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Part No. 15212SL

Service Manual

ReelmasterR 5010- H
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Reelmaster 5010- H (Hybrid).
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Additional copies of the Operator’s
Manual and Parts Catalog are available on the internet
at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.

This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.

NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.

E The Toro Company - 2015

This page is intentionally blank.

Reelmaster 5010- H

Chapter 5 - Electrical System

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 - 6

General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Electrical System Operation . . . . . . . . . . . . . . . . . 5 - 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
InfoCenter Display . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
Electrical System Quick Checks . . . . . . . . . . . . . 5 - 40
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 42
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 - 46
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 - 77

Chapter 3 - Kubota Diesel Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05- E4B SERIES
Chapter 4 - Hydraulic System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .

6666-

2
2
3
4

Chapter 7 - Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
Factors That Can Affect Cutting Performance . . 7 - 8
Set- Up and Adjustments . . . . . . . . . . . . . . . . . . . 7 - 12
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 7 - 14

Cutting
Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 - 12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 - 52
SAUER- DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS REPAIR MANUAL
SAUER- DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS SERVICE INSTRUCTIONS
EATON DELTA MOTORS PARTS AND REPAIR
MANUAL
PARKER TORQMOTORTM SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER- DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL

Chapter 6 - Chassis
Kubota Diesel
Engine

1
1
2
3

Hydraulic
System

2222-

Electrical
System

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .

Chassis

Chapter 2 - Product Records and Maintenance

Product Records
and Maintenance

Chapter 1 - Safety

Safety

Table Of Contents

Reelmaster 5010- H

This page is intentionally blank.

Reelmaster 5010- H

General Information . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grooming Performance . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .

Reelmaster 5010- H

Chapter 9 - Foldout Drawings
888888-

2
3
4
5
7
8

Electrical Drawing Designations . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . .
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . .

9999-

2
3
4
6

Foldout
Drawings

Chapter 8 - Groomer

Groomer

Table Of Contents (Continued)

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Reelmaster 5010- H

Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS . . . . . . . . . .

Reelmaster 5010- H

2
2
3
4
5
6

Page 1 - 1

Safety

Chapter 1

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. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the
following safety instructions.

WARNING
To reduce the potential for injury or death, comply with the following safety instructions.

Before Operating
1. Review and understand the contents of the Operator’s Manuals and Operator Training DVD before starting and operating the machine. Become familiar with the
controls and know how to stop the machine and engine
quickly. Additional copies of the Operator’s Manual are
available on the internet at www.Toro.com.

4. Since fuel is flammable, handle it carefully:

2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and Enable/Disable switch is OFF (disabled).

Safety

Page 1 - 2

A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove machine fuel tank cap while engine is hot or running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Replace fuel tank and fuel container caps securely after refueling machine.
F. If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of spillage. Avoid creating any source of ignition until fuel
vapors have dissipated. Wipe up any spilled fuel.

Reelmaster 5010- H

1. Sit on the seat when starting and operating the machine.
2. Before starting the engine:
A. Apply the parking brake.

4. Do not touch engine, radiator, exhaust system or hydraulic components while engine is running or soon after
it is stopped. These areas could be hot enough to cause
burns.
5. Before getting off the seat:

B. Make sure the traction pedal is in NEUTRAL, the
Enable/Disable switch is in the disabled position and
the engine speed switch is in the mid- speed position.

A. Ensure that traction pedal is in NEUTRAL.

C. Turn the ignition switch to the ON/PREHEAT position to energize the glow plugs. After allowing the
glow plugs to preheat, turn the switch to the START
position. Release the switch to the ON/PREHEAT
position when the engine starts.

C. Apply parking brake.

D. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage is
adjusted incorrectly; therefore, shut engine off and
adjust traction pedal linkage until machine does not
move when traction pedal is released (see Traction
Unit Operator’s Manual).
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.

Reelmaster 5010- H

B. Lower and disengage cutting units. Wait for all
movement to stop.

D. Move the engine speed switch to the low idle position and allow the engine to reach low idle speed.
E. Stop engine and remove key from ignition switch.
6. Anytime the machine is parked (short or long term),
the cutting units should be lowered to the ground. This
relieves pressure from the hydraulic lift circuit and eliminates the risk of the cutting units unexpectedly lowering
to the ground.
7. Do not park on slopes unless wheels are chocked or
blocked.

Page 1 - 3

Safety

While Operating

Maintenance and Service
1. Before servicing or making adjustments, lower cutting units, apply parking brake, stop engine and remove
key from the ignition switch.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
4. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.
5. Keep body and hands away from pin hole leaks in hydraulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be relieved by using all of the hydraulic controls with the engine not running (see Relieving Hydraulic Pressure in
the General Information section of Chapter 4 - Hydraulic System).

13.Before installing, removing or working on 48 VDC
system components (e.g. cutting units, motor/generator), separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect
(see 48 VDC Battery Disconnect in the General Information section of Chapter 5 - Electrical System). Plug
the connector back in before operating the machine.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.When changing tires, attachments or performing
other service, use correct jacks, hoists and supports.
Make sure machine is parked on a solid level floor such
as a concrete floor. Prior to raising the machine, remove
any attachments that may interfere with the safe and
proper raising of the machine. Always chock or block
wheels. Use jack stands or appropriate load holding devices to support the raised machine. If the machine is
not properly supported, the machine may move or fall,
which may result in personal injury (see Jacking Instructions in this section).
17.If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.

8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.

18.When welding on machine, disconnect battery
cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect wire harness connector
from the TEC controller and disconnect the terminal
connector from the alternator. Attach welder ground
cable no more than two (2) feet (0.6 meters) from the
welding location.

9. If engine must be running to perform maintenance or
to make an adjustment, keep hands, feet, clothing and
other parts of the body away from the cutting units and
other moving parts. Keep bystanders away.

19.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, batteries) in an environmentally safe manner. Follow all local codes and
regulations when recycling or disposing of waste.

10.To assure safety and accuracy, check maximum engine speed.

20.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.

7. Use care when checking or servicing the cutting
units. Wear appropriate gloves and use caution when
servicing them.

11. Shut engine off before checking or adding oil to the
engine crankcase.
12.Disconnect 12 VDC battery located at the rear of the
machine before servicing the machine. Disconnect negative battery cable first and positive cable last. If battery
voltage is required for troubleshooting or test procedures, temporarily connect the battery. Reconnect positive battery cable first and negative cable last.

Safety

Page 1 - 4

Reelmaster 5010- H

Jacking Instructions
Safety

CAUTION
When changing tires, attachments or performing other service, use correct hoists, jacks and
jack stands. Make sure machine is parked on a
solid, level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or
block wheels. Use jack stands or other appropriate load holding devices to support the
raised machine. If the machine is not properly
supported, the machine may move or fall,
which may result in personal injury.

2
1
Figure 1
1. Front wheel

Front End Jacking (Fig. 1)

2. Front jacking point

1. Apply parking brake and chock both rear tires to prevent the machine from moving.
2. Position jack securely below the rectangular pad under the frame axle tube, just to the inside of the front
wheel.
3. Jack front of machine off the ground.
4. Position jack stands under the frame as close to the
raised wheel as possible to support the machine.
Rear End Jacking
1. Apply parking brake and chock both front tires to prevent the machine from moving.
2. Place jack securely at the center of the rear axle under the axle pivot bracket. Jack rear of machine off the
ground.
3. To support the raised machine, position jack stands
under the frame rail next to the axle support bracket.

Reelmaster 5010- H

Page 1 - 5

Safety

Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the traction unit and the cutting units of your Reelmaster.
If any decal becomes illegible or damaged, install a new
decal. Part numbers for decals are listed in your Part
Catalogs. Order replacement decals from your Authorized Toro Distributor.

Safety

Page 1 - 6

Reelmaster 5010- H

Chapter 2

Product Records and Maintenance
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Using a Torque Wrench with an Offset Wrench . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Series) . . . . . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .

Product Records
and Maintenance

Table of Contents
1
1
2
2
2
3
3
3
4
5
6
6

Product Records
Insert Operator’s Manual and Parts Catalog for your
Reelmaster at the end of this chapter. Refer to Operator’s Manual for recommended maintenance intervals.
Additionally, insert Installation Instructions, Operator’s
Manuals and Parts Catalogs for any accessories that
have been installed on your Reelmaster at the end of
this section.

Maintenance
Maintenance procedures and recommended service intervals for your Reelmaster are covered in the Operator’s Manual. Refer to that publication when performing
regular equipment maintenance. Several maintenance
procedures have break- in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual
for additional engine specific maintenance procedures.

Reelmaster 5010- H

Page 2 - 1

Product Records and Maintenance

Equivalents and Conversions

0.09375

Product Records and Maintenance

Page 2 - 2

Reelmaster 5010- H

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. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.

As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.

Fastener Identification

Grade 1

Grade 5

Grade 8

Class 8.8

Inch Series Bolts and Screws

Class 10.9

Metric Bolts and Screws

Figure 1

Figure 2

Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommendation.

If the listed torque recommendation for a fastener is
from 76 to 94 ft- lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft- lb.
Offset wrench

Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Reelmaster 5010- H

Page 2 - 3

(effective length of
torque wrench)
A

Torque wrench

B
(effective length of torque
wrench + offset wrench)

TORQUE CONVERSION FACTOR = A / B
Figure 3
Product Records and Maintenance

Product Records
and Maintenance

Torque Specifications

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

N- cm

10 + 2

13 + 2

147 + 23

# 6 - 40 UNF
# 8 - 32 UNC

13 + 2

25 + 5

282 + 30

# 8 - 36 UNF
# 10 - 24 UNC

18 + 2

30 + 5

339 + 56

# 10 - 32 UNF

SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)

in- lb

N- cm

in- lb

N- cm

15 + 2

169 + 23

23 + 3

262 + 34

17 + 2

192 + 23

25 + 3

282 + 34

29 + 3

328 + 34

41 + 5

463 + 56

31 + 4

350 + 45

43 + 5

486 + 56

42 + 5

475 + 56

60 + 6

678 + 68

48 + 5

542 + 56

68 + 7

768 + 79

1/4 - 20 UNC

48 + 7

53 + 7

599 + 79

100 + 10

1130 + 113

140 + 15

1582 + 169

1/4 - 28 UNF

53 + 7

65 + 10

734 + 113

115 + 12

1299 + 136

160 + 17

1808 + 192

5/16 - 18 UNC

115 + 15

105 + 15

1186 + 169

200 + 25

2260 + 282

300 + 30

3390 + 339

5/16 - 24 UNF

138 + 17

128 + 17

1446 + 192

225 + 25

2542 + 282

325 + 33

3672 + 373

ft- lb

N- m

ft- lb

N- m

ft- lb

N- m

3/8 - 16 UNC

16 + 2

22 + 3

30 + 3

41 + 4

43 + 5

58 + 7

3/8 - 24 UNF

17 + 2

18 + 2

24 + 3

35 + 4

47 + 5

50 + 6

68 + 8

7/16 - 14 UNC

27 + 3

37 + 4

50 + 5

68 + 7

70 + 7

95 + 9

7/16 - 20 UNF

29 + 3

39 + 4

55 + 6

75 + 8

77 + 8

104 + 11

1/2 - 13 UNC

30 + 3

48 + 7

65 + 9

75 + 8

102 + 11

105 + 11

142 + 15

1/2 - 20 UNF

32 + 4

53 + 7

72 + 9

85 + 9

115 + 12

120 + 12

163 + 16

5/8 - 11 UNC

65 + 10

88 + 12

119 + 16

150 + 15

203 + 20

210 + 21

285 + 28

5/8 - 18 UNF

75 + 10

95 + 15

129 + 20

170 + 18

230 + 24

240 + 24

325 + 33

3/4 - 10 UNC

93 + 12

140 + 20

190 + 27

265 + 27

359 + 37

375 + 38

508 + 52

3/4 - 16 UNF

115 + 15

165 + 25

224 + 34

300 + 30

407 + 41

420 + 43

569 + 58

7/8 - 9 UNC

140 + 20

225 + 25

305 + 34

430 + 45

583 + 61

600 + 60

813 + 81

7/8 - 14 UNF

155 + 25

260 + 30

353 + 41

475 + 48

644 + 65

667 + 66

904 + 89

NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Product Records and Maintenance

NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.

Page 2 - 4

Reelmaster 5010- H

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)

Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)

M5 X 0.8

57 + 6 in- lb

644 + 68 N- cm

78 + 8 in- lb

881 + 90 N- cm

M6 X 1.0

96 + 10 in- lb

1085 + 113 N- cm

133 + 14 in- lb

1503 + 158 N- cm

M8 X 1.25

19 + 2 ft- lb

26 + 3 N- m

28 + 3 ft- lb

38 + 4 N- m

M10 X 1.5

38 + 4 ft- lb

52 + 5 N- m

54 + 6 ft- lb

73 + 8 N- m

M12 X 1.75

66 + 7 ft- lb

90 + 10 N- m

93 + 10 ft- lb

126 + 14 N- m

M16 X 2.0

166 + 17 ft- lb

225 + 23 N- m

229 + 23 ft- lb

310 + 31 N- m

M20 X 2.5

325 + 33 ft- lb

440 + 45 N- m

450 + 46 ft- lb

610 + 62 N- m

NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.

NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.

Reelmaster 5010- H

Page 2 - 5

Product Records and Maintenance

Product Records
and Maintenance

Thread Size

Other Torque Specifications
SAE Grade 8 Steel Set Screws

Wheel Bolts and Lug Nuts

Recommended Torque

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 8.8

80 + 10 ft- lb

108 + 14 N- m

M12 X 1.5
Class 8.8

80 + 10 ft- lb

108 + 14 N- m

** For steel wheels and non- lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size

Baseline Torque*

No. 6 - 32 UNC

20 + 5 in- lb

No. 8 - 32 UNC

Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size

Threads per Inch

Baseline Torque*

Type A

Type B

No. 6

20 + 5 in- lb

30 + 5 in- lb

No. 8

30 + 5 in- lb

No. 10 - 24 UNC

38 + 7 in- lb

No. 10

38 + 7 in- lb

1/4 - 20 UNC

85 + 15 in- lb

No. 12

85 + 15 in- lb

5/16 - 18 UNC

110 + 20 in- lb

3/8 - 16 UNC

200 + 100 in- lb

* Hole size, material strength, material thickness and finish must be considered when determining specific
torque values. All torque values are based on non- lubricated fasteners.

Conversion Factors
in- lb X 11.2985 = N- cm
ft- lb X 1.3558 = N- m

Product Records and Maintenance

N- cm X 0.08851 = in- lb
N- m X 0.7376 = ft- lb

Page 2 - 6

Reelmaster 5010- H

Chapter 3

Kubota Diesel Engine
Table of Contents

Reelmaster 5010- H

Page 3 - 1

Kubota Diesel
Engine

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Traction Unit Operator’s Manual . . . . . . . . . . . . . . . 3
Kubota Workshop Manual . . . . . . . . . . . . . . . . . . . . 3
48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Bellhousing Assembly . . . . . . . . . . . . . . . . 18
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05- E4B SERIES

Kubota Diesel Engine

Specifications
Item

Description

Make / Designation

Kubota Model D1105- E4B: 4- Cycle, 3 Cylinder,
Water Cooled, Tier 4 Diesel Engine

Number of Cylinders

Bore x Stroke

3.07” x 3.09” (78 mm x 78.4 mm)
68.5 in3 (1123 cc)

Total Displacement
Firing Order

1 (fan end) - 2 - 3 (flywheel end)

Direction of Rotation

Counterclockwise (viewed from flywheel)

Fuel

Diesel or Biodiesel (up to B20) Fuel with
Low or Ultra Low Sulfur Content

Fuel Injection Pump

Bosch MD Type Mini Pump

Injection Nozzles

Mini Nozzle (DNOPD)

Fuel Tank Capacity

14 U.S. Gallons (53 Liters)

Governor

All Speed Mechanical

Low Idle Speed (no load)

1400 RPM

High Idle Speed (no load)

3000 RPM

Engine Oil

API CH- 4, CI- 4 or higher

Engine Oil Viscosity

See Traction Unit Operator’s Manual

Oil Pump

Gear Driven Trochoid Type

Crankcase Oil Capacity

3.5 U.S. Quarts (3.3 Liters) with Filter

Cooling System Capacity (including reserve tank)

5.5 U.S. Quarts (5.2 Liters)

Starter

12 VDC 1.4 KW

Alternator/Regulator

12 VDC 40 Amp

Dry Weight (approximate)

205 lb. (93 kg)

NOTE: The Kubota engine used in your Reelmaster is
equipped with a mechanical governor as listed above.
During normal machine operation however, engine
speed control is electronically managed by the machine
TEC controller, the 48 VDC motor/generator controller
and the engine mounted fuel actuator. These three (3)
machine components determine engine/generator
speed during use and modify fuel settings at the fuel actuator as necessary to maintain appropriate engine
speed based on load.
Kubota Diesel Engine

Page 3 - 2

Reelmaster 5010- H

General Information
This Chapter gives information about specifications,
troubleshooting, testing and repair of the Kubota diesel
engine used in Reelmaster 5010- H machines.
Most repairs and adjustments require tools which are
commonly available in many service shops. The use of
some specialized test equipment is explained in the engine Kubota Workshop Manual included at the end of
this chapter. However, the cost of the test equipment
and the specialized nature of some repairs may dictate
that the work be done at an engine repair facility.

Service and repair parts for Kubota diesel engines are
supplied through your local Toro Distributor. If an engine
parts list is not available, be sure to provide your distributor with the Toro model and serial number.

Kubota Diesel
Engine

Traction Unit Operator’s Manual
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for the Kubota diesel engine that
powers your Reelmaster machine. The Kubota Operator’s Manual includes information specific to the engine
used in your Reelmaster. Refer to these publications for
additional information when servicing the machine.

Kubota Workshop Manual
The engine that powers your Reelmaster machine is a
Kubota model D1105- E4B (Tier 4 compliant). The Kubota Workshop Manual, Diesel Engine, 05- E4B Series is
available for this engine. Make sure that the correct engine manual is used when servicing the engine on your
Reelmaster.

48 VDC Battery Disconnect

CAUTION

FRONT

Before installing, removing or servicing components in the 48 VDC system (e.g. cutting unit motors, motor/generator), separate the 48 VDC battery disconnect. This will prevent unexpected
operation of 48 VDC system components.
The 48 VDC battery disconnect is attached to the right
frame rail under the operator seat (Fig. 1). Unplug the
disconnect to make sure that 48 VDC components do
not operate unexpectedly. Apply dielectric grease to the
contact surfaces of the battery disconnect and plug the
battery disconnect back in after service to the 48 VDC
system is completed.
Figure 1
1. RH frame rail

Reelmaster 5010- H

Page 3 - 3

2. 48V battery disconnect

Kubota Diesel Engine

Service and Repairs
Air Cleaner Assembly

30 to 40 in- lb
(3.4 to 4.5 N- m)

Thread
Sealant

3
10

2
4
9
3

11
12

12
13

30 to 40 in- lb
(3.4 to 4.5 N- m)

16
17
15

RIGHT
12

FRONT

Figure 2
1.
2.
3.
4.
5.
6.

Diesel engine
Air cleaner assembly
Hose clamp (4 used)
Air intake hose
Air intake hose
Service indicator

Kubota Diesel Engine

7.
8.
9.
10.
11.
12.

Indicator adapter
Shoulder bolt
Nut
Compression spring
Air cleaner mounting band
Flange nut (6 used)

Page 3 - 4

13.
14.
15.
16.
17.

Flange head screw (2 used)
Cap screw (2 used)
Flange head screw (2 used)
Air cleaner bracket
Air cleaner stand

Reelmaster 5010- H

Removal (Fig. 2)
12 to 15 in- lb
(1.4 to 1.6 N- m)

1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch. Raise and support hood.
2. Remove air cleaner components as needed using
Figure 2 as a guide.

3. See Traction Unit Operator’s Manual for air cleaner
service and maintenance procedures.

IMPORTANT: Any leaks in the air filter system will
allow dirt into engine and will cause serious engine
damage. Make sure that all air cleaner components
are in good condition and are properly secured during assembly.

Thread
Sealant

1. Assemble air cleaner system using Figure 2 as a
guide.
A. If service indicator (item 6 in Fig. 2) and adapter
(item 7 in Fig. 2) were removed from air cleaner
housing, apply thread sealant to adapter threads before installing adapter and indicator to housing.
Install adapter so that grooves in adapter hex and
adapter filter element are installed toward service indicator (shown in Fig. 3). Torque indicator from 12 to
15 in- lb (1.4 to 1.6 N- m).

Figure 3
1. Air cleaner assembly
2. Service indicator

3. Indicator adapter
4. Evacuator valve

B. Make sure that evacuator valve on air cleaner assembly is pointed down after assembly.
C. Torque hose clamps from 30 to 40 in- lb (3.4 to
4.5 N- m).
2. After air cleaner has been properly installed, lower
and secure hood.

Reelmaster 5010- H

Page 3 - 5

Kubota Diesel Engine

Kubota Diesel
Engine

Installation (Fig. 2)

Exhaust System
11

12
13
14
17

3
4

15
16

RIGHT

FRONT

Figure 4
1.
2.
3.
4.
5.
6.

Diesel engine
Exhaust muffler
Clamp
Hex nut (2 used)
Flange nut (4 used)
Carriage bolt (4 used)

Kubota Diesel Engine

7.
8.
9.
10.
11.
12.

Bellhousing
Tailpipe bracket
Flange head screw
Flange nut
Exhaust header
Flange nut (4 used)

Page 3 - 6

13.
14.
15.
16.
17.

Exhaust gasket
Flange head screw (6 used)
Muffler guard
Washer head screw (2 used)
Muffler bracket

Reelmaster 5010- H

3. Adjust muffler guard (item 15) on frame so there is
⅜” (9.5 mm) clearance between exhaust tailpipe and
guard in all directions.

Removal (Fig. 4)

CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system.

4. After all exhaust components have been installed,
lower and secure hood.

D
C

1. Raise and support hood to gain access to exhaust
system. Allow engine and exhaust system to cool before
doing any disassembly of exhaust system components.
2. Remove exhaust system components from the engine as necessary using Figure 4 as a guide. Discard exhaust gasket (item 13) if exhaust header (item 11) was
removed.

Installation (Fig. 4)
IMPORTANT: If exhaust studs were removed from
engine cylinder head, thoroughly clean threads in
head and apply Loctite #277 (or equivalent) to stud
threads before installing studs into head.
NOTE: Make sure that all exhaust system flanges and
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Install new exhaust gasket (item 13) if gasket was
removed. Do not use any type of gasket sealant on gasket or flange surfaces.

E
F
Figure 5

2. Install all removed exhaust system components using Figure 4 as a guide. Hand tighten exhaust system
fasteners and after all exhaust system components
have been installed, fully tighten the fasteners as shown
in Figure 5:
A. Tighten flange head screws that secure muffler
bracket to engine bellhousing.
B. Tighten carriage screws and flange nuts that secure exhaust muffler to muffler bracket.
C. Tighten flange nuts that secure exhaust header
to engine exhaust manifold.
D. Tighten clamp that secures exhaust muffler to exhaust header.
E. Tighten flange head screw and flange nut that secures exhaust muffler to tailpipe bracket.
F. Tighten flange head screws that secure tailpipe
bracket to engine bellhousing.

Reelmaster 5010- H

Page 3 - 7

Kubota Diesel Engine

Kubota Diesel
Engine

Fuel System

RIGHT
18

FRONT

12
3

16
15

11
12

14
13

Figure 6
1.
2.
3.
4.
5.
6.
7.

Fuel tank
Fuel tank cap
Screw (7 used)
Strap
Sender cover
Hose clamp
Fuel supply hose

8.
9.
10.
11.
12.
13.
14.

Hose clamp
Fuel return hose
Clamp (2 used)
Flange head screw (2 used)
Flange nut (3 used)
Draincock
Hose clamp

15.
16.
17.
18.
19.
20.

Cap screw
Flat washer
Bumper
Fuel sender cap
Fuel sender
Gasket

Check Fuel Lines and Connections

DANGER
Because diesel fuel is 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.

Kubota Diesel Engine

Check fuel lines and connections periodically as recommended in the Traction Unit Operator’s Manual. Check
lines for deterioration, damage, leakage or loose connections. Replace fuel hoses, clamps and connections
as necessary.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommended in the Traction Unit Operator’s Manual. Also,
drain and clean the fuel tank if the fuel system becomes
contaminated or if the machine is to be stored for an extended period.

Page 3 - 8

Reelmaster 5010- H

To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of all contaminates and debris.

Fuel Tank Installation (Fig. 6)
1. Install fuel tank to frame using Figure 6 as a guide.
Secure fuel hoses with cable ties as noted during fuel
tank removal.
A. If fuel sender was removed from fuel tank, make
sure that fuel fittings on sender are orientated at 90o
from right side of tank as shown in Figure 7. Also, to
prevent damage to fuel sender during assembly,
make sure that fuel sender does not turn as sender
cap is tightened.

Priming the Fuel System
The fuel system needs to be primed before starting the
engine for the first time, after running out of fuel or after
fuel system maintenance (e.g. draining the filter/water
separator, replacing a fuel hose). To prime the fuel system, make sure that the fuel tank has fuel in it. Then, turn
the ignition key to the RUN position for ten (10) to fifteen
(15) seconds which allows the fuel pump to prime the
fuel system. DO NOT use the engine starter motor to
crank the engine in order to prime the fuel system.
Fuel Tank Removal (Fig. 6)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Place drain pan under fuel tank. Make sure that drain
pan is large enough to hold fuel tank contents (see
Specifications in this chapter).

2. Correctly connect supply (item 7) and return (item 9)
fuel hoses to fittings on the top of the fuel sender. Secure
fuel hoses with hose clamps.
3. Secure wire harness connector to fuel sender.
4. Make sure that fuel tank draincock is closed. Fill fuel
tank with clean fuel.
5. Prime the fuel system (see above).
6. Before returning machine to operation, make sure
that no fuel leaks exist.
1

3. Open draincock on bottom of fuel tank and allow tank
to fully drain. Close draincock.

4. Disconnect wire harness connection from the fuel
sender (item 19).
NOTE: Before removing fuel hoses from tank fittings,
label hoses for assembly purposes.

IMPORTANT: To prevent damage to fuel hoses, numerous cable ties are used to secure hoses to machine components. Take note of all cable ties that
are removed from machine during fuel tank removal
so they can be properly replaced during tank installation.
5. Loosen hose clamps and carefully disconnect supply (item 7) and return (item 9) fuel hoses from fittings
on the top of the fuel sender.

FRONT

Figure 7
1. Fuel sender
2. Fuel supply fitting

3. Fuel return fitting

6. Remove fuel tank using Figure 6 as a guide.
IMPORTANT: If fuel sender is removed from fuel
tank, note orientation of fittings for assembly purposes (Fig. 7).

Reelmaster 5010- H

Page 3 - 9

Kubota Diesel Engine

Kubota Diesel
Engine

IMPORTANT: Follow all local codes and regulations when recycling or disposing waste fuel.

Radiator Assembly
11

6
1

14
15

3
2
26
20 25

10
23
5

27
30

RIGHT
FRONT
30 to 40 in- lb
(3.4 to 4.5 N- m)

Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Coolant reservoir
Hose clamp (3 used)
Hose
Foam seal (2 used)
Oil cooler
Hose
Hose clamp (4 used)
Foam seal (2 used)
Radiator cap
Flange nut (14 used)
Rear screen

Kubota Diesel Engine

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Foam seal
Spacer (5 used)
Flange head screw (5 used)
Air intake screen
Draincock
Foam seal (2 used)
Radiator
Radiator frame
Reservoir bracket
Reservoir bracket

Page 3 - 10

22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

Upper radiator hose
Lower radiator hose
Fan shroud
Flange head screw
Lock nut
Flange head screw (9 used)
Foam seal (2 used)
Foam seal (2 used)
Mount plate (2 used)
Washer head screw (6 used)

Reelmaster 5010- H

Removal (Fig. 8)
30 to 40 in- lb
(3.4 to 4.5 N- m)

1. Park machine on a level surface, lower cutting
decks, stop engine, apply parking brake and remove
key from the ignition switch.
2. Unlatch rear screen, lift screen from hinges and remove screen from machine.

RIGHT
3

FRONT

3. Remove 12 volt battery from rear of machine to ease
oil cooler removal (see 12 VDC Battery Service in the
Service and Repairs section of Chapter 5 - Electrical
System).
4. Rotate clamps that secure oil cooler to radiator
frame. Carefully lift and remove oil cooler from radiator
frame. Position and support oil cooler away from the radiator.

5. Raise and support the hood.

4
30 to 40 in- lb
(3.4 to 4.5 N- m)

CAUTION
Figure 9
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.
6. Drain radiator into a suitable container either by using the draincock (item 16) on the left side of the radiator
or by disconnecting the lower radiator hose from the radiator. Make sure that drain container is large enough to
hold cooling system contents (see Specifications in this
Chapter).

1. Fan shroud
2. Air cleaner intake hose
3. Hose clamp

4. Generator intake hose
5. Hose clamp

12.Plug radiator and hose openings to prevent contamination.
13.Disassemble radiator assembly as needed using
Figure 8 as a guide.
Installation (Fig. 8)
1. Inspect all foam seals placed between radiator, fan
shroud and radiator frame. Replace damaged foam
seals.

IMPORTANT: Follow all local codes and regulations when recycling or disposing engine coolant.

2. Remove plugs placed in radiator and hose openings
during the removal procedure.

7. Disconnect air cleaner and motor/generator intake
hoses from fan shroud (Fig. 9).

3. Install all removed components to radiator frame using Figure 8 as a guide.

8. Disconnect radiator hoses (upper and lower) from
the radiator.

4. Carefully lower radiator assembly with radiator, fan
shroud, coolant reservoir and radiator frame to the machine frame.

9. At rear of radiator frame, carefully cut the upright
foam seals (item 4) at the junction of the radiator frame
and the machine frame. This will allow the radiator frame
to be removed from the machine without removing the
foam seal from the radiator and machine frames.
10.Remove six (6) washer head screws (item 31) that
secure the radiator frame (item 19) to the frame.
11. Carefully raise radiator assembly (radiator, fan
shroud, coolant reservoir and radiator frame) from the
machine.
Reelmaster 5010- H

5. Secure the radiator frame (item 19) to the frame with
six (6) washer head screws (item 31).
6. Make sure that at least 0.250” (6.4 mm) clearance
exists at all points between fan shroud opening and fan.
7. Connect upper and lower radiator hoses to radiator
and secure with hose clamps. Torque hose clamps from
30 to 40 in- lb (3.4 to 4.5 N- m).

Page 3 - 11

Kubota Diesel Engine

Kubota Diesel
Engine

8. Connect air cleaner and motor/generator intake
hoses to fan shroud and secure with hose clamps (Fig.
9). Torque hose clamps from 30 to 40 in- lb (3.4 to 4.5
N- m).

12.Carefully position and install oil cooler to radiator
frame. Rotate clamps to secure oil cooler to radiator
frame.

9. Make sure radiator draincock is closed (threaded out
fully).

13.Install 12 volt battery (see 12 VDC Battery Service
in the Service and Repairs section of Chapter 5 - Electrical System).

10.Fill radiator and coolant reservoir with coolant.

14.Install and latch rear screen.

11. Lower and secure hood.

Kubota Diesel Engine

Page 3 - 12

Reelmaster 5010- H

Kubota Diesel
Engine

This page is intentionally blank.

Reelmaster 5010- H

Page 3 - 13

Kubota Diesel Engine

Engine

30 to 40 in- lb
(3.4 to 4.5 N- m)

Thread
Sealant

22
19
32 46

12
44
27
26

6
44
29

43 7

34
37

15
42
41
45
7

13
34 to 42 ft- lb
(47 to 56 N- m)

7
21

39 31
2

3
5
10

RIGHT

7
8

FRONT
4
6

Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Diesel engine
Cap screw (12 used)
Flange head screw (4 used)
Snubbing washer (4 used)
Cap screw (4 used)
Flange nut (8 used)
Flange nut (8 used)
Spacer (4 used)
Lock washer (12 used)
Engine mount (2 used)
RH engine mount
Exhaust gasket
Bellhousing
Flange nut (4 used)
Tailpipe bracket
Service indicator

Kubota Diesel Engine

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

Air cleaner assembly
Air intake hose
Air intake hose
Air cleaner bracket
Air cleaner stand
Hose clamp (4 used)
Indicator adapter
Muffler bracket
Exhaust header
Exhaust muffler
Clamp
Flange head screw (2 used)
Nut
Air cleaner mounting band
Cap screw (2 used)

Page 3 - 14

32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.

Compression spring
Muffler guard
Washer head screw (2 used)
Temperature sender
Socket head screw (2 used)
Fuel actuator
LH engine mount
Extension spring
Throttle spring bracket
Cap screw
Cap screw
Fuel actuator gasket
Flange head screw (6 used)
Carriage bolt (4 used)
Shoulder bolt

Reelmaster 5010- H

Engine Removal (Fig. 10)
2

FRONT

1. Park machine on a level surface, lower cutting units,
stop engine and remove key from the ignition switch.
Chock wheels to keep the machine from moving.
2. Disconnect negative (- ) and then positive (+) battery
cables from the 12 volt battery at the rear of the machine
(see 12 VDC Battery Service in the Service and Repairs
section of Chapter 5 - Electrical System).

3. Open and support hood.

5. Remove air cleaner from machine (see Air Cleaner
Assembly in this section).

Figure 11
1. Fuel supply hose
2. Hose clamp
3. Fuel return hose

6. Remove exhaust muffler from machine (see Exhaust System in this section).

Kubota Diesel
Engine

4. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect.
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation.

4. Hose clamp
5. Separator

CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

2
3

Ethylene- glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
7. Drain radiator into a suitable container either by using the draincock on the left side of the radiator or by disconnecting the lower radiator hose from the radiator.
Make sure that drain container is large enough to hold
cooling system contents (see Specifications in this
Chapter).

4
Figure 12
1. Fuel actuator
2. Fuel actuator connector

3. Wire harness ground
4. Negative battery cable

IMPORTANT: Follow all local codes and regulations when recycling or disposing engine coolant.
8. Disconnect hoses from engine:

A. Loosen clamps and remove upper and lower radiator hoses from the engine.

B. Disconnect fuel supply and return hoses from engine (Fig. 11).
C. Plug disconnected hoses and engine openings to
prevent leakage and contamination. Position disconnected hoses away from engine.

Reelmaster 5010- H

4
5
3

Figure 13
1. Engine mount (4 used)
2. Screw (2 per mount)
3. Nut (2 per mount)

Page 3 - 15

4. Lock washer
5. Ground cable

Kubota Diesel Engine

9. Disconnect hydraulic pump drive shaft from 48 VDC
motor/generator (see Hydraulic Pump Drive Shaft in the
Service and Repairs section of Chapter 4 - Hydraulic
System). Position and support drive shaft away from
motor/generator and engine.
IMPORTANT: To prevent damage to electrical wire
harness, numerous cable ties are used to secure
harness to machine components. Take note of all
cable ties that are removed from machine during
engine removal so they can be properly replaced
during engine installation.
10.Note location of cable ties used to secure wire harness to the machine for assembly purposes. Disconnect
wires and/or electrical connections from the following
engine electrical components:
A. The wire harness connectors from the alternator,
temperature sender, oil pressure switch, starter motor solenoid and fuel actuator.
B. The wire harness ring terminals from the alternator and glow plug bus.
C. The positive battery cable and fusible link harness from the engine starter motor.
D. The negative battery cable and wire harness
ground at the engine block under the fuel actuator
(Fig. 12).
E. The wire harness connector from the 48 VDC
motor/generator assembly.

CAUTION
Make sure that hoist or lift used to remove engine assembly can properly support engine and
attached components. Engine assembly weighs
approximately 280 pounds (127 kg).
11. Connect suitable lift or hoist to the lift brackets on
each end of the engine cylinder head.
12.Remove flange nuts, rebound washers, spacers and
cap screws that secure the engine mount brackets to
the engine mounts.

IMPORTANT: Make sure to not damage the engine,
fuel hoses, hydraulic lines, electrical harness, radiator or other parts while removing the engine.
13.Carefully raise engine from machine moving it toward the front of the machine and away from radiator assembly.
14.If necessary, remove engine mount brackets from
engine.
15.If necessary, remove engine mounts from machine
frame (Fig. 13). Note that front engine mount on left side
of machine has the negative battery cable ground connection secured with one of the mount bolts. If removed,
make sure to locate lock washer that should be installed
between the cable connection and the frame.
16.If necessary, remove 48 VDC motor/generator from
engine (see 48 VDC Motor/Generator Assembly in the
Service and Repairs section of Chapter 5 - Electrical
System).
Engine Installation (Fig. 10)
1. Locate machine on a level surface with cutting units
lowered and key removed from the ignition switch.
Chock wheels to keep the machine from moving.
2. Make sure that all parts removed from the engine
during maintenance or rebuilding are installed to the engine.
3. If engine mount brackets were removed from the engine, secure brackets to engine with lock washers and
cap screws. Torque cap screws from 34 to 42 ft- lb (47
to 56 N- m).
4. If removed, install 48 VDC motor/generator and bellhousing assembly to engine (see 48 VDC Motor/Generator Assembly in the Service and Repairs section of
Chapter 5 - Electrical System).
5. If removed, secure engine mounts to frame machine
frame (Fig. 13). Make sure that negative battery cable
ground connection is secured with lock washer between
the cable connection and the frame if front engine mount
on left side of machine was removed.
6. Connect suitable lift or hoist to the engine lift brackets.

CAUTION
One person should operate hoist or lift while a
second person guides the engine out of the machine.

Kubota Diesel Engine

Page 3 - 16

Reelmaster 5010- H

12.Install air cleaner (see Air Cleaner Assembly in this
section).

One person should operate lift or hoist while a
second person guides the engine into the machine.
IMPORTANT: Make sure to not damage the engine,
fuel hoses, hydraulic lines, electrical harness, radiator or other parts while installing the engine.

13.Install exhaust muffler to machine (see Exhaust System in this section). Make sure that exhaust tube has ⅜”
(9.5 mm) clearance with guard in all directions after assembly.
14.Make sure radiator draincock is closed (threaded out
fully). Fill radiator and coolant reservoir with coolant.
15.Check engine oil level and adjust if needed.

7. Carefully lower engine to the mounts secured to the
machine frame. Make sure fastener holes of the engine
mount brackets are aligned with the holes in the engine
mounts.

16.Check and adjust oil level in hydraulic reservoir as
needed.

8. Insert cap screw down through each engine mount
bracket and mount. Place spacer, snubbing washer and
then flange nut on four (4) cap screws. Tighten fasteners
to secure engine to engine mounts.

18.Close and secure hood.

9. Connect hydraulic pump drive shaft to motor/generator output shaft (see Hydraulic Pump Drive Shaft in the
Service and Repairs section of Chapter 4 - Hydraulic
System).
10.Connect all wire harness connectors to correct engine components. Secure wire harness to the machine
with cable ties in locations noted during engine removal.

17.Plug the 48 VDC battery disconnect back in.

19.Connect positive (+) and then negative (- ) battery
cables to the 12 volt battery (see 12 VDC Battery Service in the Service and Repairs section of Chapter 5 Electrical System).
20.Prime the fuel system (see Fuel System in this section).
21.Start engine and operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System
in the Service and Repairs section of Chapter 4 - Hydraulic System).

11. Remove plugs installed in fuel and coolant hoses
and engine openings during disassembly. Connect
hoses to the engine:
A. Connect fuel supply and fuel return hoses to engine fittings (Fig. 11). Secure fuel hoses with hose
clamps.
B. Connect upper and lower radiator hoses to the
engine. Secure hoses with hose clamps. Torque
hose clamps from 30 to 40 in- lb (3.4 to 4.5 N- m).

Reelmaster 5010- H

Page 3 - 17

Kubota Diesel Engine

Kubota Diesel
Engine

CAUTION

Engine Bellhousing Assembly

50 to 60 ft- lb
(68 to 81 N- m)
1
20

19
18
Antiseize
Lubricant

7
9
8

2
5

Antiseize
Lubricant

14
3

12
10

RIGHT

13
25 to 31 ft- lb
(34 to 42 N- m)

FRONT

Figure 14
1.
2.
3.
4.
5.
6.
7.

Diesel engine
Motor/generator assembly
Flange head screw
Collar
Coupler hub
Woodruff key
Bellhousing

8.
9.
10.
11.
12.
13.
14.

Cap screw (2 used)
Flat washer (2 used)
Flange head screw (7 used)
Flange nut (2 used)
R- clamp (for generator wire harness)
Clamp (for fuel return hose)
Caplug

15.
16.
17.
18.
19.
20.

Flange head screw (6 used)
Dowel pin (2 used)
Coupler flange
Socket head screw (3 used)
Muffler bracket
Flange head screw (4 used)

The 48 VDC motor/generator is attached to the engine
bellhousing with six (6) flange head screws. Access to
these screws requires the bellhousing and motor/generator to be removed from the engine as an assembly. For
recommended procedures to remove the bellhousing
and motor/generator assembly from the engine, see 48
VDC Motor/Generator Assembly in the Service and Repairs section of Chapter 5 - Electrical System.

Kubota Diesel Engine

Page 3 - 18

Reelmaster 5010- H

Chapter 4

Hydraulic System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Traction Unit Operator’s Manual . . . . . . . . . . . . . . 3
48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 3
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3
Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hose and Tube Installation . . . . . . . . . . 5
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 6
Relieving Hydraulic System Pressure . . . . . . . . . . 8
Traction Circuit Component Failure . . . . . . . . . . . . 8
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 12
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lift Circuit: Raise Cutting Units . . . . . . . . . . . . . . . 14
Lift Circuit: Lower Cutting Units . . . . . . . . . . . . . . 16
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 25
General Hydraulic System Problems . . . . . . . . . . 25
Traction Circuit Problems . . . . . . . . . . . . . . . . . . . 26
Lift Circuit Problems . . . . . . . . . . . . . . . . . . . . . . . . 27
Steering Circuit Problems . . . . . . . . . . . . . . . . . . . 28
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Traction Circuit Relief Valve (R3) and (R4)
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Traction Circuit Charge Pressure Test . . . . . . . . . 34
Gear Pump (P2) Flow Test . . . . . . . . . . . . . . . . . . 36
Front Wheel Motor Efficiency Test . . . . . . . . . . . . 38
Piston (Traction) Pump Flow Test . . . . . . . . . . . . 40
Lift Relief Valve (SVRV) Pressure Test . . . . . . . . 42
Gear Pump (P1) Flow Test . . . . . . . . . . . . . . . . . . 44
Lift Cylinder Internal Leakage Test . . . . . . . . . . . . 46
Steering Relief Valve (R10) Pressure Test . . . . . 48
Steering Cylinder Internal Leakage Test . . . . . . . 50

Reelmaster 5010- H

SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 52
General Precautions for Removing and Installing
Hydraulic System Components . . . . . . . . . . . . . 52
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 53
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 54
Filtering Closed- Loop Traction Circuit . . . . . . . . 55
Hydraulic System Start- up . . . . . . . . . . . . . . . . . . 56
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 58
Piston (Traction) Pump Control Assembly . . . . . 60
Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . 62
Piston (Traction) Pump Service . . . . . . . . . . . . . . 66
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Pump Drive Shaft . . . . . . . . . . . . . . . . . 70
Hydraulic Pump Drive Shaft Cross and
Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . 74
Front Wheel Motor Service . . . . . . . . . . . . . . . . . . 76
Rear Wheel Motors (Machines with Optional
CrossTraxTM Kit) . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rear Wheel Motor Service (Machines with Optional
CrossTraxTM Kit) . . . . . . . . . . . . . . . . . . . . . . . . . 80
Control Manifold Cartridge Valve Service . . . . . . 81
Lift Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . 82
Lift Control Manifold Service . . . . . . . . . . . . . . . . . 84
CrossTraxTM AWD Manifold (Machines with
Optional CrossTraxTM Kit) . . . . . . . . . . . . . . . . . 86
CrossTraxTM AWD Manifold Service (Machines
with Optional CrossTraxTM Kit) . . . . . . . . . . . . . 88
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . 92
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . 94
Steering Control Valve Service . . . . . . . . . . . . . . . 96
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Steering Cylinder Service . . . . . . . . . . . . . . . . . . 100
Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . 102
SAUER- DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS REPAIR MANUAL
SAUER- DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS SERVICE INSTRUCTIONS
EATON DELTA MOTORS PARTS AND REPAIR
MANUAL
PARKER TORQMOTORTM SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER- DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL

Page 4 - 1

Hydraulic System

Hydraulic
System

Table of Contents

Specifications
Item

Description

Piston (Traction) Pump
Maximum Pump Displacement (per revolution)

Closed Circuit Axial Piston Design
2.14 Cubic Inches (35 cc)

Gear Pump
Section P1 Displacement (per revolution) (all models)
Section P2 Displacement (per revolution) (all models)

2 Section, Positive Displacement Gear Type Pump
0.24 Cubic Inches (3.96 cc)
0.40 Cubic Inches (6.61 cc)

Charge Circuit Relief (R5) Pressure

200 PSI (14 bar)

Traction Circuit Relief Pressure: Forward (R3) and Reverse (R4)

3625 PSI (250 bar)

Front Wheel Motors
Displacement (per revolution)

Geroler Motor
24.7 in3 (405 cc)

Rear Wheel Motors (if equipped)
Displacement (per revolution)

Rotor Motor
19.0 in3 (310 cc)

Steering Valve
Displacement (per revolution)

Hydrostatic Steering Unit, Open Center
6.1 in3 (100 cc)

Steering Circuit Relief (R10) Pressure

1000 PSI (70 bar)

Lift Circuit Relief (SVRV) Pressure

2000 PSI (138 bar)

Lift Circuit Lower Relief (R7) Pressure
Hydraulic Filter (Steering Circuit)

500 PSI (35 bar)
Spin- on Cartridge Type with 25 PSI (1.7 bar) Relief in Adapter

Hydraulic Oil

See Traction Unit Operator’s Manual

Hydraulic Reservoir Capacity

Hydraulic System

11 U.S. Gallons (41.6 L)

Page 4 - 2

Reelmaster 5010- H

General Information
Traction Unit Operator’s Manual
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for your Reelmaster machine.
Refer to that publication for additional information when
servicing the machine.

48 VDC Battery Disconnect

CAUTION

FRONT
1

Hydraulic
System

Figure 1
1. RH frame rail

2. 48V battery disconnect

Check Hydraulic Fluid
The hydraulic system on Reelmaster 5010- H machines
is designed to operate on high quality hydraulic fluid.
The hydraulic system reservoir holds approximately 11
gallons (41.6 liters) of hydraulic fluid. Check level of hydraulic fluid daily. See Traction Unit Operator’s Manual for fluid level checking procedure and hydraulic oil
recommendations.

1
2

Figure 2
1. Hydraulic reservoir

Reelmaster 5010- H

Page 4 - 3

2. Cap with dipstick

Hydraulic System

Towing Traction Unit
IMPORTANT: If towing limits are exceeded, severe
damage to the piston (traction) pump may occur.

If it becomes necessary to tow or push the machine, tow
or push at a speed below 3 mph (4.8 kph), and for a very
short distance. If the machine needs to be moved a considerable distance, machine should be transported on a
trailer. The piston (traction) pump is equipped with a bypass valve that needs to be loosened for towing or pushing (Fig. 3). See Traction Unit Operator’s Manual for
Towing Procedures.

Figure 3
1. Piston (traction) pump

2. Bypass valve

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 hose damage and deterioration. Some hoses are more susceptible to these
conditions than others. Inspect all machine hydraulic
hoses frequently for signs of deterioration or damage:
Hard, cracked, cut, abraded, charred, leaking or
otherwise damaged hose.
Kinked, crushed, flattened or twisted hose.
Blistered, soft, degraded or loose hose cover.
Cracked, damaged or badly corroded hose fittings.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint (layline) on
the hose. Use two wrenches when tightening a hose;
hold the hose straight with one wrench and tighten the
hose swivel nut onto the fitting with the second wrench
(see Hydraulic Hose and Tube Installation in this section). If the hose has an elbow at one end, tighten the
swivel nut on that end before tightening the nut on the
straight end of the hose.

WARNING
Before disconnecting or performing any work on
hydraulic system, relieve all pressure in system
(see Relieving Hydraulic System Pressure in this
section).
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. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.

For additional hydraulic hose information, refer to Toro
Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).

Hydraulic System

Page 4 - 4

Reelmaster 5010- H

Hydraulic Hose and Tube Installation (O- Ring Face Seal Fitting)
1. Make sure threads and sealing surfaces of the hose/
tube and the fitting are free of burrs, nicks, scratches or
any foreign material.

C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The
markings on the nut and fitting body will verify that the
connection has been properly tightened.

2. As a preventative measure against leakage, it is recommended that the face seal O- ring be replaced any
time the connection is opened. Make sure the O- ring is
installed and properly seated in the fitting groove. Lightly
lubricate the O- ring with clean hydraulic oil.

Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)

3. Place the hose/tube against the fitting body so that
the flat face of the hose/tube sleeve fully contacts the Oring in the fitting.

Swivel Nut

4. Thread the swivel nut onto the fitting by hand. While
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque shown in Figure 6. This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
using a torque wrench with an offset wrench will be lower
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 - Product Records and Maintenance).

Fitting Body

O- ring

Hydraulic
System

Tube or Hose

Figure 4

5. If a torque wrench is not available or if space at the
swivel nut prevents use of a torque wrench, an alternate
method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 2).
A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approximately 30 in- lb).

F.F.W.R.
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/3 to 1/2
1/3 to 1/2

Mark Nut
and Fitting
Body

Final
Position

Initial
Position

Extend Line
AT WRENCH RESISTANCE

B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.

AFTER TIGHTENING

Figure 5

Fitting Dash Size

Hose/Tube Side Thread Size

Installation Torque

9/16 - 18

18 to 22 ft- lb (25 to 29 N- m)

11/16 - 16

27 to 33 ft- lb (37 to 44 N- m)

13/16 - 16

37 to 47 ft- lb (51 to 63 N- m)

1 - 14

60 to 74 ft- lb (82 to 100 N- m)

1 3/16 - 12

85 to 105 ft- lb (116 to 142 N- m)

1 7/16 - 12

110 to 136 ft- lb (150 to 184 N- m)

1 11/16 - 12

140 to 172 ft- lb (190 to 233 N- m)
Figure 6

Reelmaster 5010- H

Page 4 - 5

Hydraulic System

Hydraulic Fitting Installation (SAE Straight Thread O- Ring Fitting into Component Port)
Non- Adjustable Fitting (Fig. 7)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.

