box. Discard cotter pin. C. Continue to unscrew the input shaft and remove the gear box from the cutting unit. Universal Groomer (Opt.
Disassembly (Fig. 3) 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 32 to 42 in−lb (4 to 5 N−m) Tighten to Specified Torque (see text) Figure 3 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 CAUTION 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. NOTE: If cutting unit is equipped with an optional powered rear roller brush, install the rear roller brush drive housing assembly, drive belt and cover (see Roller Brush (Optional) in Chapter 7 − Cutting Units in this manual for additional information). 5.
Universal Groomer (Opt.) This page is intentionally left blank.
Idler Assembly Loctite #243 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 5 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. 5) 1.
Installation (Fig. 5) 1. If shields, bearing or bushing was removed from idler arm, install new components. 1 A. Press bushing into groomer plate until the bushing is centered in the idler arm bore. 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 7 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. 7) 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 Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn blades or reverse the individual blades to put the sharpest blade edge forward (Fig. 8). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. 2 1 MIDPOINT Disassembly (Fig. 9) 3 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. 10). Make sure brushes are seated in groomer blade slots (Fig. 11) 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. 10).
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 The grooming brush element or shaft can be serviced separately (Fig. 13). 1 3 2 Figure 13 3. Roll pin (2) Universal Groomer (Opt.) 1. Brush element 2.
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 14 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. 14) 1.
Assembly (Fig. 14) 1. Apply antiseize lubricant to upper threads of adjustment rod and lower threads of height adjusters. Assemble height adjuster assembly as shown. 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. Ensure the height adjustment bolt and one (1) washer is above slot in side plate and one (1) washer and lock nut is below slot in side plate. 3.
This page is intentionally left blank.
Chapter 9 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATICS Reelmaster 5210 and 5410 . . . . . . . . . . . . . . . . . . . 3 Reelmaster 5510 and 5610 . . . . . . . . . . . . . . . . . . . 4 ELECTRICAL SCHEMATICS Reelmaster 5010 Series (Serial Number Below 310000000) . . . . . . . . . . . . . . . . . . . . . . . . 5 Reelmaster 5010 Series (Serial Number Above 310000000) . . . . . . . . . . . . . . . . . . . . . . . .
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.
G4 C4 L SV1 P4 SV2 CV4 GEAR PUMP C4 SVRV C1 L C1 OUT T P IN CV1 T R7 P1 P3 P2 C5 C5 L NOTE: EXTERNAL CASE DRAIN FROM PISTON (TRACTION) PUMP ELIMINATED AFTER SERIAL NUMBER 280000800 SV3 R10 CV23 EXTERNAL CASE DRAIN LIFT CONTROL MANIFOLD C2/3 C2/3 L RIGHT FRONT G5 A V1 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN CV5 P4 LEFT FRONT FORWARD FRONT CENTER R3 A TRACTION WHEEL MOTORS P5 LH A B B B PISTON (TRACTION) PUMP LEFT REAR G6 STEERING CYLINDER RIGHT REAR R9 G1 OR
G4 C4 L SV1 P4 SV2 CV4 GEAR PUMP C4 SVRV C1 L C1 OUT T P IN CV1 T R7 P1 P3 P2 C5 C5 L NOTE: EXTERNAL CASE DRAIN FROM PISTON (TRACTION) PUMP ELIMINATED AFTER SERIAL NUMBER 280000800 SV3 R10 CV23 EXTERNAL CASE DRAIN LIFT CONTROL MANIFOLD C2/3 C2/3 L V1 100 MESH SUCTION STRAINER INTERNAL CASE DRAIN CV5 P4 RIGHT FRONT G5 A LEFT FRONT FORWARD FRONT CENTER R3 A TRACTION WHEEL MOTORS P5 A M7 M6 LH B B PISTON (TRACTION) PUMP LEFT REAR G6 STEERING CYLINDER RIGHT REAR R9 RE
ALTERNATOR PK RUN SOLENOID (HOLD) B R L PK HOUR METER R/BK R/BK HR W (PULL) (+) 1 4 2 3 TEMP GAUGE (−) BK W R OT WARNING GY BU/W GY TEMP SENDER PK GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP.
(3 GLOW PLUGS USED ON RM5210) INDICATOR LIGHTS PARKING BRAKE SWITCH (BRAKE APPLIED) SEAT SWITCH (UNOCCUPIED) NEUTRAL SWITCH (NOT IN NEUTRAL) FRONT BACKLAP SWITCH (IN MOW) REAR BACKLAP SWITCH (IN MOW) MOW/TRANSPORT SWITCH (IN MOW) UP LIMIT SWITCH (C.U. RAISED) Reelmaster 5010 Series Electrical Schematic (Serial Number Above 310000000) All relays and solenoids are shown as de−energized. All ground wires are black.
ALTERNATOR PK RUN SOLENOID (HOLD) B R L (PULL) PK R/BK HOUR METER R/BK HR W 1 4 2 3 TEMP GAUGE (−) BK W OT WARNING GY BU/W GY TEMP SENDER PK GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP.
ALTERNATOR PK RUN SOLENOID (HOLD) B R L PK R/BK HOUR METER R/BK HR W (PULL) 4 (−) 2 3 OT WARNING GY BU/W GY TEMP SENDER PK GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP.