5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method.

2. As a preventative measure against leakage, it is recommended that the O- ring be replaced any time the
connection is opened.
3. Lightly lubricate the O- ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 8.

A. Install the fitting into the port and tighten it down
full length until finger tight.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)

NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 - Product
Records and Maintenance to determine necessary conversion information.

F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25

Fitting

O- ring

Figure 7

Fitting
Dash Size

Fitting Port Side
Thread Size

Installation Torque Into
Steel Port

Installation Torque Into
Aluminum Port

7/16 - 20

15 to 19 ft- lb (21 to 25 N- m)

9 to 11 ft- lb (13 to 15 N- m)

1/2 - 20

18 to 22 ft- lb (25 to 29 N- m)

11 to 15 ft- lb (15 to 20 N- m)

9/16 - 18

34 to 42 ft- lb (47 to 56 N- m)

20 to 26 ft- lb (28 to 35 N- m)

3/4 - 16

58 to 72 ft- lb (79 to 97 N- m)

35 to 43 ft- lb (48 to 58 N- m)

7/8 - 14

99 to 121 ft- lb (135 to 164 N- m)

60 to 74 ft- lb (82 to 100 N- m)

1 1/16 - 12

134 to 164 ft- lb (182 to 222 N- m)

81 to 99 ft- lb (110 to 134 N- m)

1 3/16 - 12

160 to 196 ft- lb (217 to 265 N- m)

96 to 118 ft- lb (131 to 160 N- m)

1 5/16 - 12

202 to 248 ft- lb (274 to 336 N- m)

121 to 149 ft- lb (165 to 202 N- m)

1 5/8 - 12

247 to 303 ft- lb (335 to 410 N- m)

149 to 183 ft- lb (202 to 248 N- m)

Figure 8

Hydraulic System

Page 4 - 6

Reelmaster 5010- H

Adjustable Fitting (Fig. 9)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is recommended that the O- ring be replaced any time the
connection is opened.

Lock Nut

3. Lightly lubricate the O- ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.

Back- up Washer

4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1 in Figure 10).

O- ring

5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2 in
Figure 10). Make sure that the fitting does not bottom in
the port during installation.
6. To put the fitting in the desired position, unscrew it by
the required amount to align fitting with incoming hose
or tube, but no more than one full turn (Step 3 in Figure
10).
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the lock nut to the
recommended installation torque shown in Figure 8.
This tightening process will require the use of an offset
wrench (e.g. crowfoot wrench). Use of an offset wrench
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be lower than the listed installation torque (see Using a
Torque Wrench with an Offset Wrench in the Torque
Specifications section of Chapter 2 - Product Records
and Maintenance).

Step 1

Step 3

Step 2

Step 4

Hydraulic
System

Figure 9

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.

Figure 10

8. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
with a second wrench to the listed F.F.F.T. (Step 4 in Figure 10). If port material is aluminum, tighten fitting to
60% of listed F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)

Reelmaster 5010- H

F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25

Page 4 - 7

Hydraulic System

Relieving Hydraulic System Pressure
Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system
must be relieved. Park machine on a level surface, lower
cutting units fully, stop engine and engage parking
brake.
To relieve hydraulic pressure in lift circuit, start engine
and fully lower the cutting units. Turn key switch to OFF
and remove key from the ignition switch.

To relieve hydraulic pressure in traction circuit, stop engine and move traction pedal to both forward and reverse directions.
To relieve hydraulic pressure in steering circuit, stop engine and rotate steering wheel in both directions.

Traction Circuit Component Failure
The traction circuit on Reelmaster 5010- H series machines is a closed loop system that includes the piston
(traction) pump and two (2) front wheel motors (four (4)
wheel motors on machines equipped with optional
CrossTraxTM AWD kit). If a component in the traction circuit should fail, debris and contamination from the failed
component will circulate throughout the traction circuit.
This contamination can damage other components in
the circuit so it must be removed to prevent additional
component failure.
The recommended method of removing traction circuit
contamination would be to temporarily install the Toro
high flow hydraulic filter (see Special Tools in this chapter) into the circuit. This filter should be used when connecting hydraulic test gauges in order to test traction
circuit components or after replacing a failed traction circuit component (e.g. traction (piston) pump or wheel
motor). The filter will ensure that contaminates are removed from the closed loop and thus, do not cause additional component damage.
Once the Toro high flow hydraulic filter kit has been
placed in the circuit, raise and support the machine with

Hydraulic System

all wheels off the ground. Then, operate the traction circuit to allow oil flow throughout the circuit. The filter will
remove contamination from the traction circuit during
operation. Because the Toro high flow filter is bi- directional, the traction circuit can be operated in both the forward and reverse direction. The filter should be
removed from the machine after contamination has
been removed from the traction circuit. See Filtering
Closed- Loop Traction Circuit in the Service and Repairs
section of this chapter for additional information on using the Toro high flow hydraulic filter.
The alternative to using the Toro high flow hydraulic filter
kit after a traction circuit component failure would be to
disassemble, drain and thoroughly clean all components, hydraulic tubes and hydraulic hoses in the traction circuit. If any debris remains in the traction circuit
and the machine is operated, the debris can cause additional circuit component failure.
NOTE: The piston (traction) pump case drain could allow traction circuit contamination to contaminate other
hydraulic circuits on the machine.

Page 4 - 8

Reelmaster 5010- H

Hydraulic
System

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Reelmaster 5010- H

Page 4 - 9

Hydraulic System

Hydraulic Schematic

NOTE: A larger hydraulic schematic is
included in Chapter 9 - Foldout Drawings

LIFT
CONTROL
MANIFOLD

Hydraulic System

Page 4 - 10

Reelmaster 5010- H

Hydraulic
System

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Reelmaster 5010- H

Page 4 - 11

Hydraulic System

Figure 11
Page 4 - 12
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Reelmaster 5010- H
Traction Circuit (Forward Shown)

Hydraulic Flow Diagrams

LIFT
CONTROL
MANIFOLD

Reelmaster 5010- H

Traction Circuit

Traction circuit pressure (forward and reverse) can be
measured at test ports located in the hydraulic tubes
that connect the front wheel motors.
NOTE: In high load traction situations, the 48 VDC motor/generator may automatically assist the engine to
maintain piston (traction) pump input speed.
Forward Direction (Fig. 11)
Pushing the top of the traction pedal angles the piston
(traction) pump swash plate to create a flow of oil. This
oil flow is directed to the wheel motors via hydraulic
hoses and tubes to drive the wheels in the forward direction. Forward traction pressure is limited to 3625 PSI
(250 bar) by the forward traction relief valve (R3) located
in the piston (traction) pump.
Oil flowing from the wheel motors returns to the variable
displacement pump and is continuously pumped
through the traction circuit as long as the traction pedal
is pushed.
The angle of the swash plate determines pump flow and
ultimately traction speed. When the traction pedal is depressed a small amount, a small swash plate rotation results in low pump output and lower traction speed. When
the traction pedal is depressed fully, the pump swash
plate rotates fully to provide maximum pump output and
traction speed.

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 piston (traction) pump
swash plate to create a flow of oil. This oil is directed to
the wheel motors to drive the wheels in the reverse
direction. Reverse traction pressure is limited to 3625
PSI (250 bar) by the reverse traction relief valve (R4) located in the piston (traction) pump.
Oil flowing from the wheel motors returns to the piston
(traction) pump and is continuously pumped through the
closed loop traction circuit as long as the traction pedal
is pushed.
The charge circuit and flushing valve function the same
in reverse as they do in the forward direction.
CrossTraxTM AWD (Optional)
On machines equipped with the optional CrossTraxTM
AWD kit, four (4) wheel motors are used (Fig. 12). Piston
(traction) pump flow is directed to the front tires and the
opposite rear tires to maximize traction. To reduce tire
scuffing when turning, traction system pressure is
equalized in the AWD manifold with an orifice and a bidirectional relief valve. Check valves in the AWD manifold allow the rear wheel motors to over run during tight
turns.
CrossTraxTM AWD Hydraulic Schematic

Gear pump section (P2) supplies oil flow for the steering
circuit and also provides a constant supply of charge oil
to the closed loop traction circuit. This charge oil provides lubrication for traction circuit components and also
replenishes traction circuit oil that is lost due to internal
leakage in the traction circuit.
The hydraulic reservoir provides fluid for the gear pump
(P2) through the suction hose. Charge pump flow is directed to the low pressure side of the closed loop traction circuit. Charge pressure is limited by the charge
relief valve (R5) located in the piston (traction) pump.
The charge relief pressure is 200 PSI (14 bar).
The piston pump (P3) includes a flushing valve that
bleeds off a small amount of hydraulic fluid for cooling
of the closed loop traction circuit. The charge system replenishes oil that is bled from the traction circuit by the
flushing valve.
Reelmaster 5010- H

Page 4 - 13

Figure 12
Hydraulic System

Hydraulic
System

The hydraulic traction circuit consists of a variable displacement piston pump (P3) connected in a closed loop,
parallel circuit to two (2) orbital roller vane wheel motors.
The piston (traction) pump input shaft is rotated by a
drive shaft connected to the motor/generator shaft that
is driven by the engine flywheel.

TO STEERING
& CHARGE
CIRCUIT

G4
C4 L

SV1

SV2

CV4

C4
C1 L

SVRV
P1

P2
CV1
T

PUMP (P3)
INTERNAL
CASE
DRAIN

CV5

C5
C5 L

100 MESH
SUCTION
STRAINER

SV3
CV23

C2/3 L

LIFT
CONTROL
MANIFOLD

C2/3

RIGHT
FRONT

FRONT

LEFT
FRONT

CENTER

LEFT
REAR

RIGHT
REAR

Reelmaster 5010- H
Lift Circuit: Raise Cutting Units
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Figure 13

Hydraulic System

Page 4 - 14

Reelmaster 5010- H

Lift Circuit: Raise Cutting Units
A two section gear pump is coupled to the piston (traction) pump. Gear pump section (P1) supplies hydraulic
flow to the lift control manifold and ultimately for the lift
cylinders. The hydraulic reservoir provides fluid for the
gear pump through the suction hose. Lift circuit pressure
is limited to 2000 PSI (138 bar) by a solenoid relief valve
(SVRV) located in the lift control manifold.
The lift control manifold includes four (4) electrically operated solenoid valves. 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. Valve (SV3) allows hydraulic flow to the rear lift cylinders when energized.
Lift circuit pressure can be monitored at lift control manifold port G4.

Raise Cutting Units (Fig. 13)
When the joystick is moved to the raise position, solenoid valve (SVRV) energizes along with solenoid valves
(SV1), (SV2) and (SV3). The energized solenoid valves
direct gear pump section P4 oil flow to the rod end of the
lift cylinders. Hydraulic pressure against the rod side of
the cylinders causes the shafts to retract, and raises the
cutting units. Fixed orifices in the lift control manifold
(C1L, C4L, C5L and C23L) control the lifting speed by
providing a restriction for the return flow from the lift cylinders.
When the joystick is returned to the neutral (center)
position, the lift manifold solenoid valves are de- energized and the lift cylinders (and cutting units) are held in
the raised position. Piloted check valves in the lift control
manifold (CV1, CV4, CV5 and CV23) prevent the lift cylinders (and cutting units) from dropping after they have
been raised.
Hydraulic
System

The TEC controller uses inputs from various machine
switches to determine when lift manifold solenoid valves
(SV1, SV2, SV3 and SVRV) are to be energized. The
TEC also provides a partial raise position of the front outside cutting units.
During conditions of not raising or lowering the cutting
units (joystick in the neutral (center) position), all four (4)
lift manifold solenoid valves (SV1, SV2, SV3 and SVRV)
are de- energized. Hydraulic flow from gear pump section (P1) by- passes the lift cylinders to the oil cooler and
then to the hydraulic reservoir.

Reelmaster 5010- H

Page 4 - 15

Hydraulic System

TO STEERING
& CHARGE
CIRCUIT

G4
C4 L

SV1

SV2

CV4

C1 L
SVRV
P1

P2
CV1
T

PISTON
PUMP (P3)
INTERNAL
CASE
DRAIN

R7
CV5

C5
C5 L

100 MESH
SUCTION
STRAINER

SV3
CV23

LIFT
CONTROL
MANIFOLD

C2/3 L

C2/3

RIGHT
FRONT

FRONT
CENTER

LEFT
FRONT

LEFT

RIGHT

REAR

Reelmaster 5010- H
Lift Circuit: Lower Cutting Units
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Figure 14

Hydraulic System

Page 4 - 16

Reelmaster 5010- H

Lift Circuit: Lower Cutting Units

The lift control manifold includes four (4) electrically operated solenoid valves. Valve (SVRV) is used to direct
gear pump flow to the lift cylinders when energized or
bypass pump flow back to the reservoir when de- energized. Valve (SV2) is used to direct oil flow to retract the
lift cylinders when energized or extend them when deenergized. Valve (SV1) allows hydraulic flow to the front
lift cylinders when energized. Valve (SV3) allows hydraulic flow to the rear lift cylinders when energized.
Lift circuit pressure can be monitored at lift control manifold port G4.
The TEC controller uses inputs from various machine
switches to determine when lift manifold solenoid valves
(SV1, SV2, SV3 and SVRV) are to be energized. The
TEC also provides a partial raise position of the front outside cutting units.
During conditions of not raising or lowering the cutting
units (joystick in the neutral (center) position), all four (4)
lift manifold solenoid valves (SV1, SV2, SV3 and SVRV)
are de- energized. Hydraulic flow from gear pump section (P1) by- passes the lift cylinders to the oil cooler and
then to the hydraulic reservoir.

Reelmaster 5010- H

Lower Cutting Units (Fig. 14)
When the joystick is moved to the lower position, solenoid valve (SVRV) energizes along with solenoid valves
(SV1) and (SV3). Solenoid valve (SV2) is in its normally
de-energized position, and directs oil flow to the piston
end of the lift cylinders. Hydraulic pressure against the
piston side of the cylinder causes the shafts to extend,
and lower the cutting units. The piloted check valves in
the lift control manifold (CV1, CV4, CV5 and CV23) are
shifted by hydraulic pressure to allow return flow from
the extending lift cylinders. Fixed orifices in the lift control manifold (C1, C4, C5 and C23) control the lowering
speed by providing a restriction for the return flow from
the lift cylinders.
Because cutting unit weight assists in extending the lift
cylinders when lowering the cutting units, less hydraulic
pressure is necessary during the cutting unit lowering
operation. Lift circuit lower relief valve (R7) allows lift circuit pressure to be limited to 500 PSI (35 bar) while lowering the cutting units.
NOTE: Adjustment of lift circuit lower relief valve (R7)
is not recommended.
When the joystick is returned to the neutral (center)
position, the solenoid valves are de- energized and the
lift cylinders (and cutting units) are held in the lowered
position.

Page 4 - 17

Hydraulic System

Hydraulic
System

A two section gear pump is coupled to the piston (traction) pump. Gear pump section (P1) supplies hydraulic
flow to the lift control manifold and ultimately for the lift
cylinders. The hydraulic reservoir provides fluid for the
gear pump through the suction hose. Lift circuit pressure
is limited to 2000 PSI (138 bar) by a solenoid relief valve
(SVRV) located in the lift control manifold.

Figure 15

Hydraulic System

Page 4 - 18

Reelmaster 5010- H

STEERING
CYLINDER

STEERING
CONTROL
VALVE

TO TRACTION
CHARGE CIRCUIT

R10

FROM PUMP (P2)

RIGHT TURN

PISTON
MOVEMENT

STEERING
CONTROL
VALVE
STEERING
CYLINDER

TO TRACTION
CHARGE CIRCUIT

PISTON
MOVEMENT

Working Pressure
Low Pressure (Charge)
Return or Suction
Flow

Reelmaster 5010- H
Steering Circuit

R10

FROM PUMP (P2)

LEFT TURN

Steering Circuit

With the steering wheel in the neutral position and the
engine running, flow enters the steering control valve at
the P port and goes through the steering control spool
valve, by- passing the rotary meter (V1) and steering
cylinder. Flow leaves the control valve through the T port
to the hydraulic oil filter and traction charge circuit.
Left Turn (Fig. 15)
When a left turn is made with the engine running, the
turning of the steering wheel positions the steering control spool valve so that flow is directed through the bottom of the spool. Flow entering the steering control valve
at the P port goes through the spool and is routed to two
places. First, most of the flow through the valve is bypassed out the T port back to the hydraulic oil filter and
traction charge circuit. Second, the remainder of the
flow is drawn through the rotary meter (V1) and out the
L port. Pressure contracts the steering cylinder piston
for a left turn. The rotary meter ensures that the oil flow
to the steering cylinder is proportional to the amount of
turning on the steering wheel. Fluid leaving the steering
cylinder flows back through the steering control spool
valve and then out of the steering control valve through
the T port and to the oil filter and traction charge circuit.

Right Turn (Fig. 15)
When a right turn is made with the engine running, the
turning of the steering wheel positions the steering control spool valve so that flow is directed through the top
of the spool. Flow entering the steering control valve at
the P port goes through the spool and is routed to two
places. As in a left turn, most of the flow through the
valve is by- passed out the T port back to the hydraulic
oil filter and traction charge circuit. Also like a left turn,
the remainder of the flow is drawn through rotary meter
(V1) but goes out port R. Pressure extends the steering
cylinder piston for a right turn. The rotary meter ensures
that the oil flow to the steering cylinder is proportional to
the amount of the turning on the steering wheel. Fluid
leaving the steering cylinder flows back through the
steering control spool valve then through the T port and
to the oil filter and traction charge circuit.
The steering control valve returns to the neutral position
when turning is completed.
Hydraulic
System

A two section gear pump is coupled to the piston (traction) pump. Gear pump section P2 supplies hydraulic
flow to the steering control valve and for the traction
charge circuit. The hydraulic reservoir provides fluid for
the gear pump through the suction hose. Steering circuit
pressure is limited to 1000 PSI (70 bar) by a relief valve
(R10) located in the steering control.

The steering control valve returns to the neutral position
when turning is completed.

Reelmaster 5010- H

Page 4 - 19

Hydraulic System

Special Tools
Order these special tools from your Toro Distributor.

Hydraulic Pressure Test Kit
Toro Part Number: TOR47009
Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each: 1000 PSI (70 bar), 5000 PSI (350
bar) and 10000 PSI (700 bar) gauges. Use gauges as
recommended in the Testing section of this chapter.

Figure 16

15 GPM Hydraulic Tester Kit (Pressure and Flow)
Toro Part Number: TOR214678
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. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
3. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
gauge to provide operating circuit pressure.
4. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated from 1 to 15
GPM (5 to 55 LPM).

Figure 17

5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
6. FITTINGS: An assortment of hydraulic fittings are included with this kit.

Hydraulic System

Page 4 - 20

Reelmaster 5010- H

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. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated from 4 to 40
GPM (20 to 150 LPM).
NOTE: This tester does not include hydraulic hoses
(see Hydraulic Hose Kit TOR6007 below).

Figure 18

Hydraulic Hose Kit
Hydraulic
System

Toro Part Number: TOR6007
This kit includes hydraulic fittings and hoses needed to
connect 40 GPM hydraulic tester (AT40002) or high flow
hydraulic filter kit (TOR6011) to machine hydraulic traction system components.

Figure 19

Reelmaster 5010- H

Page 4 - 21

Hydraulic System

High Flow Hydraulic Filter Kit
Toro Part Number: TOR6011
The high flow hydraulic filter kit is designed with large
flow (40 GPM/150 LPM) and high pressure (5000
PSI/345 bar) capabilities. This kit provides for bi- directional filtration which prevents filtered debris from being
allowed back into the circuit regardless of flow direction.
If a component failure occurs in the closed loop traction
circuit, contamination from the failed part will remain in
the circuit until removed. When connecting hydraulic
test gauges in order to test traction circuit components
or after replacing a failed traction circuit component (e.g.
piston pump or wheel motor), the high flow hydraulic filter can be installed in the traction circuit. The filter will
ensure that contaminates are removed from the closed
loop and thus, do not cause additional component damage.

Figure 20

NOTE: This kit does not include hydraulic hoses (see
Hydraulic Hose Kit TOR6007 above).
NOTE: Replacement filter element is Toro part number
TOR6012. Filter element cannister tightening torque is
25 ft- lb (34 N- m).

O- Ring Kit
Toro Part Number: 117- 2727
The O- ring kit includes O- rings in a variety of sizes for
face seal and port seal hydraulic connections. It is recommended that O- rings be replaced whenever a hydraulic connection is loosened.

Figure 21

Hydraulic System

Page 4 - 22

Reelmaster 5010- H

Hydraulic Test Fitting Kit
Toro Part Number: TOR4079

TORO TEST FITTING KIT (TOR4079)

This kit includes a variety of O- ring face seal fittings to
enable the connection of test gauges into the system.
The kit includes: tee’s, unions, reducers, plugs, caps
and male test fittings.

Figure 22

Measuring Container
Toro Part Number: TOR4077

Hydraulic
System

Use this graduated container for doing hydraulic motor
efficiency testing (motors with case drain lines only).
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.
The table in Figure 24 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Figure 23

Figure 24

Reelmaster 5010- H

Page 4 - 23

Hydraulic System

Wheel Hub Puller
The wheel hub puller allows safe removal of the wheel
hub from the wheel motor shaft.
Toro Part Number: TOR6004

Figure 25

Hydraulic System

Page 4 - 24

Reelmaster 5010- H

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.

Continued use of an improperly functioning hydraulic
system could lead to extensive hydraulic component
damage.
The charts that follow contain information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
Refer to the Testing section of this chapter for precautions and specific hydraulic test procedures.

General Hydraulic System Problems
Problem

Possible Cause

Hydraulic oil leaks from machine

Fitting(s), hose(s) or tube(s) is (are) loose or damaged.
O- ring(s) or seal(s) is (are) missing or damaged.
Oil level in hydraulic reservoir is low.
Hydraulic system has wrong kind of oil.
Pump suction line has an air leak.

Hydraulic system operates hot

Traction system pressure is high due to excessive load or brake
dragging or binding.
Oil level in hydraulic reservoir is low.
Hydraulic oil is contaminated or too light.
Engine speed is too low.
Engine fan is not operating properly.
Oil cooler is damaged or plugged. Air flow through oil cooler is obstructed.
Hydraulic oil filter is plugged.
Charge pressure is low.
Piston (traction) pump bypass valve is open or faulty.
Piston (traction) pump check valve is not seating or is damaged.
Wheel motor(s) and/or piston (traction) pump are worn or damaged
(NOTE: If a traction circuit component has internal wear or damage, it is possible that other traction components are also damaged).

Reelmaster 5010- H

Page 4 - 25

Hydraulic System

Hydraulic
System

Foaming hydraulic fluid

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.
Hydraulic oil is very cold.
Parking brake is dragging or binding.
Piston (traction) pump bypass valve is not seated.
Flushing valve in piston (traction) pump is not seating or is damaged.
Piston (traction) pump charge relief valve is not seating or is damaged.
Piston (traction) pump check relief valve is not seating or is damaged (NOTE: Check relief valves for forward and reverse are identical and can be reversed for testing purposes).
Piston (traction) pump is worn or damaged.

No traction in either direction

Parking brake is dragging or binding.
Traction control linkage is misadjusted, disconnected, binding or
damaged.
Oil level in hydraulic reservoir is low (other hydraulic systems affected as well).
Piston (traction) pump bypass valve is loosened.
Flushing valve in piston (traction) pump is not seating or is damaged.
Piston (traction) pump check valve is not seating or is damaged.
Charge pressure is low.
Wheel motor(s) and/or piston (traction) pump are worn or damaged
(NOTE: If a traction circuit component has internal wear or damage, it is possible that other traction components are also damaged).

Single wheel motor turns while unloaded, but slows down or stops
when load is applied

Hydraulic System

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)
Page 4 - 26

Reelmaster 5010- H

Traction Circuit Problems (Continued)
Problem

Possible Cause

Wheel motor will not turn

Brakes are binding.
Wheel motor is worn or damaged.
(NOTE: If a traction circuit component has internal wear or damage, it is possible that other traction components are also damaged)

Lift Circuit Problems
Problem

Possible Cause

Single cutting unit lifts slowly or not
at all

Affected cutting unit has excessive debris buildup.

Pilot piston in lift control manifold for the affected cutting unit is
stuck or damaged.
Lift cylinder for the affected cutting unit leaks internally.
Flow control orifice in lift control manifold for the affected cutting
unit is plugged or damaged.
Cutting units raise, but will not remain in the raised position
(NOTE: Lift cylinders and control
manifold check valves cannot provide an absolutely perfect seal. The
cutting units will eventually lower if
left in the raised position)

Lift cylinder leaks internally.

None of the cutting units will raise or
lower

Oil level in hydraulic reservoir is low (other hydraulic systems affected as well).

Lift control manifold check valve(s) (CV1, CV4, CV5 and CV23)
and solenoid valve (SV1 and SV3) leaks.
Pilot piston in lift control manifold is stuck and is preventing check
valve from seating.

Cutting units are in the backlap position (NOTE: Operator advisory
should be displayed on InfoCenter Display).
Solenoid valve SVRV on lift control manifold is faulty.
An electrical problem exists that prevents SVRV solenoid coil on
the lift control manifold from being energized (see Troubleshooting
in Chapter 5 - Electrical System).
Gear pump section for lift/lower function (P1) is worn or damaged.

Reelmaster 5010- H

Page 4 - 27

Hydraulic System

Hydraulic
System

Lift arm or lift cylinder for the affected cutting unit is binding.

Lift Circuit Problems (Continued)
Problem

Possible Cause

None of the front cutting units will
raise or lower but the rear cutting
units will raise and lower

Solenoid valve SV1 on lift control manifold is faulty.

Neither of the rear cutting units will
raise or lower but the front cutting
units will raise and lower

Solenoid valve SV3 on lift control manifold is faulty.

An electrical problem exists that prevents SV1 solenoid coil on the
lift control manifold from being energized (see Troubleshooting in
Chapter 5 - Electrical System).

An electrical problem exists that prevents SV3 solenoid coil on the
lift control manifold from being energized (see Troubleshooting in
Chapter 5 - Electrical System).
Flow control orifice in lift control manifold for the rear cutting units
(C23 or C23L) is plugged or damaged.
Check valve in lift control manifold for the rear cutting units (CV23)
is stuck or damaged.

Single cutting unit lowers very slowly
or not at all

Lift arm or lift cylinder for the affected cutting unit is binding.
Lift cylinder for the affected cutting unit 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. tie rods, steering cylinder ends) are
worn or binding.
Steering cylinder is binding.
Oil level in hydraulic reservoir is low (other hydraulic systems affected as well).
Steering relief valve (R10) in steering control valve is stuck or damaged.
Steering cylinder leaks internally.
Steering control valve is worn or damaged.
Internal gear pump drive coupler is damaged.
Gear pump section (P2) is worn or damaged (NOTE: A worn or
damaged gear pump section (P2) will also affect the traction
(charge) circuit).

Hydraulic System

Page 4 - 28

Reelmaster 5010- H

Hydraulic
System

This page is intentionally blank.

Reelmaster 5010- H

Page 4 - 29

Hydraulic System

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. Operate the machine under load for at least ten (10) minutes before performing hydraulic tests.

IMPORTANT: All obvious areas such as oil supply,
oil filter, binding linkages, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of
a hydraulic system problem.
Precautions for Hydraulic Testing

CAUTION
Failure to use gauges with expected pressure
(psi) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.

WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic
System Pressure in the General Information section.
5. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or component removal.
6. When using hydraulic tester (pressure and flow), the
inlet and the outlet hoses must be properly connected
and not reversed to prevent damage to the hydraulic
tester or components.

CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine and the other should monitor
test equipment and record test results.

WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for leaks;
use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result
from such an injury.
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hydraulic equipment. Contamination can cause excessive
wear or binding of hydraulic components.

Hydraulic System

3. Before testing, check all control linkages for improper adjustment, binding or broken parts.

7. Install hydraulic fittings finger tight and far enough to
make sure that they are not cross- threaded before tightening them with a wrench.
8. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester.
9. After connecting test equipment, check oil level in
the hydraulic reservoir to make sure that oil level is correct.
10.When using hydraulic tester (pressure and flow),
open tester load valve completely before starting engine
to minimize the possibility of damaging components.
11. The engine must be in good operating condition. Use
a phototac when performing a hydraulic test. Engine
speed can affect the accuracy of the tester readings.
Check actual speed of the pump when performing hydraulic flow tests.
12.After hydraulic test procedures have been completed, check oil level in the hydraulic reservoir to make
sure that oil level is correct.

Page 4 - 30

Reelmaster 5010- H

Which Hydraulic Tests Are Necessary?
Before beginning any hydraulic test, identify if the problem is related to the traction circuit, lift circuit or steering
circuit. Once the faulty system has been identified, perform tests that relate to that circuit.

3. If a steering circuit problem exists, consider performing one or more of the following tests: Steering Relief
Valve (R10) Pressure, Steering Cylinder Internal Leakage and/or Gear Pump (P2) Flow Tests.

Hydraulic
System

1. If a traction circuit problem exists, consider performing one or more of the following tests: Traction Circuit
Relief Valve (R3) and (R4) Pressure, Traction Circuit
Charge Pressure, Gear Pump (P2) Flow, Front Wheel
Motor Efficiency and/or Piston (Traction) Pump Flow
Tests.

2. If a lift circuit problem exists, consider performing
one or more of the following tests: Lift Relief Valve
(SVRV) Pressure, Gear Pump (P1) Flow and/or Lift Cylinder Internal Leakage Tests.

Reelmaster 5010- H

Page 4 - 31

Hydraulic System

Traction Circuit Relief Valve (R3) and (R4) Pressure Test

TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

FORWARD (R3) RELIEF
VALVE TEST SHOWN
100 MESH
SUCTION
STRAINER

INTERNAL
CASE
DRAIN

PRESSURE
GAUGE
G5

FORWARD

R3
A

TRACTION
WHEEL
MOTORS

M6
B

A
M7

RH
B

FROM STEERING CONTROL VALVE

Figure 26
The traction circuit relief pressure test should be performed to make sure that forward and reverse traction
circuit relief pressures are correct.
Procedure for Traction Circuit Relief Valve (R3) and
(R4) Pressure Test
1. Drive machine to an open area. Park machine on a
level surface with the cutting units lowered and disengaged. Make sure engine is off. Apply the parking brake.

2. Read Precautions For Hydraulic Testing at the beginning of this section.

Hydraulic System

Page 4 - 32

Reelmaster 5010- H

NOTE: If machine is equipped with optional
CrossTraxTM AWD, reverse relief pressure test ports
are located on CrossTraxTM hydraulic manifold.

2WD MACHINE SHOWN

3. Thoroughly clean traction circuit test port on hydraulic tube for direction to be checked (Fig. 27). Connect a
5000 PSI (350 bar) pressure gauge to test port.

4
1

4. After installing tester, start engine and run at low idle
speed. Check for any hydraulic leakage from test connections and correct before proceeding with test.

RIGHT
FRONT

5. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for
approximately ten (10) minutes.

Figure 27
1. RH wheel motor
2. LH wheel motor

7. Apply brakes and slowly depress the traction pedal
in the direction to be tested (forward or reverse). While
pushing traction pedal down, carefully watch the pressure gauge needle. As the traction relief valve lifts, the
gauge needle will momentarily stop. Traction system
pressure as the relief valve opens should be:

3. Forward test port
4. Reverse test port

Approximately 3625 PSI (250 bar) in both forward
(R3) and reverse (R4)

NOTE: If traction pedal continues to be pressed after
the relief valve has opened, system pressure may increase higher than relief pressure.
2

8. When relief pressure has been identified, release
traction pedal, stop engine and record test results.
NOTE: Forward (R3) and reverse (R4) relief valves are
identical. Relief valves can be switched in piston (traction) pump to help in identifying a faulty relief valve.
9. If traction pressure problem occurs in one direction
only, interchange the relief valves in the piston (traction)
pump (Fig. 28) to see if the problem changes to the other
direction. Clean or replace valves as necessary. These
cartridge type valves are factory set, and are not adjustable. If traction relief pressure is low and relief valves are
in good condition, piston (traction) pump and/or wheel
motors should be suspected of wear and inefficiency.

RIGHT
FRONT
Figure 28
1. Piston (traction) pump
2. Reverse relief valve (R4)

3. Forward relief valve (R3)

10.After testing is completed, make sure that engine is
stopped and then relieve hydraulic system pressure
(See Relieving Hydraulic System Pressure in the General Information section of this chapter). Remove pressure gauge from machine and install dust cap to test
port.

Reelmaster 5010- H

Page 4 - 33

Hydraulic System

Hydraulic
System

6. Sit on seat and increase engine speed to high idle
speed (3000 RPM).

Traction Circuit Charge Pressure Test

TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

100 MESH
SUCTION
STRAINER

INTERNAL
CASE
DRAIN

FORWARD

R3
A

TRACTION
WHEEL
MOTORS

M6
B

PRESSURE
GAUGE

A
M7

RH
B

FROM STEERING CONTROL VALVE

Figure 29
The traction circuit charge pressure test should be performed to make sure that the traction charge circuit is
functioning correctly.
Procedure for Traction Circuit Charge Pressure Test
1. Park machine on a level surface with the cutting units
lowered and disengaged. Make sure engine is off. Apply
the parking brake.
2. Read Precautions For Hydraulic Testing in this section.
3. Raise and support operator seat to allow access to
hydraulic pump assembly.

Hydraulic System

Page 4 - 34

Reelmaster 5010- H

5. Start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test.

3
1

6. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for
approximately ten (10) minutes.
7. Make sure that traction pedal is in neutral, the steering wheel is stationary and parking brake is engaged.
8. Increase engine speed to high idle speed (3000
RPM) and monitor pressure gauge to determine no load
charge pressure. Record test results.

GAUGE READING TO BE approximately 200 to
250 PSI (13.8 to 17.2 bar)

Figure 30
1. Piston (traction) pump
2. Oil filter

3. Test fitting

GAUGE READING TO BE approximately 150 to
250 PSI (13.8 to 17.2 bar)

Hydraulic
System

9. Next, determine charge pressure under traction load
by operating the machine in a direct forward and reverse
direction (not steering). Make sure that engine is running at full speed (3000 RPM). Apply the brakes and
press the traction pedal in the forward direction and then
to reverse while monitoring the pressure gauge. Stop
engine and record test results.

5
6

10.Compare measured charge pressure from step 8
with pressure from step 9:
A. If charge pressure is good under no load (step 8),
but drops below specification when under traction
load (step 9), the piston (traction) pump should be
suspected of wear and inefficiency. When the pump
is worn or damaged, the charge system is not able to
replenish lost traction circuit oil due to excessive
leakage in the worn pump.
B. If there is no charge pressure, or pressure is low,
check for restriction in gear pump intake line. Inspect
charge relief valve and valve seat in the piston (traction) pump (see Piston (Traction) Pump Service in
the Service and Repairs section of this chapter).
Also, consider a worn or damaged gear pump section (P2) (see Gear Pump Flow Test in this section).

RIGHT
FRONT
1

Figure 31
1. Piston (traction) pump
2. Plug
3. O- ring

4. Shim kit
5. Spring
6. Charge relief poppet

NOTE: If gear pump (P2) is worn or damaged, both
charge circuit and steering circuit will be affected.
11. After charge pressure testing is completed, make
sure that engine is not running and then relieve hydraulic system pressure (See Relieving Hydraulic System
Pressure in the General Information section of this
chapter). Remove pressure gauge from test port and install dust cap to test port.
12.Lower and secure operator seat.

Reelmaster 5010- H

Page 4 - 35

Hydraulic System

Gear Pump (P2) Flow Test
(Using Tester with Pressure Gauges and Flow Meter)
TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

100 MESH
SUCTION
STRAINER

INTERNAL
CASE
DRAIN

FORWARD

R3
A

TRACTION
WHEEL
MOTORS

M6
B

A
M7

RH
B

TESTER
FROM STEERING CONTROL VALVE

OIL FILTER
AND TUBE
REMOVED

Figure 32
The gear pump (P2) flow test should be performed to
make sure that the traction charge circuit and steering
circuit have adequate hydraulic flow.
Procedure for Gear Pump (P2) Flow Test
1. Park machine on a level surface with the cutting units
lowered and disengaged. Make sure engine is off. Apply
the parking brake.

2. Read Precautions For Hydraulic Testing in this section.
Hydraulic System

Page 4 - 36

Reelmaster 5010- H

3. Raise and prop operator seat to allow access to hydraulic pump assembly.
4. Thoroughly clean the ends of the hydraulic tubes
connected to the oil filter and piston pump inlets (Fig.
33). Disconnect hydraulic tubes from oil filter inlet and
piston pump inlet. Remove two (2) flange head screws
that secure oil filter adapter to frame. Remove oil filter
assembly and hydraulic tube from machine.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow meter is showing that the oil will
flow from the hydraulic tube, through the tester and
into the piston (traction) pump.

NOTE: If the flow from gear pump (P2) is low, the operation of both the charge circuit and the steering circuit will
be affected.
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). Remove hydraulic
tester from hydraulic tube and pump fitting. Install oil filter assembly and then connect removed hydraulic tube
to oil filter and piston pump fitting.
14.Lower and secure operator seat.

5. Install tester with pressure gauge and flow meter in
place of the removed oil filter assembly and hydraulic
tube (Fig. 34). Connect tester inlet hose to the hydraulic
tube. Connect the tester outlet hose to the piston (traction) pump fitting. Make sure the flow control valve on
tester is fully open.

3
4

Hydraulic
System

6. Make sure that the traction pedal is in neutral, the
steering wheel is stationary and the parking brake is engaged.

Figure 33
1. Hydraulic tube
2. Oil filter

9. Increase engine speed to high idle speed (3000
RPM). Use InfoCenter Display to verify that engine
speed is correct.

3. Hydraulic tube
4. Gear Pump (P2)

IMPORTANT: The gear pump is a positive displacement type. If pump flow is completely restricted or
stopped, damage to the pump, tester or other components could occur.
10.While watching tester pressure gauge, slowly close
the tester flow control valve until 800 PSI (55 bar) is obtained on gauge.

FLOW TESTER READING TO BE: A pump in good
condition should have a flow of approximately 4.7
GPM (17.8 LPM) at 800 PSI (55 bar).
11. Open the tester flow control valve, stop engine and
record test results.
12.If flow is less than 4 GPM (15.1 LPM) or a pressure
of 800 PSI (55 bar) cannot be obtained, consider that a
gear pump problem exists. Check for restriction in pump
intake line. If intake is not restricted, remove gear pump
and repair or replace pump as necessary (see Hydraulic
Pump Assembly and Gear Pump Service in the Service
and Repairs section of this chapter).
Reelmaster 5010- H

Figure 34
1. Tester inlet connection

Page 4 - 37

2. Tester outlet connection

Hydraulic System

Front Wheel Motor Efficiency Test
TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

100 MESH
SUCTION
STRAINER

INTERNAL
CASE
DRAIN

TESTER
A

FORWARD

CAP

TRACTION
WHEEL
MOTORS

M6
B

CAP

FROM STEERING CONTROL VALVE

RH FRONT WHEEL
MOTOR EFFICIENCY
TEST SHOWN

Figure 35
Procedure for Front Wheel Motor Efficiency Test
NOTE: Over a period of time, a wheel motor can wear
internally. A worn motor may by- pass oil causing the
motor to be less efficient. Eventually, enough oil loss will
cause the wheel motor to stall under heavy load conditions. Continued operation with a worn, inefficient motor
can generate excessive heat, cause damage to seals
and other components in the hydraulic system and affect overall machine performance.
IMPORTANT: Refer to Traction Circuit Component
Failure in the General Information section for information regarding the importance of removing contamination from the traction circuit.
NOTE: This test procedure includes steps to test both
front wheel efficiency together before testing individual
wheel motors.
1. Make sure that traction pedal is adjusted to the neutral position (see Traction Unit Operator’s Manual).
Hydraulic System

2. Drive machine to an open area. Park machine on a
level surface with the cutting units lowered and disengaged. Make sure engine is off.
3. Read Precautions For Hydraulic Testing in this section.

5. Chock front wheels to prevent wheel rotation.
Page 4 - 38
Reelmaster 5010- H

6. Thoroughly clean junction of hydraulic hose and
right side elbow fitting on bottom of piston (traction)
pump (Fig. 36). Disconnect hose from piston (traction)
pump fitting.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow meter is showing that the oil will
flow from the pump, through the tester and into the
hydraulic hose.
7. Install tester with pressure gauges and flow meter in
series with the piston (traction) pump and the disconnected hose. Make sure the tester flow control valve
is fully open.
8. Start engine and increase engine speed to high idle
speed (3000 RPM). Make sure hydraulic oil is at normal
operating temperature by operating the machine under
load for approximately ten (10) minutes.

CAUTION
Use extreme caution when performing test. The
front tires on the ground will be trying to move
the machine forward.
9. Fully apply the brakes to prevent the front wheels
from rotating and slowly push traction pedal in forward
direction until 1000 PSI is displayed on the tester pressure gauge.

13.To test individual front wheel motors:
A. Remove front wheel from wheel motor that is not
being tested. Remove wheel shield to allow access
to hydraulic tubes and fittings on wheel motor. Remove fasteners that secure front hydraulic tube rclamps to frame.
B. On the front wheel motor that is not being tested,
thoroughly clean junction of both hydraulic tubes and
wheel motor fittings. Disconnect both hydraulic lines
from wheel motor that is not being tested. Install a
steel cap on disconnected hydraulic lines and wheel
motor fittings.
C. Use the procedure described in steps 8 to 10
above to identify individual front wheel motor leakage. Individual motor internal leakage will be shown
on flow meter in GPM (LPM). Flow should be less
than 1.5 GPM (5.7 LPM) for the tested wheel motor.
If leakage for the tested motor is more than 1.5 GPM
(5.7 LPM), the tested motor is faulty.
D. If other front wheel motor requires testing, complete steps A, B and C for remaining wheel motor.
14.After testing is completed, stop engine and then relieve hydraulic system pressure (See Relieving Hydraulic System Pressure in the General Information section
of this chapter). Disconnect tester from hydraulic fitting
and hose. Connect hose to pump elbow fitting. Remove
caps from hydraulic tubes and reconnect tubes to wheel
motor. Secure hydraulic tubes to machine with r- clamps
and removed fasteners. Install wheel shield and
wheel(s) (see Wheels in the Service and Repairs section of Chapter 6 - Chassis).

10.Combined front wheel motor internal leakage will be
shown on flow meter in GPM (LPM).

2WD MACHINE SHOWN

11. Release traction pedal, release brake pedal, shut
engine off, rotate both front wheels and retest. Testing
of wheel motor leakage in three (3) different wheel positions will provide the most accurate test results. Record
measured front wheel motor internal leakage for all
three (3) wheel positions.

12.If combined leakage for the front wheel motors is
less than 1.5 GPM (5.7 LPM), consider that the front
wheel motors are in good condition. If combined 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.

RIGHT
FRONT

Figure 36
1. Piston (traction) pump
2. RH elbow fitting
3. Hyd hose (forward)

Reelmaster 5010- H

Page 4 - 39

4. LH elbow fitting
5. Hyd hose (reverse)

Hydraulic System

Hydraulic
System

NOTE: If machine is equipped with optional
CrossTraxTM AWD, jack up and support the rear wheels
off the ground to allow flow through the rear wheel motors.

Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge)
TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

100 MESH
SUCTION
STRAINER

INTERNAL
CASE
DRAIN

TESTER
A

FORWARD
R3
A

TRACTION
WHEEL
MOTORS

M6
B

A
RH

M7
B

FROM STEERING CONTROL VALVE

Figure 37
Procedure for Piston (Traction) Pump Flow Test
This test measures piston (traction) pump output (flow).
During this test, pump load is created at the flow meter
using the adjustable load valve on the tester.
IMPORTANT: Traction circuit flow for your Reelmaster is approximately 30 GPM (113.5 LPM). Use 40
GPM Hydraulic Tester #AT40002 (pressure and flow)
for this test (see Special Tools in this chapter).
1. Park machine on a level surface with the cutting units
lowered and disengaged. Make sure engine is off. Apply
the parking brake. Make sure mow speed limiter is in the
transport position to allow full movement of traction pedal.
2. Read Precautions For Hydraulic Testing in this section.

Hydraulic System

CAUTION
Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and
avoid injury from pressurized hydraulic oil. See
Relieving Hydraulic System Pressure in the General Information section of this chapter.
3. Make sure that traction pedal is adjusted to the neutral position. Also, ensure that piston (traction) pump is
at full stroke when traction pedal is pushed into fully forward position.
4. Raise and support machine so all wheels are off the
ground (see Jacking Instructions in Chapter 1 - Safety).

Page 4 - 40

Reelmaster 5010- H

5. Thoroughly clean junction of hydraulic hose and
right side fitting on bottom of piston (traction) pump (Fig.
38). Disconnect hose from right side pump fitting.

11. Observe flow gauge. For a piston pump in good condition, flow indication should be approximately 26 GPM
(98 LPM).

IMPORTANT: Make sure that the oil flow indicator
arrow on the flow meter is showing that the oil will
flow from the pump, through the tester and into the
disconnected hydraulic hose.

12.Open flow control valve on tester, release traction
pedal to the neutral position and shut off engine. Record
test results.

6. Install tester with pressure gauge and flow meter in
series between piston pump fitting and disconnected
hose to allow flow from piston pump to tester. Use hydraulic hose kit (see Special Tools in this chapter) to connect tester to machine. Make sure that fitting and hose
connections are properly tightened. Also, make sure the
flow control valve on tester is fully open.

CAUTION

13.If measured flow is less than 23 GPM (87 LPM), consider the following:
A. The piston (traction) pump swash plate is not being rotated fully (e.g. traction pedal linkage may need
adjustment, mow speed limiter is not in the transport
position).
B. The piston (traction) pump needs to be repaired
or replaced as necessary.
C. Make necessary repairs before performing additional hydraulic tests on the traction system.

7. Start engine and run at idle speed. Check for any hydraulic leakage from tester and hose connections. Correct any leaks before proceeding.

14.When testing is complete, disconnect tester and
hose kit from pump fitting and machine hydraulic hose.
Reconnect hose to pump fitting.
2WD MACHINE SHOWN

9. Slowly push traction pedal to fully forward position.
Keep pedal fully depressed in the forward position during the flow test.

Reelmaster 5010- H

8. Increase engine speed to high idle speed (3000
RPM). Make sure hydraulic oil is at normal operating
temperature by operating the machine under load for
approximately ten (10) minutes. Make sure the hydraulic reservoir is full.

10.Have second person watch pressure gauge on tester carefully while slowly closing the tester flow control
valve until 1000 PSI (69 bar) is obtained. Verify with the
InfoCenter Display that the engine speed is still 3000
RPM.

Hydraulic
System

Drive wheels will be off the ground and rotating
during this test. Make sure machine is supported
so it will not move and accidentally fall to prevent
injuring anyone near the machine.

RIGHT
FRONT

Figure 38
1. Piston (traction) pump
2. RH elbow fitting
3. Hyd hose (forward)

Page 4 - 41

4. LH elbow fitting
5. Hyd hose (reverse)

Hydraulic System

Lift Relief Valve (SVRV) Pressure Test

TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

G4
SV2

C4 L

SV1
CV4

SVRV

C1 L
C1

PRESSURE
GAUGE

CV1
T

CV5

C5
C5 L

PISTON
PUMP (P3)
INTERNAL
CASE
DRAIN

100 MESH
SUCTION
STRAINER

SV3
CV23

LIFT
CONTROL
MANIFOLD

C2/3 L

C2/3
RIGHT
FRONT

LEFT
FRONT

FRONT
CENTER

LEFT
REAR

RIGHT
REAR

Figure 39

Hydraulic System

Page 4 - 42

Reelmaster 5010- H

The lift relief valve (SVRV) pressure test should be performed to make sure that the lift circuit relief pressure is
correct.

8. Once relief pressure has been determined, return
the lower mow/raise lever to the neutral position and
stop the engine.

Procedure for Lift Relief Valve (SVRV) Pressure Test

9. If measured pressure is incorrect, remove solenoid
relief valve (SVRV) in lift control manifold and clean or
replace valve (see Lift Control Manifold Service in the
Service and Repairs section of this chapter). Also, if
pressure is low, check for restriction in gear pump suction hose. Internal lift cylinder leakage in one or more
cylinders would also cause low lift circuit pressure (see
Lift Cylinder Internal Leakage Test in this section). Gear
pump section (P1) could also be suspected of wear,
damage or inefficiency (see Gear Pump (P1) Flow Test
in this section).

2. Read Precautions For Hydraulic Testing in this section.

10.After lift relief valve pressure 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). Disconnect pressure gauge from test port at
gear pump and install dust cap to test port.
11. Lower and secure operator seat.

4. Thoroughly clean test port attached to tee fitting on
1st gear pump section (P1) (Fig. 40). Connect a 5000
PSI (350 bar) pressure gauge to test port.

Hydraulic
System

1. Park machine on a level surface with the cutting units
lowered and disengaged. Make sure engine is off. Apply
the parking brake.

2
1

5. After installing pressure gauge to test port, start engine and run at low idle speed. Check for any hydraulic
leakage from test connections and correct before proceeding with test.
6. Increase engine speed to high idle speed (3000
RPM). Make sure hydraulic oil is at normal operating
temperature by operating the machine under load for
approximately ten (10) minutes.
IMPORTANT: Do not allow circuit pressure to exceed 2500 PSI (172 bar).
IMPORTANT: While performing this test, hold lower
mow/raise lever in the raise position only long
enough to get a system pressure reading. Holding
the lever in raise for an extended period may damage system components.

Figure 40
1. 1st gear pump section

2. Test port

7. Make sure that reel engage/disengage switch is OFF
and then pull lower mow/raise lever rearward (raise position) to pressurize lift circuit. While holding lever rearward, watch pressure gauge carefully. As the cutting
units raise fully and the lift relief valve lifts, system pressure should be:
Approximately 2000 PSI (138 bar)

Reelmaster 5010- H

Page 4 - 43

Hydraulic System

Gear Pump (P1) Flow Test
(Using Tester with Pressure Gauges and Flow Meter)

TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

TESTER

SV1

P2
T

CV4

SVRV
(NOT ENERGIZED)

C4 L

SV2

C4
C1 L
C1

CV1
R7
CV5

C5
C5 L

PISTON
PUMP (P3)
INTERNAL
CASE
DRAIN

100 MESH
SUCTION
STRAINER

SV3
CV23

LIFT
CONTROL
MANIFOLD

C2/3 L

C2/3
RIGHT
FRONT

LEFT
FRONT

FRONT
CENTER

LEFT
REAR

RIGHT
REAR

Figure 41

Hydraulic System

Page 4 - 44

Reelmaster 5010- H

Procedure for Gear Pump (P1) Flow Test
1. Park machine on a level surface with the cutting units
lowered and disengaged. Make sure engine is off. Apply
the parking brake.
2. Read Precautions For Hydraulic Testing in this section.

CAUTION
Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and
avoid injury from pressurized hydraulic oil. See
Relieving Hydraulic System Pressure in the General Information section of this chapter.
3. Raise and prop operator seat to allow access to hydraulic pump assembly.
4. Thoroughly clean junction of hydraulic hose and tee
fitting on left side of 1st gear pump section (Fig. 42). Disconnect hose from left 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 1st pump section (P1), through the
tester and to the hydraulic hose.
5. Install tester with pressure gauge and flow meter between gear pump fitting and disconnected hose to allow
flow from gear pump section to tester. Connect tester inlet hose to the pump fitting. Connect the tester outlet
hose to the disconnected hydraulic hose. Make sure
the flow control valve on tester is fully open.

IMPORTANT: The gear pump is a positive displacement type. If pump flow is completely restricted or
stopped, damage to the pump, tester or other components could occur.
10.While carefully watching pressure gauge on tester,
slowly close the tester flow control valve until 1000 PSI
(69 bar) is obtained on gauge. Make sure that engine
speed is still correct.
FLOW TESTER READING TO BE: A pump in good
condition should have a flow of approximately 3
GPM (11.4 LPM) at 1000 PSI (69 bar).
11. Once the gear pump flow has been determined,
open the tester flow control valve, stop engine and record test results.
12.If flow is less than 2.5 GPM (9.6 LPM) or a pressure
of 1000 PSI (69 bar) cannot be obtained, consider that
a gear pump problem exists. Check for restriction in
gear pump suction hose. If intake is not restricted, remove gear pump and repair or replace pump as necessary (see Hydraulic Pump Assembly and Gear Pump
Service in the Service and Repairs section of this chapter).
NOTE: If the flow from the 1st gear pump section (P1)
is low, the operation of all lift cylinders will be affected.
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). Disconnect tester
from gear pump tee fitting and hydraulic hose. Reconnect machine hose to pump fitting.
14.Lower and secure operator seat.

6. Make sure that the traction pedal is in neutral and the
parking brake is engaged.

7. Start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test.
8. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for
approximately ten (10) minutes.
9. Increase engine speed to high idle speed (3000
RPM). Use the InfoCenter Display to verify that engine
speed is correct.

Reelmaster 5010- H

2
Figure 42
1. 1st gear pump section

Page 4 - 45

2. Hydraulic hose

Hydraulic System

Hydraulic
System

The gear pump section (P1) flow test should be performed to make sure that the cutting unit lift circuit has
adequate hydraulic flow.

Lift Cylinder Internal Leakage Test
TO STEERING CONTROL VALVE AND CHARGE CIRCUIT

G4
SV2

C4 L

SV1
CV4

SVRV

C1 L
C1

CV1
T

CV5

C5
C5 L

PISTON
PUMP (P3)
INTERNAL
CASE
DRAIN

SV3

100 MESH
SUCTION
STRAINER

CV23

LIFT
CONTROL
MANIFOLD

C2/3 L

C2/3
RIGHT
FRONT

LEFT
FRONT
(PARTIALLY
RAISED)

PLUG

FRONT
CENTER

CAP

CHECK FOR
CYLINDER
EXTENDING
LEFT
REAR

RIGHT
REAR

LEFT FRONT (#5) LIFT CYLINDER TEST SHOWN

Figure 43
The lift cylinder internal leakage test should be performed if a cutting unit raise and lower problem is identified. This test will determine if a lift cylinder is faulty.
NOTE: Cutting unit raise/lower circuit operation will be
affected by lift cylinder binding, extra weight on the cutting units and/or binding of lift components. Make sure
that these items are checked before proceeding with lift
cylinder internal leakage test.
Procedure for Lift Cylinder Internal Leakage Test:

2. Read Precautions For Hydraulic Testing in this section.
3. For the lift cylinder that is to be tested, use a jack to
raise the lift arm slightly. This will remove the load from
the lift cylinder and relieve lift cylinder hydraulic pressure. Leave the jack under the lift arm to support the lift
arm and to prevent the lift arm from lowering.
NOTE: If either of the rear lift cylinders is being tested,
both rear lift arms need to be supported.

1. Park machine on a level surface with the cutting units
disengaged and in the turn- around position. Turn the
engine off and apply the parking brake.

Hydraulic System

Page 4 - 46

Reelmaster 5010- H

IMPORTANT: When capping lift cylinder fitting and
hydraulic hose end, use a steel cap and plug to ensure that fluid leakage will not occur. Plastic plugs
will not hold hydraulic pressure that will be developed during this test procedure.

11. If needed, repeat steps 3 through 9 for other lift cylinders.
12.After lift cylinder testing is completed, check oil level
in hydraulic reservoir and adjust as necessary.

5. 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.
6. Slowly lower the jack and remove it from under the
lift arm. The cutting unit should settle slightly and then
be supported by the capped lift cylinder.

7. Mark the position of the lift cylinder rod at the lift cylinder head with a piece of tape (Fig. 45).
8. Leave the machine parked for two (2) hours and
monitor the lift cylinder. The weight of the cutting unit
may cause the lift cylinder to gradually extend. Use the
tape location to determine lift cylinder rod movement
(Fig. 46).

Figure 44
1. Lift cylinder (#5 shown)
2. Cylinder rod end fitting

Figure 45
1. Lift cylinder rod
2. Lift cylinder head

3. Tape (initial position)

9. Once lift cylinder condition has been determined,
use a jack to raise the lift arm slightly which will remove
the load from the lift cylinder. Allow the jack to support
the lift arm and to prevent it from lowering. Remove the
cap from the cylinder fitting and the plug from the hydraulic hose. Connect the hydraulic hose to the lift cylinder fitting.
10.Remove jack from under the lift arm. Start engine
and operate lift cylinders through several up and down
cycles. Stop the engine and check for any hydraulic
leakage.

Reelmaster 5010- H

A. If lift cylinder rod movement is less than 1.250”
(31.7 mm) after two (2) hours, make sure that the cutting unit has not settled to the ground. If the cutting
unit is still suspended after two (2) hours and lift cylinder rod movement is less than 1.250” (31.7 mm),
consider that the lift cylinder is in good condition. A
cylinder in good, usable condition will show minimal
movement.
B. Rod movement in excess of 1.250” (31.7 mm) after two (2) hours indicates that the lift cylinder may
have internal seal damage or excessive wear. Remove and inspect the lift cylinder (see Lift Cylinder
and Lift Cylinder Service in the Service and Repairs
section of this chapter).

3. Hydraulic hose

Figure 46
1. Tape (after 2 hours)

Page 4 - 47

2. Cylinder rod movement

Hydraulic System

Hydraulic
System

4. Thoroughly clean the area around the end of the hydraulic hose at the rod end of the lift cylinder for the supported lift arm. Disconnect the hydraulic hose from the
lift cylinder rod end fitting (Fig. 44).

Steering Relief Valve (R10) Pressure Test

TO LIFT CONTROL
MANIFOLD

PISTON
PUMP (P3)
INTERNAL
CASE
DRAIN

100 MESH
SUCTION
STRAINER
TO TRACTION
CHARGE CIRCUIT

OUT

R10

STEERING WHEEL TURNED
FOR RIGHT TURN
STEERING
CONTROL
VALVE
R

PRESSURE
GAUGE

STEERING
CYLINDER

Figure 47

Hydraulic System

Page 4 - 48

Reelmaster 5010- H

The steering relief valve (R10) pressure test should be
performed to make sure that the steering circuit relief
pressure is correct.

IMPORTANT: As steering wheel is turned, make
sure that pressure gauge is not contacted by any
machine parts.

Procedure for Steering Relief Valve (R10) Pressure
Test:

9. Watch pressure gauge carefully while turning the
steering wheel for a left hand turn (counter- clockwise)
and holding.

2. Read Precautions For Hydraulic Testing in this section.

10.System pressure should be approximately 1000 PSI
(69 bar) as the relief valve lifts. After determining relief
pressure, return steering wheel to the neutral position.
11. Shut off engine. Record test results.
12.If specification is not met, repair or replace steering
control valve (relief valve in steering control valve is not
replaceable). Gear pump section (P2) could also be
suspected of wear, damage or inefficiency (see Gear
Pump (P2) Flow Test in this section).
NOTE: If the flow from the 2nd gear pump section (P2)
is low, the traction charge circuit and steering circuit will
both be affected.
13.After steering relief valve 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).
Remove tee fitting and pressure gauge from hydraulic
hose and steering cylinder. Reconnect hydraulic hose to
steering cylinder fitting.

6. After installing pressure gauge, start engine and run
at idle speed. Check for any hydraulic leakage from test
connections and correct before proceeding with test.
7. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for
approximately ten (10) minutes.
8. Increase engine speed to high idle speed (3000
RPM).
IMPORTANT: Hold steering wheel at full lock only
long enough to get a system pressure reading.
Holding the steering wheel against the stop for an
extended period may damage the steering control
valve.

Reelmaster 5010- H

Figure 48
1. Steering cylinder

Page 4 - 49

2. Rod end fitting

Hydraulic System

Hydraulic
System

1. Park machine on a level surface with the cutting units
lowered and disengaged. Make sure engine is off. Apply
the parking brake.

Steering Cylinder Internal Leakage Test

R10

STEERING WHEEL
TURNED FOR
RIGHT TURN

STEERING
CONTROL
VALVE
PLUG

LOOK FOR LEAKAGE

STEERING
CYLINDER

(FULLY EXTENDED)

Figure 49

Hydraulic System

Page 4 - 50

Reelmaster 5010- H

The steering cylinder internal leakage test should be
performed if a steering problem is identified. This test
will determine if the steering cylinder is faulty.

8. Remove all hydraulic oil from drain pan. Make sure
that empty drain pan remains under the open fitting of
the steering cylinder.

NOTE: Steering circuit operation will be affected by
rear tire pressure, steering cylinder binding, extra
weight on the vehicle and/or binding of rear axle steering
components. Make sure that these items are checked
before proceeding with steering cylinder internal leakage test.

9. With the engine off, continue turning the steering
wheel for a right turn (clockwise) with the steering cylinder fully extended. Observe the open fitting on the steering cylinder as the wheel is turned. If oil comes out of the
fitting while turning the steering wheel to the right, the
steering cylinder has internal leakage and must be repaired or replaced (see Steering Cylinder and Steering
Cylinder Service in the Service and Repairs section of
this chapter). Check drain pan for any evidence of oil
that would indicate cylinder leakage.

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 disengaged. Make sure engine is off. Apply
the parking brake.
3. Read Precautions For Hydraulic Testing.

10.When testing is completed, remove plug from the hydraulic hose. Reconnect hose to the steering cylinder fitting.
11. If a steering problem exists and the steering cylinder
tested acceptably, the steering control valve requires
service (see Steering Control Valve and Steering Control Valve Service in the Service and Repairs section of
this chapter). Gear pump section (P2) could also be suspected of wear, damage or inefficiency (see Gear Pump
(P2) Flow Test in this section).
NOTE: If the flow from the 2nd gear pump section (P2)
is low, the traction charge circuit and steering circuit will
both be affected.
12.Check oil level in hydraulic reservoir and adjust if
needed.

4. Turn the steering wheel for a right turn (clockwise) so
the steering cylinder rod is fully extended.

5. Thoroughly clean the area around the hydraulic hose
at the rod end of the steering cylinder (Fig. 50).
6. Place a drain pan under the steering cylinder. Remove hydraulic hose from the fitting on the rod end of the
steering cylinder. Plug the end of the hose.
IMPORTANT: When capping hydraulic hose end,
use a steel cap to ensure that fluid leakage will not
occur. Plastic plugs will not hold hydraulic pressure
that may be developed during this test procedure.

7. Install a steel plug in the open end of the disconnected hose to prevent leakage or contamination.

Figure 50
1. Steering cylinder

Reelmaster 5010- H

Page 4 - 51

2. Rod end fitting

Hydraulic System

Hydraulic
System

Procedure for Steering Cylinder Internal Leakage
Test:

Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Components

After Repair or Replacement of Components

1. Before removing any parts from the hydraulic system, park machine on a level surface, lower cutting
units, engage parking brake and stop engine. Remove
key from the ignition switch.

1. If component failure is severe or hydraulic system is
contaminated, flush hydraulic system (see Flush Hydraulic System in this section).

2. Thoroughly clean machine before disconnecting, removing or disassembling any hydraulic components.
Make sure hydraulic components, hose connections
and fittings are thoroughly cleaned. Always keep in mind
the need for cleanliness when working on hydraulic
components.

CAUTION

2. Lubricate O- rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure all caps or plugs are removed from hydraulic tubes, hydraulic fittings and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Hose and Tube
Installation and Hydraulic Fitting Installation in the General Information section of this chapter).

Before loosening any hydraulic component, 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. After repairs, check control linkages and cables for
proper adjustment, binding or broken parts.

3. Operate all hydraulic controls to relieve system pressure before loosening any hydraulic connection (see
Relieving Hydraulic System Pressure in the General Information section of this chapter).

7. Check for hydraulic oil leaks. If any leaks are discovered, shut off engine and correct leaks before continuing
machine operation.

4. Put caps or plugs on any hydraulic lines, hydraulic fittings or components left open or exposed to prevent
contamination.

6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system (see Hydraulic System Start Up in this section).

8. After performing any hydraulic repairs, check oil level in hydraulic reservoir and add correct oil if necessary.

5. Before disconnecting hydraulic lines or hoses, place
labels to ensure proper installation after repairs are
completed.
6. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removing
the fittings. Mark parts if necessary to make sure that fittings will be aligned properly when reinstalling hydraulic
hoses and tubes.

Hydraulic System

Page 4 - 52

Reelmaster 5010- H

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. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.

Reelmaster 5010- H

Page 4 - 53

Hydraulic System

Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or the system is
contaminated. Contaminated oil appears milky or
black or contains metal particles.
1. Park machine on a level surface. Lower cutting units,
stop engine, engage parking brake and remove key
from ignition switch.
2. Drain hydraulic reservoir.
3. Clean area around the mounting area of the hydraulic filter. Remove and discard hydraulic filter.
4. Drain entire hydraulic system. Drain all hoses, tubes
and components while the system is warm. Flush hoses
and tubes to remove any contamination.

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.
Wait sixty (60) seconds to allow the starter motor and
starter solenoid to cool. Repeat this step again.
9. Connect wire harness connector to the fuel actuator
to allow engine to start.
10.Start engine and let it idle at low speed for a minimum
of two (2) minutes.
11. Increase engine speed to high idle for minimum of
one (1) minute under no load.
12.Rotate steering wheel in both directions several
times. Raise and lower cutting units several times.

IMPORTANT: Follow all local codes and regulations
when recycling or disposing hydraulic fluid and oil
filter.

13.Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct oil
if necessary.

IMPORTANT: If a failure occurred in the traction circuit, traction circuit component disassembly and
thorough cleaning may be required to remove contaminates from the traction circuit. Because the
traction circuit is a closed loop, any contamination
will remain in the circuit and can cause additional
component damage unless it is removed.

14.Operate the machine for two (2) hours under normal
operating conditions.
15.Check condition of hydraulic oil. If the fluid shows any
signs of contamination, repeat steps 1 through 14 again.
16.Resume normal operation and follow recommended
maintenance intervals.

5. Make sure the mounting surface of the hydraulic filter
is clean. Apply clean hydraulic oil to gasket on new filter.
Screw filter onto filter head until gasket contacts mounting plate, then tighten filter an additional 1/2 turn.
IMPORTANT: Use only hydraulic fluids specified in
Traction Unit Operator’s Manual. Other fluids could
cause system damage.
6. Fill hydraulic reservoir with new hydraulic oil to proper level.
7. Disconnect wire harness connector from the fuel actuator to prevent the engine from starting.

Hydraulic System

Page 4 - 54

Reelmaster 5010- H

Filtering Closed- Loop Traction Circuit

1. Park machine on a level surface with engine stopped
and key removed from ignition switch.
2. Raise and support machine so all wheels are off the
ground (see Jacking Instructions in Chapter 1 - Safety).
NOTE: If wheel motor was replaced, install high flow filter to the inlet of the new motor instead of to the piston
pump fitting. This will prevent system contamination
from entering and damaging the new wheel motor.
3. Thoroughly clean junction of hydraulic hose and left
side elbow fitting on bottom of piston (traction) pump
(Fig. 51). Disconnect hose from left side pump fitting.
4. Connect Toro high flow hydraulic filter in series between piston (traction) pump fitting and disconnected
hose. Use hydraulic hose kit (see Special Tools in this
chapter) to connect filter to machine. Make sure that fitting and hose connections are properly tightened.
IMPORTANT: Use only hydraulic fluids specified in
Operator’s Manual. Other fluids could cause system
damage.
5. After installing high flow filter to machine, check and
fill hydraulic reservoir with new hydraulic oil as required.

7. With engine running at low idle speed, slowly move
the traction pedal to the forward direction to allow flow
through the traction circuit and high flow filter. Keep traction circuit engaged for five (5) minutes while gradually
increasing both forward pressure on traction pedal and
engine speed. Monitor filter indicator to make sure that
green color is showing during operation.
8. With engine running at high idle speed and traction
pedal moved to the forward direction, periodically apply
brakes to increase pressure in traction circuit. While
monitoring filter indicator, continue this process for an
additional five (5) minutes.
IMPORTANT: If using a filter that is not the Toro high
flow filter that is bi- directional, do not press the
traction pedal in the reverse direction. If flow is reversed when using a filter that is not bi- directional,
debris from the filter will re- enter the traction circuit.
9. With engine running at high idle speed, alternately
move traction pedal from forward to reverse. While monitoring filter indicator, continue this process for an additional five (5) minutes.
10.Shut engine off and remove key from ignition switch.
11. Remove high flow hydraulic filter and hydraulic hose
kit from machine. Connect hydraulic hose to left side piston (traction) pump fitting. Make sure to properly tighten
hose (see Hydraulic Hose and Tube Installation in the
General Information section of this chapter).
12.Lower machine to ground.
13.Check oil level in hydraulic reservoir and add correct
oil if necessary.
1

6. Start engine and run at idle speed. Check for any hydraulic leakage from filter and hose connections. Correct any leaks before proceeding.

CAUTION

RIGHT
FRONT

All wheels will be off the ground and rotating during this procedure. Make sure machine is well
supported so it will not move and accidentally
fall to prevent injuring anyone around machine.
IMPORTANT: While engaging the traction circuit,
monitor the indicator on the high flow hydraulic filter. If the indicator should show red, either reduce
pressure on the traction pedal or reduce engine
speed to decrease hydraulic flow through the filter.
Reelmaster 5010- H
Page 4 -

2
5
4

Figure 51
1. Piston (traction) pump
2. RH elbow fitting
3. Hyd hose (forward)

4. LH elbow fitting
5. Hyd hose (reverse)

Hydraulic System

Hydraulic
System

Filtering of a closed- loop hydraulic system after a major
component failure (e.g. traction (piston) pump or wheel
motor) is a requirement to prevent debris from transmitting throughout the system. If a closed- loop hydraulic
system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to
other hydraulic components in the affected system, will
occur. To effectively remove contamination from
closed- loop traction circuit, use of the Toro high flow hydraulic filter and hydraulic hose kits are recommended
(see Special Tools in this chapter).

Hydraulic System Start- up
NOTE: When initially starting the hydraulic system with
new or rebuilt components such as pumps, wheel motors or lift cylinders, it is important that this start- up procedure be used. This procedure reduces the chance of
damaging the system or its components from not purging the system of air.
1. After the hydraulic system components have been
properly installed and if the piston (traction) pump was
rebuilt or replaced, make sure piston (traction) pump
housing is at least half full of clean hydraulic oil.
2. Make sure all hydraulic connections and lines are secured tightly.
3. Drain, flush and refill hydraulic system and change
hydraulic oil filter if component failure was severe or system is contaminated (see Flush Hydraulic System in this
section).
4. Make sure hydraulic reservoir is full. Add correct oil
if necessary.
5. Check control linkage for proper adjustment, binding
or broken parts.
6. Disconnect electrical connector to the engine fuel
actuator to prevent the engine from starting.

Hydraulic System

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.
Wait sixty (60) seconds to allow the starter motor and
starter solenoid to cool. Repeat this step again.
8. Connect fuel actuator to allow engine to start.
9. Make sure traction pedal is in neutral and the PTO
switch is OFF. Start engine and run it at low idle. The
charge pump should pick up oil and fill the hydraulic system. If there is no indication of fill in thirty (30) seconds,
stop the engine and determine the cause.
10.If the piston (traction) pump was replaced or rebuilt,
run the traction unit so the wheels turn slowly for ten (10)
minutes.
11. Operate the traction unit (including steering and cutting unit lift/lower) by gradually increasing the work load
to full over a ten (10) minute period.
12.Stop the machine. Check oil level in hydraulic reservoir and add correct oil if necessary. Check hydraulic
components for leaks and tighten any loose connections.

Page 4 - 56

Reelmaster 5010- H

Hydraulic
System

This page is intentionally blank.

Reelmaster 5010- H

Page 4 - 57

Hydraulic System

Hydraulic Reservoir

7
12

16
10

13
3

4
2
18
14

17
15

RIGHT

9
9

FRONT

Figure 52
1.
2.
3.
4.
5.
6.
7.

Suction strainer
Hydraulic reservoir
Recess bumper
Clamp (2 used)
Suction hose
Hose clamp (2 used)
Reservoir cap

Hydraulic System

8.
9.
10.
11.
12.
13.
14.

Washer head screw (2 used)
Flange nut (3 used)
Cap screw
Flat washer
Filter screen
Hydraulic tube
O- ring

Page 4 - 58

15.
16.
17.
18.
19.
20.

90o hydraulic fitting
O- ring
SAE #16 plug
O- ring
Bulkhead nut
O- ring

Reelmaster 5010- H

Removal (Fig. 52)

Installation (Fig. 52)

1. Thoroughly clean hydraulic hose ends and fittings on
hydraulic reservoir to prevent hydraulic system contamination.

1. If fitting (item 15) was removed from reservoir, lubricate and place new O- ring onto fitting. Install fitting into
reservoir opening using marks made during the removal
process to properly orientate fitting. Tighten fitting (see
Hydraulic Fitting Installation in the General Information
section of this chapter).

3. Disconnect hydraulic lines from fittings on the reservoir. Allow hydraulic lines to drain into a suitable container. Plug or cap openings of reservoir and hydraulic lines
to prevent leakage or contamination.
4. Remove hydraulic reservoir using Figure 52 as a
guide.

2. Lubricate new suction strainer O- ring and install
onto strainer. Thread suction strainer into hydraulic reservoir until finger tight. Then, using a wrench, turn strainer into reservoir port 1- 1/2 to 2 full turns beyond finger
tight.

5. Remove suction strainer (item 1) from reservoir. Discard O- ring.

3. Position hydraulic reservoir to machine. Make sure
that recess bumper (item 3) on right side of frame is inserted into recess in reservoir.

6. If hydraulic fitting (item 15) is to be removed from reservoir, mark fitting orientation to allow correct assembly. Remove fitting from reservoir and discard O- ring.

4. Secure reservoir to frame with two (2) clamps (item
4), washer head screws (item 8) and flange nuts (item
9).

Inspection (Fig. 52)

5. Remove plugs and caps placed in hoses and fittings
during the removal process.

1. Clean hydraulic reservoir and suction strainer with
solvent.
2. Inspect hydraulic reservoir for leaks, cracks or other
damage.

6. Install and secure hydraulic lines to fittings on hydraulic reservoir (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
7. Fill hydraulic reservoir with new hydraulic fluid.
8. Operate machine. Check hydraulic lines and fittings
for leaks. Tighten any loose connections. Check hydraulic oil level in reservoir and adjust if necessary.

Reelmaster 5010- H

Page 4 - 59

Hydraulic System

Hydraulic
System

2. Drain hydraulic oil from reservoir.

Piston (Traction) Pump Control Assembly
8

6
5
7

3
10
14

21
22

21
17
11

15
1
TO TRACTION
PEDAL

RIGHT

FRONT

Figure 53
1.
2.
3.
4.
5.
6.
7.
8.

Flange head screw (2 used)
Piston (traction) pump
Lever damper
Flange nut
Pump plate
Cap screw (3 used)
Carriage screw
Lock nut

Hydraulic System

9.
10.
11.
12.
13.
14.
15.

Pump lever
Flat washer
Flange nut
Lock nut
Cap screw
Cap screw
Traction cable bracket

Page 4 - 60

16.
17.
18.
19.
20.
21.
22.

Cable rod end
Traction neutral switch
Traction control cable
Flat washer
Flat washer
Jam nut (2 used)
Lock washer (2 used)

Reelmaster 5010- H

Disassembly (Fig. 53)
5

1. Park the machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.
2. Remove components from piston (traction) pump
control assembly as needed using Figures 53 and 54 as
guides.

Assembly (Fig. 53)
IMPORTANT: To prevent traction neutral switch
(item 17) damage, make sure that no pump control
components contact switch through entire piston
(traction) pump control arm movement.

1. Install removed components to piston (traction)
pump control assembly using Figures 53 and 54 as
guides along with the following:

Figure 54
1. Pump lever
2. Traction neutral switch
3. Traction control cable

4. Cable jam nut
5. Cable rod end

Hydraulic
System

A. If traction neutral switch (item 17) was removed
from pump plate, adjust location of switch so that
there is from 0.094” to 0.100” (2.4 to 2.5 mm) clearance between the head of neutral switch and the piston (traction) pump lever (Refer to Traction Neutral
Switch in the Adjustments section of Chapter 5 Electrical System for additional neutral switch information).

2. After piston (traction) pump control assembly has
been installed, make sure that the piston pump is adjusted for the neutral position so that the machine does
not move or creep when the traction pedal is in neutral
(see Traction Unit Operator’s Manual).

3
0.094” to 0.100”
(2.4 to 2.5 mm)

Figure 55
1. Piston pump
2. Pump lever

Reelmaster 5010- H

Page 4 - 61

3. Traction neutral switch

Hydraulic System

Hydraulic Pump Assembly

RIGHT
FRONT

29
30
31

32
28
7

35
34

21
9

4
1

23
6
16

3
4

2
17

Antiseize
Lubricant

14
11

12
13

Figure 56
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Gear pump assembly
O- ring
O- ring
Flat washer (4 used)
O- ring
Hydraulic fitting
Piston (traction) pump assembly
Socket head screw (2 used)
Lock washer (2 used)
Lock nut (2 used)
Flange nut (2 used)
Carriage screw (2 used)
Hydraulic tube

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Hydraulic fitting
O- ring
Pump support bracket
Hydraulic tee fitting
Hydraulic test fitting
Dust cap
Hydraulic hose
Hose clamp
Hydraulic (suction) hose
O- ring
90o hydraulic fitting (2 used)
O- ring
Hydraulic hose (2 used)

27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.

Flange head screw (2 used)
Flange nut (2 used)
Hydraulic tube
O- ring
90o hydraulic fitting
O- ring
Engine bellhousing
48 VDC motor/generator
Pump drive shaft
Cap screw (2 used)
Flange nut (2 used)
Hood saddle

NOTE: Piston (traction) pump and gear pump should
be removed from machine as an assembly. Once removed from machine, pumps can be separated for necessary service.
Hydraulic System

Page 4 - 62

Reelmaster 5010- H

Removal (Fig. 56)
3

1. Park the machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.
2. Raise and support hood and operator seat. Lift hood
saddle from frame brackets and remove from machine.
3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

CAUTION

Figure 57
3. Traction cable bracket

To prevent draining the pumps,
install plugs in piston pump case
drain and gear pump suction port
after gear pump is removed.
Remove plugs before installing
gear pump to piston pump.

4. To prevent contamination of the hydraulic system,
thoroughly clean piston (traction) and gear pump assembly and all hydraulic connections.

Hydraulic
System

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.

1. Piston (traction) pump
2. Gear pump

5. Label hydraulic hoses to assist in assembly. Disconnect all hydraulic hoses and tubes from fittings on the
piston (traction) and gear pump assembly. Allow hydraulic lines to drain into a suitable container. Plug or
cap openings of pumps and lines to prevent contamination.
6. Remove two (2) cap screws (item 36) and flange nuts
(item 37) that secure pump drive shaft to piston (traction) pump input shaft.
7. Disconnect traction control cable from piston (traction) pump (see Piston (Traction) Pump Control Assembly in this section). Carefully position traction control
cable away from piston pump.
8. Disconnect wire harness electrical connector from
traction neutral switch on piston pump control assembly
and position harness away from pump assembly.
IMPORTANT: Dry weight of pump assembly is approximately 68 pounds (31 kg).
9. Connect a lift or hoist to hole in traction cable bracket
on piston pump to support pump assembly and for pump
removal.
10.Loosen and remove two (2) carriage screws (item
12) and flange nuts (item 11) that secure pump support
bracket to frame.

Figure 58
1. Piston pump case drain

2. Gear pump suction port

IMPORTANT: Make sure to not damage machine
components while removing the pump assembly.
12.Carefully lift pump assembly from the machine.
Place assembly on suitable workbench.
NOTE: A case drain exists in the piston (traction) pump
and a suction port is near the input shaft of the gear
pump (Fig. 58). When the gear pump is removed from
the piston pump, plug piston pump case drain hole to
prevent draining the piston pump.

11. Remove two (2) flange screws (item 27) and flange
nuts (item 28) that secure piston (traction) pump flange
to machine frame.
Reelmaster 5010- H

Page 4 - 63

Hydraulic System

13.Remove two (2) socket head screws, lock washers
and flat washers that secure gear pump to piston (traction) pump. Remove gear pump from piston (traction)
pump. Locate and discard O- ring (item 15) from between pumps.
14.If necessary, remove hydraulic fittings from pumps.
Note orientation of fittings for assembly purposes.
15.Remove and discard all O- rings from removed hydraulic lines and fittings.
16.If necessary, remove two (2) lock nuts (item 10) that
secure pump support bracket (item 16) to gear pump.
Remove bracket and two (2) flat washers (item 4) from
gear pump.
Installation (Fig. 56)
1. If fittings were removed from pump assembly, lightly
lubricate new fitting O- rings with clean hydraulic oil.
Install fittings with O- rings to the pump assembly (see
Hydraulic Fitting Installation in the General Information
section of this chapter). Orientate fittings as noted during removal.
2. If pump support bracket (item 16) was removed from
gear pump, fit flat washers and bracket to gear pump
and secure with two (2) lock nuts.
IMPORTANT: A case drain exists in the piston (traction) pump and a suction port is near the input shaft
of the gear pump (Fig. 58). Before the gear pump is
installed to the piston pump, make sure that plugs
placed in either of these ports are removed. Failure
to remove plugs will cause excessive pressure in
the piston pump and damage seals. Also, before securing gear pump to piston pump, fill piston pump
housing with clean hydraulic oil through case drain
hole.
3. Remove plugs that were placed in piston pump case
drain and gear pump suction port. Fill piston pump housing with new hydraulic oil through case drain hole.

IMPORTANT: Make sure to not damage machine
components while installing the pump assembly.
5. Carefully lower pump assembly to machine frame.
Align piston pump input shaft to pump drive shaft and
slide pump assembly to machine frame.
6. Secure pump assembly to machine frame with two
(2) flange screws and flange nuts.
7. Secure pump support bracket to inside of frame
bracket with two (2) carriage screws (item 12) and
flange nuts (item 11).
8. Install hydraulic hoses to fittings on pump assembly
in positions noted during removal (see Hydraulic Hose
and Tube Installation in the General Information section
of this chapter).
9. Connect machine wire harness electrical connector
to traction neutral switch on piston pump control assembly.
10.Position traction control cable to piston (traction)
pump. Secure cable to pump lever and cable bracket
(see Piston (Traction) Pump Control Assembly in this
section).
11. Secure pump drive shaft to piston (traction) pump input shaft with two (2) cap screws (item 36) and flange
nuts (item 37).
12.Install hood saddle onto frame brackets. Lower and
secure hood and operator seat.
13.Check oil level in hydraulic reservoir and add correct
oil if necessary.
14.Follow hydraulic system start- up procedures (see
Hydraulic System Start- up in this section).
15.Check traction drive for neutral and traction neutral
switch operation. Adjust if necessary.

4. Lubricate and position new O- ring (item 15) between pumps. Position gear pump to piston (traction)
pump and secure with two (2) socket head screws, lock
washers and flat washers.

Hydraulic System

Page 4 - 64

Reelmaster 5010- H

Hydraulic
System

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Reelmaster 5010- H

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Hydraulic System

Piston (Traction) Pump Service
7
16

5
4

15
14

9
8

25
26

32 33

29
20

18
19

35
40

23
24

45
46

Figure 59
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Piston (traction) pump housing
Auxiliary shaft
Retaining ring
Ball bearing
Retaining ring
Seal
Backup washer
Bearing (2 used)
O- ring
Trunnion cover
Screw (4 used)
Plug (2 used)
O- ring
Seal
Trunnion cover
Screw (4 used)

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

Spring
Charge relief poppet
Seal kit
Relief valve (forward)
Screw (4 used)
Coupling
End cap
Seal kit
Seal nut
Pin
Swashplate
Thrust plate
Shim kit
O- ring
Charge relief plug
Retaining ring

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.

Hydraulic System

33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.

Bearing
Neutral return arm
Neutral return pivot
Spring
Cylinder block kit
Valve plate
Slotted pin
End cap gasket
Seal kit
Relief valve (reverse)
Needle bearing
Loop flushing spool
Spring
Plug
O- ring
Bypass valve

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.

Page 4 - 66

Reelmaster 5010- H

Hydraulic
System

This page is intentionally blank.

Reelmaster 5010- H

Page 4 - 67

Hydraulic System

Gear Pump Service
15

9
2

6
1

5
18

8
19
12

16
14
33 ft- lb
(45 N- m)

Figure 60
1.
2.
3.
4.
5.
6.
7.

Front cover
Dowel pin (4 used)
Square section seal (4 used)
Back- up seal (4 used)
Pressure seal (4 used)
Thrust plate (4 used)
Drive shaft

8.
9.
10.
11.
12.
13.
14.

Driven gear
Body
Flange
Splined connecting shaft
Drive gear
Driven gear
Body

Disassembly (Fig. 60)
NOTE: The gear pump must be replaced as a complete
assembly. Individual gears, housings and thrust plates
are not available separately. Disassemble gear pump
for cleaning, inspection and seal replacement only.
IMPORTANT: Keep bodies, gears and thrust plates
for each pump section together; do not mix parts
between pump sections.
1. Plug pump ports and thoroughly clean exterior of
pump with cleaning solvent. Make sure work area is
clean.
2. Use a marker to make a diagonal line across the
gear pump for assembly purposes (Fig. 61).

Hydraulic System

15.
16.
17.
18.
19.
20.

Dowel pin (2 used)
Rear cover
Washer (4 used)
Stud bolt (2 used)
Nut (2 used)
Cap screw (2 used)

IMPORTANT: Use caution when clamping gear
pump in a vise to avoid distorting any pump components.
3. Secure the front cover of the pump in a vise with the
drive shaft pointing down.
4. Loosen the two (2) cap screws and two (2) nuts that
secure pump assembly.
5. Remove pump from vise and remove loosened fasteners.
6. Support the pump assembly and gently tap the pump
case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear
mesh.

Page 4 - 68

Reelmaster 5010- H

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. Keep the parts for each pump
section together; do not mix parts between sections.
8. Clean all gear pump parts. Check all components for
burrs, scoring, nicks and other damage.
9. Replace the entire pump assembly if component
parts are excessively worn or scored.
Figure 61

Assembly (Fig. 60)
1. Apply clean hydraulic oil to all parts before assembling.

Hydraulic
System

NOTE: Pressure and back- up seals fit in grooves machined into thrust plates. Square section seals fit in
grooves machined in body faces.
2. Assemble pump sections starting at front cover end.
Apply grease or petroleum jelly to new section seals to
hold them in position during gear pump assembly.
3. After pump has been assembled, tighten cap screws
and nuts by hand.
4. Place a small amount of clean hydraulic fluid into the
inlet of the gear pump and rotate the drive shaft away
from the inlet one revolution. Protect the shaft if using pliers for turning the shaft. If any binding is noted, disassemble the pump and check for assembly problems.
5. Tighten the cap screws and nuts evenly in a crossing
pattern to a torque of 33 ft- lb (45 N- m).

Reelmaster 5010- H

Page 4 - 69

Hydraulic System

Hydraulic Pump Drive Shaft

RIGHT
FRONT

2
1

3
6
8
7
13

14
9

11
5

Antiseize
Lubricant

Figure 62
1.
2.
3.
4.
5.

Hood saddle
Air intake hose
Hose clamp (2 used)
Flange head screw (4 used)
Flange nut (4 used)

Hydraulic System

6.
7.
8.
9.
10.

Upper intake shroud
Lower intake shroud
Brush seal (2 used)
48 VDC motor/generator assembly
Engine bellhousing

Page 4 - 70

11.
12.
13.
14.

Hydraulic pump assembly
Drive shaft assembly
Cap screw (4 used)
Flange nut (4 used)

Reelmaster 5010- H

1. Park the machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.
2. Raise and support hood and operator seat. Lift hood
saddle (item 1) from frame brackets and remove from
machine.
3. Loosen hose clamp that secures air intake hose
(item 2) to upper intake shroud. Carefully slide intake
hose from upper shroud.
4. Remove intake shrouds (items 6 and 7) and brush
seals (item 8) from machine.
A. Remove four (4) flange head screws (item 4) and
flange nuts (item 5) that secure upper and lower intake shrouds.
B. Separate tabs on upper shroud from slots on lower shroud. Remove shrouds and brush seals from
machine.
C. Note location of four (4) compression limiter
spacers in the upper shroud mounting holes.
5. Remove cap screws (item 13) and flange nuts (item
14) that secure drive shaft yokes to hydraulic pump input
shaft and motor/generator output shaft.

3. Secure drive shaft yokes to pump and motor/generator shafts with two (2) cap screws (item 5) and flange
nuts (item 9).
4. Lubricate drive shaft grease fittings.
5. Secure intake shrouds (items 6 and 7) and brush
seals (item 8) to machine.
A. Make sure that four (4) compression limiter spacers are placed in the mounting holes in the upper intake shroud.
B. Position intake shrouds and brush seals around
drive shaft. Make sure that brush seals fit in grooves
of shrouds and grooves in shrouds fit onto flange on
motor/generator cover. Insert upper shroud tabs into
lower shroud openings.
C. Secure upper and lower intake shrouds with four
(4) flange head screws (item 4) and flange nuts (item
5).
6. Carefully slide intake hose (item 2) onto upper
shroud and secure in place with hose clamp.
7. Install hood saddle (item 1) onto frame brackets.
Lower and secure hood and operator seat.

6. Slide drive shaft yokes from hydraulic pump and motor/generator shafts and remove drive shaft assembly
from machine.
Installation (Fig. 62)
1. Apply antiseize lubricant to hydraulic pump input
shaft and motor/generator output shaft.
2. Position drive shaft assembly to hydraulic pump and
motor/generator shafts. The drive shaft male yoke
should be installed onto motor/generator shaft (Fig. 63).
Position female yoke fully onto pump shaft so the shaft
end is flush with the inside of the yoke flange.

Reelmaster 5010- H

3
Figure 63
1. Male yoke (generator)
2. Female yoke (pump)

Page 4 - 71

3. Inside of flange

Hydraulic System

Hydraulic
System

Removal (Fig. 62)

Hydraulic Pump Drive Shaft Cross and Bearing Service

2
3

5
6
1
3

2
8

7
3

Figure 64
1. End yoke (motor/generator)
2. Grease fitting (2 used)
3. Snap ring (4 per cross and bearing)

Hydraulic System

4. Cross and bearing assembly
5. Shaft yoke (male)
6. Grease fitting

Page 4 - 72

7. Telescoping yoke (female)
8. End yoke (piston pump)

Reelmaster 5010- H

Disassembly (Fig. 64)

Assembly (Fig. 64)

1. Remove hydraulic pump drive shaft from vehicle
(see Hydraulic Pump Drive Shaft in this section).

1. To install new cross and bearings:

2. Lightly clamp drive shaft yoke in vise. Use two screwdrivers to remove snap rings that secure bearings at the
inside of each yoke. Remove yoke from vise.
IMPORTANT: Yokes must be supported when removing and installing bearings to prevent damage.
3. Use a press to remove cross and bearings from
yokes:
A. Place a small socket against one bearing and a
large socket against the yoke on the opposite side.
B. While supporting the large socket, apply pressure on small socket to partially push the opposite
bearing into the large socket.
C. Remove yoke from press, grasp partially removed bearing and tap on yoke to completely remove the bearing.
D. Repeat process for remaining bearings.
4. Thoroughly clean and inspect all components.

A. Apply a coating of grease to bearing bores of end
yoke and shaft yoke. Also, apply grease to bearings
and seal of bearing assembly. Make sure that all
bearing rollers are properly seated in bearing cage.
B. Press one bearing partially into yoke.
IMPORTANT: Take care when installing cross
into bearing to avoid damaging bearing seal.
C. Carefully insert cross into bearing and yoke.
D. Hold cross in alignment and press bearing in until
it hits the yoke.
E. Carefully place second bearing into yoke bore
and onto cross shaft. Press bearing into yoke.
F. Install snap rings to bearings to secure bearings
in place.
G. Repeat procedure for other yoke.
H. Grease cross until grease comes out of all four (4)
bearing cups.
2. Make sure that assembled joint moves without binding. Slight binding can usually be eliminated by lightly
rapping the yoke lugs with a soft faced hammer. If binding continues, disassemble joint to identify source of
binding.
3. Install hydraulic pump drive shaft to vehicle (see Hydraulic Pump Drive Shaft in this section).

Reelmaster 5010- H

Page 4 - 73

Hydraulic System

Hydraulic
System

IMPORTANT: When placing yoke in vise, clamp
lightly on the solid part of the yoke to prevent yoke
damage. Also, the use of a vise with soft jaws is recommended.

Front Wheel Motors
24

26
27
25

10
26

22
21

23
11

13
15
8

4
9
7

1
19
17
16
14

3
12

80 to 100 ft- lb
(109 to 135 N- m)

6
315 to 385 ft- lb
(428 to 522 N- m)

RIGHT
2

FRONT

70 to 90 ft- lb
(95 to 122 N- m)

Figure 65
1.
2.
3.
4.
5.
6.
7.
8.
9.

Wheel motor (LH shown)
Lug nut (5 used per wheel)
Hub
Wheel stud (5 used per wheel)
Wheel assembly
Brake drum
Front wheel shield (2 used)
Cap screw (2 used per shield)
Flat washer (2 used per shield)

Hydraulic System

10.
11.
12.
13.
14.
15.
16.
17.
18.

Lock nut (2 used per shield)
Rear wheel shield (LH shown)
Lock nut
Square key
Brake assembly (LH shown)
Cap screw (4 used per brake assy)
Cap screw (4 used per motor)
Spring clip (LH shown)
Lock nut (4 used per motor)

Page 4 - 74

19.
20.
21.
22.
23.
24.
25.
26.
27.

Brake adapter
O- ring
90o hydraulic fitting
O- ring
Hydraulic tube
Hydraulic tube
Dust cap
Test fitting
O- ring

Reelmaster 5010- H

Removal (Fig. 65)

Installation (Fig. 65)

1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the
ignition switch.

1. If fittings were removed from wheel motor, lubricate
and place new O- rings to fittings. Install fittings into motor ports using marks made during the removal process
to properly orientate fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).

2. Chock rear wheels to prevent machine from moving
or shifting.
3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

2. Position wheel motor and brake adapter to frame. Install spring clip (item 17) and four (4) cap screws to
wheel motor and frame. Make sure that spring clip is positioned as noted during disassembly.

4. Remove front wheel, brake drum, wheel hub and
brake assembly from machine (see Brake Service in the
Service and Repairs section of Chapter 6 - Chassis).

3. Install and tighten four (4) lock nuts onto cap screws
to secure motor and brake bracket to frame. Torque lock
nuts from 80 to 100 ft- lb (109 to 135 N- m).

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.
5. Thoroughly clean hydraulic tube ends and fittings on
wheel motor to prevent hydraulic system contamination.
6. Label hydraulic connections at wheel motor for assembly purposes.
7. Disconnect hydraulic tubes from fittings on wheel
motor. Allow tubes to drain into a suitable container.
8. Put caps or plugs on disconnected tubes and fittings
to prevent contamination.
NOTE: Right and left front wheel motors are the same
basic design with some minor differences. The left side
wheel motor can be identified by the machined groove
on the end of the output shaft. If both motors are removed from the machine, label motors for assembly
purposes.

5. Lubricate and position new O- rings to fittings on
wheel motor. Use labels placed during the removal process to properly install and secure hydraulic tubes to
wheel motor fittings (see Hydraulic Hose and Tube Installation in the General Information section of this chapter)
6. Install brake assembly, wheel hub, brake drum and
front wheel to machine (see Brake Service in the Service
and Repairs section of Chapter 6 - Chassis).
7. Make sure that wheel hub lock nut (item 12) is tightened from 315 to 385 ft- lb (428 to 522 N- m) and wheel
lug nuts are tightened from 70 to 90 ft- lb (95 to 122
N- m).
8. Check and adjust oil level in hydraulic reservoir.
IMPORTANT: If a wheel motor 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.
9. Operate machine functions slowly until air is out of
system (see Charge Hydraulic System in this section).

9. Support wheel motor to prevent it from falling. Remove four (4) lock nuts from cap screws that secure motor and brake adapter to frame.
10.Note location of spring clip (item 17) for assembly
purposes. Remove four (4) cap screws and brake
adapter from wheel motor and frame.
11. Remove wheel motor from machine.
12.If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly.
Remove fittings from motor and discard O- rings.

Reelmaster 5010- H

Page 4 - 75

Hydraulic System

Hydraulic
System

4. Remove caps and plugs from disconnected hydraulic tubes and fittings.

Front Wheel Motor Service
11

12
13
12
14

15
16
17
18

1
2
4
20

45 to 55 ft- lb
(61 to 75 N- m)

Figure 66
1.
2.
3.
4.
5.
6.
7.

Cap screw (7 used)
End cap
O- ring (3 used)
Geroler assembly
Valve plate
Thrust bearing
Bearing

8.
9.
10.
11.
12.
13.
14.

Valve
Dowel pin (4 used)
Balancing ring
Valve spring
Back- up ring
O- ring
Drive

NOTE: The front wheel motors are Eaton Delta motors
of the same basic design with minor differences. The
right side motor has a reverse timed manifold to allow
correct rotation direction for forward and reverse. The
left side wheel motor can be identified by the machined
groove on the end of the output shaft.

15.
16.
17.
18.
19.
20.
21.

Output shaft
Bearing race (2 used)
Thrust bearing
Shaft seal
Housing
Bearing
Grease seal

IMPORTANT: If a wheel motor 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.

NOTE: For front wheel motor repair procedures, see
the Eaton Delta Motors Parts and Repair Manual at the
end of this chapter.

Hydraulic System

Page 4 - 76

Reelmaster 5010- H

Hydraulic
System

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Reelmaster 5010- H

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Hydraulic System

Rear Wheel Motors (Machines with Optional CrossTraxTM Kit)

12
14

6
8

11
10
4

RIGHT

270 to 330 ft- lb
(367 to 447 N- m)

FRONT

70 to 90 ft- lb
(95 to 122 N- m)

70 to 80 ft- lb
(95 to 108 N- m)

Figure 67
1.
2.
3.
4.
5.

Lug nut (5 used per wheel)
Rear wheel assembly
Wheel hub assembly
Lock nut
Woodruff key

6.
7.
8.
9.
10.

45o hydraulic fitting (2 per motor)
O- ring
O- ring
Hydraulic hose (4 used)
Cap screw (4 per motor)

Removal (Fig. 67)
1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the
ignition switch.
2. Chock rear wheels to prevent machine from moving
or shifting.

11.
12.
13.
14.

Lock washer (4 per motor)
LH rear wheel motor
RH rear wheel motor
CrossTraxTM control manifold

4. Loosen, but do not remove, lock nut (item 4) from
rear wheel motor shaft.
5. Remove rear wheel from machine (see Wheels in
the Service and Repairs section of Chapter 6 - Chassis).

3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

Hydraulic System

Page 4 - 78

Reelmaster 5010- H

6. Remove wheel hub from rear wheel motor:

Installation (Fig. 67)

IMPORTANT: DO NOT hit wheel hub, puller or wheel
motor with a hammer during wheel hub removal or
installation. Hammering may cause damage to the
wheel motor.

B. Remove lock nut and wheel hub from wheel motor shaft. Locate and retrieve woodruff key (item 5).

CAUTION
Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and
avoid injury from pressurized hydraulic oil. See
Relieving Hydraulic System Pressure in the General Information section of this chapter.
7. Thoroughly clean hydraulic hose ends and fittings on
wheel motor to prevent hydraulic system contamination.
8. Label hydraulic connections at wheel motor for assembly purposes.
9. Disconnect hydraulic hoses from fittings on wheel
motor. Allow hoses to drain into a suitable container.
10.Put caps or plugs on disconnected hoses and fittings
to prevent contamination.
NOTE: Right and left rear wheel motors are the same
basic design with some minor differences. The left side
wheel motor is identified with a yellow dot on the motor
housing near the B port. If both motors are removed
from the machine, label motors for assembly purposes.
11. Support wheel motor to prevent it from falling. Remove four (4) cap screws and lock washers that secure
motor to housing.
12.Remove rear wheel motor from machine.
13.If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly.
Remove fittings from motor and discard O- rings.

Reelmaster 5010- H

2. Position rear wheel motor to housing. Secure wheel
motor to housing with four (4) cap screws and lock washers. Torque cap screws from 70 to 80 ft- lb (95 to 108
N- m).
3. Remove caps and plugs from disconnected hydraulic hoses and fittings.
4. Lubricate and position new O- rings to fittings on
wheel motor. Use labels placed during the removal process to properly install and secure hydraulic hoses to
wheel motor fittings (see Hydraulic Hose and Tube Installation in the General Information section of this chapter)
IMPORTANT: Before wheel hub is installed, thoroughly clean tapers of wheel hub and wheel motor
shaft. Make sure that tapers are free of grease, oil
and dirt. DO NOT use antiseize lubricant when
installing wheel hub.
5. Install woodruff key (item 5) and then wheel hub
(item 3) to wheel motor shaft. Secure wheel hub to the
wheel motor shaft with lock nut (item 4).
6. Install rear wheel to machine (see Wheels in the Service and Repairs section of Chapter 6 - Chassis).
7. Make sure that wheel hub lock nut (item 5) is tightened from 270 to 330 ft- lb (367 to 447 N- m) and wheel
lug nuts are tightened from 70 to 90 ft- lb (95 to 122
N- m).
8. Check and adjust oil level in hydraulic reservoir.
IMPORTANT: If a rear wheel motor 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.
9. Operate machine functions slowly until air is out of
system (see Charge Hydraulic System in this section).