ALTERNATOR PK RUN SOLENOID (HOLD) B R L PK R/BK HOUR METER R/BK HR W (PULL) 1 4 2 3 TEMP GAUGE (−) BK W OT WARNING GY BU/W GY TEMP SENDER PK GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP.
ALTERNATOR PK RUN SOLENOID (HOLD) B R L (PULL) PK R/BK R/BK (+) HR W 1 4 2 3 TEMP GAUGE (−) BK W OT WARNING GY BU/W GY TEMP SENDER PK GN/W ENGINE OIL PRESSURE ENGINE OVER TEMP.
This page is intentionally blank.
Reelmaster 5010 Series Main Wire Harness Drawing (Serial Number Below 310000000) Page 10 − 12
RED/WHITE RED BROWN PINK VIOLET RED RED BLACK BLUE BLACK PINK PINK RED BROWN BLACK BLACK ORANGE BLACK/WHITE RED BLACK WHITE GREEN/WHITE BLUE YELLOW GRAY PINK GREEN BLACK WHITE/BLUE RED YELLOW/BLACK TAN YELLOW BLACK RED BLUE BLACK GRAY BLACK BLACK BLACK RED/BLACK VIOLET RED/BLACK GRAY/BLUE BLACK WHITE BLACK BLACK ORANGE BLACK GRAY BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK GRAY GREEN Reelmaster 5010 Series Main Wire Harness Diagram (Serial Numb
Reelmaster 5010 Series Main Wire Harness Drawing (Serial Number Above 310000000) Page 10 − 14
RED/WHITE BLACK/WHITE PINK RED BROWN VIOLET RED RED/WHITE RED BLACK/WHITE BLUE BLACK ORANGE BLACK PINK PINK RED RED/WHITE RED BLACK PINK BROWN BLACK BLACK BLACK/WHITE WHITE GREEN/WHITE BLUE GRAY YELLOW PINK BLACK WHITE/BLUE RED YELLOW/BLACK TAN YELLOW BLACK GREEN BLUE BLACK BLACK WHITE GRAY PINK ORANGE BLACK BLACK RED/BLACK BLACK BLACK RED/BLACK VIOLET BLACK GRAY/BLUE RED/BLACK RED PINK GRAY BLACK BLACK BLACK PINK BLACK BLACK BLACK BLACK BLACK BLACK GRAY
Reelmaster 5010 Series Seat Wire Harness Drawing (Serial Number Below 310000000) Page 10 − 16
WHITE/BLUE RED/WHITE VIOLET GRAY/BLUE PINK PINK PINK BLUE/WHITE BLACK PINK YELLOW/BLACK BROWN GREEN YELLOW ORANGE ORANGE/BLACK GREEN/BLACK GRAY GREEN/WHITE PINK WHITE BLUE GREEN GRAY TAN BLUE/WHITE YELLOW/BLACK BLACK/WHITE GREEN/WHITE WHITE RED/BLACK BROWN BLUE WHITE BLUE PINK PINK PINK YELLOW TAN BLACK BLACK ORANGE RED BROWN/ WHITE BLACK BLACK RED PINK BLACK RED TAN/BLACK RED GRAY/BLACK BLACK BLACK GRAY BLACK BLACK BLACK BLACK BLACK GRAY ORANGE VIOLET YELLOW
Reelmaster 5010 Series Seat Wire Harness Drawing (Serial Number Above 310000000) Page 10 − 18
VIOLET GREEN/WHITE WHITE PINK RED/WHITE BLACK/WHITE WHITE/BLUE PINK PINK GRAY/BLUE BLUE/WHITE PINK BLACK PINK YELLOW/BLACK GREEN BROWN YELLOW ORANGE ORANGE/BLACK GREEN/BLACK GRAY BLUE GREEN GRAY TAN ORANGE BLUE/WHITE YELLOW/BLACK RED/WHITE BLACK/WHITE GREEN/WHITE WHITE RED/BLACK BROWN BLUE WHITE BLUE PINK PINK YELLOW PINK TAN BLACK BLACK RED BROWN/ WHITE BLACK RED/WHITE BLACK/WHITE BLACK RED PINK BLACK RED BLACK GRAY BLACK BLACK BLACK BLACK BLACK BLACK GRAY VIOLET ORANG
Reelmaster 5010 Series Engine Wire Harness Drawing Page 10 − 20
RED BLACK WHITE RED/BLACK FUSIBLE LINK BLUE WHITE PINK ORANGE BLACK GREEN/WHITE TAN GRAY BLUE Reelmaster 5010 Series Engine Wire Harness Diagram Page 10 − 21
TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS A C D ALARM + RED/YELLOW RED − BLACK/YELLOW BLACK/BLUE ORANGE/BLACK BLACK/WHITE BLACK RED RED/WHITE B YELLOW BLACK/ORANGE GREEN/WHITE 94−6345 ELECTRIC SOLENOID VALVE BLACK 2D 1B 3B 2C 1E TURF DEFENDER Reelmaster 5010 Series TurfDefenderTM (Optional) Electrical Schematic Page 10 − 22 2E TM 1C 3C 2A LEAK DETECTOR 2F 1F 3F TURF DEFENDER LOOPBACK I.D.