Page 4 - 79

Hydraulic System

Hydraulic
System

A. Make sure that lock nut (item 4) on wheel motor
shaft is loose. Use hub puller (see Special Tools in
this chapter) to loosen wheel hub from wheel motor
shaft.

Rear Wheel Motor Service (Machines with Optional CrossTraxTM Kit)
14
17
21
20

15
12

22
23

45 to 55 ft- lb
(61 to 75 N- m)

3
9

3
3

Figure 68
1.
2.
3.
4.
5.
6.
7.
8.

Cap screw (7 used)
End cover
Body seal (5 used)
Commutator ring
Commutator
Commutator ring
Manifold
Stator

9.
10.
11.
12.
13.
14.
15.
16.

Vane (7 used)
Rotor
Wear plate
Drive link
Thrust bearing
Coupling shaft
Thrust bearing
Thrust washer

NOTE: The rear wheel motors used on machines with
the optional CrossTraxTM Kit are Parker TorqmotorTM
motors of the same basic design with minor differences.
The right side motor has a reverse timed manifold to allow correct rotation direction for forward and reverse.
The left side wheel motor is identified with a yellow dot
on the motor housing near the B port.

17.
18.
19.
20.
21.
22.
23.

Inner bearing
Shaft seal
Back- up washer
Back- up ring
Housing
Outer bearing
Dirt and water seal

NOTE: For Parker wheel motor repair procedures, see
the Parker TorqmotorTM Service Procedure (TC, TB,
TE, TJ, TF, TG, TH and TL Series) at the end of this
chapter.
Hydraulic System

Page 4 - 80

Reelmaster 5010- H

Control Manifold Cartridge Valve Service

2. If cartridge valve is solenoid operated, remove nut
securing solenoid coil to the cartridge valve. Carefully
slide coil off the valve.
IMPORTANT: Use care when handling the cartridge
valve. Slight bending or distortion of the stem tube
can cause binding and malfunction. When removing cartridge valve from manifold, make sure that
deep well socket fully engages the valve base.
3. Remove cartridge valve from manifold using a deep
socket wrench. Note correct location for O- rings, sealing rings and backup rings. Remove seal kit from cartridge valve and discard removed seals.
4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads and contamination.

6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. If cartridge design allows, use a wood or plastic probe to push
the internal spool in and out 20 to 30 times to flush out
contamination. Be extremely careful to not damage cartridge. Use compressed air for cleaning.
7. Install the cartridge valve into the manifold:
A. Lubricate new seal kit components with clean hydraulic oil and install on valve. The O- rings, sealing
rings and backup rings must be arranged properly on
the cartridge valve for proper operation and sealing.
B. Dip assembled cartridge into clean hydraulic oil.

5. Visually inspect cartridge valve for damaged sealing
surfaces and contamination.

IMPORTANT: Use care when handling the valve
cartridge. Slight bending or distortion of the
stem tube can cause binding and malfunction.
When installing cartridge valve into manifold,
make sure that deep well socket fully engages
the valve base.

A. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small valve
orifices or seal areas causing malfunction.

C. Thread cartridge valve carefully into manifold
port by hand until the top O- ring is met. The valve
should go into manifold port easily without binding.

B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or
there may be water in the system.

D. Torque cartridge valve using a deep socket
wrench to value identified in control manifold illustration.
8. If cartridge valve is solenoid operated, carefully
install solenoid coil to the cartridge valve. Secure coil to
valve with nut and torque nut to 60 in- lb (6.8 N- m).

CAUTION
Use eye protection such as goggles when using
compressed air for cleaning manifold components.

Reelmaster 5010- H

9. If problems still exist after assembly, remove valve
and clean again or replace valve.

Page 4 - 81

Hydraulic System

Hydraulic
System

1. Make sure the control manifold is clean before removing the cartridge valve from the control manifold.

Lift Control Manifold

10
17

3
14
19
5

4
9

7
2

RIGHT
FRONT

Figure 69
1.
2.
3.
4.
5.
6.
7.

Lift control manifold
Flange head screw
O- ring
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose

Hydraulic System

8.
9.
10.
11.
12.
13.

Hydraulic hose
Hydraulic hose
Hydraulic tube
Hydraulic tube
O- ring
O- ring

Page 4 - 82

14.
15.
16.
17.
18.
19.

90o hydraulic fitting (2 used)
O- ring
Hydraulic tube
Hydraulic hose
Plug
O- ring

Reelmaster 5010- H

Removal (Fig. 69)

IMPORTANT: When installing orifice in manifold
(Fig. 70), make sure that orifice is flat in the base
of the fitting cavity. Manifold damage is possible
if the orifice is cocked in the cavity.

1. Park the machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.

B. For manifold ports with orifice, place correct orifice in port with the orifice slot facing out.

2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

C. Install fittings into manifold (see Hydraulic Fitting
Installation in the General Information section of this
chapter). Torque fittings to torque values identified in
Figure 70.

3. Locate hydraulic lift control manifold that is attached
to frame bracket under the front platform.

2. Position lift control manifold to frame. Install two (2)
flange head screws but do not fully tighten.
3. Remove caps and plugs from hydraulic lines and fittings.
4. Lubricate and install new O- ring(s) on manifold fittings. Connect and tighten hydraulic lines to hydraulic
manifold fittings (see Hydraulic Hose and Tube Installation in the General Information section of this chapter)
5. Secure hydraulic manifold to frame by tightening two
(2) flange head screws.
6. Connect wire harness leads to solenoid coils on
manifold using labels placed during removal.
7. Check oil level in hydraulic reservoir and add correct
oil if necessary.
8. Follow Hydraulic System Start- up procedures (see
Hydraulic System Start- up in this section).

10 ft- lb
(14 N- m)

8. Remove two (2) flange head screws that secure
manifold to machine frame.

9. Remove lift control manifold from machine.

IMPORTANT: A flow control orifice is placed beneath several hydraulic fittings on the lift control
manifold (Fig. 70). The lift manifold uses three (3)
different orifice sizes. If fittings are removed from
manifold and an orifice is in the manifold port, make
sure to remove orifice and label its position for assembly purposes.

6
3
1

10.If necessary, remove hydraulic fittings from manifold.
Discard any removed O- rings. Locate, retrieve and label orifice from manifold ports (if equipped).

6
2

10 ft- lb
(14 N- m)

Installation (Fig. 69)

Figure 70

1. If fittings were removed from manifold:
A. Lubricate new O- rings with clean hydraulic oil.
Install lubricated O- rings on fittings.
Reelmaster 5010- H

10 ft- lb
(14 N- m)

1. Fitting (2 used)
2. O- ring
3. Orifice (0.046)

Page 4 - 83

4. Orifice (0.028)
5. Fitting (6 used)
6. Orifice (0.055)

Hydraulic System

Hydraulic
System

4. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to
loosening hydraulic lines.

Lift Control Manifold Service
60 in- lb
(6.7 N- m)

25 ft- lb
(33 N- m)

9
7
6

60 in- lb
(6.7 N- m)

25 ft- lb
(33 N- m)
10

60 in- lb
(6.7 N- m)

4
11
20 ft- lb
(27 N- m)

20 ft- lb
(27 N- m)

3
12

20 ft- lb
(27 N- m)

RIGHT

75 ft- lb
(101 N- m)

FRONT

15
16

Figure 71
1.
2.
3.
4.
5.
6.

Lift control manifold
Check valve (4 used)
Solenoid valve (SV3)
Solenoid coil (2 used)
Solenoid coil spacer (2 used)
Nut (3 used)

7.
8.
9.
10.
11.

Solenoid valve (SV2)
Solenoid coil (2 used)
Nut
Solenoid relief valve (SVRV)
Solenoid valve (SV1)

12.
13.
14.
15.
16.

Relief valve (R7)
O- ring
Pilot piston (4 used)
O- ring
Hex plug (4 used)

NOTE: The ports on the lift control manifold are marked
for easy identification of components. Example: P4 is
the gear pump connection port and SV2 is the location
for solenoid valve SV2 (see Hydraulic Schematic to
identify the function of the hydraulic lines and cartridge
valves at each port location).

Hydraulic System

Page 4 - 84

Reelmaster 5010- H

For lift control manifold service procedures, see Control
Manifold Cartridge Valve Service in this section. Refer
to Figure 71 for cartridge valve installation torque. Refer
to Figures 71 and 72 for hydraulic fitting installation
torque values.
NOTE: Solenoid valves SV1 and SV2 on the lift control
manifold use a coil spacer between the solenoid coil and
nut.

10 ft- lb
(14 N- m)

10 ft- lb
(14 N- m)
3

NOTE: Adjustment of Relief Valve (R7) is NOT recommended.

IMPORTANT: A flow control orifice is placed beneath several of the hydraulic fittings on the lift control manifold (Fig. 72). The lift manifold uses three
(3) different orifice sizes. If a fitting is removed from
the lift control manifold and an orifice is in the manifold port, make sure to remove orifice and label its
position for assembly purposes.

3
1

6
2

10 ft- lb
(14 N- m)

Figure 72
1. Fitting (2 used)
2. O- ring
3. Orifice (0.046)

4. Orifice (0.028)
5. Fitting (6 used)
6. Orifice (0.055)

Hydraulic
System

IMPORTANT: When installing orifice in manifold
(Fig. 72), 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.

Reelmaster 5010- H

Page 4 - 85

Hydraulic System

CrossTraxTM AWD Manifold (Machines with Optional CrossTraxTM Kit)
11
15

14
8

13
10

7
1

6
5

RIGHT

FRONT
3

Figure 73
1.
2.
3.
4.
5.

CrossTrax AWD manifold
Hydraulic tube
Hydraulic tube
Hydraulic tube
O- ring

6.
7.
8.
9.
10.

Hydraulic fitting (7 used)
O- ring
Dust cap (2 used)
Diagnostic fitting (2 used)
O- ring

Removal (Fig. 73)
1. Park the machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. Locate CrossTraxTM AWD manifold that is attached
to bracket at rear of frame.
4. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to
loosening hydraulic lines.

Hydraulic System

11.
12.
13.
14.
15.

Cap screw (3 used)
Lock washer (3 used)
Spacer (3 used)
Hydraulic hose (4 used)
Frame bracket

Page 4 - 86

Reelmaster 5010- H

6. Put caps or plugs on disconnected lines and fittings
to prevent contamination.

3. Remove caps and plugs from disconnected hydraulic lines and fittings.

7. Support manifold to prevent it from falling. Remove
three (3) cap screws and lock washers that secure manifold to machine frame. Locate and retrieve three (3)
spacers from between frame bracket and manifold.

4. Lubricate and install new O- ring(s) on manifold fittings. Connect hydraulic lines to hydraulic manifold fittings. Properly tighten all connections (see Hydraulic
Hose and Tube Installation in the General Information
section of this chapter).

8. Remove AWD manifold from machine.
9. If necessary, remove hydraulic fittings from manifold.
Discard any removed O- rings.
Installation (Fig. 73)
1. If fittings were removed from AWD manifold, lubricate and place new O- rings to fittings. Install fittings into
manifold (see Hydraulic Fitting Installation in the General Information section of this chapter).

5. Secure AWD manifold to frame by tightening three
(3) cap screws.
6. Check oil level in hydraulic reservoir and add correct
oil if necessary.
7. Follow hydraulic system start- up procedures (see
Hydraulic System Start- up in this section).

Hydraulic
System

2. Position manifold and three (3) spacers to frame
bracket. Install three (3) lock washers and cap screws
but do not fully tighten.

Reelmaster 5010- H

Page 4 - 87

Hydraulic System

CrossTraxTM AWD Manifold Service (Machines with Optional CrossTraxTM Kit)
220 in- lb
(24.8 N- m)

25 ft- lb
(33 N- m)

3
2

11
4
220 in- lb
(24.8 N- m)

25 ft- lb
(33 N- m)
2

220 in- lb
(24.8 N- m)

4
5

8
7

46 ft- lb
(62 N- m)

120 in- lb
(13.5 N- m)

Figure 74
1.
2.
3.
4.

CrossTrax AWD manifold
O- ring
Plug (NWD #6)
Seal kit

5.
6.
7.
8.

Check valve
Plug (NWD #4)
O- ring
Orifice (.040)

9.
10.
11.
12.

Plug (NWD #8)
O- ring
Seal kit
Bi- Directional relief valve

For CrossTraxTM AWD control manifold service procedures, see Control Manifold Cartridge Valve Service in
this section. Refer to Figure 74 for cartridge valve and
plug installation torque.
NOTE: Adjustment of bi- directional relief valve (item
12) is NOT recommended.

Hydraulic System

Page 4 - 88

Reelmaster 5010- H

Hydraulic
System

This page is intentionally blank.

Reelmaster 5010- H

Page 4 - 89

Hydraulic System

Lift Cylinders

Medium strength
Threadlocker
77 to 93 ft- lb
(105 to 126 N- m)

18
2

17
5
15

3
16

9
11
12
13

8
7
4

8
6

RIGHT
FRONT
11

Figure 75
1.
2.
3.
4.
5.
6.

Lift cylinder
Cylinder pin
Flange head screw
Lift arm (#4 shown)
Flat washer
Hydraulic hose

7.
8.
9.
10.
11.
12.

O- ring
90o hydraulic fitting
O- ring
Hydraulic hose
Retaining ring
Thrust washer

13.
14.
15.
16.
17.
18.

Cylinder slide pin
Carriage screw
Flange nut
R- clamp
Cap screw
Lock nut

NOTE: The procedure for lift cylinder removal and
installation is the same for all Reelmaster 5010- H lift cylinders. Figure 75 shows the lift cylinder for the #4 cutting
unit (left front).

Hydraulic System

Page 4 - 90

Reelmaster 5010- H

1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.

9. Remove flange head screw (item 3) and flat washer
(item 5) that retain lift cylinder to cylinder pin.
10.Slide lift cylinder from cylinder pin and remove from
machine.

2. To prevent unexpected cutting unit operation, disconnect the cutting units from the electrical power supply by unplugging the 48 VDC battery disconnect (see
48 VDC Battery Disconnect in the General Information
section of this chapter).

11. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly.
Remove fittings from lift cylinder and discard O- rings.

3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

1. 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.

4. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to
loosening hydraulic lines from lift cylinder.
5. If lift cylinder for outside front cutting units (#4 or #5)
is being removed, remove flange nut and carriage screw
that secure the hydraulic hose R- clamp to lift cylinder.

2. Position lift cylinder to the frame with the barrel end
up.
3. Slide lift cylinder clevis onto cylinder pin.
4. Apply medium strength threadlocker to threads of
flange head screw (item 3). Secure cylinder with flange
head screw (item 3) and flat washer (item 5). Torque
screw from 77 to 93 ft- lb (105 to 126 N- m).
5. Align lift cylinder to lift arm mounting slot. Slide cylinder slide pin (item 13) with retaining ring (item 12) and
thrust washer (item 12) through the lift arm and lift cylinder. Install second thrust washer on pin and secure with
second retaining ring.
6. Remove caps and plugs from disconnected hoses
and fittings.

WARNING
Make sure that cutting units are fully lowered before loosening hydraulic lines from lift cylinders.
If cutting units are not fully lowered as hydraulic
lines are loosened, the cutting units may drop
unexpectedly.
6. Disconnect hydraulic hoses from fittings in lift cylinder that is to be removed. Allow hoses to drain into a suitable container. Remove and discard O- rings.
7. Put caps or plugs on disconnected hoses and fittings
to prevent contamination.
8. Remove one retaining ring (item 11) and thrust washer (item 12) from the cylinder slide pin (item 13) that secures lift cylinder to lift arm. Pull slide pin from the lift
cylinder and lift arm. Locate and retrieve second thrust
washer.

Reelmaster 5010- H

Installation (Fig. 75)

7. Coat new O- rings lightly with clean hydraulic oil,
install new O- rings and connect hydraulic hoses to fittings on lift cylinder. Tighten hose connections (see Hydraulic Hose and Tube Installation in the General
Information section of this chapter).
8. Check oil level in hydraulic reservoir and add correct
oil if necessary.
9. Lubricate lift cylinder grease fittings.
10.Plug the cutting unit power disconnect connector
back in before operating the machine.
11. Follow hydraulic system start- up procedures (see
Hydraulic System Start- up in this section).

Page 4 - 91

Hydraulic System

Hydraulic
System

Removal (Fig. 75)

Lift Cylinder Service
1

9
14
4
7

11
12

40 ft- lb
(54 N- m)

2
8

Figure 76
1.
2.
3.
4.
5.

Grease fitting
Shaft
Dust seal
Head
BS seal

6.
7.
8.
9.
10.

Retaining ring
Back up washer
O- ring
Piston
Wear ring

NOTE: The front, outside lift cylinders are longer with
more stroke than the other lift cylinders which are identical. Service procedures for all lift cylinders used on Reelmaster 5010- H machines are the same.
Disassembly (Fig. 76)
1. Remove oil from lift cylinder into a drain pan by slowly
pumping the cylinder shaft. Plug both ports and clean
the outside of the cylinder.

Hydraulic System

11.
12.
13.
14.
15.

BP seal
O- ring
Lock nut
Barrel
Grease fitting

IMPORTANT: Prevent damage when clamping the
lift cylinder into a vise; clamp on the clevis end of
the barrel ONLY.
2. Mount lift cylinder securely in a vise by clamping on
the clevis end of the barrel. Use of a vise with soft jaws
is recommended.

Page 4 - 92

Reelmaster 5010- H

4. Remove plugs from ports. Extract shaft, head and
piston by carefully twisting and pulling on the shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Clamp on the clevis ONLY.
5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Remove lock nut and piston from the
shaft. Carefully slide head off the shaft.
6. Taking care to not scratch or damage the piston, remove wear ring, BP seal and O- ring from the piston.
7. Taking care to not scratch or damage the head, remove O- ring, back- up washer, dust seal and BS seal
from the head.

2. Coat new O- rings, back- up washer and other seals
with clean hydraulic oil.
A. Carefully install wear ring, BP seal and O- ring to
the piston.
B. Carefully install back- up washer, O- ring, dust
seal and BS seal to the head.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Clamp on the clevis ONLY.
3. Mount shaft securely in a vise by clamping on the clevis of the shaft.
A. Coat shaft with clean hydraulic oil.
B. Slide head assembly onto the shaft.
C. Install piston assembly onto the shaft and secure
with lock nut. Torque lock nut 40 ft- lb (54 N- m).
D. Remove shaft assembly from the vise.
IMPORTANT: Prevent damage when clamping the
hydraulic cylinder into a vise; clamp on the clevis
end of the barrel ONLY.

8. Discard removed seals and O- rings.
Inspection

4. Mount barrel securely in a vise by clamping on the
clevis end of the barrel.

CAUTION
Use eye protection such as goggles when using
compressed air to clean lift cylinder components.

IMPORTANT: When installing the head into the barrel, pay careful attention to the retaining ring slot in
the barrel to insure that the piston and head seals do
not lodge in the slot.

1. Wash all lift cylinder components in solvent. Dry
parts with compressed air.

5. Coat all internal parts with a light coat of clean hydraulic oil. Slide piston, shaft and head assembly into
the barrel being careful not to damage the seals.

2. Inspect internal surface of barrel for deep scratches,
out- of- roundness and bending.

6. Secure head in barrel by installing retaining ring.

3. Inspect head, shaft and piston for excessive pitting,
scoring and wear.
4. Replace lift cylinder if internal components are found
to be worn or damaged.
Assembly (Fig. 76)

A. Align retaining ring hole in the head with the access slot in the barrel.
B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are
covered.

1. Make sure all lift cylinder parts are clean before assembly.

Reelmaster 5010- H

Page 4 - 93

Hydraulic System

Hydraulic
System

3. Using a spanner wrench, rotate head clockwise until
the edge of the retaining ring appears in the barrel opening. Insert a screwdriver under the beveled edge of the
retaining ring to start the retaining ring through the opening. Rotate the head counter- clockwise to remove retaining ring from barrel and head.

Steering Control Valve
Antiseize
Lubricant

7
5

RIGHT

FRONT

20 to 26 ft lb
(28 to 35 N- m)

10
11

2nd

12
7 to 10 ft- lb
(9.5 to 13.5 N- m)

Antiseize
Lubricant

FRONT

3rd

4th
Tightening
Sequence
(Item 9)

1st

Figure 77
1.
2.
3.
4.
5.

Steering control valve
Flange head screw (2 used)
Socket head screw (4 used)
Steering wheel
Flat washer

6.
7.
8.
9.
10.

Lock nut
Steering wheel cover
Steering column
Socket head screw (4 used)
O- ring

Removal (Fig. 77)
1. 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. Remove fasteners that secure shroud to front of machine (Fig. 78). Remove shroud from machine to allow
access to steering control valve. Locate and retrieve two
(2) rubber bushings and spacers.
3. Slide rubber bellows up from bottom of steering column. Support steering column to prevent it from falling.

Hydraulic System

11.
12.
13.
14.

Hydraulic fitting (4 used)
O- ring
Steering column brace
Flange nut (6 used)

4. Loosen and remove four (4) flange head screws and
flange nuts that secure steering column brace (item 13)
to machine. Remove brace.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
6. Label all hydraulic connections for assembly purposes. Note port designations on steering control valve
(Fig. 79). Thoroughly clean hydraulic connections prior
to loosening hydraulic lines.

Page 4 - 94

Reelmaster 5010- H

7. Position steering column brace (item 13) to machine
and secure with four (4) flange head screws and flange
nuts.

8. Slide rubber bellows to bottom of steering column.
9. Place rubber bushings and spacers into holes of
shroud (Fig. 78). Position shroud in place and secure
with removed fasteners.
10.Check oil level in hydraulic reservoir and add correct
oil if necessary.
11. Follow Hydraulic System Start- up procedures (see
Hydraulic System Start- up in this section).

9. Remove two (2) socket head screws and flange nuts
that secure steering column to machine.

10.Remove steering column assembly with steering
control valve attached from machine.

12.Remove steering control valve from steering column.
13.If necessary, remove fittings and O- rings from steering control valve. Discard all removed O- rings.

6
7

Installation (Fig. 77)
1. If fittings were removed, lubricate new O- rings with
clean hydraulic oil and install fittings to steering control
valve (see Hydraulic Fitting Installation in the General
Information section of this chapter).
2. Apply antiseize lubricant to splines of steering control valve shaft.
3. Slide steering control valve shaft into steering column universal joint. Position control valve with ports toward front of machine. Secure steering control valve to
steering column with four (4) socket head screws. Hand
tighten screws in the sequence shown in Figure 77.
Then, using the same sequence, torque screws from 7
to 10 ft- lb (9.5 to 13.5 N- m).

Figure 78
1.
2.
3.
4.

Shroud
Screw (2 used)
Flat washer (2 used)
Phillips screw (2 used)

5. Lock nut (2 used)
6. Rubber bushing (2 used)
7. Spacer (2 used)

4. Position steering column assembly to machine. Secure steering column in place with two (2) socket head
screws and flange nuts at rear two mounting holes.
5. Remove caps and plugs from disconnected lines
and fittings.
6. Lubricate new O- rings and connect hydraulic lines
to fittings on steering control valve. Tighten connections
(see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
Reelmaster 5010- H

Page 4 - 95

R
P
Figure 79
Hydraulic System

Hydraulic
System

11. Loosen and remove four (4) socket head screws that
secure steering control valve to steering column.

Steering Control Valve Service
26

25
24

20
19
18

12
11

9
17
8

15
7
4
13

6
5
4
3
20 to 24 ft- lb
(27 to 33 N- m)

2
1

Figure 80
1.
2.
3.
4.
5.
6.
7.
8.
9.

Screw (5 used)
O- ring (5 used)
End cover
O- ring
Outer gearwheel
Inner gearwheel
Distributor plate
O- ring
Cardan shaft

10.
11.
12.
13.
14.
15.
16.
17.
18.

Spool
Sleeve
Cross pin
Spring set
Ring
Thrust washer
Bearing
Shaft seal
Ball stop

19.
20.
21.
22.
23.
24.
25.
26.

Check ball
Housing
Dust seal ring
Relief valve
Spring
O- ring
Plug
Plug

NOTE: For repair of the steering control valve, see the
Sauer- Danfoss Steering Unit Type OSPM Service
Manual at the end of this chapter.

Hydraulic System

Page 4 - 96

Reelmaster 5010- H

Hydraulic
System

This page is intentionally blank.

Reelmaster 5010- H

Page 4 - 97

Hydraulic System

Steering Cylinder

6
7

5
3
2
15

14
13

12
11

RIGHT
FRONT

Figure 81
1.
2.
3.
4.
5.

Steering cylinder
Retaining ring
Grease fitting
Hydraulic hose
O- ring

6.
7.
8.
9.
10.

90o hydraulic fitting
O- ring
Hydraulic hose
Grease fitting
Ball joint

11.
12.
13.
14.
15.

Removal (Fig. 81)
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

Hydraulic System

Jam nut
Cotter pin
Slotted hex nut
Washer
Ball joint

Page 4 - 98

Reelmaster 5010- H

4. Disconnect hydraulic hoses from fittings in steering
cylinder.
5. Put caps or plugs on disconnected hoses and fittings
to prevent contamination.
6. Remove two (2) jam nuts (item 11) that secure steering cylinder to axle. Remove cotter pin (item 12), washer
(item 14) and slotted hex nut (item 13) that secure steering cylinder to RH drag link.
7. Separate ball joints from axle assembly and remove
steering cylinder from machine.
8. If necessary, remove ball joints from steering cylinder barrel and shaft (Fig. 82). If ball joint is to be removed
from cylinder shaft, fully retract cylinder shaft and measure center to center length to ease installation of ball
joint onto cylinder shaft (Fig. 83).

8. Remove caps and plugs from hydraulic hoses and
fittings.
9. Lubricate and install new O- rings on steering cylinder fittings. Correctly connect hydraulic hoses to steering cylinder fittings (see Hydraulic Hose and Tube
Installation in the General Information section of this
chapter).
10.Check oil level in hydraulic reservoir and add correct
oil if necessary.
11. Lubricate cylinder ball joint grease fittings.
12.Follow Hydraulic System Start- up procedures (see
Hydraulic System Start- up in this section).
13.Check that steering cylinder does not contact the
axle or frame as cylinder moves from fully retracted to
fully extended. Also, check that distance between the
drag links and steering stops are equal on both sides of
the machine. If necessary, adjust location of ball joint on
cylinder shaft.

9. If hydraulic fittings are to be removed from steering
cylinder, mark fitting orientation to allow correct assembly. Remove fittings from steering cylinder and discard
O- rings.

Installation (Fig. 81)

4
3

1. If hydraulic fittings were removed from steering cylinder, lubricate new O- rings with clean hydraulic oil, position O- rings to fittings and install fittings into steering
cylinder ports (see Hydraulic Fitting Installation in the
General Information section of this chapter). Make sure
that fittings are orientated correctly.

2. If removed, press ball joint into barrel and secure with
retaining ring. Make sure that retaining ring is fully seated in groove in steering cylinder barrel.
3. If ball joint was removed from cylinder shaft, fully retract cylinder shaft and thread ball joint onto shaft so that
center to center length is as measured during removal
process. Tighten clamp bolt and nut.

Figure 82
1.
2.
3.
4.
5.

Steering cylinder
Ball joint
Retaining ring
Grease fitting
Ball joint

6.
7.
8.
9.

Hex nut
Cap screw
Seal
Grease fitting

4. Thoroughly clean tapers on ball joints and axle assembly.
5. Position steering cylinder to machine.
6. Secure steering cylinder to axle with jam nuts (item
11). Tighten first jam nut and then, while holding first jam
nut with wrench, tighten second jam nut.
7. Secure steering cylinder to RH drag link with washer
(item 14) and slotted hex nut (item 13). Install cotter pin
(item 12).

MEASURE CENTER TO CENTER LENGTH
FOR ASSEMBLY PURPOSES

Figure 83
Reelmaster 5010- H

Page 4 - 99

Hydraulic System

Hydraulic
System

3. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic hose ends prior to
disconnecting hoses from the steering cylinder.

Steering Cylinder Service

40 ft- lb
(54 N- m)
12

9
11

13
1

Figure 84
1.
2.
3.
4.
5.

Shaft
Dust seal
BP seal
Head
Retaining ring

6.
7.
8.
9.

Back- up ring
O- ring
O- ring
Piston

Disassembly (Fig. 84)
1. Remove oil from steering cylinder into a drain pan by
slowly pumping the cylinder shaft. Plug both ports and
clean the outside of the cylinder.
IMPORTANT: Prevent damage when clamping the
steering cylinder into a vise; clamp on the clevis end
of the barrel ONLY.
2. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft
jaws is recommended.
3. Using a spanner wrench, rotate head clockwise until
the edge of the retaining ring appears in the barrel opening. Insert a screwdriver under the beveled edge of the
retaining ring to start the retaining ring through the opening. Rotate the head counter- clockwise to remove retaining ring from barrel and head.
Hydraulic System

10.
11.
12.
13.

BS seal
Barrel
Wear ring
Lock nut

4. Remove plugs from ports. Extract shaft, head and
piston by carefully twisting and pulling on the shaft.
IMPORTANT: To prevent shaft damage, do not
clamp shaft surface in a vise.
5. Using a wrench on shaft flats to prevent shaft from
rotating, remove lock nut.
6. Carefully slide piston and then head from shaft.
7. Taking care to not scratch or damage the piston, remove wear ring, BP seal and O- ring from the piston.
8. Taking care to not scratch or damage the head, remove O- ring, back- up ring, dust seal and BS seal from
the head.
9. Discard removed seals and O- rings.

Page 4 - 100

Reelmaster 5010- H

Inspection

IMPORTANT: To prevent shaft damage, do not
clamp shaft surface in a vise.

Use eye protection such as goggles when using
compressed air to clean steering cylinder components.
1. Wash all cylinder components in solvent. Dry parts
with compressed air.
2. Inspect internal surface of barrel for deep scratches,
out- of- roundness and bending. Replace if worn or
damaged.
3. Inspect head, shaft and piston for excessive pitting,
scoring and wear. Replace any worn or damaged parts.

4. Using a wrench on shaft flats to prevent shaft from
rotating, install lock nut. Torque lock nut 40 ft- lb (54
N- m).
IMPORTANT: Prevent damage when clamping the
steering cylinder into a vise; clamp on the clevis end
of the barrel ONLY.
5. Mount barrel securely in a vise by clamping on the
clevis end of the barrel.
IMPORTANT: When installing the head into the barrel, pay careful attention to the retaining ring slot in
the barrel to insure that the piston and head seals do
not lodge in the slot.

Assembly (Fig. 84)

6. Coat all internal parts with a light coat of clean hydraulic oil. Slide piston, shaft and head assembly into
the barrel being careful not to damage the seals.

1. Make sure all cylinder parts are clean before assembly.

7. Secure head in barrel by installing retaining ring.

2. Coat new O- rings, back- up ring and other seals with
clean hydraulic oil.

A. Align retaining ring hole in the head with the access slot in the barrel.

A. Carefully install O- ring, BP seal and wear ring to
the piston.

B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are
covered.

B. Carefully install back- up ring, O- ring, BS seal
and dust seal to the head.
3. Coat shaft with clean hydraulic oil. Slide head and
piston onto the shaft.

Reelmaster 5010- H

Page 4 - 101

Hydraulic System

Hydraulic
System

CAUTION

Hydraulic Oil Cooler

RIGHT

30 to 40 in- lb
(3.4 to 4.5 N- m)

FRONT
13

11 10

9
5

7
6

5
14
15

6
3

8
4
17

30 to 40 in- lb
(3.4 to 4.5 N- m)

Figure 85
1.
2.
3.
4.
5.
6.

Oil cooler
Hose clamp (4 used)
Hydraulic hose (2 used)
Radiator
Cooler clamp (16 used)
Flat washer (8 used)

Hydraulic System

7.
8.
9.
10.
11.
12.

Cap screw (4 used)
Flange nut (10 used)
Top cooler bracket
Cap screw (2 used)
Washer (4 used)
Clamp (2 used)

Page 4 - 102

13.
14.
15.
16.
17.

Flange nut (4 used)
Cooler mount plate (2 used)
Cap screw (4 used)
Rear screen
Hydraulic tube (2 used)

Reelmaster 5010- H

Removal (Fig. 85)

2. Unlatch and open the rear screen.
3. Remove battery to ease oil cooler removal (see 12
Volt Battery Service in the Service and Repairs section
of Chapter 5 - Electrical System).
4. Label all oil cooler hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to loosening hydraulic hoses at oil cooler.
5. Loosen hose clamps that secure hydraulic hoses to
oil cooler fittings. Remove hoses from oil cooler. Allow
hoses to drain into a suitable container.
6. Rotate clamps that secure oil cooler to radiator
frame.

CAUTION
Use eye protection such as goggles when using
compressed air to clean the oil cooler.
2. Dry inside of oil cooler using compressed air in the
opposite direction of oil flow.
3. Plug both ends of oil cooler. Clean exterior of cooler.
Make sure oil cooler fins are clear of dirt and debris.
4. The oil cooler should be free of corrosion, cracked
tubes or excessive pitting of tubes.
Installation (Fig. 85)
1. If removed, install clamps and brackets to oil cooler
using Figure 85 as a guide.

7. Carefully remove oil cooler from machine.

2. Position oil cooler to radiator and secure with
clamps.

8. If necessary, remove clamps and brackets from oil
cooler using Figure 85 as a guide.

3. Install hydraulic hoses to oil cooler fittings and secure with hose clamps.

Inspection

4. Install battery (see 12 Volt Battery Service in the Service and Repairs section of Chapter 5 - Electrical System).

1. Back flush oil cooler with cleaning solvent. After cooler is clean, make sure all solvent is drained from the
cooler.

5. Close and secure rear screen.
6. Check oil level in hydraulic reservoir and add correct
oil if necessary.

Reelmaster 5010- H

Page 4 - 103

Hydraulic System

Hydraulic
System

1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.

This page is intentionally blank.

Hydraulic System

Page 4 - 104

Reelmaster 5010- H

Chapter 5

Electrical System
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2
48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 2
Toro Electronic Controller (TEC) . . . . . . . . . . . . . . 3
CAN- bus Communications . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SYSTEM OPERATION . . . . . . . . . . . . 4
12 VDC System Operation . . . . . . . . . . . . . . . . . . . 4
48 VDC System Operation . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INFOCENTER DISPLAY . . . . . . . . . . . . . . . . . . . . . . 10
Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main Information Screens . . . . . . . . . . . . . . . . . . . 11
Access Protected Display Screens . . . . . . . . . . . 12
Main Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . 13
Faults Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Diagnostics Screen . . . . . . . . . . . . . . . . . . . . . . . . . 15
Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
About Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator Advisories . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General Run and Transport Problems . . . . . . . . . 37
Cutting Unit Operating Problems . . . . . . . . . . . . . 38
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . 40
12 VDC Battery Test (Open Circuit Test) . . . . . . 40
Engine Charging System Test . . . . . . . . . . . . . . . 40
Glow Plug System Test . . . . . . . . . . . . . . . . . . . . . 40
Check Operation of Interlock Switches . . . . . . . . 41
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . . 42
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 43
Cutting Unit Down Limit Switch . . . . . . . . . . . . . . 44
Mow/Transport Switch . . . . . . . . . . . . . . . . . . . . . . 45

Reelmaster 5010- H

COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 VDC System Fuses . . . . . . . . . . . . . . . . . . . . . .
48 VDC System Fuses . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Switch . . . . . . . . . . . . . . . . . . . . . . .
Reel Engage/Disengage Switch . . . . . . . . . . . . . .
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . .
Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . .
Cutting Unit Down Limit Switch . . . . . . . . . . . . . .
Joystick Raise and Lower Switches . . . . . . . . . . .
Mow/Transport Switch . . . . . . . . . . . . . . . . . . . . . .
Main Power, Glow and 48 VDC Logic Relays . .
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toro Electronic Controller (TEC) . . . . . . . . . . . . .
Fusible Link Harness . . . . . . . . . . . . . . . . . . . . . . .
Diode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 VDC System Protection Diode . . . . . . . . . . . .
Location ID Module . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . .
CAN- bus Termination Resistors . . . . . . . . . . . . .
Hydraulic Solenoid Valve Coil . . . . . . . . . . . . . . . .
Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . .
Hydraulic Solenoid Valve Coils . . . . . . . . . . . . . . .
12 VDC Battery Service . . . . . . . . . . . . . . . . . . . . .
48 VDC Battery Pack Service (Cutting Reel
and Motor/Generator Systems) . . . . . . . . . . . . .
48 VDC Electrical Power Connections . . . . . . . .
Cutting Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Reel Motor Service . . . . . . . . . . . . . . . . . .
Motor/Generator Assembly . . . . . . . . . . . . . . . . . .
Motor/Generator Assembly Service . . . . . . . . . . .

Page 5 - 1

46
46
47
48
49
50
51
52
53
54
55
56
57
58
60
61
62
64
65
66
67
68
69
70
71
72
73
74
76
77
77
78
82
86
88
90
92
96

Electrical System

Electrical
System

Table of Contents

General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Reelmaster machine. Refer to that
publication for additional information when servicing the
machine.

Electrical Drawings
The electrical schematic and wire harness drawings for
Reelmaster 5010- H machines are located in Chapter 9
- Foldout Drawings.

48 VDC Battery Disconnect

CAUTION

FRONT
1

The 48 VDC battery disconnect is attached to the right
frame rail under the operator seat (Fig. 1). Unplug the
disconnect to make sure that 48 VDC components do
not operate unexpectedly. Apply dielectric grease to the
contact surfaces of the battery disconnect and plug the
battery disconnect back in after service to the 48 VDC
system is completed.

Figure 1
1. RH frame rail

Electrical System

Page 5 - 2

2. 48V battery disconnect

Reelmaster 5010- H

Toro Electronic Controller (TEC)
Reelmaster 5010- H machines use a Toro Electronic
Controller (TEC) to manage machine electrical functions. The controller is microprocessor controlled that
senses the condition of various switches and sensors
(inputs). The controller then directs electrical power to
control appropriate machine functions (outputs) based
on the input state. Communication between the TEC
controller, the InfoCenter Display, the cutting unit motors
and the motor/generator is provided by a CAN- bus system. The status of inputs to the TEC controller as well as
outputs from the TEC controller can be monitored with
the InfoCenter Display.

The TEC controller is located behind the access panel
on the outside of the control arm (Fig. 2).
IMPORTANT: To prevent machine electrical system
damage while welding on the machine, disconnect
the battery cables from the batteries, disconnect the
wire harness connectors from the Toro Electronic
Controller and disconnect the terminal connector
from the alternator.

1
Figure 2
1. Control arm

2. TEC controller

System communication between electrical components
on Reelmaster 5010- H machines is accomplished on
two (2) CAN- bus communication systems. These
CAN- bus systems reduce the number of electrical components and connections used on the machine and allow the number of wires in the wire harness to be
reduced. The integration of machine electrical functions
also allows the InfoCenter Display to assist with electrical system diagnostics.
One of these CAN- bus systems allows TEC controller
communication between machine 12 VDC components
(e.g. engine components, InfoCenter display). The second CAN- bus system provides necessary control for
the electric cutting reels system (motor/generator, cutting reel motors). An isolation module is included in the
machine electrical system to allow communication between the two systems while maintaining ground isolation for the 48 VDC system.

Reelmaster 5010- H

CAN identifies the Controller Area Networks that is used
on the Reelmaster. Two (2) specially designed, twisted
wires form the bus for both of the networks used on the
Hybrid machines. These wires provide the data pathways between machine components. The engineering
term for these two (2) wires are CAN- high and CANlow. At the ends of the twisted pair of bus wires are 120
ohm termination resistors. The bus wires for the 12 VDC
circuits are black/white and red/white and the bus wires
for the 48 VDC circuits are green and yellow.
Each of the components that is controlled by the CANbus link needs only four (4) wires to operate and communicate to the system: CAN High, CAN Low, B+ (power)
and ground. The CAN- bus needs the ignition switch ON
input for the TEC, InfoCenter Display, motor/generator
and cutting unit motors to be activated.
IMPORTANT: The termination resistors at the ends
of the bus wires are required for proper electrical
system operation.

Page 5 - 3

Electrical System

Electrical
System

CAN- bus Communications

Electrical System Operation
Reelmaster 5010- H machines use two (2) separate
electrical systems. Most machine functions operate on
a typical 12 VDC system. The second system exists to
operate the electric cutting reels and is a 48 VDC electrical system. Basic information about the two systems is
included below.

12 VDC System Operation
Engine electrical components, machine operation
switches, hydraulic solenoid coils, the machine Toro
electronic controller (TEC) and the InfoCenter display
are all included in the 12 VDC system on Reelmaster
5010- H machines. A 12 volt battery at the rear of the
machine and the engine alternator provide system electrical power. Circuit protection for the 12 VDC system includes two (2) fuse blocks, an inline TEC logic fuse and
several fusible links.

Electrical System

12 VDC system communication between the TEC controller, InfoCenter display and the motor/generator is accomplished on a CAN- bus communication system. Two
(2) specially designed, twisted wires form the bus for this
network. The bus wires for the 12 VDC circuits are black/
white and red/white.
Information about electrical components in the 12 VDC
system is included in the Component Testing and Service and Repairs sections of this chapter.

Page 5 - 4

Reelmaster 5010- H

48 VDC System Operation
The Reelmaster 5010- H 48 VDC system includes a 48
VDC battery pack, an engine driven motor/generator assembly, five (5) cutting reel motors, a main contactor
used to energize the system and additional circuit control components. Circuit protection for the 48 VDC system includes five (5) fuses in a single fuse block, an
inline system logic fuse and a system Maxi- fuse.

The 48 VDC system is an isolated system so the vehicle
frame is not used for any ground connections in this system. A 48 VDC battery disconnect is included on the machine which should be used to disconnect 48 VDC
system components from the electrical power supply to
prevent unexpected component operation when performing service.

The battery pack is composed of four (4) 12 VDC sealed
batteries connected in series to achieve the necessary
48 VDC system voltage. The batteries are absorbed
glass mat (AGM), valve regulated lead acid batteries
that are maintenance free.

Information about electrical components in the 48 VDC
system is included in the Component Testing and Service and Repairs sections of this chapter.

IMPORTANT: When connecting the battery pack in
the 48 VDC system, make sure that battery polarity
is carefully checked. System damage can occur if
batteries are not connected correctly.

The PowerMatchTM system allows the Reelmaster
5010- H to control 48 VDC motor/generator operation so
that changing load conditions can be handled by the machine automatically.

The motor/generator is a 48 VDC, air cooled, brushless,
permanent magnet device. The motor/generator has its
own integral invertor and on- board controller. The InfoCenter Display can be used to monitor motor/generator
activity during machine operation.

In typical, lighter load conditions (e.g. mowing on flat
ground), engine output provides sufficient power to
drive the motor/generator and hydraulic pump package.
In this situation, the motor/generator keeps the 48 VDC
battery pack fully charged and the cutting reel motors
operational.

The main contactor exists in the 48 VDC system to connect the 48 VDC battery pack with the motor/generator
and reel motor controllers. The motor/generator controller determines when the main contactor is engaged.
Control for the components in the 48 VDC system is
handled by integral controllers in the motor/generator
and reel motors along with direction from the machine
TEC controller via the CAN- bus system. Since the TEC
controller (12 VDC component) sends and receives information with the motor/generator and reel motors (48
VDC components), the CAN- bus circuit needs to communicate with both systems. The isolation module is included in the system to allow effective machine
communication while keeping the two electrical systems
isolated. Also, the location ID module exists to identify
the location of the five (5) cutting reel motors. This allows
such machine features as starting the rear cutting units
slightly later than the front cutting units.

Reelmaster 5010- H

In moderate load conditions (e.g. mowing on intermediate slopes), the motor/generator transfers some or all of
its load from the engine. In these conditions, the cutting
reel motors can be driven exclusively by the battery pack
if needed. With the motor/generator load reduced or
possibly inactive, the engine maintains hydraulic traction performance while the battery pack assists in keeping the reels running at the proper set speed.
If load conditions demand maximum performance (e.g.
mowing on severe inclines), the battery pack can be
used to power both the cutting unit motors and the motor/generator. The battery powered motor/generator assists the engine in maintaining traction performance and
the battery pack keeps the reels running at the proper
set speed.

Page 5 - 5

Electrical System

Electrical
System

The five (5) cutting reel motors are identical 48 VDC,
brushless, permanent magnet motors. Each motor has
its own integral invertor and on- board controller. The InfoCenter Display can be used to monitor the speed and
current draw for the five (5) cutting unit motors during
machine operation.

PowerMatchTM System

Special Tools
Order Special Tools from your Toro Distributor.

Digital Multimeter
The multimeter can test electrical components and circuits for current, resistance or voltage. Obtain this tool
locally.
NOTE: Toro recommends the use of a DIGITAL 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. This excess
current could cause damage to circuits not designed to
carry it.
Figure 3

Battery Terminal Protector
Toro Part Number: 107- 0392
Aerosol spray that should be used on battery terminals,
ring terminals and fork terminals to reduce corrosion
problems. Apply terminal protector to the connection after the battery cable, ring terminal or fork terminal has
been secured.

Figure 4

Dielectric Gel
Toro Part Number: 107- 0342
Dielectric gel should be used to prevent corrosion of unsealed connection terminals. To ensure complete coating of terminals, liberally apply gel to both component
and wire harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and
reconnect harness connector to component. Connectors should be thoroughly packed with gel for effective
results.
Do not use dielectric gel on sealed connection terminals
as the gel can unseat connector seals during assembly.

Electrical System

Page 5 - 6

Figure 5

Reelmaster 5010- H

Cutting Reel Motor Rotor Tool Set
Toro Part Number: 127- 2574 (for both 5” and 7” cutting
unit motors)
The rotor tool set for the cutting reel motor is required to
remove and install the rotor from the reel motor housing.
Tool set includes puller hub, threaded shaft, handle and
four (4) screws (Fig. 6).
NOTE: Toro part number TOR6028 can be used to service cutting unit motors on 5” cutting units and is also
used on other Toro products. TOR6028 will not work on
7” cutting unit motors.
NOTE: For cutting reel motor service procedures, see
Cutting Reel Motor Service in the Service and Repairs
section of this chapter.

2. Make sure that threaded shaft is installed into base
plate so that the end of the threaded shaft prevents the
rotor body from entering the motor housing.
IMPORTANT: The rotor magnets are very powerful
and can cause the rotor to shift position very rapidly
during installation. Be cautious during rotor installation to prevent component damage or personal injury.
3. While guiding rotor into motor housing, slowly rotate
threaded shaft to allow the rotor to be drawn into the
housing. Once rotor is fully installed into housing, remove tool set from motor housing.

IMPORTANT: When working on the cutting reel motor, use a clean work space with a non- metal surface. The cutting reel rotor includes very powerful
magnets.

Cutting Reel Motor Rotor Removal

1. Remove gearbox cover and output gear from motor
assembly (see Cutting Reel Motor Service in the Service and Repairs section of this chapter).

3. Secure tool set base plate to motor housing with four
(4) of the cover screws.

Figure 6
1. Puller hub
2. Threaded shaft

3. Handle

4. Install threaded shaft into base plate.

IMPORTANT: The rotor magnets are very powerful
and can cause the rotor to shift position very rapidly
during removal. Be cautious during rotor removal to
prevent component damage or personal injury.

7
10

5. Turn threaded shaft with handle to remove rotor and
motor cover from motor housing. Support rotor to prevent it from falling from housing during removal.

6
8

6. Leave threaded shaft installed in same position in
base plate for rotor installation purposes.

Cutting Reel Motor Rotor Installation

Figure 7

1. Secure tool set base plate to motor housing with four
(4) of the cover screws.

Reelmaster 5010- H

Electrical
System

2. Remove screws that secure motor cover. Do not remove cover from motor assembly because it will be removed with reel motor rotor during rotor removal.

1.
2.
3.
4.
5.

Page 5 - 7

Screw (6 used)
Motor cover
O- ring
O- ring
Wave washer

6.
7.
8.
9.
10.

Bearing
Rotor
Bearing
O- ring
Housing assembly

Electrical System

Generator Rotor Tool Set
Toro Part Number: TOR6029
The generator rotor tool set is required to remove and
install the rotor from the motor/generator housing. Tool
set includes base plate, threaded shaft and handle (Fig.
8).
NOTE: For motor/generator service procedures, see
Motor/Generator Assembly Service in the Service and
Repairs section of this chapter.
IMPORTANT: When working on the motor/generator, use a clean work space with a non- metal surface. The motor/generator rotor includes very
powerful magnets.

IMPORTANT: The rotor magnets are very powerful
and can cause the rotor to shift position very rapidly
during installation. Be cautious during rotor installation to prevent component damage or personal injury.
3. While guiding rotor into motor/generator housing,
slowly rotate threaded shaft to allow the rotor to be
drawn into the housing. Once rotor is fully installed into
housing, remove special tool set from motor/generator
housing.

Motor/Generator Rotor Removal (Fig. 9)

1. Remove screws that secure motor/generator cover.
Do not remove cover from motor/generator assembly
because it will be removed with motor/generator rotor
during rotor removal.

2. Secure tool set base plate to motor/generator housing with three (3) 3/8” - 16 X 3” cap screws.
IMPORTANT: To prevent damage to motor/generator rotor shaft threads, position a thick washer or
spacer on end of the rotor shaft when using tool set.
3. Position thick washer or spacer on the end of the motor/generator rotor shaft. Install threaded shaft into base
plate and against washer or spacer on rotor shaft.

Figure 8
1. Base plate
2. Threaded shaft

3. Handle

IMPORTANT: The rotor magnets are very powerful
and can cause the rotor to shift position very rapidly
during removal. Be cautious during rotor removal to
prevent component damage or personal injury.
4. Turn threaded shaft with handle to remove motor/
generator rotor and cover from motor/generator housing. Support rotor to prevent it from falling during
removal.

5. Leave threaded shaft installed in same position in
tool base plate for rotor installation purposes.
4

Motor/Generator Rotor Installation (Fig. 9)
1. Secure tool set base plate to motor/generator housing with three (3) 3/8” - 16 X 3” cap screws.
2. Make sure that threaded shaft is installed into tool
base plate so that the end of the threaded shaft prevents
rotor body from entering the motor/generator housing.

Electrical System

8
10

Figure 9
1.
2.
3.
4.
5.

Page 5 - 8

Housing/stator assembly
O- ring
Bearing
Rotor assembly
Bearing

6.
7.
8.
9.
10.

Wave washer
O- ring
O- ring
Cover
Flange screw (6 used)

Reelmaster 5010- H

Battery Hydrometer
Use the battery hydrometer when measuring specific
gravity of battery electrolyte in the machine 12 VDC battery. Obtain this tool locally.
NOTE: A battery hydrometer is not usable for the batteries in the Reelmaster 5010- H 48 VDC battery system. These batteries are valve regulated, sealed lead
acid batteries that are maintenance free with no provision for checking or adjusting electrolyte level.

Figure 10

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 cutting unit side
plate when the cutting reel motor is removed. It prevents
dirt and debris from entering the cutting reel bearing
area.

Electrical
System

Figure 11

Reelmaster 5010- H

Page 5 - 9

Electrical System

InfoCenter Display
The InfoCenter Display used on your Reelmaster is a
LCD device that is located on the console. The InfoCenter provides information for the machine operator during
machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings.

Power for the InfoCenter is available when energized by
the main power relay (ignition switch in the ON/PREHEAT or START position). CAN- bus systems involving
the machine TEC controller, the InfoCenter, the motor/
generator and the cutting unit motors are used to provide necessary machine communication for InfoCenter
operation.
NOTE: Icons that are used on the InfoCenter display
are identified in the Traction Unit Operator’s Manual.

Splash Screen
The InfoCenter splash screen (Fig. 12) is displayed
when the ignition switch is initially turned to the ON/
PREHEAT or START position. The splash screens allow
basic machine information to be reviewed by the operator. After the splash screens has been on the InfoCenter
for several seconds, the main information screen will be
displayed on the InfoCenter.

2
3
T

The splash screen can be used to identify machine 12
VDC battery voltage, hourmeter reading, fuel tank level
and whether the glow plugs are energized.

12.6V

95.2

6
Figure 12

1.
2.
3.
4.

Electrical System

Page 5 - 10

12 VDC battery voltage
Hour meter
Fuel gauge
Glow plugs energized

5. Right button
6. Middle button
7. Menu/back button

Reelmaster 5010- H

Main Information Screens
The two (2) InfoCenter main information screens (Figs.
13 and 14) are displayed after the initial splash screen
has been displayed for several seconds. During normal
machine operation, the main information screens
provide machine information for the operator. Toggling
between the main information screens is done by pressing the right button on the InfoCenter.

100

The main information screens can be used to monitor
engine coolant temperature, fuel tank level, 48 VDC battery voltage, engine RPM, motor/generator temperature
and traction speed range. The screens will also identify
if the parking brake is applied or if the cutting decks are
engaged.

170

240

The main information screens will also display arrows
whenever the cutting deck sections are either raising
(up arrows) or lowering (down arrows).

7
Figure 13

1.
2.
3.
4.

Parking brake applied
Traction speed range
Coolant temperature
Indicator light

5.
6.
7.
8.

Fuel gauge
Right button
Middle button
Menu/back button

If an electrical machine fault occurs during machine operation, the InfoCenter indicator light will blink to notify
the operator. Accessing the fault log is described below
in Faults Screen.

4
100

The main menu and additional information screens can
be accessed from the InfoCenter main information
screen by pressing and releasing the menu/back button
(left button) on the display. Information on the main
menu and menu item screens is included below.

170

1400

240

120

RPM

190

Electrical
System

If controls are not selected properly to allow certain machine operations, the InfoCenter indicator light will illuminate and an advisory will be displayed on the
InfoCenter Display (see Advisories in the Troubleshooting section of this chapter). Typically, an advisory can be
eliminated with a change in controls by the operator.

260

52.3V

7
Figure 14

1.
2.
3.
4.

Reelmaster 5010- H

Page 5 - 11

Engine RPM
Coolant temperature
Indicator light
Generator temperature

5.
6.
7.
8.

48 VDC battery voltage
Right button
Middle button
Menu/back button

Electrical System

Access Protected Display Screens
The protected display screens are available on the InfoCenter to view the electrical status of the 48 VDC power
circuit. The protected display screens can be viewed after the Protected Menus are available by entering the
machine PIN (see Settings Screen in this section). Toggling between the protected display screens is done by
pressing the middle button on the InfoCenter when they
are active.

1
eReel Info
n

1600 min
13A

1600 min
13A
n

1600 min
13A

1600 min
13A
n

1600 min
13A

The eReel Info screen (Fig. 15) displays the speed and
current draw for the five (5) individual cutting unit motors.
In typical, lighter load conditions (e.g. mowing on flat
ground), engine output provides sufficient power to
drive the motor/generator and hydraulic pump package.
In this situation, the motor/generator keeps the 48 VDC
battery pack fully charged and the cutting reel motors
operational (Fig. 16).

Figure 15
1. Reel information screen
2. Front motors

In moderate load conditions (e.g. mowing on intermediate slopes), the 48 VDC battery system can be used to
power the cutting reel motors and the motor/generator
load is reduced or removed from the engine. With the
motor/generator inactive, the engine maintains traction
performance while the batteries keep the reels running
at the set speed.
If load conditions demand maximum machine performance (e.g. mowing on severe inclines), the battery
pack can be used to power both the cutting unit motors
and the motor/generator (Fig. 17). The battery powered
motor/generator assists the engine in maintaining traction performance and the battery pack keeps the reels
running at the proper set speed.

3. Rear motors

5
1

5A
55.0 V

3000

RPM

Figure 16
1. 48V battery pack status
2. Motor/generator
3. Reel motor circuit

4. Engine RPM
5. Energy flow

5
1

5
- 80A
46.0

2850

RPM

Figure 17
1. 48V battery pack status
2. Motor/generator
3. Reel motor circuit

Electrical System

Page 5 - 12

4. Engine RPM
5. Energy flow

Reelmaster 5010- H

Main Menu Screen
The main menu screen can be accessed from the InfoCenter main information by pressing and releasing the
menu/back button (left button) on the display twice.
Once at the main menu screen (Fig. 18), navigation to
the five (5) different menu items can occur. Pressing the
move to menu item button (middle button) allows a different menu item to be highlighted. Selection of the highlighted item is completed by pressing the choose menu
item button (right button).

1
Main Menu
Faults
Service
Diagnostics

5
3

The main menu items include faults, service, diagnostics, settings and about. These menu items are described below.

To return to the main information screen from the main
menu screen, press the back button (left button).

Figure 18
1. Main menu
2. Menu items
3. Move to menu items

4. Choose menu item
5. Back button

Faults Screen
The faults screen (Fig. 19) will list all machine electrical
faults that have occurred since the faults were last
cleared from the InfoCenter. The faults will be identified
by a fault number and when the fault occurred. Faults
that might occur on the machine are listed in Fault
Codes in the Troubleshooting section of this chapter.

1
4
Electrical
System

After entry of the PIN code (see Protected Menus in the
Settings Screen of this section), the InfoCenter fault log
can be cleared by selecting the clear system faults menu
item in the faults screen. The cleared faults will be removed from the InfoCenter list but will be retained in the
TEC controller memory.
If a fault occurs during machine use, there may be a
change in machine functionality due to the fault. Should
there be machine operation issues due to a fault, a first
step to remedy the issue would be to disengage the cutting units, release the traction pedal, wait for the machine to stop moving, turn the ignition switch OFF and
allow all machine functions to stop. Then, attempt to restart the machine to see if operation has returned to normal. Some faults will be reset during the restart and will
then allow normal function. If a fault continues to occur,
further system evaluation and possible component repair or replacement will be necessary.

Faults
Cleared @ - 27.6 Ago
#39
- 13.3 Ago

2
5
3

3
Figure 19

1. Fault menu
2. Fault items
3. Move to menu items

4. Choose menu item
5. Back button

To return to the main menu screen from the faults
screen, press the back button (left button).

Reelmaster 5010- H

Page 5 - 13

Electrical System

Service Screen
The service screen (Fig. 20) contains machine operational information including hours, counts, reset defaults
and cutting unit backlap engage. Values listed for these
service menu items cannot be changed. If the machine
PIN has been entered to allow access to protected menu
items in the settings screen, the protected service menu
items will be listed and available in the service screen.
NOTE: If the protected menu items are available, PIN
will be shown in the upper right corner of the InfoCenter
display.

D Engine Coolant Excessive identifies the number of
times that excessive engine coolant temperature
caused the engine to stop.
D Battery kW- H identifies the total electrical energy
(in kilowatt hours) that has been provided by the 48 VDC
battery pack. The battery kW- H listed on the InfoCenter
will increase as the machine is used. The battery kW- H
can be reset when needed (e.g. battery pack is replaced).

The options listed for hours include the following:

The reset defaults service screen option allows machine settings to be returned to factory defaults.

D Key On identifies the number of hours that the ignition switch has been in the ON/PREHEAT position.

The front cutting units backlap service screen option
allows the front cutting units to be placed in backlap.

D Machine Run identifies the number of hours that the
engine has been running.

The rear cutting units backlap service screen option
allows the rear cutting units to be placed in backlap.

D PTO On identifies the number of hours that the machine has been operated with the cutting units engaged.

IMPORTANT: If the backlap function is not returned
to the OFF setting after backlapping, the cutting
units will not raise or function properly.

D Front Cutting Units in Backlap identifies the number of hours that the front cutting units have been operated in the backlap position.
D Rear Cutting Units in Backlap identifies the number of hours that the rear cutting units have been operated in the backlap position.
D Transport Speed identifies the number of hours that
the machine has been operated in transport speed.

To reset the service due hours or battery kW- H count,
access the protected menu so that PIN is shown on InfoCenter display. The protected menu items for resetting
the service due hours and battery kW- H count will be
available on the InfoCenter.
To return to the main menu screen from the service
screen, press the back button (left button).

D Service Due identifies the number of hours before
the next scheduled maintenance is due. The service
due hours listed on the InfoCenter will decrease as the
machine is used. The service due hours can be reset after maintenance is performed.

The options listed for counts include the following:

D Starts identifies the number of times that the engine
has been started.

D Rear Cutting Units in Backlap identifies the number of times that the rear cutting units have been operated in the backlap position.

38.9 Hours
36.8 Hours
13.9 Hours

D PTO identifies the number of times that the engage/
disengage switch has been engaged.
D Front Cutting Units in Backlap identifies the number of times that the front cutting units have been operated in the backlap position.

Hours
:
Run:
:

3
Figure 20

1. Service menu
2. Service items
3. Move to menu items

4. Choose menu item
5. Back button

D Engine Coolant Caution identifies the number of
times that engine coolant temperature was elevated.
Electrical System

Page 5 - 14

Reelmaster 5010- H

Diagnostics Screen

For each of the diagnostics screen items, inputs, qualifiers and outputs are identified. The diagnostics screen
includes the following:
D Cutting Units identifies machine requirements to allow the cutting units to raise and lower. Inputs indicate
the state of the joystick raise and lower switches and the
position of the ignition switch. Qualifiers include whether
the engine is running and the seat is occupied, that the
traction system is in the LOW range speed and inputs
are OK to lower and raise. Identified outputs consist of
SV1, SV2, SV3 and SVRV solenoid coils.

D Backlap identifies machine requirements to allow
the cutting unit backlap process to be engaged. Inputs
indicate the state of the backlap settings (ON or OFF
from Service menu screen) and the PTO status (ON or
OFF). Qualifiers identify that the parking brake is applied, the mow/transport lever is in the MOW position,
the cutting units are lowered and that the engine is running. Outputs indicate whether the front and/or the rear
cutting units are in the backlap mode.
To return to the main menu screen from the diagnostics
screen, press the back button (left button).

D Hi/Low Range identifies machine requirements to
allow LOW (mow) or HI (transport) speed range to be
engaged. Inputs indicate the state of the mow/transport
switch. Qualifiers identify the position of the seat switch,
whether the cutting units are raised and the position of
the engage/disengage (PTO) switch. There are no outputs from the TEC controller for the Hi/Low range function.
D PTO identifies machine requirements to allow the
cutting units to be engaged. Inputs indicate the state of
the PTO (engage/disengage) switch. Qualifiers identify
whether LOW speed range is selected, if the engine is
running, if the seat is occupied, if the engine temperature is not excessive and if the cutting units are lowered.
Outputs indicate that the rear cutting units and/or the
front cutting units are engaged.

Diagnostics
Cutting Units
Hi/Low Range
PTO

4
3

3
Figure 21

1. Diagnostics menu
2. Diagnostics items
3. Move to menu items

4. Choose menu item
5. Back button

D Engine Start identifies whether necessary TEC outputs exists to allow the engine to start and run. Inputs indicate the state of the ignition switch (ON and START).
Qualifiers identify whether the joystick is in the neutral
position (neither lower nor raise engaged), that the PTO
(engage/disengage) switch is OFF, if the traction pedal
is in neutral and if the seat is occupied or parking brake
is applied. Outputs indicate that the fuel actuator is energized and, when the ignition switch is in the START position, that the start output is energized.

Reelmaster 5010- H

Page 5 - 15

Electrical System

Electrical
System

The diagnostics screen (Fig. 21) lists the various states
of machine electrical components. The diagnostics
screen should be used to check operation of machine
controls and to verify that switches and circuit wiring are
functioning correctly.

Settings Screen
The settings screen identifies the InfoCenter units (English or Metric) and language. The settings screen also
allows the operator to customize the backlight (brightness) and contrast settings for the InfoCenter display.

If either the backlight (brightness) or contrast items are
selected, the middle button (- ) or right button (+) can be
used to change the display settings.

The settings screen includes the current setting for
backlapping speed (B’lap RPM) for the front (F) and
rear (R) cutting units. Backlapping speed can be adjusted by selecting either the front or rear cutting units and
using the right button on the InfoCenter to modify the
speed.
Protected menus allows the machine PIN to be entered so that hidden machine settings screen items can
be viewed and modified. Protected menu items include
protect settings, auto idle, blade count, mow speed,
height of cut (HOC), front reel RPM, rear reel RPM and
economy mode.

To change the machine PIN, access the protected menu
items by entering the current PIN. The InfoCenter display screen should indicate “PIN” in the upper right hand
corner after the current PIN number is entered. Select
the protected menu item again and note that “Edit PIN”
is indicated on InfoCenter display screen. A new PIN
can be entered and then saved.
Protected settings allows the settings for auto idle,
blade count, mow speed, height of cut (HOC), front reel
RPM, rear reel RPM and economy mode to be hidden
so they cannot be changed unless the PIN is entered. If
the protect settings is ON, these settings will not be seen
when using the InfoCenter until the protected menus is
selected and the machine PIN is entered. If protect settings is OFF (default setting), settings for these functions will be visible on the InfoCenter and can be
adjusted by the operator at any time.
Electrical System

English
English
40%
+/-

3
Figure 22

1. Settings menu
2. Settings items
3. Move to menu items

4. Change menu item
5. Back button

To allow access to the protected menu items when protected settings is ON (see Protected settings below),
enter the four (4) digit pin PIN using the middle and right
InfoCenter buttons. After PIN has been entered, a check
mark should be visible above middle InfoCenter button.
Press middle button and the InfoCenter display screen
should indicate “PIN” in the upper right hand corner if the
correct PIN number was entered. The protected menu
items should be available in the settings menu and can
be changed as long as the ignition switch remains in
RUN and “PIN” is displayed on the InfoCenter.
NOTE: The initial PIN will either be 1234 or 0000. If the
PIN has been changed and is forgotten, a temporary
PIN can be obtained from your Toro distributor.

Settings
Units:
Language:
Backlight:

7
Settings
Auto Idle:
Blade Count:
Mow Speed:
+

2
6

PIN
20s
5
6.0 mph
-

3
5

4
Figure 23

1.
2.
3.
4.

Settings menu
Settings items
Current settings
Increase setting

5. Decrease setting
6. Back button
7. PIN activated

Auto Idle causes the engine speed to decrease to low
idle after the machine has not been in use for the set time
delay in seconds. Auto idle can be adjusted to 8, 10, 15,
20 or 30 seconds or the auto idle feature can be turned
OFF. Engine speed automatically returns to the previously set speed when either the traction pedal is moved
from neutral or the joystick is moved to either raise or
lower.
Blade Count identifies the number of blades on the cutting units installed on the machine. This information is
used by machine controllers to determine cutting unit
reel speed.
Mow Speed identifies the traction speed to be used
when in LOW (mow) speed. This information is used by
machine controllers to determine cutting unit reel speed.

Page 5 - 16

Reelmaster 5010- H

Height of Cut (HOC) identifies the setting for cutting
unit height of cut. This information is used by machine
controllers to determine cutting unit reel speed.
F Reel RPM displays the front reel speed that has been
determined by the machine controllers based on entered information for blade count, mow speed and HOC.
Front reel speed can also be manually adjusted.
R Reel RPM displays the rear reel speed that has been
determined by the machine controllers based on entered information for blade count, mow speed and HOC.
Rear reel speed can also be manually adjusted.

Economy Mode displays whether the machine has the
economy mode feature ON or OFF. When in economy
mode with the mow/transport lever in the MOW position,
the engine speed is lowered to reduce noise and fuel
consumption. When in economy mode with the mow/
transport lever in the TRANSPORT position, engine
speed is not lowered.
To return to the main menu screen from the settings
screen, press the back button (left button).

About Screen
The about screen (Fig. 24) identifies the machine model
number, machine serial number and software revisions
for the TEC controller. If the machine PIN has been entered to allow protected menu items to be visible, the
about screen will also identify software revisions for the
cutting unit and motor/generator controller and list the
CAN- bus status.

1
About
Model:
SN:
S/W Rev:

03674
315000153
122- 0059B

To return to the main menu screen from the about
screen, press the back button (left button).

3
4

3
Figure 24

1. About menu
2. About items
3. Move to menu items

Reelmaster 5010- H

Page 5 - 17

4. Choose menu item
5. Back button

Electrical System

Electrical
System

Troubleshooting
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and components used on this machine (see Chapter 9 - Foldout
Drawings).

CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.

If the machine has any interlock switches by- passed,
they must be reconnected for proper troubleshooting
and safety.
NOTE: Use the InfoCenter Display to test TEC controller inputs and outputs when troubleshooting an electrical problem on your Reelmaster (see InfoCenter
Display in this chapter).

Operator Advisories
If controls are not selected properly to allow certain machine operations, the InfoCenter indicator light will illuminate and an advisory will be displayed on the
InfoCenter Display. Typically, an advisory can be eliminated with a change in controls by the operator.

1
2
ADVISORY #162

Advisory numbers, descriptions and reason for advisories are listed in the table on the next page. Some advisories can be caused by several machine settings.

Denied
H

NOTE: Icons that are used on the InfoCenter display
are identified in the Traction Unit Operator’s Manual.

Figure 25
1. Indicator light
2. Advisory number

Electrical System

Page 5 - 18

3. Advisory description
4. Reason for advisory

Reelmaster 5010- H

Advisory Description

Advisory
Number
160

Start Denied

Possible Reason for Advisory
Neither seat occupied nor parking brake
applied
Traction pedal is NOT in neutral position
Wait to start until system functions have been
initialized
Joystick is in RAISE position
Joystick is in LOWER position
Reel engage/disengage switch is in engaged
position

161

Mow Denied

No operator in seat
Engine coolant temperature is excessive
Low voltage in 48 VDC battery pack

162

Lowered Denied

Mow stop lever is in TRANSPORT position

163

Backlap Denied

Traction pedal is not in neutral position
Mow stop lever is in TRANSPORT position
Engine coolant temperature is excessive
Parking brake is NOT applied
Reel engage/disengage switch is NOT in
engaged position
Cutting units are NOT fully lowered

169

Engine Shutdown

No operator in seat
Engine coolant temperature is excessive
Engine oil pressure is low

170

Recycle Keyswitch (ignition switch)

173

Master Address Claim

175

Check Reel Speed Settings

Check that reel speed settings are correct for
cutting units on machine

176

Reel Speed Changed

Identifies that reel speed has been changed

177

Reel Speed Changed Out Of Range

178

Low 48 VDC Battery

Reelmaster 5010- H

Engine starter motor has been engaged for 30
seconds

Heavy 48 VDC battery pack use has
decreased battery pack charge

Page 5 - 19

Electrical System

Electrical
System

Parking brake IS applied

Fault Codes
The InfoCenter Display will identify electrical system
malfunctions (faults) if they occur. Should a fault occur
during machine operation, the InfoCenter indicator light
will illuminate and the fault will be displayed on the InfoCenter Display (Fig. 26).
The InfoCenter display faults screen will list all machine
electrical faults that have occurred since the faults were
last cleared from the InfoCenter. The faults will be identified by a fault number and when the fault occurred.
Fault codes, fault descriptions and recommended service suggestions for fault codes are listed in the table on
the following pages.
NOTE: Icons that are used on the InfoCenter display
are identified in the Traction Unit Operator’s Manual.
NOTE: Fault codes identify electrical problems that typically will prevent normal machine operation. For fault
codes that identify problems with TEC controller inputs
(e.g. switches, sensors), use the InfoCenter Display to
check the different switch positions before removing or
replacing the component. Fault codes that identify problems with TEC controller outputs (e.g. solenoid coils)
might involve issues with the wire harness or the actual
output device.
Using Fault Codes
If an electrical fault is identified by the machine controllers (TEC, motor/generator, cutting unit motors), the
InfoCenter display will identify the fault code number
and when the fault occurred. An electrical fault can
cause disruption in how the machine functions but in
some instances, the fault may occur with little, if any,
change in machine operation. The following suggestions should be considered when using fault codes that
are displayed.

S There is the possibility that an electrical issue can result with several fault codes being generated. For example, a broken wire or faulty fuse would prevent operation
of a cutting unit motor and multiple fault codes could be
displayed. Reviewing the fault code descriptions should
suggest possible causes for the circuit problem. Using
the electrical schematic and electrical wire harness
drawings will also help in problem diagnosis.
S The InfoCenter will display fault code numbers as an
indication that the machine electrical system has experienced an abnormal change that might be very minor resulting in no change of machine operation or more
severe which could prevent machine use. Use fault
codes in conjunction with noting what machine operations have changed, when did the change occur and
whether the problem occurs all the time or is intermittent
to help identify the source of a machine problem.
S The InfoCenter faults screen can be used to list all machine electrical faults that have occurred since the faults
were last cleared from the InfoCenter. If a fault that is listed on the InfoCenter faults screen occurred at some
point in the distant past and has not reoccurred, that fault
is likely not causing a current machine problem. Recurring faults may indicate a problem with a particular circuit
or component.
S When machine electrical issues occur and fault codes
have been displayed on the InfoCenter display, consider
contacting your Toro Distributor for additional assistance.
1
2
FAULT #28

S If a fault code is displayed on the InfoCenter and machine operation remains normal, continue to use the
machine. The fault code number can be retrieved in the
future by using the InfoCenter faults screen.
S If a fault code is displayed on the InfoCenter and machine operation has changed, move the machine to a
level surface, disengage the cutting units and turn the ignition switch to the OFF position. Leave switch in the
OFF position for thirty (30) seconds and then restart the
machine. During this system reboot process, the machine controllers often can reset electrical components
to allow normal machine operation. Assuming that the
fault code is no longer displayed, continue to use the
machine. The fault code number can be retrieved in the
future by using the InfoCenter faults screen.
Electrical System

48V Devices Offline

4
Figure 26
1. Indicator light
2. Fault number

Page 5 - 20

3. Fault description
4. Back button

Reelmaster 5010- H

Fault Code

Fault Description

Service Suggestions

Excessive engine coolant temperature (above
105oC) caused PTO to disengage

Check radiator and screen for debris buildup
Check engine cooling fan and drive belt
Check engine coolant level

Excessive engine coolant temperature (above
115oC) caused engine to stop

Check radiator and screen for debris buildup
Check engine cooling fan and drive belt
Check engine coolant level

One of the TEC output fuses (7.5 Amp) is
faulty

Check TEC output fuses

IPE voltage is low indicating that TEC fuses or
TEC controller is faulty

Check TEC fuses

Main power relay is faulty

Check main power relay and circuit wiring

Ignition switch was held in the START position Cycle ignition switch
for more than thirty (30) seconds or the ignition Check fuel level in fuel tank
switch is faulty
Check ignition switch and circuit wiring

Consider that TEC controller is faulty

Check fuel actuator and fuel pump
7

TEC software needs to be reprogrammed

Contact Toro Distributor for reprogramming
assistance

Engine alternator charging is too high

Check engine alternator

Engine alternator charging is too low

Check alternator drive belt

Ignition switch is faulty

Check ignition switch and circuit wiring

Engine speed switch is faulty

Check control arm engine speed switch and
circuit wiring

Engine alternator is faulty

Check engine alternator and circuit wiring

48 VDC logic relay current is excessive

Check 48V logic relay and circuit wiring

Engine coolant temperature sensor circuit has
open or short

Check engine coolant sensor and circuit wiring

ID Module is faulty

Unplug cutting unit motors one at a time to find
a possible faulty cutting unit motor
Check ID module and circuit wiring

Joystick raise and lower switches closed at
same time

Check joystick switches and circuit wiring

TEC output current to energize start relay is
excessive

Check start relay and circuit wiring

TEC output current to fuel pump is excessive

Check fuel pump and circuit wiring

Reelmaster 5010- H

Page 5 - 21

Electrical System

Electrical
System

Check engine alternator and circuit wiring

Fault Description

Fault Code
28

Service Suggestions

48 VDC devices (motor/generator and all cutting reel motors) are all off- line

Make sure that 48 VDC battery disconnect is
securely plugged in
Check 10A logic relay fuse
Check 48 VDC master fuse (250A maxi fuse)
Check 48 VDC battery system voltage
Check 48 VDC logic relay and circuit wiring
Check isolation module and circuit wiring
Check CAN- bus termination resistors and circuit wiring

48 VDC system (motor/generator and all cutting reel motors) is under voltage

Check 48 VDC battery voltage
Check 48 VDC battery connections
Check internal motor/generator connections
Consider that motor/generator is faulty

48 VDC system (motor/generator and all cutting reel motors) is over voltage

Check 48 VDC battery voltage
If engine is running when fault occurred, check
internal motor/generator connections
Consider that motor/generator is faulty

48 VDC system (motor/generator and all cutCheck 48 VDC battery voltage
ting reel motors) logic voltage are all excessive If engine is running when fault occurred, check
internal motor/generator connections
Consider that motor/generator is faulty

Cutting unit fault

Contact Toro distributor for cutting unit service
assistance

Motor/generator fault

Contact Toro distributor for motor/generator
service assistance

Master (TEC controller) fault

Contact Toro distributor for TEC service assistance

TEC output current to energize glow relay is
excessive

Check glow relay and circuit wiring

CAN- bus fault for #1 cutting reel motor

Check CAN- bus connection to #1 motor
Verify battery power exists at #1 motor
Check CAN- bus termination resistors

CAN- bus fault for #2 cutting reel motor

Check CAN- bus connection to #2 motor
Verify battery power exists at #2 motor
Check CAN- bus termination resistors

CAN- bus fault for #3 cutting reel motor

Check CAN- bus connection to #3 motor
Verify battery power exists at #3 motor
Check CAN- bus termination resistors

CAN- bus fault for #4 cutting reel motor

Check CAN- bus connection to #4 motor
Verify battery power exists at #4 motor
Check CAN- bus termination resistors

CAN- bus fault for #5 cutting reel motor

Check CAN- bus connection to #5 motor
Verify battery power exists at #5 motor
Check CAN- bus termination resistors

Electrical System

Page 5 - 22

Reelmaster 5010- H

Fault Description

Fault Code
43

Service Suggestions

CAN- bus fault for motor/generator

Check CAN- bus connection to
motor/generator
Verify battery power exists at motor/generator
Check CAN- bus termination resistors

CAN- bus fault for InfoCenter

Check CAN- bus connection to InfoCenter
Display
Verify battery power exists at InfoCenter
Display

Software version incompatible with #1 cutting
reel motor

Contact Toro distributor to update software

Software version incompatible with #2 cutting
reel motor

Contact Toro distributor to update software

Software version incompatible with #3 cutting
reel motor

Contact Toro distributor to update software

Software version incompatible with #4 cutting
reel motor

Contact Toro distributor to update software

Software version incompatible with #5 cutting
reel motor

Contact Toro distributor to update software

Software version incompatible with
motor/generator

Contact Toro distributor to update software

Software version incompatible with InfoCenter

Contact Toro distributor to update software

Software version incompatible within entire
system

Contact Toro distributor to update software

TEC output current for hydraulic solenoid coil
SV1 is excessive

Check lift manifold solenoid coil SV1 and circuit wiring

TEC output current for hydraulic solenoid coil
SV2 is excessive

Check lift manifold solenoid coil SV2 and circuit wiring

TEC output current for hydraulic solenoid coil
SV3 is excessive

Check lift manifold solenoid coil SV3 and circuit wiring

TEC output current for hydraulic solenoid coil
SVRV is excessive

Check lift manifold solenoid coil SVRV and circuit wiring

Cutting unit motor sizes (5” and 7”) are mixed

Check that all 5 cutting unit motors are for the
same size cutting unit on the machine

Current sensor fault in motor/generator
controller

Motor/generator controller is faulty if this fault
continues to occur (generator motor should
be OK)

Line contactor - open fault

Check main contactor and circuit wiring
Replace main contactor if faulty

Line contactor - closed fault

Check main contactor and circuit wiring
Replace main contactor if faulty

Line contactor - over current

Motor/generator is faulty if this fault continues
to occur

Fault latch - phase OC

Motor/generator is faulty if this fault continues
to occur

Reelmaster 5010- H

Page 5 - 23

Electrical System

Electrical
System

Check CAN- bus termination resistors

Fault Description

Fault Code
63

Service Suggestions

48 VDC pre- charge fault

Disconnect one cutting reel motor at a time
until the fault is no longer active to identify
faulty motor
NOTE: If cutting reel motor is faulty, additional
fault codes will likely be displayed

Motor/generator temperature sensor fault

If this fault continues to occur, consider that
motor/generator may be faulty

Motor stalled on #1 cutting unit

Check #1 cutting unit for excessive rotating
resistance
Check #1 cutting unit bedknife adjustment and
reel condition
Check #1 cutting unit motor for excessive rotating resistance
Check that #1 cutting unit motor can rotate
without load
Replace #1 cutting unit motor if above items do
not identify problem and issue is not resolved

Motor stalled on #2 cutting unit

Check #2 cutting unit for excessive rotating
resistance
Check #2 cutting unit bedknife adjustment and
reel condition
Check #2 cutting unit motor for excessive rotating resistance
Check that #2 cutting unit motor can rotate
without load
Replace #2 cutting unit motor if above items do
not identify problem and issue is not resolved

Motor stalled on #3 cutting unit

Check #3 cutting unit for excessive rotating
resistance
Check #3 cutting unit bedknife adjustment and
reel condition
Check #3 cutting unit motor for excessive rotating resistance
Check that #3 cutting unit motor can rotate
without load
Replace #3 cutting unit motor if above items do
not identify problem and issue is not resolved

Electrical System

Page 5 - 24

Reelmaster 5010- H

Fault Description

Fault Code
68

Service Suggestions

Motor stalled on #4 cutting unit

Check #4 cutting unit for excessive rotating
resistance
Check #4 cutting unit bedknife adjustment and
reel condition
Check #4 cutting unit motor for excessive rotating resistance
Check that #4 cutting unit motor can rotate
without load
Replace #4 cutting unit motor if above items do
not identify problem and issue is not resolved

Motor stalled on #5 cutting unit

Check #5 cutting unit for excessive rotating
resistance
Check #5 cutting unit bedknife adjustment and
reel condition
Check #5 cutting unit motor for excessive rotating resistance
Check that #5 cutting unit motor can rotate
without load
Replace #5 cutting unit motor if above items do
not identify problem and issue is not resolved

High temperature warning for #1 cutting unit

Let machine cool to lower cutting unit motor
temperature
Open the rear discharge of the cutting unit
Reduce reel speed if possible
If fault does not seem to be related to cutting
load conditions, check 48 VDC ground for #1
cutting unit motor
Consider replacement of #1 cutting unit motor
if this fault continues to occur
NOTE: A faulty sensor will not cause this fault

High temperature warning for #2 cutting unit

Let machine cool to lower cutting unit motor
temperature
Open the rear discharge of the cutting unit
Reduce reel speed if possible
Reduce mow speed if possible
If fault does not seem to be related to cutting
load conditions, check 48 VDC ground for #2
cutting unit motor
Consider replacement of #2 cutting unit motor
if this fault continues to occur
NOTE: A faulty sensor will not cause this fault

Reelmaster 5010- H

Page 5 - 25

Electrical System

Electrical
System

Reduce mow speed if possible

Fault Description

Fault Code
72

Service Suggestions

High temperature warning for #3 cutting unit

Let machine cool to lower cutting unit motor
temperature
Open the rear discharge of the cutting unit
Reduce reel speed if possible
Reduce mow speed if possible
If fault does not seem to be related to cutting
load conditions, check 48 VDC ground for #3
cutting unit motor
Consider replacement of #3 cutting unit motor
if this fault continues to occur
NOTE: A faulty sensor will not cause this fault

High temperature warning for #4 cutting unit

Let machine cool to lower cutting unit motor
temperature
Open the rear discharge of the cutting unit
Reduce reel speed if possible
Reduce mow speed if possible
If fault does not seem to be related to cutting
load conditions, check 48 VDC ground for #4
cutting unit motor
Consider replacement of #4 cutting unit motor
if this fault continues to occur
NOTE: A faulty sensor will not cause this fault

High temperature warning for #5 cutting unit

Let machine cool to lower cutting unit motor
temperature
Open the rear discharge of the cutting unit
Reduce reel speed if possible
Reduce mow speed if possible
If fault does not seem to be related to cutting
load conditions, check 48 VDC ground for #5
cutting unit motor
Consider replacement of #5 cutting unit motor
if this fault continues to occur
NOTE: A faulty sensor will not cause this fault

Electrical System

Page 5 - 26

Reelmaster 5010- H

Fault Code

Fault Description

Service Suggestions

High temperature warning for motor/generator

Make sure that hood screen is clean
Check that air intake to motor/generator is not
restricted or blocked and that air is moving
through intake when engine is running
Check for motor/generator cooling fin debris
obstruction
Let machine cool to lower motor/generator
temperature
Reduce cutting system load by reducing reel
speed, reducing mow speed or by opening the
rear discharge of the cutting unit
If this fault continues to occur when the machine is not at full operating temperature,
consider that the motor/generator is faulty
NOTE: A faulty sensor will not cause this fault

System voltage under 32 VDC has disabled #1 Check logic power connection to #1 cutting
cutting unit
unit
If this fault is displayed for more than one
cutting unit, check 48 VDC battery voltage
when engine is OFF and also check 48 VDC
logic relay and circuit wiring
If 48 VDC battery voltage is correct when engine is OFF but drops when engine is ON, consider that motor/generator is faulty
System voltage under 32 VDC has disabled #2 Check logic power connection to #2 cutting
cutting unit
unit
If this fault is displayed for more than one
cutting unit, check 48 VDC battery voltage
when engine is OFF and also check 48 VDC
logic relay and circuit wiring
If 48 VDC battery voltage is correct when engine is OFF but drops when engine is ON, consider that motor/generator is faulty

System voltage under 32 VDC has disabled #3 Check logic power connection to #3 cutting
cutting unit
unit
If this fault is displayed for more than one
cutting unit, check 48 VDC battery voltage
when engine is OFF and also check 48 VDC
logic relay and circuit wiring
If 48 VDC battery voltage is correct when engine is OFF but drops when engine is ON, consider that motor/generator is faulty

Reelmaster 5010- H

Page 5 - 27

Electrical System

Electrical
System

Fault Description

Fault Code
79

Service Suggestions

System voltage under 32 VDC has disabled #4 Check logic power connection to #4 cutting
cutting unit
unit
If this fault is displayed for more than one
cutting unit, check 48 VDC battery voltage
when engine is OFF and also check 48 VDC
logic relay and circuit wiring
If 48 VDC battery voltage is correct when engine is OFF but drops when engine is ON, consider that motor/generator is faulty

System voltage under 32 VDC has disabled #5 Check logic power connection to #5 cutting
cutting unit
unit
If this fault is displayed for more than one
cutting unit, check 48 VDC battery voltage
when engine is OFF and also check 48 VDC
logic relay and circuit wiring
If 48 VDC battery voltage is correct when engine is OFF but drops when engine is ON, consider that motor/generator is faulty

System voltage under 36 VDC has disabled
motor/generator

Check logic power connection to motor/generator
If this fault is also displayed for cutting unit(s),
check 48 VDC battery voltage when engine is
OFF and also check 48 VDC logic relay and
circuit wiring
If 48 VDC battery voltage is correct when engine is OFF but drops when engine is ON, consider that motor/generator is faulty

Logic voltage over 67.5 VDC has disabled #1
cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48 VDC components (motor/generator and cutting unit motors) generate this
fault, system fault 31 will be displayed on the
InfoCenter

Electrical System

Page 5 - 28

Reelmaster 5010- H

Fault Description

Fault Code
83

Service Suggestions

Logic voltage over 67.5 VDC has disabled #2
cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48 VDC components (motor/generator and cutting unit motors) have this fault,
system fault 31 will be displayed on the InfoCenter

Logic voltage over 67.5 VDC has disabled #3
cutting unit

NOTE: If all 48 VDC components (motor/generator and cutting unit motors) generate this
fault, system fault 31 will be displayed on the
InfoCenter
85

Logic voltage over 67.5 VDC has disabled #4
cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48 VDC components (motor/generator and cutting unit motors) have this fault,
system fault 31 will be displayed on the InfoCenter

Reelmaster 5010- H

Page 5 - 29

Electrical System

Electrical
System

If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed

Fault Description

Fault Code
86

Service Suggestions

Logic voltage over 67.5 VDC has disabled #5
cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 31 will be displayed on the InfoCenter

Logic voltage over 65 VDC has disabled
motor/generator

If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 31 will be displayed on the InfoCenter

System bus voltage under 32 VDC has
disabled #1 cutting unit (main contactor is
engaged)

Check 35A reel motor fuse for #1 cutting unit
Check the 2 pin 48 VDC bus connector for the
#1 cutting unit
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 29 will be displayed on the InfoCenter

System bus voltage under 32 VDC has
disabled #2 cutting unit (main contactor is
engaged)

Check 35A reel motor fuse for #2 cutting unit
Check the 2 pin 48 VDC bus connector for the
#2 cutting unit
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 29 will be displayed on the InfoCenter

System bus voltage under 32 VDC has
disabled #3 cutting unit (main contactor is
engaged)

Check 35A reel motor fuse for #3 cutting unit
Check the 2 pin 48 VDC bus connector for the
#3 cutting unit
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 29 will be displayed on the InfoCenter

System bus voltage under 32 VDC has
disabled #4 cutting unit (main contactor is
engaged)

Check 35A reel motor fuse for #4 cutting unit
Check the 2 pin 48 VDC bus connector for the
#4 cutting unit
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 29 will be displayed on the InfoCenter

System bus voltage under 32 VDC has
disabled #5 cutting unit (main contactor is
engaged)

Check 35A reel motor fuse for #5 cutting unit
Check the 2 pin 48 VDC bus connector for the
#5 cutting unit
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 29 will be displayed on the InfoCenter

Electrical System

Page 5 - 30

Reelmaster 5010- H

Fault Description

Fault Code
93

Service Suggestions

System bus voltage under 36 VDC has
disabled motor/generator (main contactor is
engaged)

Check to see if a pre- charge fault (fault 63)
has occurred
Check that main contactor is functional
Check the motor/generator connections
NOTE: If all 48 VDC components (motor/generator and cutting unit motors) have this fault,
system fault 29 will be displayed on the InfoCenter

System bus voltage over 67.5 VDC has
disabled #1 cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48 VDC components (motor/generator and cutting unit motors) have this fault,
system fault 30 will be displayed on the InfoCenter

System bus voltage over 67.5 VDC has
disabled #2 cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 30 will be displayed on the InfoCenter

System bus voltage over 67.5 VDC has
disabled #3 cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 30 will be displayed on the InfoCenter

Reelmaster 5010- H

Page 5 - 31

Electrical System

Electrical
System

Fault Description

Fault Code
97

Service Suggestions

System bus voltage over 67.5 VDC has
disabled #4 cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 30 will be displayed on the InfoCenter

System bus voltage over 67.5 VDC has
disabled #5 cutting unit

If multiple cutting units are reporting this fault,
check 48 VDC batteries and motor/generator
operation
If 48 VDC batteries are at correct voltage with
engine OFF, consider connections between
motor/generator and motor/generator
controller are loose or faulty
If TEC controller has lost communication with
motor/generator, engine speed will not be
controllable and this fault may be displayed
NOTE: If all 48V components (motor/generator
and cutting unit motors) have this fault, system
fault 30 will be displayed on the InfoCenter

System bus voltage over 65 VDC has disabled
motor/generator

100

Excessive system current has disabled #1
cutting unit

#1 cutting unit motor is likely faulty if this fault
continues to occur

101

Excessive system current has disabled #2
cutting unit

#2 cutting unit motor is likely faulty if this fault
continues to occur

102

Excessive system current has disabled #3
cutting unit

#3 cutting unit motor is likely faulty if this fault
continues to occur

103

Excessive system current has disabled #4
cutting unit

#4 cutting unit motor is likely faulty if this fault
continues to occur

104

Excessive system current has disabled #5
cutting unit

#5 cutting unit motor is likely faulty if this fault
continues to occur

105

Excessive system current has disabled
motor/generator

Motor/generator is likely faulty if this fault
continues to occur

106

Excessive voltage occurred at internal motor
regulator for #1 cutting unit

#1 cutting unit motor is likely faulty if this fault
continues to occur

107

Excessive voltage occurred at internal motor
regulator for #2 cutting unit

#2 cutting unit motor is likely faulty if this fault
continues to occur

Electrical System

Page 5 - 32

Reelmaster 5010- H

Fault Description

Fault Code

Service Suggestions

108

Excessive voltage occurred at internal motor
regulator for #3 cutting unit

#3 cutting unit motor is likely faulty if this fault
continues to occur

109

Excessive voltage occurred at internal motor
regulator for #4 cutting unit

#4 cutting unit motor is likely faulty if this fault
continues to occur

110

Excessive voltage occurred at internal motor
regulator for #5 cutting unit

#5 cutting unit motor is likely faulty if this fault
continues to occur

111

Excessive voltage occurred at internal motor/
generator regulator and disabled
motor/generator

Motor/generator is likely faulty if this fault
continues to occur

112

Insufficient voltage occurred at internal motor
Check electrical connections to #1 cutting unit
regulator for #1 cutting unit and disabled motor motor
If fault occurs for multiple cutting unit motors,
check 48 VDC logic relay and circuit wiring
Check 48 VDC battery system cables for
proper connections
Consider that #1 cutting unit motor is faulty

113

Insufficient voltage occurred at internal motor
Check electrical connections to #2 cutting unit
regulator for #2 cutting unit and disabled motor motor
If fault occurs for multiple cutting unit motors,
check 48 VDC logic relay and circuit wiring
Check 48 VDC battery system cables for
proper connections
Consider that #2 cutting unit motor is faulty
Insufficient voltage occurred at internal motor
Check electrical connections to #3 cutting unit
regulator for #3 cutting unit and disabled motor motor
If fault occurs for multiple cutting unit motors,
check 48 VDC logic relay and circuit wiring
Check 48 VDC battery system cables for
proper connections
Consider that #3 cutting unit motor is faulty

115

Insufficient voltage occurred at internal motor
Check electrical connections to #4 cutting unit
regulator for #4 cutting unit and disabled motor motor
If fault occurs for multiple cutting unit motors,
check 48 VDC logic relay and circuit wiring
Check 48 VDC battery system cables for
proper connections
Consider that #4 cutting unit motor is faulty

116

Insufficient voltage occurred at internal motor
Check electrical connections to #5 cutting unit
regulator for #5 cutting unit and disabled motor motor
If fault occurs for multiple cutting unit motors,
check 48 VDC logic relay and circuit wiring
Check 48 VDC battery system cables for
proper connections
Consider that #5 cutting unit motor is faulty

Reelmaster 5010- H

Page 5 - 33

Electrical System

Electrical
System

114

Fault Code

Fault Description

Service Suggestions

117

Insufficient voltage occurred at internal motor/
generator regulator and disabled motor/
generator

Check electrical connections to
motor/generator
If fault occurs for multiple cutting unit motors
and motor/generator, check 48 VDC logic relay
and circuit wiring
Check 48 VDC battery system cables for
proper connections
Consider that motor/generator is faulty

123

Excessive motor/generator speed

Engine speed is incorrect which causes the
motor/generator to overspeed

124

Hall effect sensors in #1 cutting unit motor are
providing different feedback

#1 cutting unit motor is likely faulty if this fault
continues to occur

125

Hall effect sensors in #2 cutting unit motor are
providing different feedback

#2 cutting unit motor is likely faulty if this fault
continues to occur

126

Hall effect sensors in #3 cutting unit motor are
providing different feedback

#3 cutting unit motor is likely faulty if this fault
continues to occur

127

Hall effect sensors in #4 cutting unit motor are
providing different feedback

#4 cutting unit motor is likely faulty if this fault
continues to occur

128

Hall effect sensors in #5 cutting unit motor are
providing different feedback

#5 cutting unit motor is likely faulty if this fault
continues to occur

129

Hall effect sensors in motor/generator are providing different feedback

Motor/generator is likely faulty if this fault
continues to occur
NOTE: If engine speed is erratic when this
fault is displayed, the motor/generator will
likely need to be replaced

Electrical System

Page 5 - 34

Reelmaster 5010- H

Starting Problems
Problem

Possible Causes

All electrical power is dead, including InfoCenter
Display.

12 VDC battery is discharged.
Ignition switch or circuit wiring is faulty.
Fusible link harness at the engine starter motor is
faulty.
12 VDC battery cables are loose or corroded.
Main fuse (15 amp) to the ignition switch is faulty.

Starter solenoid clicks, but starter will not crank.

12 VDC battery is discharged.

NOTE: If the starter solenoid clicks, the problem is not 12 VDC battery cables are loose or corroded.
in the interlock circuit.
Ground cable is loose or corroded.
Wiring at the starter motor is faulty.
Starter solenoid or starter motor is faulty.
Engine starts, but stops when the ignition switch is
released from the START position.

Engine fuel actuator or circuit wiring is faulty.

Engine cranks, but does not start.

Engine and/or fuel may be too cold.

NOTE: After 30 seconds of engine cranking, the TEC Fuel tank is empty.
controller output to the engine starter motor will de- energize even if the ignition switch is kept in the START posi- Glow plugs, glow plug relay or circuit wiring is faulty.
tion. This is designed to prevent overheating of the
Engine fuel actuator or circuit wiring is faulty.
starter motor.
Engine fuel filter is clogged.
Engine or fuel system is malfunctioning (see Chapter 3
- Kubota Diesel Engine).
Engine cranks, but should not, when the traction pedal
is depressed.

Reelmaster 5010- H

Traction neutral switch is out of adjustment.
Traction neutral switch or circuit wiring is faulty.

Page 5 - 35

Electrical System

Electrical
System

Engine or fuel system is malfunctioning (see Chapter 3
- Kubota Diesel Engine).

Starting Problems (Continued)
Problem

Possible Causes

Nothing happens when start attempt is made.
InfoCenter Display operates with the ignition switch in
RUN.

Traction pedal is not in neutral position.
Operator seat is unoccupied OR the parking brake is
not applied.

NOTE: If machine controls are not in the correct position
to start the engine (e.g. the traction pedal is pressed), an Cutting units are engaged (reel engage/disengage
advisory message may be displayed on the InfoCenter switch is ON).
Display.
The joystick is not in the center position.
Traction neutral switch is out of adjustment.
Traction neutral switch or circuit wiring is faulty.
Seat switch or circuit wiring is faulty.
Parking brake switch or circuit wiring is faulty.
Joystick switch (raise or lower position) is faulty.
Ignition switch or circuit wiring is faulty.
Start relay or circuit wiring is faulty.

Main power relay or circuit wiring is faulty (headlights
and powerpoint inoperative as well).
TEC controller fuses are faulty.
Fusible link at battery is open.
Wiring to start circuit components is loose, corroded or
damaged (see electrical drawings in Chapter 9 Foldout Drawings).
Temperature sender or circuit wiring is faulty.
Starter solenoid or starter motor is faulty.
TEC controller is faulty.

Electrical System

Page 5 - 36

Reelmaster 5010- H

General Run and Transport Problems
Problem

Possible Causes

Engine continues to run, but should not, when the
ignition switch is turned off.

Engine fuel actuator or circuit wiring is faulty.
Ignition switch or circuit wiring is faulty.
Main power relay or circuit wiring is faulty.

Engine continues to run, but should not, when the
traction pedal is engaged with no operator in the seat.

Seat switch or circuit wiring is faulty.
TEC controller fuses are faulty.
Traction neutral switch is out of adjustment.
Traction neutral switch or circuit wiring is faulty.
TEC controller is faulty.
Parking brake is engaged.

NOTE: If excessive coolant temperature or low engine
oil pressure causes engine shutdown, the operator can
restart the engine to allow the machine to be moved a
short distance. After a restart in this condition, the engine
will run for approximately ten (10) seconds before the engine shuts down again unless engine temperature has
decreased or oil pressure issue has been resolved.
The engine kills when the traction pedal is depressed.

Operator is raising from the seat (seat switch not fully
depressed).
Seat switch or circuit wiring is faulty.
Temperature sender or circuit wiring is faulty.
Ignition switch or circuit wiring is faulty.
Parking brake is engaged.

NOTE: If machine controls are not in the correct position Operator is not fully depressing the seat switch.
for operating the machine (e.g. the parking brake is engaged), an advisory message may be displayed on the TEC controller fuses are faulty.
InfoCenter Display.
Seat switch or circuit wiring is faulty.
TEC controller fuses are faulty.
TEC controller is faulty.
12 VDC battery does not charge.

Wiring to alternator or other charging circuit
components is loose, corroded or damaged (see
Electrical Schematic and Wire Harness Drawings in
Chapter 9 - Foldout Drawings).
Alternator belt is loose or damaged.
12 VDC battery cables are loose or corroded.
Fusible link harness at the engine starter motor is
faulty.
Alternator is faulty.
12 VDC battery is faulty.

Reelmaster 5010- H

Page 5 - 37

Electrical System

Electrical
System

The engine stops during operation, but is able to
restart.

Cutting Unit Operating Problems
Problem

Possible Causes

The cutting units remain engaged, but should not, with
no operator in the seat.

Seat switch or circuit wiring is faulty.

Cutting units run, but should not, when raised. Cutting
units shut off with reel engage/disengage switch.

Cutting unit down limit switch or circuit wiring is faulty.

Cutting units run, but should not, when raised. Cutting
units do not shut off with reel engage/disengage
switch.

Both the cutting unit down limit switch (or circuit wiring)
and reel engage/disengage switch switch (or circuit
wiring) are faulty.

TEC controller is faulty.

TEC controller is faulty.
None of the cutting units operate in either direction
(mow or backlap). Cutting units are able to raise and
lower.

Reel engage/disengage switch is in the OFF position.
Mow stop lever is not in the MOW position.

NOTE: If machine controls are not in the correct position Operator seat is unoccupied.
to engage the cutting units, an advisory message may be
The 48 VDC battery disconnect is unplugged or
displayed on the InfoCenter Display.
damaged.
Logic or Maxi fuse for 48 VDC system is faulty.
High engine coolant temperature has disabled cutting
unit operation.
Seat switch or circuit wiring is faulty.
Reel engage/disengage switch or circuit wiring is
faulty.
Cutting unit down limit switch or circuit wiring is faulty.
Mow/transport switch or circuit wiring is faulty.
Temperature sender or circuit wiring is faulty.
Cutting units run, but should not, when lowered with
joystick and reel engage/disengage switch in the OFF
position.

The reel engage/disengage switch or circuit wiring is
faulty.
TEC controller is faulty.

Individual cutting unit does not operate in either
Fuse for affected cutting unit motor is faulty.
direction (mow or backlap). Other cutting units operate.
Electrical connections to affected cutting unit motor are
All cutting units are able to raise and lower.
loose or faulty.
Problem exists with affected cutting unit (see Chapter 7
- Cutting Units).
Cutting unit motor is damaged. NOTE: If appropriate,
transfer a suspected damaged motor to another cutting
unit. If problem follows the motor, motor needs repair or
replacement.

Electrical System

Page 5 - 38

Reelmaster 5010- H

Cutting Unit Operating Problems (Continued)
Problem

Possible Causes

The cutting units do not run when placed in the
backlap direction.

The parking brake is not applied.
Reel engage/disengage switch is in the OFF position.
High engine coolant temperature has disabled cutting
unit operation.
The joystick is not in the center position.
Cutting units are not fully lowered to ground.
Cutting unit down limit switch or circuit wiring is faulty.

None of the cutting units will lower.

Mow stop lever is in the TRANSPORT position.

NOTE: If machine controls are not in the correct position Lower/mow switch on joystick or circuit wiring is faulty.
to lower the cutting units, an advisory message may be
displayed on the InfoCenter Display.
Mow/transport switch or circuit wiring is faulty.
Hydraulic lift manifold solenoid SVRV or circuit wiring
is faulty.
Hydraulic lift manifold solenoid SV2 or circuit wiring is
faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 - Hydraulic System).
Cutting circuit is in the backlap position.
Raise switch on joystick or circuit wiring is faulty.
Hydraulic lift manifold solenoid SVRV or circuit wiring
is faulty.
Hydraulic lift manifold solenoid SV2 or circuit wiring is
faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 - Hydraulic System).
Front cutting units will not raise or lower, but the rear
cutting units will raise and lower.

Hydraulic lift manifold solenoid SV1 or circuit wiring is
faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 - Hydraulic System).

The rear cutting units will not raise or lower, but the
front cutting units will raise and lower.

Hydraulic lift manifold solenoid SV3 or circuit wiring is
faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 - Hydraulic System).

One cutting unit (either front or rear) will not raise or
lower, but all other cutting units will raise and lower.

Binding of lift cylinder or lift components for affected
cutting unit exists.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 - Hydraulic System).

Reelmaster 5010- H

Page 5 - 39

Electrical System

Electrical
System

None of the cutting units will raise.

Electrical System Quick Checks
12 VDC Battery Test (Open Circuit Test)
Use a digital multimeter to measure the battery voltage.

Voltage Measured

Battery Charge Level

Remove battery cover to access the battery at the rear
of the machine. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to
100o F (16o to 38o C). The ignition switch should be in
the OFF position and all accessories turned off. Connect
the positive (+) multimeter lead to the positive battery
post and the negative (- ) multimeter lead to the negative
battery post. Record the battery voltage.

12.68 volts or above

Fully charged (100%)

12.45 volts

75% charged

12.24 volts

50% charged

12.06 volts

25% charged

11.89 volts or below

0% charged

NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information (see Battery Service in
the Service and Repairs section of this chapter).

Engine Charging System Test
This is a simple test used to determine if the engine
charging system is functioning. It will tell you if the charging system has an output, but not its capacity.

Start the engine and run at high idle (3000 RPM). Allow
the battery to charge for at least three (3) minutes. Record the battery voltage.

Remove battery cover to access the battery at the rear
of the machine. Use a digital multimeter set to DC volts.
Connect the positive (+) multimeter lead to the positive
battery post and the negative (- ) multimeter lead to the
negative battery post. Keep the test leads connected to
the battery posts and record the initial battery voltage.

After running the engine for at least three (3) minutes,
battery voltage should be at least 0.50 volt higher than
initial battery voltage.

NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the battery voltage will
increase at different rates as the battery charges.

An example of a charging system that is functioning:
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage

= 12.30 V

Battery Voltage after 3 Minute Charge

= 12.95 V

Difference

= +0.65 V

Glow Plug System Test
This is a fast, simple test that can help to determine the
integrity and operation of your Reelmaster 5010- H glow
plug system. The test should be run anytime hard starting (cold engine) is encountered on a diesel engine
equipped with a glow plug system.
Use a digital multimeter and/or inductive Ammeter (AC/
DC Current Transducer). Properly connect the ammeter
to the digital multimeter (refer to manufacturer’s instructions) and set the multimeter to the correct scale. With
the ignition switch in the OFF position, place the

Electrical System

ammeter pickup around the main glow plug power supply wire and read the meter prior to activating the glow
plug system. Adjust the meter to read zero (if applicable). Activate the glow plug system by turning the ignition switch to ON/PREHEAT and record the multimeter
results.
The Reelmaster 5010- H glow plug system should have
a reading of approximately 27 Amps total (9 Amps per
glow plug). If low current reading is observed during the
test, one (or more) glow plugs is faulty.

Page 5 - 40

Reelmaster 5010- H

Check Operation of Interlock Switches

CAUTION
The interlock switches are for the protection of
the operator and bystanders and to ensure correct operation of the machine. Do not bypass or
disconnect switches. Check the operation of the
interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine.

NOTE: Use the InfoCenter Display to test TEC controller inputs and outputs before further troubleshooting
of an electrical problem on your Reelmaster. Inputs and
outputs can be tested using the InfoCenter Diagnostic
menu (see InfoCenter Display in this chapter).

Electrical
System

Interlock switch operation is described in the Traction
Unit Operator’s Manual. Your Reelmaster is equipped
with an Toro Electronic Controller (TEC) which monitors
interlock switch operation. Information on the TEC is described in the Traction Unit Operator’s Manual and in the
Component Testing section of this Chapter.

The interlock system used on your Reelmaster includes
the seat switch, the traction neutral switch, the parking
brake switch, the cutting unit down limit switch, the mow/
transport switch and the cutting reel engage/disengage
switch. Testing of individual interlock switches is included in the Component Testing section of this Chapter.

Reelmaster 5010- H

Page 5 - 41

Electrical System

Adjustments
Traction Neutral Switch
The traction neutral switch is a normally open proximity
switch that closes when the traction pedal is in the neutral position. The switch mounts to a bracket on the traction pump. The sensing element for the traction neutral
switch is the traction pump lever that is secured to the
pump control arm (Fig. 27).

Adjustment
1. Before adjusting the traction neutral switch, check
and adjust traction system neutral position (refer to
Traction Unit Operator’s Manual).
2

IMPORTANT: To prevent traction neutral switch
damage, make sure that no components contact
switch through entire traction pump control arm
movement.

2. When the traction lever is in the neutral position, the
clearance between the head of traction neutral switch
and the traction lever bracket should be from 0.094” to
0.100” (2.4 to 2.5 mm).
3. If clearance is incorrect, loosen jam nuts that secure
neutral switch to pump bracket. Position switch with jam
nuts to allow correct clearance between switch and traction lever bracket. Jam nuts should be torqued from 162
to 198 in- lb (18.4 to 22.4 N- m). After jam nuts are tightened, make sure that clearance has not changed.

0.094” to 0.100”
(2.4 to 2.5 mm)

Figure 27
1. Traction pump
2. Traction pump lever

3. Traction neutral switch

4. After adjustment to the traction neutral switch, use
the InfoCenter Display to verify that traction neutral
switch and circuit wiring are functioning correctly (see
Diagnostics Screen (Engine Run item) in the InfoCenter
Display section of this chapter).

Electrical System

Page 5 - 42

Reelmaster 5010- H

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. 28).
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.

Adjustment
3 2

The distance between the parking brake switch and the
tab on the parking brake detent should be from 0.094”
to 0.100” (2.4 to 2.5 mm) when the parking brake is not
applied. If distance is incorrect, loosen jam nuts that secure brake switch to brake pedal. Position switch with
jam nuts to allow correct clearance between switch and
brake detent tab. Jam nuts should be torqued from 162
to 198 in- lb (18.4 to 22.4 N- m). After jam nuts are tightened, make sure that clearance has not changed.

2
3
1

6
Figure 28
1. Parking brake switch
2. Lock washer (2 used)
3. Jam nut (2 used)

4. Parking brake detent
5. Brake pedal
6. Switch LED location

Electrical
System

After adjustment to the parking brake switch, use the InfoCenter Display to verify that brake switch and circuit
wiring are functioning correctly (see Diagnostics Screen
(Engine Run item) in the InfoCenter Display section of
this chapter).

Reelmaster 5010- H

Page 5 - 43

Electrical System

Switch
LED Location
3

Adjustment
The down limit switch should be secured to the switch
bracket at the midpoint of the bracket mounting slots.
NOTE: The vertical location of the down limit switch on
the switch bracket will determine the turn- around position of the front, outside cutting units (cutting units #4
and #5). Raising the switch on the bracket will allow a
lower turn- around position of the cutting units. Lowering
the switch on the bracket will allow a higher turn- around
position of the cutting units.
The distance between the down limit switch and the
sensing plate on lift arm should be from 0.094” to 0.100”
(2.4 to 2.5 mm). If distance is incorrect, loosen jam nuts
that secure down limit switch to machine frame. Position
switch with jam nuts to allow correct clearance between
switch and sensing plate. Jam nuts should be torqued
from 162 to 198 in- lb (18.4 to 22.4 N- m). After jam nuts
are tightened, make sure that clearance has not
changed.

FRONT
Figure 29
1. Down limit switch
2. Lock washer

3. Jam nut
4. Lift arm

After adjustment to the down limit switch, use the InfoCenter Display (see Diagnostics Screen (PTO item) in
the InfoCenter Display section of this chapter) to verify
that down limit switch and circuit wiring are functioning
correctly.

Electrical System

Page 5 - 44

Reelmaster 5010- H

Mow/Transport Switch
The mow/transport switch is a normally closed proximity
switch that is attached to the bottom of the floor platform
(Fig. 30).

1
4

When the mow stop lever is in the MOW position, the tab
on the mow stop lever is positioned away from the target
end of the mow/transport switch so the switch is closed.
The tab on the mow stop lever is moved next to the mow/
transport switch when the mow stop lever is in the
TRANSPORT position causing the switch to open.
Adjustment

The distance between the mow/transport switch and the
tab on the mow stop lever should be from 0.094” to
0.100” (2.4 to 2.5 mm) when the mow stop lever is in the
TRANSPORT position. If distance is incorrect, loosen
jam nuts that secure brake switch to frame bracket.
Position switch with jam nuts to allow correct clearance
between switch and mow stop lever. Jam nuts should be
torqued from 162 to 198 in- lb (18.4 to 22.4 N- m). After
jam nuts are tightened, make sure that clearance has
not changed and that mow stop lever does not contact
switch as it is moved between positions.

FRONT

LED location

Figure 30
1. Traction pedal
2. Mow stop lever
3. Mow/transport switch

4. Lever tab
5. Lock washer (2 used)
6. Jam nut (2 used)

Reelmaster 5010- H

Page 5 - 45

Electrical
System

After adjustment to the mow/transport switch, use the
InfoCenter Display to verify that mow/transport switch
and circuit wiring are functioning correctly (see Diagnostics Screen (Hi/Low Range item) in the InfoCenter
Display section of this chapter).

Electrical System

Component Testing
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check of the switch).

NOTE: See the Kubota Workshop Manual, Diesel Engine, 05- E4B Series for engine electrical component repair information.

CAUTION

NOTE: Electrical troubleshooting of any 12 volt power
connection can be performed through voltage drop tests
without disconnecting the component.
NOTE: Use the InfoCenter display to test TEC controller inputs and outputs before further troubleshooting
of an electrical problem on your Reelmaster. Inputs and
outputs can be tested using the InfoCenter Diagnostic
menu (see InfoCenter Display in this chapter).

When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.

Ignition Switch
The ignition (key) switch has three (3) positions (OFF,
ON/PREHEAT and START). The switch is mounted on
the control console. The Toro Electronic Controller
(TEC) monitors the operation of the ignition switch.

CIRCUIT

POSITION
NONE

OFF
ON/PREHEAT

B+I+S

START

Testing
NOTE: Before disconnecting the ignition switch for
testing, the switch and its circuit wiring should be tested
as a TEC input with the InfoCenter Display (see Diagnostics Screen (Engine Start item) in the InfoCenter Display section of this chapter). If the InfoCenter Display
verifies that the ignition switch and circuit wiring are
functioning correctly, no further switch testing is necessary. If the InfoCenter Display determines that the ignition switch and circuit wiring are not functioning
correctly, proceed with ignition switch testing using the
following steps.

B + I + A, X + Y

5. Replace ignition switch if testing determines that the
switch is faulty.
6. If ignition switch tests correctly and circuit problem
still exists, check wire harness (see Electrical Schematic and Circuit Drawings in Chapter 9 - Foldout Drawings).
7. After ignition switch testing is complete, connect wire
harness connector to the ignition switch. Install control
arm cover to machine (see Control Arm in the Service
and Repairs section of Chapter 6 - Chassis).

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. Remove outside control arm cover to gain access to
ignition switch (see Control Arm in the Service and Repairs section of Chapter 6 - Chassis).
3. Disconnect wire harness connector from the ignition
switch.
4. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
ignition switch position. The ignition switch terminals are
marked as shown in Figure 31. The circuitry of this
switch is shown in the chart below. Verify continuity between switch terminals.

OFF
45 

ON/PREHEAT

45 
START

B
I

Figure 31
Electrical System

Page 5 - 46

Reelmaster 5010- H

12 VDC System Fuses
The fuse block is located behind the control arm access
cover (Fig. 32).
In addition to the 12 VDC fuses in the fuse block, a 2
Amp fuse is included in the wire harness to protect the
logic power circuit for the TEC controller. This fuse resides in a fuse holder near the engine starter motor and
is secured to the wire harness with a cable tie (Fig. 33).

Identification and Function
The fuses are held in the fuse block. Use Figure 34 to
identify each individual fuse and its correct amperage.
Fuses for your Reelmaster have the following function:
Left Fuse 1 (15 Amp): Protects main and starter circuit power supply.

Figure 32
1. Fuse block

Left Fuse 2 (10 Amp): Protects main power supply.
Left Fuse 3 (10 Amp): Protects power supply for
headlights.

Left Fuse 4 (10 Amp): Protects power supply for
power point.
Right Fuse 1 (7.5 Amp): Protects power supply for
TEC controller outputs.

Electrical
System

Right Fuse 2 (7.5 Amp): Protects power supply for
TEC controller outputs.
Right Fuse 3 (7.5 Amp): Protects power supply for
TEC controller outputs.
Right Fuse 4: Available for 20 Amp fuse used with
optional power operator seat.

Figure 33
1. Fuse
2. Main wire harness

3. Starter motor

Fuse Testing
LEFT

1. Make sure that ignition switch is in the OFF position
and key is removed from ignition switch.

RIGHT

2. Remove control arm access cover to locate fuses.
3. Remove fuse(s) from the fuse block for testing. Fuse
should have continuity between fuse terminals.
4. After fuse testing is completed, install control arm access cover.

10A

7.5A

10A

7.5A

15A

7.5A

Figure 34
Reelmaster 5010- H

Page 5 - 47

Electrical System

48 VDC System Fuses
Several fuses are used in the 48 VDC system (motor/
generator and cutting unit motors) for circuit protection.
Fuse Identification and Function
1

35 Amp Reel Motor Fuses: Protect the 48 VDC
power supply circuits for the electric reel motors. The
reel motor fuses are located in a fuse holder behind
the hood saddle under the hood (Fig. 35).
10 Amp Logic Relay Fuse: Protects the 48 VDC
logic circuit for the motor/generator and main contactor, The logic relay fuse is located in an in- line fuse
holder attached near the reel motor fuse holder (Fig.
35).
250 Amp Maxi Fuse: Protects main 48 VDC power
supply. The 250 amp fuse is connected to the isolator
terminal and the main contactor behind the 48 VDC
battery disconnect attached to the right side frame
rail (Fig. 36).

Figure 35
1. Hood saddle
2. Reel motor fuses

3. Logic relay fuse

FRONT

Fuse Testing
1. Make sure that ignition switch is in the OFF position
and key is removed from ignition switch.

2. To prevent unexpected 48 VDC system component
operation, unplug the 48 VDC battery disconnect (see
48 VDC Battery Disconnect in the General Information
section of this chapter).
3. Locate and remove fuse(s) for testing. Fuse should
have continuity between fuse terminals. Replace fuse if
testing determines that it is faulty.
4. After fuse testing is completed, install removed covers and plug the 48 VDC battery disconnect into the
socket.

Figure 36
1. RH frame rail
2. 48V battery disconnect

Electrical System

Page 5 - 48

3. 250A fuse
4. Main contactor

Reelmaster 5010- H

Engine Speed Switch
The engine speed switch is a momentary switch that is
used as an input for the TEC controller to raise or lower
the engine speed. When the switch is depressed and
held in the forward position, the engine speed will increase. Conversely, when the rear of the switch is depressed, engine speed will decrease. The engine speed
switch is located on the control arm (Fig. 37).

1
2

Testing
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.
2. Disassemble control arm to gain access to engine
speed switch (see Control Arm in the Service and Repairs section of Chapter 6 - Chassis).

Figure 37
1. Console arm

2. Engine speed switch

3. Disconnect wire harness connector from the engine
speed switch.

SWITCH
POSITION

CLOSED
CIRCUITS

OPEN
CIRCUITS

FRONT OF
SWITCH
PRESSED

2+3
5+6

2+1
5+4

NEUTRAL

NONE

ALL

REAR OF
SWITCH
PRESSED

2+1
5+4

2+3
5+6

BACK OF SWITCH
Figure 38
NOTE: Reel engine speed switch terminals 4, 5 and 6
are not used on Reelmaster 5010- H machines.

5. If speed switch tests correctly and circuit problem still
exists, check circuit wire harness (see Electrical
Schematic and Wire Harness Drawings in Chapter 9 Foldout Drawings).
6. After testing is completed, connect wire harness
connector to the switch.
7. Assemble control arm (see Control Arm in the Service and Repairs section of Chapter 6 - Chassis).

Reelmaster 5010- H

Page 5 - 49

Electrical System

Electrical
System

4. The speed switch terminals are marked as shown in
Figure 38. The circuit logic of the switch is shown in the
chart below. With the use of a multimeter (ohms setting),
the switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verify continuity between switch terminals. Replace switch if testing identifies that switch is faulty.

Reel Engage/Disengage Switch
The reel engage/disengage switch is used to allow the
cutting units to operate. An indicator light on the switch
identifies when the engage/disengage switch is engaged. The reel engage/disengage switch is mounted
on the control panel (Fig. 39). The Toro Electronic Controller (TEC) monitors the operation of the reel engage/
disengage switch.

5. Replace reel engage/disengage switch if testing determines that it is faulty.

NOTE: To raise or lower the cutting units, the operator
seat has to be occupied. Also, to lower the cutting units,
the traction speed has to be in LOW (mow) range.

7. After reel engage/disengage switch testing is completed, connect wire harness connector to the reel engage/disengage switch. Install control arm cover to
machine (see Control Arm in the Service and Repairs
section of Chapter 6 - Chassis).

Testing

6. If engage/disengage switch tests correctly and circuit problem still exists, check circuit wire harness (see
Electrical Schematic and Circuit Drawings in Chapter 9
- Foldout Drawings).

NOTE: Before disconnecting the reel engage/disengage switch for testing, the switch and its circuit wiring
should be tested as a TEC input with the InfoCenter Display (see Diagnostics Screen (PTO item) in the InfoCenter Display section of this chapter). If the InfoCenter
Display verifies that the engage/disengage switch and
circuit wiring are functioning correctly, no further switch
testing is necessary. If the InfoCenter Display determines that the engage/disengage switch and circuit wiring are not functioning correctly, proceed with
engage/disengage switch testing using the following
steps.
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.

Figure 39
1. Console arm

2. Reel switch

2. Remove control arm covers to gain access to engage/disengage switch (see Control Arm in the Service
and Repairs section of Chapter 6 - Chassis).
3. Disconnect wire harness connector from the engage/disengage switch.
4. With the use of a multimeter (ohms setting), the
switch functions can be tested to determine whether
continuity exists between the various terminals for each
switch position. The reel engage/disengage switch terminals are marked as shown in Figure 40. The circuitry
of this switch is shown in the chart below. Verify continuity between switch terminals.
SWITCH
POSITION

NORMAL
CIRCUITS

OTHER
CIRCUITS

2+3

5+6

OFF

2+1

5+4

Electrical System

BACK OF SWITCH
Figure 40
NOTE: Reel engage/disengage switch terminals 1 and
4 are not used on Reelmaster 5010- H machines.

Page 5 - 50

Reelmaster 5010- H

Headlight Switch
The headlight switch allows the headlights to be turned
on and off. This rocker switch is located on the operator
side of the control arm (Fig. 41).

NOTE: The Toro Electronic Controller (TEC) does not
monitor the operation of the headlight switch.
Testing
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.
2. Remove inside control arm cover to gain access to
headlight switch (see Control Arm in the Service and Repairs section of Chapter 6 - Chassis).

2
Figure 41
1. Console arm

2. Headlight switch

3. Disconnect wire harness connector from the headlight switch.
4. With the use of a multimeter (ohms setting), the
headlight switch functions may be tested to determine
whether continuity exists between the various terminals
for each switch position. The switch terminals are
marked as shown in Figure 42. The circuitry of the headlight switch is shown in the chart below. Verify continuity
between switch terminals.
NORMAL
CIRCUITS

OTHER
CIRCUITS

2+3

5+6

OFF

2+1

5+4

Figure 42
NOTE: Headlight switch terminals 1, 4, 5 and 6 are not
used on Reelmaster 5010- H machines.

5. Replace headlight switch if testing determines that it
is faulty.
6. When headlight switch testing is complete, connect
wire harness connector to the switch. Install control arm
cover to machine (see Control Arm in the Service and
Repairs section of Chapter 6 - Chassis).

Reelmaster 5010- H

Page 5 - 51

Electrical System

Electrical
System

SWITCH
POSITION

BACK OF SWITCH

Seat Switch
The seat switch is normally open and closes when the
operator seat is occupied. If the traction system or reel
engage/disengage switch is engaged when the operator raises out of the seat, the engine will stop. The seat
switch is located directly under the operator seat. The
Toro Electronic Controller (TEC) monitors the operation
of the seat switch.
1

Testing
NOTE: Before disconnecting the seat switch for testing, the switch and its circuit wiring should be tested as
a TEC input with the InfoCenter Display (see Diagnostics Screen (PTO item) in the InfoCenter Display section
of this chapter). If the InfoCenter Display verifies that the
seat switch and circuit wiring are functioning correctly,
no further switch testing is necessary. If the InfoCenter
Display determines that the seat switch and circuit wiring are not functioning correctly, proceed with seat
switch testing using the following steps.

Figure 43
1. Seat switch lead

2. Electrical connector

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. Disconnect wire harness connector from the seat
switch electrical lead near the manual tube under the
operator seat (Fig. 43).
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
4. With no pressure on the seat, there should be no
continuity between the seat switch terminals.
5. Press directly onto the seat switch through the seat
cushion. There should be continuity between the seat
switch terminals as the seat cushion approaches the
bottom of its travel.
6. If testing determines that seat switch is faulty, replace switch (see Operator Seat in the Service and Repairs section of Chapter 6 - Chassis).
7. If the seat switch tests correctly and a circuit problem
still exists, check circuit wire harness (see Electrical
Schematic and Wire Harness Drawings in Chapter 9 Foldout Drawings).
8. When seat switch testing is complete, connect wire
harness connector to the seat switch electrical lead.

Electrical System

Page 5 - 52

Reelmaster 5010- H

Parking Brake Switch

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.
Testing
NOTE: Before disconnecting the parking brake switch
for testing, the switch and its circuit wiring should be
tested as a TEC controller input with the InfoCenter Display (see Diagnostics Screen (Backlap item) in the InfoCenter Display section of this chapter). If the InfoCenter
Display verifies that the parking brake switch and circuit
wiring are functioning correctly, no further brake switch
testing is necessary. If the InfoCenter Display determines that the parking brake switch and circuit wiring
are not functioning correctly, proceed with parking
brake switch testing using the following steps.

C. Using a multimeter, verify that the machine wire
harness connector terminal for black wire is closed
(continuity) to ground.
D. Turn ignition switch to the ON/PREHEAT position
(do not start engine) and verify with a multimeter that
machine wire harness connector terminal for parking
brake switch pink wire has system voltage (12 VDC)
present.
E. Turn ignition switch to the OFF position.
F. If black wire is closed to ground, pink wire has
system voltage present and switch LED did not function, replace parking brake switch. Adjust switch during installation (see Parking Brake Switch in the
Adjustments section of this chapter).
4. If the parking brake switch tests correctly and a circuit problem still exists, check circuit wire harness (see
Electrical Schematic and Wire Harness Drawings in
Chapter 9 - Foldout Drawings).
5. Make sure that wire harness electrical connector is
connected to the parking brake switch.

1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine.

2. Turn ignition switch to the ON/PREHEAT position (do
not start engine) and check LED on cable end of parking
brake switch.

3
2

A. Switch LED should be illuminated when the
parking brake is released (brake not applied).
4

B. Switch LED should not be illuminated when the
parking brake pedal is depressed (brake applied).

2
3

3. If the parking brake switch LED did not function correctly:
A. Make sure that parking brake switch is properly
adjusted (see Parking Brake Switch in the Adjustments section of this chapter). If necessary, adjust
switch and return to step 2 above.

Electrical
System

The parking brake switch is a normally open proximity
switch. The parking brake switch is attached to the bottom of the brake pedal (Fig. 44). The Toro Electronic
Controller (TEC) monitors the operation of the parking
brake switch.

6
Figure 44
1. Parking brake switch
2. Lock washer (2 used)
3. Jam nut (2 used)

4. Parking brake detent
5. Brake pedal
6. Switch LED location

B. Make sure ignition switch is OFF and disconnect
the parking brake switch connector from the machine wire harness.

Reelmaster 5010- H

Page 5 - 53

Electrical System

Traction Neutral Switch
The traction neutral switch is a normally open proximity
switch that closes when the traction pedal is in the neutral position. The switch mounts to the pump plate on the
piston (traction) pump. The sensing element for the traction neutral switch is the traction pump lever that is secured to the pump control arm (Fig. 45). The Toro
Electronic Controller (TEC) monitors the operation of
the traction neutral switch.
Testing

NOTE: Before disconnecting the traction neutral switch
for testing, the switch and its circuit wiring should be
tested as a TEC controller input with the InfoCenter Display (see Diagnostics Screen (Engine Start item) in the
InfoCenter Display section of this chapter). If the InfoCenter Display verifies that the traction neutral switch
and circuit wiring are functioning correctly, no further
neutral switch testing is necessary. If the InfoCenter Display determines that the traction neutral switch and circuit wiring are not functioning correctly, proceed with
neutral switch testing using the following steps.

5. If the traction neutral switch tests correctly and a circuit problem still exists, check circuit wire harness (see
Electrical Schematic and Wire Harness Drawings in
Chapter 9 - Foldout Drawings).

1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine.

6. Make sure that wire harness electrical connector is
connected to the traction neutral switch. Lower operator
seat.

F. If black wire is closed to ground, pink wire has
system voltage present and switch LED did not function, replace traction neutral switch. Adjust switch
during installation (see Traction Neutral Switch in the
Adjustments section of this chapter).

2. Tilt operator seat to gain access to traction neutral
switch.

3. Turn ignition switch to the ON/PREHEAT position (do
not start engine) and check LED on cable end of traction
neutral switch.

FRONT
4
2

A. Switch LED should be illuminated when the traction pedal is in the neutral position.
5

B. Switch LED should not be illuminated when the
traction pedal is in either the forward or reverse position.

4. If the neutral switch LED did not function correctly:
A. Make sure that traction neutral switch is properly
adjusted (see Traction Neutral Switch in the Adjustments section of this chapter). If necessary, adjust
switch and return to step 3 above.
B. Make sure ignition switch is OFF and disconnect
the traction neutral switch connector from the machine wire harness.

Electrical System

LED location
1

Figure 45
1. Piston (traction) pump
2. Traction neutral switch
3. Traction pump lever

Page 5 - 54

4. Pump plate
5. Jam nut (2 used)
6. Lock washer (2 used)

Reelmaster 5010- H

Cutting Unit Down Limit Switch
The cutting unit down limit switch is a normally open
proximity switch that closes when the front, outside cutting units are in the turn- around position. The down limit
switch is attached to a frame bracket inside the front,
right lift arm pivot tube. A bracket on the front, right lift
arm acts as the sensing plate for the down limit switch
(Fig. 46). The Toro Electronic Controller (TEC) monitors
the operation of the cutting unit down limit switch.
Testing
NOTE: Before disconnecting the cutting unit down limit
switch for testing, the switch and its circuit wiring should
be tested as a TEC controller input with the InfoCenter
Display (see Diagnostics Screen (Backlap item) in the
InfoCenter Display section of this chapter). If the InfoCenter Display verifies that the down limit switch and circuit wiring are functioning correctly, no further down limit
switch testing is necessary. If the InfoCenter Display determines that the down limit switch and circuit wiring are
not functioning correctly, proceed with down limit switch
testing using the following steps.

D. Turn ignition switch to the ON/PREHEAT position
(do not start engine) and verify with a multimeter that
machine wire harness connector terminal for down
limit switch pink wire has system voltage (12 VDC)
present.
E. Turn ignition switch to the OFF position.
F. If black wire is closed to ground, pink wire has
system voltage present and switch LED did not function, replace cutting unit down limit switch. Adjust
switch during installation (see Cutting Unit Down
Limit Switch in the Adjustments section of this chapter).
4. If the down limit switch tests correctly and a circuit
problem still exists, check circuit wire harness (see Electrical Schematic and Wire Harness Drawings in Chapter
9 - Foldout Drawings).
5. Make sure that wire harness electrical connector is
connected to the down limit switch after testing.

1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine.

Switch
LED Location
3

2. Test cutting unit down limit switch as follows:

Electrical
System

A. Turn ignition switch to the ON position (do not
start engine) and check LED on cable end of down
limit switch.
B. LED should be illuminated when the cutting units
are lowered. LED should not be illuminated when
the cutting units are raised to the turn around position.
3. If the cutting unit down limit switch LED did not function correctly:
A. Make sure that down limit switch is properly adjusted (see Cutting Unit Down Limit Switch in the Adjustments section of this chapter). If necessary,
adjust switch and return to step 2 above.

B. Make sure ignition switch is OFF and disconnect
the down limit switch connector from the machine
wire harness.
C. Using a multimeter, verify that the machine wire
harness connector terminal for black wire is closed
(continuity) to ground.

Reelmaster 5010- H

FRONT
Figure 46
1. Down limit switch
2. Lock washer

Page 5 - 55

3. Jam nut
4. Lift arm

Electrical System

Joystick Raise and Lower Switches
Two (2) micro switches for the joystick are located on the
lower mow/raise lever that is attached to the control arm.
The rear switch on the control is used to lower (and engage) the cutting units and the front switch to raise (and
disengage) them. A normally open contact in the switch
closes when the joystick is positioned to either lower or
raise the cutting units. Each switch has an electrical connector to make sure the normally closed contact on the
switch is not used. The raise switch has pink/blue and
black harness wires connected to it and the lower switch
has orange/white and black harness wires connected to
it. The Toro Electronic Controller (TEC) monitors the operation of the joystick switches.
NOTE: To raise or lower the deck sections, the operator
seat has to be occupied. Also, to lower the cutting deck
sections, the traction speed has to be in LOW (mow)
range.

6. Move and hold the joystick to activate the switch being tested. There should be continuity across the switch
terminals.
7. If testing determines that joystick switch is faulty, replace switch.
8. If the joystick switch tests correctly and a circuit problem still exists, check wire harness (see Electrical Schematic and Circuit Drawings in Chapter 9 - Foldout
Drawings).
9. After switch testing is completed, connect wire harness electrical connector to the joystick switch.
10.Install control arm covers to machine (see Control
Arm in the Service and Repairs section of Chapter 6 Chassis).

Testing
NOTE: Before disconnecting the joystick switches for
testing, the switches and their circuit wiring should be
tested as a TEC controller input with the InfoCenter Display (see Diagnostics Screen (Cutting Units item) in the
InfoCenter Display in this chapter). If the InfoCenter Display verifies that the joystick switches and circuit wiring
are functioning correctly, no further switch testing is necessary. If the InfoCenter Display determines that either
joystick switch and circuit wiring are not functioning correctly, proceed with testing procedure

1
2

FRONT

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. Remove control arm covers to gain access to joystick switches (see Control Arm in the Service and Repairs section of Chapter 6 - Chassis).

Figure 47
1. Lower mow/raise lever
2. Raise switch

3. Disconnect wire harness electrical connector from
the raise or lower switch that is to be tested (Fig. 47).

4. Connect a multimeter (ohms setting) across the normally open (NO) and common terminals of the switch
(Fig. 48).
5. With the joystick in the neutral (center) position,
there should be no continuity across the switch terminals.

Electrical System

3. Lower switch

Figure 48
1. Common terminal
2. NO terminal

Page 5 - 56

3. NC terminal
4. Switch lever

Reelmaster 5010- H

Mow/Transport Switch
The mow/transport switch is a normally closed proximity
switch that opens when the mow stop lever is placed in
the transport position. The sensing plate for the mow/
transport switch is the mow stop lever (Fig. 49). The Toro
Electronic Controller (TEC) monitors the operation of
the mow/transport switch.
Testing
NOTE: Before disconnecting the mow/transport switch
for testing, the switch and its circuit wiring should be
tested as a TEC controller input with the InfoCenter Display (see Diagnostics Screen (Hi/Low Range item) in
the InfoCenter Display section of this chapter). If the InfoCenter Display verifies that the mow/transport switch
and circuit wiring are functioning correctly, no further
mow/transport switch testing is necessary. If the InfoCenter Display determines that the mow/transport
switch and circuit wiring are not functioning correctly,
proceed with mow/transport switch testing using the following steps.
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine.

C. Using a multimeter, verify that the machine wire
harness connector terminal for black wire is closed
(continuity) to ground.
D. Turn ignition switch to the ON/PREHEAT position
(do not start engine) and verify with a multimeter that
machine wire harness connector terminal for mow/
transport switch pink wire has system voltage (12
VDC) present.
E. Turn ignition switch to the OFF position.
F. If black wire is closed to ground, pink wire has
system voltage present and switch LED did not function, replace mow/transport switch. Adjust switch
during installation (see Mow/Transport Switch in the
Adjustments section of this chapter).
4. If the mow/transport switch tests correctly and a circuit problem still exists, check wire harness (see Electrical Schematic and Wire Harness Drawings in Chapter
9 - Foldout Drawings).
5. Make sure that wire harness electrical connector is
connected to the mow/transport switch after testing.

2. Test mow/transport switch as follows:

1
Electrical
System

A. Turn ignition switch to the ON position (do not
start engine) and check LED on cable end of mow/
transport switch.
B. LED should be illuminated when the mow stop
lever is in the mow position. LED should not be illuminated when the mow stop lever is in the transport
position.
2

3. If the mow/transport switch LED did not function correctly:

A. Make sure that mow/transport switch is properly
adjusted (see Mow/Transport Switch in the Adjustments section of this chapter). If necessary, adjust
switch and return to step 2 above.
B. Make sure ignition switch is OFF and disconnect
the mow/transport switch connector from the machine wire harness.

Reelmaster 5010- H

FRONT

LED location

Figure 49
1. Traction pedal
2. Mow stop lever
3. Mow/transport switch

Page 5 - 57

4. Lock washer (2 used)
5. Jam nut (2 used)

Electrical System

Main Power, Glow and 48 VDC Logic Relays
Your Reelmaster uses three (3) identical electrical relays that have four (4) terminals. The main power and
glow relays are attached to a frame bracket under the
hood near the engine exhaust muffler (Fig. 50). The 48
VDC logic relay is attached to a frame bracket under the
hood behind the reel motor fuse block (Fig. 51). A tag
near the relay harness connector identifies each relay.

The main power relay is used to provide current to the
TEC controller, headlights, power point and optional
electric equipment. When the ignition switch is in the
ON/PREHEAT or START position, the main power relay
is energized. A fault code will be displayed on the InfoCenter Display if the main power relay or circuit wiring
is faulty.
The glow relay is used to provide current to the engine
glow plugs when energized by the TEC controller. The
TEC controls and monitors the operation of the glow
relay. The glow relay and its circuit wiring should be
tested as a TEC output with the InfoCenter Display before disconnecting and testing the relay (see InfoCenter
Display in this chapter). A fault code may be displayed
on the InfoCenter Display if the glow relay or circuit
wiring is faulty.

2
3

Figure 50
1. Exhaust muffler
2. Main power relay

3. Glow relay
4. Hood saddle

The 48 VDC logic relay is used to provide 48 VDC logic
power to the motor/generator and reel motor controllers.
It also supplies power to the main contactor in the electric reel circuit. This relay is energized by an output from
the TEC controller.

3
1

Testing
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.

Figure 51
1. 48 VDC logic relay
2. Reel motor fuses

3. Generator air intake

2. Open hood to gain access to relays.
30

3. Locate relay and disconnect the machine wire harness connector from the relay. If main power or glow relay are to be removed, remove hood saddle from
machine for easier access to start relay. Remove relay
from machine for easier testing.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
4. Verify coil resistance between terminals 85 and 86
with a multimeter (ohms setting) (Fig. 52). Resistance
should be approximately 72 ohms.
Electrical System

Page 5 - 58

86
87

Figure 52
Reelmaster 5010- H

6. When relay testing is complete, disconnect voltage
and multimeter leads from the relay terminals.
7. Replace relay if testing determines that it is faulty.
8. Secure relay to machine and connect machine wire
harness connector to relay. Install hood saddle to machine if it was removed. Lower and secure hood.

Electrical
System

5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should have continuity between terminals 30 and 87 as +12 VDC is applied to terminal 85. The relay should not have continuity between
terminals 30 and 87 as +12 VDC is removed from terminal 85.

Reelmaster 5010- H

Page 5 - 59

Electrical System

Start Relay
The start relay is used in the engine starting circuit.
When energized by the TEC controller, the start relay
provides a current path to energize the engine starter
solenoid. The start relay has five (5) terminals and is attached to a frame bracket under the hood near the engine exhaust muffler (Fig. 53). Relays can be identified
by a tag on the wire harness.
Testing
NOTE: The start relay should be tested as a TEC controller output with the InfoCenter Display before disconnecting and testing the relay (see Diagnostics Screen
(Engine Start item) in the InfoCenter Display section of
this chapter). The InfoCenter Display will identify if the
TEC output to the start relay exists when machine controls are in the correct position. If the TEC controller output exists for the start relay but the relay is not
functioning correctly, suspect a failed start relay or an
open in the start relay circuit.

6. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
7. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should not have continuity between terminals 30
and 87A as +12 VDC is applied to terminal 85. The relay
should have continuity between terminals 30 and 87A
as +12 VDC is removed from terminal 85.
8. When testing is complete, disconnect voltage and
multimeter leads from the relay terminals.
9. Replace start relay if testing determines that it is
faulty.
10.Secure start relay to machine and connect machine
wire harness connector to relay. Install hood saddle to
machine. Lower and secure hood.
2

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. Open hood to gain access to start relay. Remove
hood saddle from machine for easier access to start
relay.
3. Locate start relay and disconnect the machine wire
harness connector from the relay. Remove relay from
machine for easier testing.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from the measured value of the component you are
testing.

Figure 53
1. Exhaust muffler
2. Start relay

4. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 54). Resistance should be between 70 and 90 ohms.
5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should have continuity between terminals 30 and 87 as +12 VDC is applied to terminal 85. The relay should not have continuity between
terminals 30 and 87 as +12 VDC is removed from terminal 85.

Electrical System

Page 5 - 60

3. Hood saddle

87A

Figure 54

Reelmaster 5010- H

Main Contactor
The main contactor provides current to the 48 VDC system circuits (e.g. motor/generator, reel motors). When
the ignition switch is ON, the 48 VDC logic relay is energized by the TEC controller which allows the main contactor to be energized if allowed by the motor/generator
controller. The main contactor is attached to the right
side frame rail under the operator seat (Fig. 55).
NOTE: If electrical problems exist with the main contactor, a fault may have occurred that would be indicated by
a fault code on the InfoCenter Display. Before considering that main contactor service work is necessary, check
for any existing fault codes that indicate problems with
the contactor.

10.Connect electrical connections to main contactor
(Fig. 56). Torque nuts that secure connections to contactor main contact posts from 40 to 50 in- lb (4.6 to 5.6
N- m) and nuts that secure connections to contactor coil
posts to 20 in- lb (2.2 N- m).
11. Plug the 48 VDC battery disconnect back into the
socket. Lower and secure operator seat.
FRONT

Testing
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.
2. Raise operator seat to access main contactor.
3. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect.
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation.

5. Disconnect all wire harness electrical connections
from contactor. Note wire connector locations on contactor for reassembly purposes.

Figure 55
1. Main contactor
2. Positive battery cable
3. 48V battery disconnect

6. Using jumper wires, apply 48 VDC directly across the
contactor coil posts (Fig. 56). The contactor should click
as the coil is energized. With the contactor coil energized, resistance across the main contact posts should
be less than 1 ohm.

4. Fuse (250A / 58V)
5. Isolator

7. Remove voltage from contactor coil posts. The contactor should click as the coil is de- energized. With the
contactor coil not energized, resistance across the main
contact posts should be infinite ohms.

CONTACTOR
WIRING
DIAGRAM

8. With no voltage applied to contactor posts, measure
resistance across the contactor coil posts (Fig. 56). The
resistance should be approximately 126 ohms.

9. Replace main contactor if testing determines that it
is faulty.

1
Figure 56

1. Main contact posts

Reelmaster 5010- H

Page 5 - 61

2. Contactor coil posts

Electrical System

Electrical
System

4. Remove cover from main contactor (not shown).

Toro Electronic Controller (TEC)
Reelmaster 5010- H machines use a Toro Electronic
Controller (TEC) to control electrical system operation.
The TEC controller senses the condition of various
switches (inputs) and directs power output to allow certain machine functions. The TEC is attached to the control arm behind the access panel on the outside of the
control arm (Fig. 57).

Logic power is provided to the controller as long as the
battery cables are connected to the battery. A 2 Amp
fuse (fuse F4) provides circuit protection for this logic
power to the controller.
Inputs from the ignition, neutral, parking brake, reel engage/disengage, seat, mow/transport, joystick lower/
raise, reels down limit, engine speed, engine
temperature sender and engine oil pressure switches
are all monitored by the TEC controller.
Current output to the lift circuit hydraulic valve solenoid
coils, engine components (glow plug relay, start relay,
fuel pump and fuel actuator) and reel circuit 48 VDC logic relay are controlled based on the inputs received by
the TEC controller. Circuit protection for TEC outputs is
provided by three (3) 7.5 Amp fuses (fuse locations
F2- 1, F2- 2 and F2- 3).
The InfoCenter Display should be used when checking
inputs and outputs of the TEC used on your Reelmaster.
If the TEC detects a malfunction in any of the controlled
circuits, the InfoCenter Display can also be used to identify the fault (see InfoCenter Display in this chapter).
The diagram in Figure 58 depicts the connection terminal functions for the TEC controller. Note that electrical
power for controller outputs is provided through three (3)
connections (PWR 2, PWR 3 and PWR 4) each protected with a 7.5 amp fuse. A fifty (50) pin wire harness
connector attaches to the controller. The connector pins
are identified in the diagram in Figure 58. The layout of
the wire harness connector that plugs into the TEC controller is shown in Fig. 59.
IMPORTANT: When testing for wire harness continuity at the connector for the TEC controller, take
care to not damage the connector pins with multimeter test leads. If connector pins are enlarged or
damaged during testing, connector repair will be
necessary for proper machine operation.

Figure 57
1. TEC controller

12V POWER
(7.5A FUSES)

OUTPUTS
(PWR2)

12V LOGIC
POWER
(2 AMP FUSE)

IGNITION
SWITCH
INPUTS

OUTPUTS
(PWR3)

OUTPUTS
(PWR4)
DIGITAL
INPUTS
(OPEN/
CLOSED)

ANALOG
INPUTS
(VARIABLE)

The machine electrical schematic and wire harness
drawings in Chapter 10 - Foldout Drawings can be used
to identify possible circuit problems between the controller and the input/output devices (e.g. switches and
solenoid coils).

Electrical System

2. Fuse block

Page 5 - 62

GROUND

CAN BUS

Figure 58
Reelmaster 5010- H

Because of the solid state circuitry built into the TEC
controller, there is no method to test it directly. The TEC
may be damaged if an attempt is made to test it with an
electrical test device, such as a digital multimeter.
IMPORTANT: Before performing welding on the machine, disconnect both positive and negative battery cables from the battery, disconnect both wire
harness connectors from the TEC controller and
disconnect the terminal connector from the alternator to prevent damage to the electrical system.

WIRE HARNESS CONNECTOR FOR
TEC CONTROLLER
41

50
40

31
21

20
1

NOTE TAB
POSITION

Electrical
System

Figure 59

Reelmaster 5010- H

Page 5 - 63

Electrical System

Fusible Link Harness
The Reelmaster 5010- H uses three (3) fusible links for
circuit protection. These fusible links are located in a
harness that connects the starter B+ terminal to the
main wire harness (Fig. 60). If any of these links should
fail, current to the protected circuit will cease. Refer to
wire harness drawings in Chapter 9 - Foldout Drawings
for additional fusible link information.

FRONT

Testing
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.
2. Disconnect negative battery cable from battery at
rear of machine. Then disconnect positive cable from
battery (see Battery Service in the Service and Repairs
section of this chapter).
3. Locate and unplug fusible link connector P1 from
platform wire harness.
4. Use a multimeter to make sure that continuity exists
between each terminal pin in connector P1 and connector J1 at the starter (Fig. 61). If any of the fusible links are
open, replace the fusible link harness.

3
2

Figure 60
1. Starter motor
2. Fusible link harness

3. Positive battery cable

5. After testing is complete, make sure that fusible link
harness connectors are securely attached to starter and
machine wire harness.
6. Connect positive battery cable to battery terminal
first and then connect negative cable to battery.

FUSIBLE LINK
FUSIBLE LINK
FUSIBLE LINK

Figure 61

Electrical System

Page 5 - 64

Reelmaster 5010- H

Diode Assembly
A diode assembly is used in the Reelmaster main wire
harness (Fig. 62). The diode is used for circuit protection
from voltage spikes that occur when the starter solenoid
is de- energized.
Testing
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.

2
1

2. Locate diode assembly near alternator on engine
and remove cable tie that secures diode to wire harness.
Unplug the diode from the wire harness for testing.
3. The diode (Fig. 63) can be tested using a digital
multimeter (diode test or ohms setting) and the table below.
Multimeter
Red Lead (+)
on Terminal

Multimeter
Black Lead (- )
on Terminal

Continuity

Female

Male

YES

Male

Female

Figure 62
1. Main wire harness

2. Diode assembly

2
1

5. After diode testing is complete, make sure that diode
is fully installed into wire harness connector and secured to harness with cable tie.

Reelmaster 5010- H

Figure 63
1. Diode
2. Male terminal

Page 5 - 65

3. Female terminal

Electrical System

Electrical
System

4. If testing determines that diode is faulty, replace
diode assembly.

48 VDC System Protection Diode
The Reelmaster 5010- H 48 VDC system includes a
diode that is used for circuit protection from voltage
spikes when the main contactor is de- energized. The
diode plugs into the main wire harness near the 48 VDC
battery disconnect and main contactor under the operator seat (Fig. 64).

Protection Diode Testing
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.

2. Raise operator seat.

Figure 64

3. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect.
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation.

1. Protection diode
2. 48V battery disconnect

4. Locate protection diode near 48 VDC battery disconnect and unplug the diode from the wire harness for testing.
5. The protection diode (Fig. 65) can be tested using a
digital multimeter (diode test or ohms setting) and the
table to the right. Replace the protection diode if testing
determines that it is faulty.

NOTE: Protection diode terminals 2, 3, 4 and 5 are not
used on Reelmaster 5010- H machines.
6. After testing is complete, make sure that protection
diode is fully installed into wire harness connector.
7. Plug the 48 VDC battery disconnect back into the
socket. Lower and secure operator seat.

Electrical System

3. Main contactor

Figure 65
Multimeter
Red Lead (+)
on Terminal

Multimeter
Black Lead (- )
on Terminal

Continuity

YES

Page 5 - 66

Reelmaster 5010- H

Location ID Module
The location ID module exists in the 48 VDC electrical
circuit to identify the location of the five (5) cutting reel
motors. This module allows such machine features as
starting and stopping the rear cutting units slightly later
than the front cutting units. The location module plugs
into the main wire harness near the 48 VDC fuse block
(Fig. 66).

8. After testing is completed, secure main wire harness
connector to location ID module connector.
9. Plug the 48 VDC battery disconnect back into the
socket.
10.Lower and secure operator seat and hood.

NOTE: If electrical problems exist with the location ID
module, a fault may have occurred that would be indicated by a fault code on the InfoCenter Display. Before
considering that location ID module service work is necessary, check for any existing fault codes that indicate
problems with the module.

Testing
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.

2. Raise and support operator seat and hood.
3. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected cutting unit operation.

Figure 66
1. Location ID module

2. 48 VDC fuse block

Electrical
System

4. Locate location ID module secured to the frame near
the 48 VDC fuse block (Fig. 66).
5. Carefully unplug main wire harness connector from
location ID module connector.

6. Using a multimeter, measure resistances between
module connector terminals as follows (Fig. 67):
Connector Terminals

Resistance

A and F

15 K ohms

B and F

10 K ohms

C and F

6.2 K ohms

D and F

3.9 K ohms

E and F

1.6 K ohms

D
E

Figure 67

7. Replace ID module if testing determines that it is
faulty.

1. Location ID module

2. ID module connector

NOTE: Do not attempt to remove cover of location ID
module. There are no replaceable parts under cover.

Reelmaster 5010- H

Page 5 - 67

Electrical System

Cutting Reel Motor
The five (5) cutting reel motors are identical 48 VDC,
brushless, permanent magnet motors. Each motor has
its own integral invertor and on- board controller. The InfoCenter Display can be used to monitor the speed and
current draw for the five (5) cutting unit motors during
machine operation. Also, if a problem exists with any
cutting reel motor, a fault may have occurred that would
be indicated by a fault code on the InfoCenter Display.
Because the cutting reel motors used on the Reelmaster
5010- H are the same motors, motors from different cutting units can be exchanged. If the problem follows a
motor to the new cutting unit, the motor is likely the issue. If the problem remains with the cutting unit, the issue is likely due to the cutting unit or electrical
components or wiring to that cutting unit.

6. If measured resistance is incorrect, consider that the
cutting reel motor is faulty.
NOTE: If cutting reel motor removal, installation, disassembly or assembly information is needed, see Cutting
Reel Motor and Cutting Reel Motor Service in the Service and Repairs section of this chapter.
7. After testing is completed, secure two (2) reel motor
cable connectors to machine wire harness connectors.
8. Plug the 48 VDC battery disconnect back into the
socket.
2

NOTE: Before considering that cutting reel motor service work is necessary, check for any existing fault
codes that indicate problems with a reel motor (see
Fault Codes in the Troubleshooting section of this chapter). If a cutting reel motor is faulty, there will likely be numerous fault codes that are listed by the InfoCenter
display.
Testing

1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.

Figure 68
1. Cable from motor
2. 4 wire connector

2. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected cutting unit operation.

3. 2 wire connector
4. Connector plate

2
4

3. Locate cutting reel motor cable electrical connections at machine wire harness for motor that is to be tested.

IMPORTANT: When disconnecting reel motor cable
connectors, take care to not damage the cable or
connectors. The reel motor cable is not available as
a separate replacement part.
3

4. Carefully disconnect two (2) reel motor cable connectors from machine wire harness (Fig. 68).
5. Using a multimeter, measure resistance between 48
VDC ground terminal (black wire) in the 2 wire connector
and location ID terminal (blue wire) in 4 wire connector
(Fig. 69). Resistance should be approximately 18.8
K- ohms.

Electrical System

Figure 69
1. 48 VDC ground (black)
2. 48 VDC power (red)
3. Location ID (blue)

Page 5 - 68

4. 48 VDC logic (white)
5. CAN- bus (green)
6. CAN- bus (yellow)

Reelmaster 5010- H

CAN- bus Termination Resistors

The twisted pair of bus wires for the 12 VDC circuits are
black/white and red/white. The twisted pair of bus wires
for the 48 VDC circuits are green and yellow.
The two (2) termination resistors for the 12 VDC electrical circuits have the following locations:
A. In the control arm next to the operator seat.
B. Near the wire harness connectors for the #3 (right
rear) cutting unit motor on the right side of the machine.
The two (2) termination resistors for the 48 VDC electrical circuits have the following locations:
A. Near the wire harness connectors for the #1 (front
center) cutting unit motor under the footrest at the
front of the machine.

Termination Resistor Test
The termination resistors (Fig. 70) can be individually
tested using a digital multimeter (ohms setting). Locate
resistor and remove cable tie that secures resistor to
wire harness. Unplug the resistor from the wire harness
for testing.
NOTE: The insulator wedge in the termination resistor
is blue for identification purposes. There also is a center
keyway to prevent the termination resistor from plugging
into the wrong wire harness connector.
Use a digital multimeter (ohms setting) to measure the
resistance value for the termination resistor. There
should be 120 ohms resistance between terminals A
and B. Refer to Fig. 70 to determine terminal locations.
Terminal C is not used on Reelmaster 5010- H machines.
If testing determines that termination resistor is faulty,
replace resistor.
After testing is complete, make sure that termination resistor is fully installed into wire harness connector and
secured to wire harness with cable tie.

B. Near the 48 VDC reel motor fuse holder behind
the hood saddle under the hood.
NOTE: Refer to the Electrical Schematics and Wire
Harness Drawings in Chapter 9 - Foldout Drawings for
additional information on termination resistor locations
and wire connections.
IMPORTANT: The termination resistors at the ends
of the bus cables are required for proper electrical
system operation.

Reelmaster 5010- H

Page 5 - 69

Termination
Resistor

Electrical
System

System communication between electrical components
on Reelmaster 5010- H machines is accomplished on
two (2) CAN- bus communication systems: one for the
12 VDC system and one for the 48 VDC system. Two (2)
specially designed, twisted cables form the bus for both
of the networks used on the 5010- H machines. These
wires provide the data pathways between machine electrical components. At the ends of the twisted pair of bus
cables are 120 ohm termination resistors.

Keyway
C
Figure 70

Electrical System

Hydraulic Solenoid Valve Coil
The Reelmaster hydraulic lift control manifold includes
four (4) solenoid valves for system control (Fig. 71).
When the solenoid coils are energized, hydraulic valve
shift occurs to control hydraulic flow. Testing of the coils
can be done with the coil installed on the hydraulic valve.
NOTE: If electrical problems exist with a solenoid valve
coil, a fault may have occurred that would be indicated
by a fault code on the InfoCenter Display. Before considering that solenoid valve coil service work is necessary,
check for any existing fault codes that indicate problems
with a coil.
Testing

NOTE: Solenoid valve coils SV2 and SVRV on the lift
control manifold are identical. The remaining two lift
manifold coils (SV1 and SV3) are identical. To assist in
troubleshooting, identical coils can be exchanged. If the
problem follows the exchanged coil, an electrical problem likely exists. If the problem remains unchanged,
something other than the solenoid coil is the problem
source (e.g. switch, circuit wiring, hydraulic problem).
6. After testing the coils, connect wire harness electrical connector to the solenoid valve coil.
7. Install operator floor plate.

NOTE: A solenoid valve coils should be tested as a
TEC controller output with the InfoCenter Display before
disconnecting and testing the coil (see Diagnostics
Screen (PTO item) in the InfoCenter Display section of
this chapter). The InfoCenter Display will identify if the
TEC output to the solenoid coil exists when machine
controls are in the correct position. If the TEC controller
output exists for a solenoid coil but the coil is not functioning correctly, suspect a failed coil or an open in the
solenoid valve coil circuit.
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
2. Access to the lift control manifold can be obtained by
removing the operator floor plate.

1
4

FRONT

Figure 71
1. Lift manifold
2. SV3 solenoid
3. SV2 solenoid

4. SVRV solenoid
5. SV1 solenoid

3. Disconnect wire harness electrical connector from
hydraulic solenoid valve coil that is to be tested (Fig. 71).
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter may display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
4. Using a multimeter (ohms setting), measure resistance between the two connector terminals on the solenoid valve coil. The resistance for the solenoid coils is
identified below:
Solenoid Valve Coil

Resistance

SV1 and SV3

8.7 ohms

SV2 and SVRV

7.1 ohms

5. If solenoid coil resistance is incorrect, replace solenoid coil (see Hydraulic Solenoid Valve Coil in the Service and Repairs section of this chapter).
Electrical System

Page 5 - 70

Reelmaster 5010- H

Temperature Sender
The temperature sender is located near the alternator
on the water flange attached to the engine cylinder head
(Fig. 72). The Toro Electronic Controller (TEC) monitors
the operation of the temperature sender.
The resistance of the temperature sender reduces as
the engine coolant temperature increases. The changing resistance of the temperature sender is used as an
analog input to the TEC controller to indicate engine
coolant temperature during machine operation.
Temperature Sender Test
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. Open
hood to gain access to engine.
2. Locate temperature sender on engine and disconnect wire harness connector from sender.

C. The meter should indicate from 0.6 to 0.7 ohms at
212 oF (100oC).
6. Replace temperature sender if specifications are not
met.
7. Install temperature sender to the water flange.
A. Clean threads of water flange and temperature
sender thoroughly. Apply thread sealant to the
threads of the sender.
B. Screw sender into the water flange until it is finger
tight. Then, tighten sender an additional 2 to 3 full
turns.
C. Connect wire harness connector to sender.
8. Fill engine cooling system. Close and secure hood.
1

FRONT

CAUTION
Make sure engine is cool before removing the
temperature sender from engine.
2

Electrical
System

3. Lower coolant level in the engine and remove the
temperature sender from water flange.
4. Put sender in a container of oil with a thermometer
and slowly heat the oil (Fig. 73).

CAUTION

Figure 72

Handle the hot oil with extreme care to prevent
personal injury or fire.

1. Temperature sender

2. Alternator

NOTE: Prior to taking resistance readings with a digital
multi meter, short the meter test leads together. The meter will display a small resistance value (usually 0.5
ohms or less) due to the internal resistance of the meter
and test leads. Subtract this value from from the measured value of the component you are testing.
5. Check resistance of the sender with a multimeter
(ohms setting) as the oil temperature increases.
A. The meter should indicate from 11.4 to 13.6 ohms
at 68oF (20oC).

Figure 73

B. The meter should indicate from 2.3 to 2.6 ohms at
140oF (60oC).
Reelmaster 5010- H

Page 5 - 71

Electrical System

Oil Pressure Switch
The engine oil pressure switch is a normally closed
switch that opens with pressure during normal engine
operation. The oil pressure switch is located on the engine near the oil filter (Fig.74). The Toro Electronic Controller (TEC) monitors the operation of the oil pressure
switch.
The oil pressure switch should open at approximately 8
PSI (0.56 kg/cm2).
If low engine oil pressure allows the oil pressure switch
to close during engine operation and the TEC controller
detects a low oil pressure input for ten (10) seconds, the
engine will be shut off by the controller. The operator will
see an advisory (advisory #169) on the InfoCenter display explaining that low engine oil pressure has caused
the engine shutdown.

5. If testing of oil pressure switch determines that
switch operation is normal and the InfoCenter display is
identifying low engine oil as the cause of engine shutdown, check for faulty wire in the oil pressure switch circuit.
6. After testing is completed, connect the wire harness
connector to the oil pressure switch. Lower and secure
hood.
NOTE: Refer to Kubota Workshop Manual, Diesel Engine, 05- E4B Series for information regarding engine
lubrication system and testing.

NOTE: A faulty oil pressure switch or faulty wiring to the
oil pressure switch could cause a closed circuit that
would lead to engine shutdown with an InfoCenter display identifying Advisory #169.

Testing
2

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. Raise and support hood. Locate oil pressure switch
on engine and disconnect the wire harness connector
from the switch.
3. Use a digital multimeter to measure continuity between the oil pressure switch terminal and the switch
base (ground connection) (Fig. 75).

Figure 74
1. Oil pressure switch

2. Oil filter

A. With the engine not running, the oil pressure
switch should be closed so there should be continuity between the switch terminal and the switch base
(0 ohms).

2
1

B. With the engine running, the oil pressure switch
should be open so there should not be continuity
between the switch terminal and the switch base (infinite ohms).
4. Replace the oil pressure switch if testing determines
that the switch is defective.

Electrical System

Figure 75
1. Switch terminal

Page 5 - 72

2. Switch base

Reelmaster 5010- H

Fuel Actuator

The fuel actuator and TEC controller work together to
maintain engine speed by adjusting the fuel delivery to
the engine. A sensor in the motor/generator provides
the generator/engine speed to the TEC controller via the
CAN- bus. If there is a change in engine speed (e.g. load
conditions change, engine speed switch pressed by operator), the TEC controller modifies the electrical output
to the actuator which adjusts fuel as required to maintain
engine speed.

4. Using a multimeter (ohms setting), measure resistance between the two terminals in the fuel actuator connector. Resistance should be from 5.0 to 5.5 ohms.
5. If actuator coil resistance is incorrect, replace fuel
actuator.
6. When testing is complete, connect wire harness connector to the fuel actuator.
7. Lower and secure hood.

The TEC controller monitors the operation of the fuel actuator. If the TEC controller detected a fuel actuator
problem during engine operation, the InfoCenter Display can be used to identify the fault (see Fault Codes
in the Troubleshooting section in this chapter).
NOTE: If a problem with the fuel actuator or circuit
wiring exists, the extension spring attached to the actuator bracket and engine speed control lever will cause the
engine to run at high idle (3150 RPM) with the engine
mechanical governor maintaining engine speed. In this
situation, the control arm mounted engine speed switch
will not change engine speed and a fault code should be
displayed on the InfoCenter Display.

3
1

Figure 76
1. Injection pump
2. Fuel actuator

Testing

3. Extension spring

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. Open
hood to gain access to engine.
2. Locate fuel actuator and disconnect wire harness
connector from fuel actuator.

NOTE: The fuel actuator may be tested in place or
removed from the engine for testing.
3. If the actuator is removed from the engine, make
sure that the actuator plunger moves freely and is free
of dirt, debris and corrosion.

Figure 77
1. Fuel actuator

2. Actuator connector

NOTE: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value
from the measured value of the component you are testing.

Reelmaster 5010- H

Page 5 - 73

Electrical System

Electrical
System

The fuel actuator used on your Reelmaster must be energized by the TEC controller for the diesel engine to
run. The actuator is mounted to the injection pump on
the engine (Fig. 76).

Fuel Sender
The fuel sender is a variable resistance device that allows the InfoCenter display to show level of the fuel tank.
The fuel sender is located in the fuel tank (Fig. 78).

RIGHT

Testing

FRONT

175 to 200 in- lb
(20 to 22 N- m)

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. Remove screws that secure sender cover to fuel
tank. Lift cover from tank.

3. Disconnect the wire harness connector from the fuel
sender.

CAUTION
When testing circuit wiring and fuel sender,
make sure wire connections are secure before
turning ignition switch to ON to prevent an explosion or fire from sparks.
4. To test the circuit wiring and InfoCenter fuel gauge,
use a jumper wire to connect the two (2) terminals in the
wire harness connector. Make sure that jumper wire
connections are secure. Turn the ignition switch to the
ON/PREHEAT position. InfoCenter display should indicate a full fuel tank if circuit wiring and InfoCenter are
working correctly. Turn ignition switch OFF and continue
testing fuel sender if circuit wiring and InfoCenter are acceptable.

Figure 78
1.
2.
3.
4.

Fuel gauge sender
Fuel sender cap
Gasket
Fuel supply hose

5.
6.
7.
8.

Fuel return hose
Fuel tank
Screw (5 used)
Sender cover

5. Loosen hose clamps and carefully disconnect supply and return fuel hoses from fittings on the top of the
fuel sender.
IMPORTANT: Before removing fuel sender from
tank, note orientation of fuel sender fittings for assembly purposes (Fig. 79).

6. Carefully remove fuel sender cap that secures the fuel sender in the fuel tank.
FRONT

7. Raise fuel sender and gasket from the fuel tank.
Clean all fuel from the sender.

Figure 79

CAUTION

1. Fuel sender
2. Fuel supply fitting

3. Fuel return fitting

Make sure fuel sender is completely dry (no fuel
on it) before testing. Perform test away from the
tank to prevent an explosion or fire from sparks.

Electrical System

Page 5 - 74

Reelmaster 5010- H

8. Use a multimeter to check resistance of the fuel
sender across the two (2) sender terminals (Fig. 80).
A. Resistance with the float in the full position (completely up) should be from 5 to 8 ohms.
B. Resistance with the float in the empty position
(completely down) should be from 89 to 95 ohms.

9. Replace fuel sender if testing determines that it is
faulty.
10.After testing, install sender into fuel tank and secure
with gasket and fuel sender cap. Make sure that fuel fittings on sender are orientated at 90o from right side of
tank as shown in Figure 79. Also, to prevent damage to
fuel sender during assembly, make sure that fuel sender
does not turn as sender cap is tightened.

11. Install fuel hoses to fittings on sender and secure
with hose clamps. Connect fuel sender connector to
wire harness.
Figure 80
1. Sender full position

2. Sender empty position

Electrical
System

12.Secure sender cover to fuel tank with removed
screws.

Reelmaster 5010- H

Page 5 - 75

Electrical System

Fuel Pump
The Reelmaster electric fuel pump is attached to the inside of the left side frame rail near the fuel tank (Fig. 81).

10.Connect wire harness electrical connector to the engine fuel actuator.

IMPORTANT: When testing fuel pump, make sure
that pump is not operated without fuel.

11. Bleed the fuel system.
12.Lower and secure operator seat and hood.
Fuel Pump Specifications

DANGER

64 fl oz/min (1.9 liters/min)

Pump Capacity
Because diesel fuel is flammable, use caution
when handling it. Do not smoke while testing the
fuel pump. Do not test fuel pump while engine is
hot. Make sure that there is adequate ventilation
when testing. Always wipe up any spilled fuel before starting the engine.

Pressure

7 PSI (48.3 kPa)

Current Draw

2.0 amp

Fuel Pump Capacity Test
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. Raise operator seat and hood.
2. Disconnect wire harness electrical connector from
the engine fuel actuator to prevent the engine from starting (see Fuel Actuator in this section).

2
1

3. Disconnect fuel hose (pump discharge) from the
fuel/water separator inlet fitting (Fig. 82).
4. Make sure fuel hoses attached to the fuel pump, fuel
filter and fuel tank suction tube screen are free of obstructions.

Figure 81
1. Fuel pump

5. Place disconnected hose into a large, graduated cylinder large enough to collect 1 quart (0.95 liter).

2. Pump discharge hose

RIGHT
FRONT

IMPORTANT: When testing the fuel pump, DO NOT
turn ignition switch to START.
6. Collect fuel in the graduated cylinder by turning ignition switch to the ON/PREHEAT position. Allow pump to
run for fifteen (15) seconds, then return ignition switch
to OFF.
7. The amount of fuel collected in the graduated cylinder should be approximately 16 fl oz (475 ml) after fifteen (15) seconds.

2
3

8. Replace fuel pump if testing proves it to be faulty.

Figure 82
1. Fuel hose (from pump)
2. Hose clamp

Electrical System

9. When testing is complete, install fuel hose to the fuel/
water separator. Make sure to secure fuel hose with
hose clamp.

Page 5 - 76

3. Fuel/water separator
4. Fuel return hose

Reelmaster 5010- H

Service and Repairs
NOTE: See the Kubota Workshop Manual, Diesel Engine, 05- E4B Series for engine electrical component repair information.

Hydraulic Solenoid Valve Coils
A hydraulic solenoid valve coil on the lift control manifold
(Fig. 83) can be replaced without opening the hydraulic
system.

60 in- lb
(6.7 N- m)

Removal

1. Park machine on a level surface, lower cutting units,
stop engine and engage parking brake. Remove key
from ignition switch.

5
4

2. The lift control manifold is attached to a frame bracket under the operator floor plate. Access to the lift control
manifold can be obtained by removing the floor plate.
Refer to Figure 83 for solenoid coil locations on the lift
control manifold.
3. Disconnect the wire harness electrical connector
from the solenoid valve coil to be replaced.
4. Remove the nut from the hydraulic valve.

6. Slide the solenoid coil from the valve.

FRONT

7. Clean any corrosion or dirt from the valve.
Figure 83

Installation
1. Slide new coil assembly onto the hydraulic valve.
2. If equipped (SV1 and SV3 on lift control manifold),
slide coil spacer onto hydraulic valve.

1.
2.
3.
4.

Lift control manifold
Solenoid coil SVRV
Nut
Solenoid coil SV2

5.
6.
7.
8.

Nut
Solenoid coil SV1
Coil spacer
Solenoid coil SV3

3. Install the nut onto the valve and torque nut 60 in- lb
(6.7 N- m) (do not over tighten).
4. Connect the machine wire harness connector to the
solenoid coil.

Reelmaster 5010- H

Page 5 - 77

Electrical System

Electrical
System

5. If equipped (SV1 and SV3 on lift control manifold), remove coil spacer from hydraulic valve.

12 VDC Battery Service
The battery is the heart of the 12 VDC electrical system.
With regular and proper service, battery life can be extended. Additionally, battery and electrical component
failure can be prevented.

Battery Inspection and Maintenance
1. Check battery for cracks. Replace battery if cracked
or leaking.
2. Check battery terminal posts for corrosion. Use wire
brush to clean corrosion from posts.

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.
Battery Specifications
BCI Group Size 55
585 CCA at 0o F (- 18oC)
95 minutes reserve capacity at 80oF (27oC)
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80oF (27oC)
Discharged: less than 1.240
Removal and Installation (Fig. 84)
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.

IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling.
Also, check battery case for dirt and oil. Clean the battery with a solution of baking soda and water, then rinse
it with clean water.
4. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking.
5. If the battery electrolyte is accessible, check the
electrolyte level in each cell. If the level is below the tops
of the plates in any cell, fill all cells with distilled water
between the minimum and maximum fill lines. Do not fill
cells above the fill line. Charge at 15 to 25 Amps for fifteen (15) minutes to allow sufficient mixing of the electrolyte.

2. Open screen at rear of machine and remove battery
cover to access battery.
3. Loosen and remove negative cable from battery. After negative cable is removed, loosen and remove positive cable.

4. Loosen flange nut that secures battery retainer.

5. Carefully remove battery from machine.

4
3
2

6. Install battery in reverse order making sure to connect and tighten positive cable to battery before connecting negative cable.
NOTE: Before connecting the negative (ground) cable
to the battery, connect a digital multimeter (set to DC
Amps) between the negative battery post and the negative (ground) cable connector. The reading should be
less than 0.1 Amp. If the reading is 0.1 Amp or more, the
machine’s electrical system should be tested for short
circuits or faulty components and repaired.

FRONT

Figure 84
1.
2.
3.
4.

12 VDC battery
Battery tray
Retainer
Flange nut

5.
6.
7.
8.

Carriage screw
Negative battery cable
Positive battery cable
Battery cover

7. Coat battery posts and cable connectors with Battery
Terminal Protector (Toro Part No. 107- 0392) or petroleum jelly to prevent corrosion.
8. Install battery cover. Close and secure screen.
Electrical System

Page 5 - 78

Reelmaster 5010- H

If the machine will be stored for more than thirty (30)
days:
1. Charge battery fully before storing the machine (see
Battery Service in this section).

H. Using the table in the column to the right, determine the minimum voltage for the battery temperature reading. If the test voltage is below the minimum
voltage for the battery temperature, replace the battery. If the test voltage is at or above the minimum,
return the battery to service.

2. Either remove battery from machine and store on a
shelf or leave battery on the machine. If the battery is
stored on the machine, leave battery cables disconnected.

Minimum
Voltage

Battery
Temperature

9.6

70oF (and up)

21oC (and up)

9.5

60oF

16oC

3. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge.

9.4

50oF

10oC

9.3

40oF

4oC

4. To help prevent the battery from freezing during storage, make sure it is fully charged (see Battery Service
in this section).

9.1

30oF

- 1oC

8.9

20oF

- 7oC

Battery Testing

8.7

10oF

- 12oC

8.5

0oF

- 18oC

1. Perform a high- discharge test with an adjustable
load tester. This is one of the most reliable means of testing a battery as it simulates the cold- cranking test. A
commercial battery load tester is required to perform
this test.

CAUTION
Follow the manufacturer’s instructions when using a battery load tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, charge the battery before performing a
load test.
B. If the battery has recently been charged, use a
battery load tester following the manufacturer’s instructions to apply a 150 Amp load for fifteen (15)
seconds. This step will remove the surface charge.

2. If the battery electrolyte is accessible, the specific
gravity of the electrolyte can be used to determine the
battery condition.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
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 warmup the hydrometer. At the same time take the temperature of the cell.
B. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific
gravity reading.
Example: Cell Temperature
100oF
Cell Gravity
1.245
100oF minus 80oF equals 20oF
(37.7oC minus 26.7oC equals 11.0oC)
20oF multiply by 0.004/10oF equals 0.008
(11oC multiply by 0.004/5.5oC equals 0.008)
ADD (conversion above)
0.008
Correction to 80oF (26.7oC)
1.253

C. Make sure battery terminals are free of corrosion.
D. Estimate the internal temperature of the battery
to the nearest 10 degrees F.
E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals.
F. Apply a test load of 270 Amps (one half the cranking performance rating of the battery) to the battery
for fifteen (15) seconds.
G. Take a battery voltage reading at fifteen (15) seconds, then remove the load.
Reelmaster 5010- H

C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Battery Charging or until all cells specific
gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell less
than 0.050. If these charging conditions can not be
met, replace the battery.

Page 5 - 79

Electrical System

Electrical
System

Battery Storage

Battery Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is readily available.

CAUTION
Follow the manufacturer’s instructions when using a battery charger.
NOTE: Using specific gravity of the battery electrolyte
is the most accurate method of determining battery
condition.
1. Determine the battery charge level from either its
open circuit voltage or electrolyte specific gravity (if
electrolyte is accessible).
Battery Charge
Level

Open Circuit
Voltage

Specific
Gravity

100%

12.6

1.265

75%

12.4

1.225

50%

12.2

1.190

25%

12.0

1.155

11.8

1.120

Charge the battery in a well- ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
3. Following the battery charger manufacturer’s
instructions, connect the charger cables to the battery.
Make sure a good connection is made.
4. Charge the battery following the battery charger
manufacturer’s instructions.

6. Determine if battery is fully charged before removing
battery from charger. Either of the following procedures
can be used:

Battery Charge Level
(Percent of Fully Charged)
75%

50%

25%

80 or less

3.8 hrs
@
3 Amps

7.5 hrs
@
3 Amps

11.3 hrs
@
3 Amps

15 hrs
@
3 Amps

81 to 125

5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@
@
@
@
4 Amps 4 Amps 4 Amps 4 Amps

126 to
170

5.5 hrs
@
5 Amps

11 hrs
@
5 Amps

16.5 hrs
@
5 Amps

22 hrs
@
5 Amps

171 to
250

5.8 hrs
@
6 Amps

11.5 hrs
@
6 Amps

17.3 hrs
@
6 Amps

23 hrs
@
6 Amps

above
250

6 hrs
@ 10
Amps

12 hrs
@ 10
Amps

18 hrs
@ 10
Amps

24 hrs
@ 10
Amps

Electrical System

Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60oF (16oC) before connecting to a charger.

5. While charging, occasionally check the battery. If the
electrolyte is violently gassing or spewing or if the battery case feels hot to the touch, the charging rate must
be lowered or temporarily stopped.

2. Determine the charging time and rate using the battery charger manufacturer’s instructions or the following
table.
Battery
Reserve
Capacity
(Minutes)

CAUTION

A. Continue charging and reduce charging rate as
needed until a two (2) hour period results in no increase in voltage. Open circuit voltage should be approximately 12.6 volts for a fully charged battery.
B. If the battery electrolyte is accessible, three (3)
hours prior to the end of the charging, measure the
specific gravity of a battery cell once per hour. The
battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three (3) consecutive readings.

Page 5 - 80

Reelmaster 5010- H

Page 5 - 81

Electrical
System

This page is intentionally blank.

Electrical System

48 VDC Battery Pack Service (Cutting Reel and Motor/Generator Systems)

5
8

25
14

22
23
7

18
11

RIGHT

FRONT
16

24
15

2
6

Figure 85
1.
2.
3.
4.
5.
6.
7.
8.
9.

Battery (4 used)
Battery tray
Push nut (2 used)
Carriage screw (2 used)
Flange nut (6 used)
Carriage bolt (4 used)
Flange nut (2 used)
Battery cover (2 used)
Hex nut (2 used)

Electrical System

10.
11.
12.
13.
14.
15.
16.
17.

Flat washer (2 used)
Carriage screw (2 used)
Flat washer (2 used)
Battery disconnect connector
Negative battery cable
Battery cable (2 used)
Battery jumper cable
Foam strip (4 used)

Page 5 - 82

18.
19.
20.
21.
22.
23.
24.
25.

Clamp (4 used)
Battery hold down (2 used)
Cable bracket
Carriage bolt (2 used)
Flat washer (4 used)
Flange nut (6 used)
Carriage screw (4 used)
Positive battery cable

Reelmaster 5010- H

The 48 volt battery pack used in the Reelmaster 5010- H
electric reel drive system is composed of four (4) 12 volt
batteries that are connected in series. The batteries are
absorbed glass mat (AGM), valve regulated batteries
that are maintenance free with no provision for checking
or adjusting electrolyte level. The batteries are equipped
with a low pressure venting system designed to release
excess gas pressure and then automatically reseal. A
low self discharge rate prevents deterioration of battery
performance during non- use or storage.

1
2

Before performing any service on the batteries in the 48
VDC system, disconnect the 48 VDC system components from the electrical power supply by separating the
48 VDC battery disconnect (see 48 VDC Battery Disconnect in the General Information section of this chapter).
This will prevent unexpected system operation.

3
4
Figure 86

1. RH front battery
2. LH front battery

Battery Specifications
Battery capacity 53 AH
650 CCA at 0o F (- 18oC)

3. Positive terminal
4. Jumper cable

WARNING

48 VDC Battery Pack Removal (Fig. 85)
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
2. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect.
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation.
3. Remove battery covers to gain access to batteries.

Electrical
System

POTENTIAL HAZARD:
The battery terminals, metal tools and metal vehicle parts could short together.
WHAT CAN HAPPEN:
Sparks can cause battery gasses to explode.
Damaged cables could short against metal vehicle parts and cause sparks.
HOW TO AVOID THE HAZARD:
When removing or installing the batteries, do
not allow the battery terminals to short against
metal parts of the vehicle.
Do not allow metal tools or metal vehicle parts to
short between the battery terminals or battery
cables.
Always keep the battery retainers in place to
protect and secure the batteries.

3
3
Figure 87
1. LH rear battery
2. RH rear battery

3. Positive terminal

4. Carefully remove battery jumper cable (item 16) from
front batteries to open battery circuit. Do not allow tools
or vehicle components to complete the battery circuit
during cable removal.
5. Remove remaining cables from battery terminals.
Position battery cables away from battery terminals.
6. Remove hex nut and battery hold down that secure
batteries to battery tray.
7. Carefully remove batteries from battery tray and machine.
8. If battery cable removal is needed, note routing of cables for installation purposes before removing cables
from machine.
9. Inspect foam strips on battery tray. Replace strips if
damaged.

Reelmaster 5010- H

Page 5 - 83

Electrical System

48 VDC Battery Pack Installation (Fig. 85)

48 VDC Battery Pack Service

1. Make sure that the 48 VDC battery disconnect is separated to prevent unexpected 48 VDC system component operation (see 48 VDC Battery Disconnect in the
General Information section of this chapter).

Clean the battery pack with clean water and a towel. Do
not use solvents or chemicals to clean the battery pack.

2. Make sure the battery tray is clean and repainted if
necessary. Make sure battery cables, battery terminals
and all hold down fasteners are in good condition.
3. If battery cables were removed, install cables in positions noted during disassembly. If cables were removed
from rear batteries, make sure that cables are correctly
routed through clamps and secured with removed fasteners.
4. Place batteries onto battery tray in machine.
5. Secure each battery with battery hold down and hex
nut.
IMPORTANT: When connecting the battery pack in
the 48 volt system, make sure that battery polarity
is carefully checked. Damage to fuses or other system components can occur if batteries are not connected correctly.
6. Install all of the battery cables except the battery
jumper cable (item 16). Make sure that cables are connected to correct battery terminal noting battery polarity
as shown in Figures 86 and 87. Torque nuts on battery
cable clamps from 50 to 70 in- lb (5.7 to 7.9 N- m).
7. Carefully install battery jumper cable (item 16) to
front batteries. Do not allow tools or vehicle components
to complete the battery circuit during cable installation.
Torque nuts on battery jumper cable clamps from 50 to
70 in- lb (5.7 to 7.9 N- m).
8. Apply Toro battery terminal protector (see Special
Tools in this chapter) to all battery posts and cable connectors to reduce corrosion after cable connections are
made. Make sure that terminal boots are positioned
over all cable connections.
9. Install battery covers.
10.Plug the 48 VDC battery disconnect back into the
socket before operating the machine.

When testing batteries in the battery pack of your Reelmaster, it is important to test all four (4) individual batteries. Proper performance of the machine depends on all
batteries being in good condition. Testing will determine
if one (or more) of the batteries needs to be replaced.
A simple battery test can be done using a multimeter to
perform a voltage test of each of the batteries in the battery pack. Measure the battery voltage with the multimeter and record battery voltage. The measured voltage
can be used to determine battery state of charge. If the
voltage of any of the batteries varies by more than 10%,
it indicates a problem with the battery that has the lower
voltage.
If the battery pack system voltage drops below 50 VDC
due to storage, age or malfunction, battery inspection
and/or charging may be necessary. The batteries
should be individually charged with a 12 VDC charger
rated for operation with absorbed glass mat (AGM),
valve regulated lead acid batteries. Charge the batteries
following the battery charger manufacturer’s instructions. Maximum charge voltage should be limited to 14.8
VDC. Operation of the machine will also charge the batteries in the 48 VDC system.
A battery load tester can be used to test individual batteries. Many locally available battery load testers do not,
however, have any adjustment on the load that is put on
the battery. Results received from using load testers
should follow the recommendations of the load tester
manufacturer.
48 VDC Battery Pack Storage
There are no special procedures or precautions for battery storage less than six (6) months. Batteries should
be disconnected from all potential load sources during
storage. Recommended storage temperatures should
be between 50oF and 77oF (10oC to 25oC). Storage at
elevated temperatures will result in accelerated rates of
self discharge. Make sure that batteries are fully
charged prior to storage. If battery pack is stored in a discharged state, battery performance and life will be diminished.
During storage, battery charging is recommended
whenever voltage of an individual battery drops below
12.7 VDC.

Electrical System

Page 5 - 84

Reelmaster 5010- H

Page 5 - 85

Electrical
System

This page is intentionally blank.

Electrical System

48 VDC Electrical Power Connections

12
40 to 50 in- lb
(4.6 to 5.6 N- m)
18

20
10
2
7
15
19

9 to 13 ft- lb
(13 to 17 N- m)
16

19
3

19
4

4
5

8
20
17

4
13

RIGHT

9 to 13 ft- lb
(13 to 17 N- m)

FRONT

40 to 50 in- lb
(4.6 to 5.6 N- m)

Figure 88
1.
2.
3.
4.
5.
6.
7.
8.

Bracket
Main contactor
Holder bracket (3 used)
Jumper strap holder (3 used)
Jumper strap (positive connections)
Isolator
Flange head screw
Flat washer (9 used)

Electrical System

9.
10.
11.
12.
13.
14.
15.

Flange nut (3 used)
Nut (2 used)
Flange nut (6 used)
Contactor cover
Jumper strap (ground connections)
250 amp fuse
Flange head screw (2 used)

Page 5 - 86

16.
17.
18.
19.
20.
21.
22.

48 VDC battery disconnect
Lock nut (2 used)
Flange nut (2 used)
Carriage screw (8 used)
Flange nut (8 used)
Positive battery cable
Negative battery cable

Reelmaster 5010- H

Disassembly

FRONT

1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.

2. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect.
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation.
3. Raise and support operator seat to access 48 VDC
power connections. If front jumper strap holders for
ground (negative) connections are to be accessed, remove operator floor plate from frame.

4
6

4. Label all wire connector locations for assembly purposes.
5. Disconnect electrical connections and remove components as needed using Figures 88, 89 and 90 as
guides.

Figure 89
1. Main contactor
2. Positive battery cable
3. 48V battery disconnect

4. Negative battery cable
5. Isolator
6. Fuse (250A / 58V)

Assembly
1. Install all removed components and electrical connections as needed using Figures 88, 89 and 90 as
guides. Use torque specifications identified in Figure 88
when installing fasteners.

2
1

2. Apply Toro battery terminal protector (see Special
Tools in this chapter) to all cable connectors to reduce
corrosion after cable connections are made. Make sure
that terminal boots and connection covers are positioned over all cable connections.

Electrical
System

3. If operator floor plate was removed, secure floor
plate to frame with removed fasteners.
4. Plug the 48 VDC battery disconnect back into the
socket when all electrical components have been installed to machine.

4
Figure 90

5. Lower and secure operator seat.

1. Main contactor
2. Positive connections

Reelmaster 5010- H

Page 5 - 87

3. Ground connections
4. Neg battery cable

Electrical System

Cutting Reel Motor
NOTE: If electrical problems exist with a cutting reel
motor, a fault may have occurred that would be indicated
by a fault code on the InfoCenter Display. Before considering that reel motor service work is necessary, check
for any existing fault codes that indicate problems with
a reel motor (see Fault Codes in the Troubleshooting
section of this chapter).

IMPORTANT: When performing service or maintenance on the cutting reel motors, take care to not
damage the motors or electrical connections.
Removal
1

1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
2. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect.
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation.

Figure 91
1. Cutting reel motor

2. Cap screw

IMPORTANT: When removing cutting reel motor,
take care to not damage the cable. The cable is not
available as a replacement part.

3. Remove cutting reel motor from cutting unit (Fig. 91):
A. Loosen two (2) cap screws that secure the cutting
reel motor to the cutting unit side plate.
B. Rotate motor clockwise to disengage motor
flange from cap screws and remove motor from cutting unit. Position and support reel motor away from
cutting unit.
4. Remove O- ring from flange of motor and discard
O- ring.

Figure 92
1. Bulkhead nut
2. Bulkhead fitting

5. Inspect cutting reel threaded insert splines for wear.
Replace inserts if necessary (see Cutting Reel Assembly in the Service and Repairs section of Chapter 7 Cutting Units).

Electrical System

6
3

6. The cutting unit side plates have threaded inserts at
the locations used for the cap screws that secure the
reel motor. Check the condition of the threaded inserts
and replace inserts if damage is found. Inserts should be
torqued from 35 to 40 ft- lb (48 to 54 N- m) during installation.
7. Place protective plastic cap (see Special Tools in this
chapter) into the hole in the cutting unit side plate to prevent debris entry into reel bearing area.

3. Connector plate

Figure 93
1. Cable from motor
2. Bulkhead nut
3. Bulkhead fitting

Page 5 - 88

4. 4 wire connector
5. 2 wire connector
6. Connector plate

Reelmaster 5010- H

8. If cutting reel motor is to be removed from machine,
disconnect reel motor cable from machine wire harness
(Figs. 92 and 93):

5. If cutting reel motor was removed from machine,
connect reel motor cable to machine wire harness (Fig.
93):

A. Locate reel motor cable electrical connections at
machine wire harness for motor that is to be removed.

A. Connect two (2) reel motor cable connectors to
machine wire harness.

B. Disconnect two (2) motor cable connectors from
machine wire harness.
C. Remove flange nut that secures reel motor cable
connector plate to machine frame and separate motor cable from machine.
D. Locate and loosen bulkhead nut that secures reel
motor cable to bulkhead bracket on machine. Separate cable from bracket.

B. Position reel motor cable connector plate to machine frame and secure with flange nut.
C. Position reel motor cable to bulkhead bracket on
machine and tighten bulkhead nut.
6. Lubricate grease fitting on cutting unit side plate that
includes reel motor.
7. After completing installation of all cutting unit motors,
plug the 48 VDC battery disconnect back into the socket.

9. Remove cutting reel motor with attached cable from
machine.

Installation

NOTE: Refer to Figure 94 for correct placement of cutting unit reel motors and weights.

2. Remove protective plastic cap from the hole in the
cutting unit side plate.

FRONT
Figure 94
1. Reel motor location

2. Weight location

3. Make sure that the two (2) cap screws for the cutting
reel motor are installed into the cutting unit side plate
with approximately 1/2 inch (12.7 mm) of threads exposed on each screw.
4. Secure cutting reel motor to cutting unit (Fig. 91):
A. Rotate the motor clockwise so the motor flanges
clear the cap screws in the cutting unit side plates.
Align reel motor shaft splines with cutting reel insert
splines. Slide motor shaft into cutting reel threaded
insert. Make sure that cable is on the upper side of
the motor after installation.
B. Rotate the motor counterclockwise until the motor flanges are encircling the cap screws in the cutting unit side plates. Tighten two (2) cap screws to
secure cutting reel motor to cutting unit.

Reelmaster 5010- H

Page 5 - 89

Electrical System

Electrical
System

1. Install new O- ring to flange of cutting unit motor.
Coat spline shaft of the reel motor with No. 2 multipurpose lithium base grease.

Cutting Reel Motor Service
2
3
4
6

1
14
10

5
7

70 to 80 in- lb
(8 to 9 N- m)

13
4
5
11
7
1

70 to 80 in- lb
(8 to 9 N- m)

Figure 95
1.
2.
3.
4.
5.

Torx head screw (12 used)
Motor cover
O- ring
Wave washer (2 used)
Bearing (2 used)

6.
7.
8.
9.
10.

Rotor
Bearing (2 used)
O- ring (2 used)
Housing/controller/cable assembly
O- ring

NOTE: If motor housing, controller or cable damage occurs, cutting reel motor replacement is necessary.
These components are not available separately.
IMPORTANT: When working on the cutting reel motor, use a clean work space with a non- metal surface. The reel motor rotor includes very powerful
magnets that can cause the rotor to move unexpectedly if working on a metal surface. Also, any metallic
debris that gets attracted to the rotor can damage
the motor after assembly.
Disassembly (Fig. 95)
1. Remove six (6) torx head screws that secure gearbox cover (item 12) to front of motor housing.

11.
12.
13.
14.

Output gear
Gearbox cover
Shaft seal
O- ring

3. Remove and discard O- rings (items 8 and 10) from
gearbox cover.
4. Slide output gear assembly (items 5, 11 and 7) from
motor housing. Remove wave washer (item 4).
5. Remove six (6) torx head screws that secure motor
cover (item 2) to rear of motor housing. Leave cover on
rotor shaft.
IMPORTANT: The rotor magnets are very powerful
and can cause the rotor to shift position very rapidly
during removal. Use cutting reel motor rotor tool set
(see Special Tools in this chapter) to remove rotor.
Be cautious during rotor removal to prevent component damage or personal injury.

2. Carefully slide gearbox cover from front of motor.
Electrical System

Page 5 - 90

Reelmaster 5010- H

7. Remove motor cover and wave washer (item 4) from
rotor assembly. Remove and discard O- rings (items 14
and 3) from cover.
8. Remove and discard O- ring (item 8) from motor
housing.
IMPORTANT: Make sure to not damage the gearbox
cover counter bore when removing the shaft seal
from the cover.
9. Carefully remove shaft seal from gearbox cover. Discard removed seal.
10.If necessary, remove bearings from output gear
(item 11) and rotor (item 6). Discard bearings if removed.
11. Inspect grease in output gear area of motor housing.
If grease is clean and not contaminated, it can remain in
housing. If grease is contaminated, clean grease from
housing and replace with 15 ml of NLGI grade 00 grease
during motor assembly.
12.Inspect cutting reel motor components for wear or
damage. Replace components or cutting unit motor assembly if necessary.
Assembly (Fig. 95)
1. Make sure that motor components are cleaned before assembly.
2. If bearings were removed from output gear (item 11)
or rotor (item 6) install new bearings. Make sure that
bearings are fully pressed onto shafts.

6. Carefully slide motor cover onto rotor until it contacts
motor housing. Secure cover with six (6) torx head
screws.
7. Make sure that rotor rotates without binding before
continuing with motor assembly.
8. Place wave washer (item 4) into housing bore for output gear bearing.
9. Make sure that output gear area of motor housing
has clean grease remaining in housing. If grease was
cleaned from housing, install 15 ml of new NLGI grade
00 grease into housing during motor assembly.
10.Slide output gear assembly (items 5, 11 and 7) into
front of housing. Make sure that output gear teeth mesh
with rotor gear.
11. Install shaft seal (item 13) into gearbox cover. Press
shaft seal into front cover until it is flush with the cover
surface. Shaft seal should have the seal lip toward the
inside of the motor (Fig. 96).
12.Lubricate new O- rings (items 8 and 10) with dielectric lubricant (see Special Tools in this chapter) and
install O- rings to grooves in gearbox cover.
IMPORTANT: Make sure to not damage the shaft
seal when installing the gearbox cover.
13.Carefully slide gearbox cover onto output gear shaft
until it contacts motor housing. Secure cover with six (6)
torx head screws.
14.Torque all torx screws (item 1) on gearbox cover and
motor cover from 70 to 80 in- lb (8 to 9 N- m).

3. Lubricate new inner O- ring (item 8) with dielectric lubricant (see Special Tools in this chapter) and install Oring into groove in motor housing.
IMPORTANT: The rotor magnets are very powerful
and can cause the rotor to shift position very rapidly
during installation. Use cutting reel motor rotor tool
set (see Special Tools in this chapter) to remove rotor. Be cautious during rotor installation to prevent
component damage or personal injury.
4. Use cutting reel motor rotor tool set (see Special
Tools in this chapter) to carefully install rotor assembly
(items 5, 6 and 7) into motor housing.
5. Lubricate new O- rings (items 14 and 3) with dielectric lubricant (see Special Tools in this chapter) and
install O- rings to grooves in motor cover. Place wave
washer (item 4) in cover.
Reelmaster 5010- H

1
2

Figure 96
1. Output gear
2. Gearbox cover

Page 5 - 91

3. Shaft seal

Electrical System

Electrical
System

6. Use cutting reel motor rotor tool set (see Special
Tools in this chapter) to carefully remove rotor assembly
(items 5, 6 and 7) and motor cover (item 2) from motor
housing.

Motor/Generator Assembly

1
20

50 to 60 ft- lb
(68 to 81 N- m)

16
18

Antiseize
Lubricant

7
9
8

5
15
Antiseize
Lubricant
14
3
10

RIGHT

13
25 to 31 ft- lb
(34 to 42 N- m)

FRONT

Figure 97
1.
2.
3.
4.
5.
6.
7.

Diesel engine
Motor/generator assembly
Flange head screw
Collar
Coupler hub
Woodruff key
Engine bellhousing

8.
9.
10.
11.
12.
13.
14.

Cap screw (2 used)
Flat washer (2 used)
Flange head screw (7 used)
Flange nut (2 used)
R- clamp (for generator wire harness)
Clamp (for fuel return hose)
Caplug

NOTE: If electrical problems exist with the motor/generator assembly, a fault should have occurred that would
be indicated by a fault code on the InfoCenter Display.
Before considering that motor/generator service work is
necessary, check for any existing fault codes that indicate problems with the motor/generator (see Fault
Codes in the Troubleshooting section of this chapter).
NOTE: The 48 VDC motor/generator is secured to the
engine bellhousing with six (6) flange head screws. Access to these screws requires the bellhousing and motor/generator to be removed from the engine as an
assembly before removing the motor/generator from the
bellhousing.
Electrical System

15.
16.
17.
18.
19.
20.

Flange head screw (6 used)
Dowel pin (2 used)
Coupler flange
Socket head screw (3 used)
Muffler bracket
Flange head screw (4 used)

Removal (Fig. 97)
1. Park machine on a level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
2. Separate system components from the 48 VDC battery pack by unplugging the 48 VDC battery disconnect.
(see 48 VDC Battery Disconnect in the General Information section of this chapter). This will prevent unexpected 48 VDC system component operation.
3. Raise and support hood and operator seat.

Page 5 - 92

Reelmaster 5010- H

4. Disconnect hydraulic pump drive shaft from 48 VDC
motor/generator output shaft (see Hydraulic Pump
Drive Shaft in the Service and Repairs section of Chapter 4 - Hydraulic System). Position drive shaft away from
engine.

5. Remove exhaust muffler from machine (see Exhaust
System in the Service and Repairs section of Chapter 3
- Kubota Diesel Engine).
6. Disconnect wire harness connector from motor/generator assembly.

CAUTION

7. For assembly purposes, note locations of r- clamps
on bellhousing (Fig. 98). Support motor/generator and
bellhousing to prevent the assembly from falling or shifting.
8. Remove fasteners that secure bellhousing to engine
plate. Position r- clamps with wire harness and fuel return hose away from bellhousing.
IMPORTANT: Make sure to not damage the motor/
generator, fuel lines, hydraulic hoses, electrical harness, control cables or other parts while removing
the motor/generator and bellhousing assembly.

Figure 98
1. Generator connector
2. R- clamp

3. Fuel return hose
4. R- clamp

Installation (Fig. 97)
1. If removed, install coupler hub to motor/generator input shaft:
IMPORTANT: Before coupler hub is installed to
motor/generator input shaft, thoroughly clean
tapers of coupler hub and motor/generator input
shaft. Make sure that tapers are free of grease, oil
and dirt. DO NOT use antiseize lubricant when
installing coupler hub.
A. Thoroughly clean tapers on motor/generator input shaft and coupler hub bore.

9. Carefully move motor/generator and bellhousing assembly away from engine so that motor/generator coupler hub (item 5) slides out of flywheel coupler flange
(item 17). Once motor/generator coupler is removed
from flange, lift motor/generator and bellhousing assembly from machine.

B. Place woodruff key in motor/generator shaft slot
and then install the coupler hub onto the shaft.

10.Note location of two (2) dowel pins (item 16) in engine plate for assembly purposes.

2. Position motor/generator to bellhousing and secure
with six (6) flange head screws. Torque screws from 50
to 60 ft- lb (68 to 81 N- m).

11. Remove six (6) flange head screws that secure motor/generator to bellhousing. Remove motor/generator
from bellhousing.
12.If necessary, remove flange head screw and spacer
that secure motor/generator coupler hub to motor/generator input shaft. Use suitable puller to remove coupler
hub from motor/generator shaft. Locate and retrieve
woodruff key from motor/generator shaft.

Reelmaster 5010- H

C. Secure coupler hub to motor/generator shaft with
collar and flange head screw. Torque screw from 25
to 31 ft- lb (34 to 42 N- m).

3. Apply antiseize lubricant to splines of coupler hub on
motor/generator shaft and coupler flange on flywheel.
4. Make sure that dowel pins (item 16) are properly positioned in bellhousing.

Page 5 - 93

Electrical System

Electrical
System

Support motor/generator and bellhousing assembly when removing it to prevent it from falling and causing personal injury. Assembly
weighs approximately 69 pounds (31 kg).

7. Connect wire harness connector to motor/generator
assembly.

CAUTION
Support motor/generator and bellhousing assembly when installing it to prevent it from falling
and causing personal injury. Assembly weighs
approximately 69 pounds (31 kg).

8. Connect hydraulic pump drive shaft to motor/generator output shaft (see Hydraulic Pump Drive Shaft in the
Service and Repairs section of Chapter 4 - Hydraulic
System). Make sure that air intake shroud fits properly
to motor/generator cover and also that air intake hose is
secured to intake shroud.

IMPORTANT: Make sure to not damage the motor/
generator, fuel lines, hydraulic hoses, electrical harness, control cables or other parts while installing
the motor/generator and bellhousing assembly.

9. Install exhaust muffler to machine (see Exhaust System in the Service and Repairs section of Chapter 3 Kubota Diesel Engine).

5. Lower motor/generator and bellhousing assembly
toward engine, engage motor/generator coupler hub
(item 5) into flywheel coupler flange (item 17) and slide
bellhousing to engine plate.

10.After completing installation of the motor/generator
assembly, plug the 48 VDC battery disconnect back into
the socket.
11. Lower and secure hood and operator seat.

6. Secure bellhousing to engine plate with removed
fasteners. Make sure that r- clamps are in locations noted during disassembly (Fig. 98). R- clamp that secures
motor/generator wire harness connection should cover
red tape on harness.

Electrical System

Page 5 - 94

Reelmaster 5010- H

Page 5 - 95

Electrical
System

This page is intentionally blank.

Electrical System

Motor/Generator Assembly Service
1
10

70 to 80 in- lb
(8.0 to 9.0 N- m)

35 to 45 in- lb
(4.0 to 5.0 N- m)
13
12

8
15

14
20
6

11
75 in- lb
(8.5 N- m)

13
16

18
18

20 to 26 ft- lb
(28 to 35 N- m)

19
95 to 105 ft- lb
(129 to 142 N- m)

5
5
3

70 to 80 in- lb
(8.0 to 9.0 N- m)

Figure 99
1.
2.
3.
4.
5.
6.
7.

Controller assembly
Motor/generator assembly
Motor/generator cover
Flange head screw (3 used)
Washer head screw (6 used)
Washer head screw (2 used)
Access cover

8.
9.
10.
11.
12.
13.
14.

Cover gasket
Flat washer (2 used)
Flange nut (2 used)
Cap screw (2 used)
Plug (2 used)
O- ring
Button head screw (2 used)

15.
16.
17.
18.
19.
20.

O- ring
Woodruff key
Motor/generator fan
Spacer (2 used)
Nut
Isolator

IMPORTANT: When working on the motor/generator, use a clean work space with a non- metal surface. The motor/generator rotor includes very
powerful magnets that can cause the rotor to move
unexpectedly if working on a metal surface. Also,
any metallic debris that gets attracted to the rotor
can damage the motor/generator after assembly.

Electrical System

Page 5 - 96

Reelmaster 5010- H

Disassembly (Fig. 99)
11

35 to 45 in- lb
(4.0 to 5.0 N- m)

1. Remove motor/generator cover (item 3) from motor/
generator assembly.

13
14

2. Remove access cover (item 7) and cover gasket
from controller. Discard cover gasket.

4. Remove three (3) flange head screws (item 4) that
secure motor/generator stator conductors to controller
connectors.

5. Remove cap screws (item 11), flat washers (item 9)
and flange nuts (item 10) that secure controller to motor/
generator assembly. Lift controller from motor/generator. Remove and discard O- ring (item 15).
NOTE: If controller (item 1) damage exists, controller
replacement is necessary. Internal controller components are not available separately.
6. Remove nut (item 19) that secures fan to motor/generator shaft.
7. Remove motor/generator fan and two (2) spacers
from motor/generator shaft. Locate and retrieve
woodruff key.
8. Remove internal motor/generator assembly components (Fig. 100):
A. Remove six (6) flange head screws that secure
cover to housing. Leave cover on rotor shaft.
IMPORTANT: The rotor magnets are very powerful and can cause the rotor to shift position very
rapidly during removal. Use generator rotor tool
set (see Special Tools in this chapter) to remove
rotor. Be cautious during rotor removal to prevent component damage or personal injury.
B. Use generator rotor tool set (see Special Tools in
this chapter) to carefully remove rotor assembly including cover from housing. Follow removal procedure listed in Special Tool section.
C. Remove cover from rotor assembly. Remove Orings and wave washer from cover. Discard O- rings.
D. Remove and discard O- ring from housing groove
in bearing bore.
E. If necessary, remove bearings from rotor. Discard
bearings if removed.

8
10

170 to 190 in- lb
(19.3 to 21.4 N- m)

Figure 100
1.
2.
3.
4.
5.
6.
7.
8.

Housing/stator assembly
O- ring
Bearing
Rotor assembly
Bearing
Wave washer
O- ring
O- ring

9.
10.
11.
12.
13.
14.
15.

Cover
Flange screw (6 used)
Screw (2 used)
O- ring
Spacer (2 used)
Isolator
Gasket

9. Inspect rotor assembly for wear or damage. Also, inspect motor/generator housing/stator assembly for evidence of damage.
NOTE: If motor/generator housing/stator damage exists, motor/generator assembly replacement is necessary. The motor/generator housing and stator are not
available separately.
Assembly (Fig. 99)
1. Make sure that all motor/generator components are
cleaned before assembly.
2. Install internal motor/generator assembly components (Fig. 100):
A. If bearings were removed from rotor assembly,
install new bearings onto rotor shaft. Make sure that
new bearings are fully pressed onto rotor shaft.
B. If isolator was removed, lubricate new gasket
with dielectric lubricant (see Special Tools in this
chapter) and install to isolator. Fit isolator to housing
assembly making sure that stator conductors and
stator harness are correctly positioned in isolator.
Secure isolator with spacers and screws. Torque
screws from 35 to 45 in- lb (4.0 to 5.0 N- m).

F. If necessary, remove isolator from housing assembly.
Reelmaster 5010- H
Page 5 - 97

Electrical System

Electrical
System

3. Carefully remove motor/generator and controller
harness connectors from controller opening. Note position of connectors and wire harnesses for assembly purposes. Unplug connectors.

C. Lubricate new O- ring (item 2) with dielectric lubricant (see Special Tools in this chapter) and install
into groove in housing bearing bore.
IMPORTANT: The rotor magnets are very powerful and can cause the rotor to shift position very
rapidly during installation. Use generator rotor
tool set (see Special Tools in this chapter) to install rotor. Be cautious during rotor installation
to prevent component damage or personal injury.
D. Use generator rotor tool set (see Special Tools in
this chapter) to carefully install rotor assembly into
housing. Make sure that rotor bearing is fully seated
in housing.
E. Lubricate new O- rings (items 7 and 8) with dielectric lubricant (see Special Tools in this chapter)
and install O- rings into grooves in cover. Place wave
washer in cover bearing bore.
F. Install cover to housing and secure with six (6)
flange head screws. Torque screws from 170 to 190
in- lb (19.3 to 21.4 N- m).
G. Make sure that rotor rotates before continuing
with motor/generator assembly.
3. Install motor/generator fan:
A. Position woodruff key (item 16) into slot on rotor
shaft.
B. Slide spacer, motor/generator fan and then second spacer onto motor/generator shaft.
C. Secure fan to motor/generator shaft with nut
(item 19). Torque nut from 95 to 105 ft- lb (129 to
142 N- m).

5. Install controller onto motor/generator:
A. Lower controller onto motor/generator and route
both controller and motor/generator harness connectors out opening in controller.
IMPORTANT: When securing stator conductors
to controller connectors, make sure that flange
head screws do not pinch electrical harnesses.
B. Loosely install three (3) flange head screws (item
4) that secure motor/generator stator conductors to
controller connectors. Make sure that controller and
motor/generator harnesses are positioned away
from the screws.
C. Secure controller with cap screws (item 11), flat
washers (item 9) and flange nuts (item 10).
D. Torque three (3) flange head screws (item 4) to 75
in- lb (8.5 N- m).
E. Pack controller harness connector with dielectric
lubricant (see Special Tools in this chapter). Plug
motor/generator connector into controller connector.
Insert harnesses and connectors to the right side of
the three (3) terminals in the controller.
6. Lubricate new cover gasket (item 8) with dielectric lubricant (see Special Tools in this chapter). Install gasket
into groove in access cover (item 7) and then install cover to controller. Secure cover with two (2) washer head
screws. Torque screws from 70 to 80 in- lb (8.0 to 9.0
N- m).
7. Install motor/generator cover (item 3) to motor/generator assembly and secure with washer head screws.
Torque screws from 70 to 80 in- lb (8.0 to 9.0 N- m).

4. Lubricate new O- ring with dielectric lubricant (see
Special Tools in this chapter) and install into groove on
isolator.

Electrical System

Page 5 - 98

Reelmaster 5010- H

Chapter 6

Chassis
Table of Contents

Chassis

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Traction Unit Operator’s Manual . . . . . . . . . . . . . . 2
48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear Wheel Bearings (2 Wheel Drive) . . . . . . . . 12
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mechanical Seat Suspension . . . . . . . . . . . . . . . . 22
Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rear Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Reelmaster 5010- H

Page 6 - 1

Chassis

Specifications
Item

Description

Front Tire Pressure
(26.5 x 14.0 - 12, 4 ply, tubeless)

12 to 15 PSI (83 to 103 kPa)

Rear Tire Pressure
(20 x 12.0 - 10, 4 ply, tubeless)

12 to 15 PSI (83 to 103 kPa)

Wheel Lug Nut Torque

70 to 90 ft- lb (95 to 122 N- m)

Wheel Motor/Wheel Hub Lock Nut Torque

315 to 385 ft- lb (428 to 522 N- m)

48 VDC Battery Disconnect
FRONT

CAUTION

Figure 1
1. RH frame rail

Chassis

Page 6 - 2

2. 48V battery disconnect

Reelmaster 5010- H

Special Tools
Order Toro special tools from your Toro Distributor.

Wheel Hub Puller
The wheel hub puller allows safe removal of the front
wheel hub from the wheel motor shaft. If machine is
equipped with optional CrossTraxTM Kit, this wheel hub
puller is needed for removing rear wheel hub from the
rear wheel motor.
Toro Part Number: TOR6004

Chassis

Figure 2

Reelmaster 5010- H

Page 6 - 3

Chassis

Service and Repairs
Wheels

2 WHEEL DRIVE AXLES SHOWN
8

13 14

70 to 90 ft- lb
(95 to 122 N- m)

2
3
7

RIGHT
5

FRONT

Figure 3
1.
2.
3.
4.
5.

Front wheel motor
Brake assembly
Front wheel hub
Lock nut
Brake drum

Chassis

6.
7.
8.
9.
10.

Front wheel
Lug nut (5 used per wheel)
Rear wheel hub
Spindle washer
Rear wheel

Page 6 - 4

11.
12.
13.
14.

Jam nut
Retainer
Cotter pin
Dust cap

Reelmaster 5010- H

Removal (Fig. 3)

Installation (Fig. 3)

1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.

1. Install wheel and secure with five (5) wheel lug nuts.
2. Lower machine to ground.

2. Chock wheels to prevent machine from shifting.

WARNING

3. Loosen, but do not remove, wheel lug nuts.

Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may
result in personal injury.

3. Torque wheel lug nuts evenly in a crossing pattern
from 70 to 90 ft- lb (95 to 122 N- m).

4. Using a jack, raise machine so wheel is off ground
(see Jacking Instructions in Chapter 1 - Safety). Support machine with jack stands.

Chassis

5. Remove wheel lug nuts and then remove wheel from
machine.

Reelmaster 5010- H

Page 6 - 5

Chassis

Steering Column
3
5
Antiseize
Lubricant

1
2
Antiseize
Lubricant

20 to 26 ft- lb
(28 to 35 N- m)

11
13
14
7
9

RIGHT
FRONT
10

Figure 4
1.
2.
3.
4.
5.

Steering column
Steering wheel
Steering wheel cover
Lock nut
Flat washer

6.
7.
8.
9.
10.

Socket head screw (4 used)
Steering control valve
Column brace
Flange nut (6 used)
Flange head screw (2 used)

Removal (Fig. 4)
1. Park the machine on a level surface, engage the
parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch.

Socket head screw (4 used)
O- ring
Hydraulic fitting (4 used)
O- ring

4. Use a suitable puller to remove steering wheel from
steering column.
5. Remove platform shroud from machine to allow access to steering column fasteners (Fig. 5).

2. Remove cover from steering wheel by carefully prying up on one of the cover spokes.
3. Remove lock nut and flat washer that secure steering wheel to steering column.
Chassis

11.
12.
13.
14.

Page 6 - 6

A. Remove cover plate from platform.
B. Remove fasteners that secure platform shroud to
machine and remove platform shroud
C. Retrieve two (2) rubber bushings and spacers.
Reelmaster 5010- H

6. Slide rubber bellows up steering column to allow access to fasteners that secure steering column to machine.

1
2

7. Support steering control valve to prevent it from shifting during steering column removal.

8. Loosen and remove four (4) socket head screws
(item 6) that secure steering control valve to steering
column.

3
6

9. Loosen and remove four (4) socket head screws
(item 11) and flange nuts (item 9) that secure steering
column to machine.

7
8

10.Slide steering column assembly from steering control valve and machine.
11. Disassemble steering column assembly as needed
using Figure 6 as a guide.
Installation (Fig. 4)

Figure 5
1.
2.
3.
4.

Washer (2 used)
Screw (2 used)
Screw (6 used)
Platform shroud

5.
6.
7.
8.

Lock nut (2 used)
Cover plate
Bushing (2 used)
Spacer (2 used)

2. Apply antiseize lubricant to input shaft of steering
control valve.
3. Slide steering column onto steering control valve.
Secure steering column in place with four (4) socket
head screws (item 11) and flange nuts (item 9).

1
14

4. Secure steering control valve to steering column with
four (4) socket head screws (item 6).

6. Place rubber bushings and spacers into holes of
platform shroud (Fig. 5). Position platform shroud in
place and secure with removed fasteners.

8. Apply antiseize lubricant to splines of steering column taking care to keep antiseize lubricant from column
taper. Slide steering wheel onto steering column.
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.

Reelmaster 5010- H

5. Slide rubber bellows to bottom of steering column.

7. Thoroughly clean tapered surfaces of steering wheel
and steering column.

Chassis

1. Assemble steering column using Figure 6 as a guide.
After assembly, make sure that release pin on end of cylinder shaft is positioned against the pedal. Jam nut on
cylinder shaft can be used to adjust location of release
pin.

6
7
8

12
3

Figure 6
1.
2.
3.
4.
5.
6.
7.
8.

Page 6 - 7

Steering column
Pin
Universal joint
Pin
Lock washer (2 used)
Cylinder
Bolt (2 used)
Pin

9.
10.
11.
12.
13.
14.
15.

Pedal block
Pedal cover
Pedal
Spring
Release pin
Cylinder shaft
Jam nut

Chassis

Brake Service

13
19
15
4

8
9
7

1
17
16
14
3

80 to 100 ft- lb
(109 to 135 N- m)

12
6
315 to 385 ft- lb
(428 to 522 N- m)

RIGHT
FRONT

70 to 90 ft- lb
(95 to 122 N- m)

Figure 7
1.
2.
3.
4.
5.
6.
7.

Wheel motor (LH shown)
Lug nut (5 used per wheel)
Wheel hub
Wheel stud (5 used per wheel)
Wheel assembly
Brake drum
Front wheel shield (2 used)

Chassis

8.
9.
10.
11.
12.
13.

Cap screw (2 used per shield)
Flat washer (2 used per shield)
Lock nut (2 used per shield)
Rear wheel shield (LH shown)
Lock nut
Square key

Page 6 - 8

14.
15.
16.
17.
18.
19.

Brake assembly (LH shown)
Cap screw (4 used per brake assy)
Cap screw (4 used per motor)
Spring clip (LH shown)
Lock nut (4 used per motor)
Brake adapter

Reelmaster 5010- H

Removal (Fig. 7)
1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the
ignition switch.

RH BRAKE ASSEMBLY SHOWN
1

RIGHT
FRONT

2. Chock wheels to prevent machine from shifting.

4. Remove front wheel assembly (see Wheels in this
section). Make sure to support raised machine with appropriate jack stands.

5
6

5. Make sure parking brake is disengaged.
NOTE: Clevis pin that secures brake cable to brake actuator lever is secured with extension spring (shown in
Fig. 8).
6. Remove extension spring from clevis pin that secures brake cable to brake actuator lever (Fig. 8). Remove clevis pin and position brake cable away from
brake actuator lever.

Figure 8
1.
2.
3.
4.

Brake assembly
Clevis pin
Spring clip
Flange nut

12
10
5
9

2
3

11. Remove shoe hold down cups and hold down
springs. Remove brake shoes and hold down pins from
backing plate.
12.If necessary, remove brake backing plate from machine by loosening and removing four (4) cap screws
that secure backing plate to brake adapter.
Installation (Fig. 7)
1. Remove rust and debris from all brake parts with a
wire brush prior to installation. Clean all parts. Inspect
brake shoe contact surfaces of the brake drum for excessive wear. Replace any worn or damaged brake
parts.
Reelmaster 5010- H
Page 6

13
1

4
5

9. Remove lock nut and wheel hub from wheel motor
shaft. Locate and retrieve square key.

10.Remove upper and lower shoe springs from brake
shoes.

8. Make sure that lock nut on wheel motor shaft is
loose. Use hub puller (see Special Tools in this chapter)
to loosen wheel hub from wheel motor shaft.

NOTE: If desired, the complete brake assembly can be
removed from the machine for disassembly (see step
12).

Jam nut
Cap screw
Extension spring
Brake cable

RH BRAKE ASSEMBLY SHOWN

7. Remove brake drum.
IMPORTANT: DO NOT hit wheel hub, puller or wheel
motor with a hammer during wheel hub removal or
installation. Hammering may cause damage to the
wheel motor.

5.
6.
7.
8.

Figure 9
1.
2.
3.
4.
5.
6.
7.

Backing plate
Rivet (4 used)
Clevis pin
Retaining ring
Brake shoe
Lower shoe spring
Hold down spring

8.
9.
10.
11.
12.
13.
14.

Hold down cup
Upper shoe spring
Brake actuator
Actuator lever
Back- up plate
Boot
Hold down pin

2. If backing plate was removed from machine, secure
backing plate to brake adapter with four (4) cap screws.
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.
5. Install upper and lower shoe springs to brake shoes.
Make sure that brake shoes are properly positioned to
pivot and actuator points.
- 9

Chassis

3. Loosen, but do not remove, lock nut (item 12) from
wheel motor shaft.

IMPORTANT: Before wheel hub is installed, thoroughly clean tapers of wheel hub and wheel motor
shaft. Make sure that tapers are free of grease, oil
and dirt. DO NOT use antiseize lubricant when
installing wheel hub.
6. Mount square key in the wheel motor shaft, then
install the wheel hub onto the wheel motor shaft.

11. Check and adjust brakes.
12.Lower machine to ground.
13.Torque wheel lug nuts evenly in a crossing pattern
from 70 to 90 ft- lb (95 to 122 N- m). Torque lock nut
(item 12) that secures wheel hub from 315 to 385 ft- lb
(428 to 522 N- m).

7. Secure wheel hub onto the wheel motor shaft with
lock nut (item 12).

CAUTION

8. Install brake drum.
9. Position brake cable end to brake actuator lever (Fig.
8). Secure brake cable clevis to brake actuator lever with
clevis pin and extension spring.

After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.

10.Install front wheel assembly (see Wheels in this section).

Chassis

Page 6 - 10

Reelmaster 5010- H

Chassis

This page is intentionally blank.

Reelmaster 5010- H

Page 6 - 11

Chassis

Rear Wheel Bearings (2 Wheel Drive)

9
6

10
7
6

5
3

11
See text for
tightening
procedure

1
4

Figure 10
1.
2.
3.
4.

Dust cap
Cotter pin
Retainer
Jam nut

Chassis

5.
6.
7.
8.

Spindle washer
Bearing cone
Bearing cup
Wheel hub

Page 6 - 12

9. Seal
10. Spindle
11. Wheel stud (5 used)

Reelmaster 5010- H

Disassembly (Fig. 10)
1. Chock front wheels to prevent machine from shifting.
2. Remove rear wheel (see Wheels in this section).
Make sure to support machine with jack stands.
3. Remove the dust cap from the wheel hub.
4. Remove the cotter pin, retainer, jam nut and spindle
washer. Slide the wheel hub from the spindle shaft.
5. Pull the seal out of the wheel hub. Discard seal.
6. Remove the bearing cones from both sides of the
wheel hub. Clean the bearings in solvent. Make sure the
bearings are in good operating condition. Clean the inside of the wheel hub. Check the bearing cups for wear,
pitting or other damage. Replace worn or damaged
parts.

3. Fill wheel hub cavity between bearings approximately 50% full of grease. Position remaining bearing into the
outer bearing cup.
4. Slide the wheel hub assembly onto the spindle shaft
and secure it in place with the spindle washer and jam
nut. DO NOT fully tighten the nut or install the cotter pin.
5. While rotating the wheel hub by hand, torque the jam
nut from 75 to 100 in-lb (8.5 to 11.3 N- m) to set the bearings. Then, loosen the nut until the hub has endplay.
6. While rotating the wheel hub by hand, torque the jam
nut from 15 to 20 in-lb (1.7 to 2.3 N- m). After tightening,
make sure that the wheel hub does not have any free
play.
7. Install retainer with slot aligned to cotter pin hole in
spindle. Install cotter pin.
8. Fill dust cap approximately 50% full of grease. Install
dust cap.

Assembly (Fig. 10)
1. If bearing cups were removed from the wheel hub,
press new cups into the hub until they seat against the
shoulder of the hub.

9. Install rear wheel (see Wheels in this section).

IMPORTANT: The lip of the seal must be toward the
bearing. The seal should be pressed in so it is flush
with the end of the wheel hub.

11. Torque lug nuts evenly in a crossing pattern from 70
to 90 ft- lb (95 to 122 N- m).

10.Lower machine to ground.

Chassis

2. Pack both bearings with grease. Install one bearing
into the bearing cup on inboard side of the wheel hub.
Lubricate the inside of a new seal and press it into the
wheel hub with the seal lip toward the bearing.

Reelmaster 5010- H

Page 6 - 13

Chassis

Rear Axle

90 to 120 ft- lb
(123 to 162 N- m)

27
9
28

10
19
14

23
21

30
29 20

28
7

20
5
16
17
13

RIGHT

FRONT
20

Figure 11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Lug nut (5 used per wheel)
Rear axle assembly
Dust cap
Hydraulic fitting
Tie rod
Axle pivot pin
Thrust washer
Roll pin
Thrust washer
Jam nut
Grease fitting

Chassis

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Tab washer
Wheel hub assembly
Grease fitting
O- ring
Jam nut
Nut retainer
Hydraulic hose
O- ring
Cotter pin
Steering cylinder

Page 6 - 14

22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

Ball joint
Ball joint
Retaining ring
Jam nut
Wheel assembly
Grease fitting
Slotted hex nut
Slotted hex nut
Washer
Hydraulic hose

Reelmaster 5010- H

Removal (Fig. 11)

Installation (Fig. 11)

1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.

1. Thoroughly clean the rear axle pivot pin. Inspect the
pin for wear or damage and replace if necessary.

2. Chock front wheels to prevent machine from shifting.
3. Thoroughly clean hydraulic hose ends and fittings on
steering cylinder to prevent hydraulic system contamination.
NOTE: To ease assembly, label hydraulic hoses to
show their correct position on the steering cylinder.
4. Disconnect the hydraulic hoses from the steering
cylinder. Put caps or plugs on all fittings and hoses to
prevent contamination.
5. Remove the jam nut (item 10) and thrust washer
(item 9) that secure the axle pivot pin (item 6) to the
frame.
6. Jack up the machine (just ahead of the rear wheels)
until clearance exists to allow rear axle removal. Support the machine with jack stands or appropriate load
holding device to prevent it from falling.
7. Support rear axle to prevent it from falling.

2. Position the rear axle assembly to the frame. Install
thrust washer (item 7) between each side of axle and
frame. Raise axle assembly to frame and slide pivot pin
through frame, thrust washers and axle. Make sure that
roll pin on pivot pin is positioned in frame reliefs.
3. Install thrust washer (item 9) and jam nut (item 10)
onto pivot pin. Torque jam nut (item 10) from 90 to 120
ft- lb (123 to 162 N- m). Make sure that axle can still pivot freely after jam nut is tightened.
4. Lower the machine to the ground.
5. Correctly install the hydraulic hoses to the steering
cylinder.
6. Check oil level in hydraulic reservoir.
7. Lubricate the rear axle pivot bushings through the
grease fitting on the axle pivot pin.
8. Operate machine and check steering cylinder hydraulic connections for leaks.

Chassis

8. Pull the axle pivot pin from frame and rear axle. This
will release the rear axle and thrust washers (item 7)
from the frame. Carefully pull the entire axle and wheel
assembly out from under the machine.

Reelmaster 5010- H

Page 6 - 15

Chassis

Rear Axle Service

17
16

19
3

11
20

7
6

5
7

15
9

RIGHT
FRONT
8

Figure 12
1.
2.
3.
4.
5.
6.
7.

Rear axle
Housing (2 used)
RH drag link
Tie rod assembly
Pivot bushing (2 used)
Grease fitting (2 used)
Flange bushing (4 used)

Chassis

8.
9.
10.
11.
12.
13.
14.

Flange head screw (7 used per side)
LH drag link
Hub and spindle assembly (2 used)
Retaining ring
Spindle cap
Flange head screw
Thrust washer

Page 6 - 16

15.
16.
17.
18.
19.
20.
21.

Cotter pin
Slotted hex nut
Steering cylinder
Ball joint
Washer
Slotted hex nut
Cotter pin

Reelmaster 5010- H

The rear axle must be held in place snugly by the axle
pivot pin. Excessive movement of the axle, which is
characterized by erratic steering, might indicate worn
axle pivot bushings (item 5). To correct the problem, replace the bushings.
1. Remove rear axle from machine (see Rear Axle in
this section).
2. Use a bushing removal tool to extract both axle pivot
bushings from the rear axle pivot tube. Take care to not
damage bore of pivot tube during bushing removal.
Clean the inside of the tube to remove all dirt and foreign
material.
3. Apply grease to the inside and outside of the new
bushings. Use an arbor press to install the bushings into
the front and back of the rear axle pivot tube. Bushings
must be flush with the axle tube after installation.
4. Install rear axle to machine (see Rear Axle in this
section).
Rear Axle Housing Bushings (Fig. 12)
The rear axle housing shafts (item 2) must fit snugly in
the rear axle. Excessive movement of the housing shaft
in the axle might indicate that the flange bushings (item
7) are worn and must be replaced.

5. Use a bushing removal tool to extract both flange
bushings (item 7) from the axle tube. Take care to not
damage the bore of the axle tube. Clean the inside of the
axle tube to remove all dirt or foreign material.
6. Apply grease to the inside and outside of the new
flange bushings. Use an arbor press to install the bushings into the top and bottom of the axle tube. Press bushings into tube until flange shoulder bottoms on tube.
7. Thoroughly clean the housing shaft. Inspect the
shaft for wear and replace if worn or damaged.
8. Install thrust washer (item 14) onto the housing shaft
and slide the shaft up through the rear axle tube. Hold
the housing shaft and wheel assembly in place and
install the retaining ring (item 11) onto the housing shaft.
Make sure that retaining ring is fully seated into housing
shaft groove after installation.
9. Install the spindle cap (item 13) and flange head
screw (item 12).
10.Connect the tie rod end to the drag link with slotted
hex nut and cotter pin.
11. If separated, secure steering cylinder ball joint to RH
drag link with slotted hex nut, washer and cotter pin.
12.Install rear axle to machine (see Rear Axle in this
section).

1. Remove rear axle from machine (see Rear Axle in
this section).

13.Lubricate the steering spindles through the grease
fittings on the rear axle.

2. Remove cotter pin and slotted hex nut that secure
the tie rod end to the drag link. Separate the tie rod end
from the drag link.

14.Check rear wheel toe- in (see Traction Unit Operator’s Manual).

3. If right side housing is being removed from axle, remove cotter pin, washer and slotted hex nut that secure
steering cylinder ball joint (item 18) to RH drag link. Separate steering cylinder from drag link.

15.After all adjustments have been made, make sure
that no contact is made between any machine components as the wheels are moved from lock to lock. Adjust
if necessary.

4. Remove the flange head screw (item 12), spindle
cap (item 13) and retaining ring (item 11) that secure the
housing shaft into the rear axle tube. Slide the housing
and wheel assembly out of the axle tube to expose the
flange bushings. Locate and retrieve thrust washer
(item 14) from housing shaft.

Reelmaster 5010- H

Page 6 - 17

Chassis

Axle Pivot Bushings (Fig. 12)

Control Arm
33
25

FRONT

16
12

RIGHT

4
21

18
19
1

14
22

9
8

32
13

30
43
35

41
40

39
37

11
34

Figure 13
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Control arm frame
InfoCenter display
Headlight switch
Reel engage/disengage switch
Screw (4 used)
Carriage screw (2 used)
Latch
Joystick assembly
Flange nut (2 used)
Screw (2 used)
Swell latch (2 used)
Washer head screw (10 used)
Bushing (2 used)
Flange nut (5 used)
RH control arm cover

Chassis

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

LH control arm cover
Knob
Boot
Boot plate
Ignition switch
Engine speed switch
Cotter pin
Lock nut
Key set
Mounting nut
Backup washer
Flat washer
Screw
Access cover
Spacer

Page 6 - 18

31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.

TEC controller
Washer head screw (4 used)
Arm rest
Foam seal
Compression spring
Clevis pin
Screw (2 used)
Flat washer (2 used)
Retainer bracket
Clevis pin
Cap screw
Latch
Cotter pin
Nut

Reelmaster 5010- H

Disassembly (Fig. 13)

1. Park machine on a level surface, lower cutting units,
stop engine and engage parking brake. Remove key
from ignition switch.
1

2. Loosen latches and remove access cover from outside of control arm.
3. At front of control arm, remove screw (item 28) and
lock nut (item 23) that secure control arm covers to each
other.
4. Remove five (5) washer head screws (item 12) that
secure each cover to control arm.
5. Remove control arm covers from machine. As LH
control arm cover (item 16) is removed from control arm,
unplug wire harness connector from headlight switch.

Figure 14
1. Wire harness

2. Harness foam seal

6. Remove electrical components from control arm as
needed using Figure 13 as a guide.
Assembly (Fig. 13)
1. Install all removed electrical components to control
arm using Figure 13 as a guide.
2. Position covers to control arm. As LH cover (item 16)
is placed, plug wire harness connector to headlight
switch. Also, make sure that wire harness is routed correctly through cover openings (shown in Fig. 14).
3. Secure each cover to control arm with five (5) washer
head screws (item 12). Install screw (item 28) and lock
nut (item 23) to secure covers at front of control arm.

Chassis

4. Install access cover to outside of control arm.

Reelmaster 5010- H

Page 6 - 19

Chassis

Operator Seat

14
9

5
6
17

8
28
27

7
2
20
21

4
15

16
13

RIGHT

24
25

FRONT

19
18

Figure 15
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Operator seat
Seat base
Seat adjuster w/latch
Flat washer (4 used)
Seat switch harness
Seat switch
Washer head screw (2 used)
Armrest bracket
Spacer
Armrest

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

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)
Cap screw (4 used)
Housing cap

21.
22.
23.
24.
25.
26.
27.
28.
29.

R- clamp (2 used)
Manual housing
Seat belt buckle
Flange nut (4 used)
Seat suspension
Flange head screw (4 used)
Cap screw (2 used)
Lock washer (2 used)
Seat belt

IMPORTANT: The operator seat, seat base and control arm assembly are attached to the machine with
the same fasteners. Make sure to support the seat
base and control arm to prevent them from shifting
when removing the seat. Damage to control arm
electrical components and control arm wiring harness can occur if the seat base and control arm are
not properly supported during seat removal.

Chassis

Page 6 - 20

Reelmaster 5010- H

Removal (Fig. 15)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Disconnect negative battery cable from 12 volt battery at rear of machine (see 12 Volt Battery Service in the
Service and Repairs section of Chapter 5 - Electrical
System).
3. Disconnect seat switch electrical connector from
wire harness (Fig. 16).

4. Position retainer bracket assembly to control arm
and secure with two (2) flange head screws and flat
washers (Fig. 17).
5. Connect seat switch electrical connector to wire harness.
6. Connect negative battery cable to 12 volt battery at
rear of machine (see 12 Volt Battery Service in the Service and Repairs section of Chapter 5 - Electrical System).

4. Remove two (2) flange head screws and flat washers
that secure retainer bracket assembly and control arm
assembly to seat base (Fig. 17). Remove retainer bracket assembly.

IMPORTANT: Take care to not damage the electrical
wire harness when removing seat and control arm
assembly from machine.

3
1

5. Carefully slide control arm assembly from seat base.
Make sure that two (2) bushings remain in pivot of control arm assembly. Position and support control arm assembly to allow seat removal.
6. Remove four (4) socket head screws (item 15) and
flat washers (item 4) that secure seat and seat base to
seat adjusters. Note location of fasteners for assembly
purposes.

Figure 16
1. Seat switch lead
2. Wire harness

7. Support seat base to keep it positioned on seat adjusters.

3. Flange screw

Installation (Fig. 15)
1. Position seat and seat base to seat adjusters. Use
forward set of mounting holes in bottom of seat when
aligning seat with seat base and adjusters.

3
5

2. Secure seat and seat base to seat adjusters with four
(4) flat washers (item 4) and socket head screws (item
15).
IMPORTANT: Take care to not damage electrical
wire harness when installing control arm assembly
to machine.

Figure 17
1. Seat base
2. Control arm assembly
3. Flange screw (2 used)

4. Flat washer (2 used)
5. Retainer bracket assy

3. Make sure that two (2) bushings are positioned in
control arm pivot area. Carefully slide control arm assembly onto seat base post.

Reelmaster 5010- H

Page 6 - 21

Chassis

8. Remove operator seat from seat base and seat adjusters. Note location of fasteners for assembly purposes.

Mechanical Seat Suspension
40

37
34
20

23
4

2
27
33

21
12

36
14

25
35
17

9
32

39
3

Figure 18
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Upper housing
Weight adjust knob
Lower housing
Scissor assembly
Lock nut
Weight adjuster
Drive arm
Extension spring (2 used)
Roller guide
Weight adjust knob
Cap
Suspension boot
Pivot block (2 used)
Damper

Chassis

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.

Lower shock bolt
Upper shock bushing (2 used)
Lower shock bushing (2 used)
Stop bumper
Height adjust rod
Lock nut
Stop bumper (2 used)
Bearing tube (2 used)
Spring shaft
Pivot pin
Roller pin
Spring bushing (2 used)
Shaft block (2 used)
Weight adjust spacer

Page 6 - 22

29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.

Weight indicator assembly
Weight adjust nut
Rivet
Roller (4 used)
Extension spring
Bumper
Hex nut (2 used)
Retainer (3 used)
Flat washer
Flat washer
Thread forming screw (8 used)
Roll pin (2 used)
Roll pin
Clip (20 used)

Reelmaster 5010- H

IMPORTANT: When removing the seat suspension,
make sure to support the control arm to prevent
damage to the control arm electrical components
and control arm wiring harness.
Removal (Figs. 18 and 19)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Disconnect negative battery cable from 12 VDC battery (see 12 Volt Battery Service in the Service and Repairs section of Chapter 5 - Electrical System).
3. Remove seat from machine (see Operator Seat in
this section).

2. Position seatbase cover and four (4) spacers (item
7 in Figure 19) to seat base.
3. Position seat suspension with attached seat brackets to seat base. Use rear set of mounting holes in seat
brackets when aligning seat suspension assembly with
seat base. Secure with four (4) flange head screws (item
8 in Figure 19) and flange nuts (item 5 in Figure 19).
4. Install seat to machine (see Operator Seat in this
section). Make sure to connect wire harness electrical
connector to the seat switch.
5. Connect negative battery cable to 12 VDC battery
(see 12 Volt Battery Service in the Service and Repairs
section of Chapter 5 - Electrical System).
12

IMPORTANT: Take care to not damage the electrical
harness when removing seat suspension from machine.

11
10

4. Tilt and support seat frame to allow access to seat
suspension fasteners.

13
1

5. Support seat suspension to prevent it from falling.
Remove four (4) flange head screws (item 8 in Figure
19) and flange nuts (item 5 in Figure 19) that secure seat
suspension with attached seat brackets to seat base.

8
2

6. Remove seat suspension assembly from machine.
Locate and retrieve four (4) spacers (item 7 in Figure 19)
from between seat suspension assembly and seat
base.

7. Remove seat suspension components as needed
using Figures 18 and 19 as guides.
4

Installation (Figs. 18 and 19)

FRONT

A. If seat adjusters (items 12 or 13 in Figure 19) were
removed from seat suspension, install adjuster studs
in rear set of holes in the suspension. Also, make
sure that washer (item 9 in Figure 19) is placed between seat adjuster and suspension.
IMPORTANT: Take care to not damage the electrical
harness when installing seat suspension to machine.

Reelmaster 5010- H

Chassis

1. Install all removed seat suspension components using Figures 18 and 19 as guides.
5

Figure 19
1.
2.
3.
4.
5.
6.
7.

Page 6 - 23

Seat suspension
Seat bracket (2 used)
Screw (4 used)
Seat base
Flange nut (8 used)
Seatbase cover
Spacer (4 used)

8.
9.
10.
11.
12.
13.

Flange screw (4 used)
Flat washer (4 used)
Manual tube
R- clamp (2 used)
Seat adjuster
Seat adjuster w/latch

Chassis

Front Lift Arms

4
3

6
26
27

11
10
22

9
20
7

23
12

26
14

19
21

Antiseize
Lubricant

13
16

18
7
Medium Strength
Threadlocker
75 to 95 ft- lb
(102 to 128 N- m)

RIGHT

Medium Strength
Threadlocker
135 to 165 ft- lb
(184 to 223 N- m)

Medium Strength
Threadlocker
75 to 95 ft- lb
(102 to 128 N- m)

FRONT

Figure 20
1.
2.
3.
4.
5.
6.
7.
8.
9.

#1 lift arm
#4 lift arm
#5 lift arm
Lift arm pivot shaft (3 used)
Roll pin (3 used)
Lock nut (4 used)
Cap screw (4 used)
Bridge plate
Cap screw (1 used per lift arm)

10.
11.
12.
13.
14.
15.
16.
17.
18.

Chain hoop (3 used)
Washer (2 used per chain hoop)
Cap screw (2 used per chain hoop)
Pivot yoke (3 used)
Lynch pin (3 used)
Thrust washer (2 used per yoke)
Grease fitting
Bridge plate
Snapper pin (1 used per lift arm)

19.
20.
21.
22.
23.
24.
25.
26.
27.

Cap (1 used per lift arm)
Thrust washer (6 used)
Cap screw (2 used)
Chain (3 used)
Up limit switch
Flange nut (2 used per chain hoop)
Flat washer (1 used per lift arm)
Jam nut (2 used)
Lock washer (2 used)

Removal (Fig. 20)

4. Pivot lift cylinder rod end away from lift arm.

1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.

5. Remove lynch pin (item 14) and slide pivot yoke assembly from lift arm. Locate and retrieve two (2) thrust
washers (item 15).

2. Remove cutting unit from front lift arm to be removed.

6. Remove fasteners that secure bridge plate (item 8 or
17) to machine.

3. Remove one retaining ring (item 3 in Fig. 21) and
thrust washer (item 4 in Fig. 21) from the cylinder slide
pin (item 5 in Fig. 21) that secures lift cylinder to lift arm.
Pull slide pin from the lift cylinder and lift arm. Locate and
retrieve second thrust washer.
Chassis

7. Slide front lift arm from lift arm pivot shaft.

Page 6 - 24

Reelmaster 5010- H

8. Inspect bushings in lift arm and pivot yoke for wear
or damage. If necessary, replace bushings (Figs. 22 and
23).

8. Check operation of lift arm up limit switch and adjust
if necessary (see Up Limit Switch in Components section of Chapter 6 - Electrical System).

A. Use bushing removal tool to extract bushings
from the lift arm or pivot yoke. Take care to not damage the bore.

B. Clean the inside of the bore to remove any dirt or
foreign material.
C. Apply grease to the inside and outside of the new
bushings.

3
1

D. Use an arbor press to install the bushings into lift
arm or pivot yoke. Lift arm bushings should be
pressed until bushing flange is against lift arm bore.
The upper pivot yoke bushing should be pressed fully to the shoulder in the pivot yoke bore. The lower
pivot yoke bushing should be flush with the yoke
tube.
9. Check lift arm pivot shaft (item 4) for wear or damage. If necessary, remove roll pin (item 5) that secures
pivot shaft to frame and remove pivot shaft. Discard removed roll pin.
Installation (Fig. 20)

4
5
3
4

Figure 21
1. Lift arm (#4 shown)
2. Lift cylinder
3. Retaining ring

1. If lift arm pivot shaft (item 4) was removed from
frame, apply antiseize lubricant to portion of pivot shaft
that is in frame bore. Slide pivot shaft into frame and secure with new roll pin (item 5).

4. Thrust washer
5. Cylinder slide pin

2. Slide front lift arm onto pivot shaft.

4. Position thrust washer (item 15) onto pivot yoke shaft
and then slide pivot yoke into lift arm bushings. Place
second thrust washer on pivot yoke shaft and secure
with lynch pin (item 14).

Figure 22
1. Lift arm (#5 shown)
2. Lift arm bushing

5. Align lift cylinder to lift arm mounting slot (Fig. 21).
Slide cylinder slide pin (item 5 in Fig. 21) with retaining
ring (item 3 in Fig. 21) and thrust washer (item 4 in Fig.
21) through the lift arm and lift cylinder. Install second
thrust washer on pin and secure with second retaining
ring.

1
3

6. Mount cutting unit to lift arm.

Figure 23

7. Lubricate grease fittings on lift arm, pivot yoke and lift
cylinder.

Reelmaster 5010- H

3. Pivot yoke bushing

1. Pivot yoke
2. Upper bushing

Page 6 - 25

3. Pivot yoke shoulder
4. Lower bushing

Chassis

3. Apply medium strength threadlocker to threads of
cap screws (items 7, 9 and 21) that secure bridge plate
(items 8 and 17). Secure lift arm to machine with bridge
plate. Torque cap screws that secure bridge plate to
torque values identified in Figure 20.

Rear Lift Arms

9
5

10
15
5

7
12

8
8

20
4

2
18
17

RIGHT
FRONT

8
16

Figure 24
1.
2.
3.
4.
5.
6.
7.
8.

Housing
#2 lift arm
#3 lift arm
Washer (2 used per chain hoop)
Washer (2 used)
Flange head screw (2 used)
Shoulder stud (6 used)
Grease fitting

9.
10.
11.
12.
13.
14.
15.

Pivot shaft (2 used)
Washer head screw (1 used per shaft)
Pivot yoke (2 used)
Lynch pin (2 used)
Thrust washer (2 used per yoke)
RH torsion spring
LH torsion spring

Removal (Fig. 24)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Remove cutting unit from rear lift arm that is to be removed.
Chassis

16.
17.
18.
19.
20.
21.
22.

Snapper pin (1 used per yoke)
Cap (1 used per yoke)
Chain hoop (2 used)
Lock nut (6 used)
Cap screw (2 used per chain hoop)
Flange nut (2 used per chain hoop)
Chain (2 used)

3. Remove one retaining ring (item 3 in Fig. 25) and
thrust washer (item 4 in Fig. 25) from the cylinder pin
(item 5 in Fig. 25) that secures lift cylinder to lift arm. Pull
cylinder pin from the lift cylinder and lift arm. Locate and
retrieve second thrust washer.
4. Pivot lift cylinder rod end away from lift arm.

Page 6 - 26

Reelmaster 5010- H

5. Remove lynch pin (item 12) and rear thrust washer
(item 13) from rear of pivot yoke. Slide pivot yoke assembly from lift arm. Locate and retrieve front thrust
washer (item 13).

CAUTION

3
4

Be careful when removing tension from the torsion spring on the rear lift arms. The spring is under heavy load and may cause personal injury.

B. Insert nut driver or small piece of pipe onto the
end of the torsion spring that is secured to the shoulder stud.

6. Remove tension from both torsion springs (items 14
and 15) on rear of lift arm pivot shaft.
A. Note on which shoulder stud (item 7) the torsion
spring end is attached for assembly purposes.

Figure 25
1. Lift arm (#2 shown)
2. Lift cylinder
3. Retaining ring

4. Thrust washer
5. Cylinder pin

C. Push down and rearward on the spring end to unhook the spring from the shouldered stud (item 7).

7. Remove two (2) flange head screws (item 6) that secure housing (item 1) to machine. Remove housing, torsion springs (items 14 and 15) and two (2) washers (item
5).
8. Remove washer head screw (item 10) that secures
pivot shaft (item 9) to frame.

9. Support rear lift arm to prevent it from falling. Slide
pivot shaft from frame and lift arm. Remove rear lift arm.

10.Inspect pivot shaft and replace if worn or damaged.

Figure 26
1. Rear lift arm (#2 shown)
2. Pivot yoke bushing

A. Use bushing removal tool to extract both bushings from the lift arm or pivot yoke. Take care to not
damage the bore.

3. Lift arm bushing

2
3

B. Clean the inside of the bore to remove any dirt or
foreign material.
4

C. Apply grease to the inside and outside of the new
bushings.
D. Use an arbor press to install the bushings into lift
arm or pivot yoke. Lift arm bushings should be
pressed until bushing flange is against lift arm bore.
The upper pivot yoke bushing should be pressed fully to the shoulder in the pivot yoke bore. The lower
pivot yoke bushing should be flush with the yoke
tube.
Reelmaster 5010- H

Figure 27
1. Pivot yoke
2. Upper bushing

Page 6 - 27

3. Pivot yoke shoulder
4. Lower bushing

Chassis

11. Inspect bushings in lift arm and pivot yoke for wear
or damage. If necessary, replace bushings (Figs. 26 and
27).

Installation (Fig. 24)
1

1. Position rear lift arm to frame and slide pivot shaft
through frame bosses and lift arm. Secure shaft with
washer head screw (item 10).

2
3

2. Place washer (item 5) over rear of each pivot shaft.
3. Place torsions springs (items 14 and 15) onto housing (item 1). Position long leg of springs forward and
pointing out from top of spring. Short leg of springs
should be against stop on housing (Fig. 28).
4. Position housing (item 1) to lift arm pivot shafts and
secure with two (2) flange head screws (item 6). Make
sure that washers (item 5) remain on ends of pivot shafts
and short end of torsion springs are against stop on
housing.
5. Align lift cylinder rod end to lift arm mounting slot.
Slide cylinder pin (item 5 in Fig. 25) with retaining ring
(item 3 in Fig. 25) and thrust washer (item 4 in Fig. 25)
through the lift cylinder and lift arm. Install second thrust
washer on pin and secure with second retaining ring.

Figure 28
1. Housing
2. Housing stop

3. RH torsion spring
4. LH torsion spring

CAUTION
Be careful when applying tension to the torsion
spring on the rear lift arms. The spring is under
heavy load and may cause personal injury.
6. Apply tension to torsion springs.
A. Insert nut driver or small piece of pipe onto the
long leg of the torsion spring on the rear of the lift arm
pivot pin.
B. Push down and forward on the spring end to hook
the spring to the stop bolt on the lift arm.
7. Mount cutting unit to lift arm.
8. Lubricate grease fittings on lift arm, pivot yoke and lift
cylinder.

Chassis

Page 6 - 28

Reelmaster 5010- H

Chassis

This page is intentionally blank.

Reelmaster 5010- H

Page 6 - 29

Chassis

Hood
3

13
14

12
18 20
22

21
6
9

5
19
12

FRONT
7

RIGHT

Figure 29
1.
2.
3.
4.
5.
6.
7.
8.

Sealed foam
Hood saddle
Hood
Catch (2 used)
Rubber latch (2 used)
Tube
Bow tie pin (2 used)
Deflector bracket (2 used)

Chassis

9.
10.
11.
12.
13.
14.
15.

Tube (2 used)
Washer head screw (8 used)
Flange head screw (10 used)
Flange nut (10 used)
Washer head screw (4 used)
Flat washer (4 used)
Lock nut (4 used)

Page 6 - 30

16.
17.
18.
19.
20.
21.
22.

Yoke pin (2 used)
Rubber bumper (2 used)
Latch
Washer head screw (4 used)
Grommet
Hex nut
Spacer

Reelmaster 5010- H

Removal (Fig. 29)

Installation (Fig. 29)

1. Park the machine on a level surface, lower the cutting units and stop the engine. Remove the key from the
ignition switch.

1. Install all removed hood components using Figure
29 as a guide.

2. Unlatch hood.

2. Position hood assembly to machine and slide tube
ends onto frame brackets.

3. Remove bow tie pin (item 7) and yoke pin (item 16)
to allow hood removal.

3. Install yoke pin (item 16) and secure with bow tie pin
(item 7).

4. Lift hood assembly from machine.

4. Latch hood.

5. Remove hood components as necessary using Figure 29 as a guide.

Chassis

6. Check condition of all seals on hood. Replace damaged or missing seals.

Reelmaster 5010- H

Page 6 - 31

Chassis

This page is intentionally blank.

Chassis

Page 6 - 32

Reelmaster 5010- H

Chapter 7

Cutting Units
Table of Contents
Bedbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Bedknife Replacement and Grinding . . . . . . . . . .
Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . .
Cutting Reel Assembly Removal and Installation
Reel Assembly Removal . . . . . . . . . . . . . . . . . .
Reel Assembly Installation . . . . . . . . . . . . . . . .
Cutting Reel Assembly Service . . . . . . . . . . . . . .
Preparing Reel for Grinding . . . . . . . . . . . . . . . . .
Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Roller Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Roller Brush (Optional) . . . . . . . . . . . . . . . . .
Rear Roller Brush Drive System (Optional) . . . .

16
18
20
22
22
24
26
28
30
31
32
34
36

Cutting
Units

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Cutting Unit Operator’s Manual . . . . . . . . . . . . . . . 3
48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FACTORS THAT CAN AFFECT CUTTING
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SET UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . 12
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Leveling Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . 13
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 14
Cutting Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . 14
Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Reelmaster 5010- H

Page 7 - 1

Cutting Units

Specifications

Figure 1
Frame Construction: Precision machined die cast aluminum cross member with two (2) bolt- on aluminum
side plates.

Bedknife: Replaceable, tool steel EdgeMaxTM bedknife
is fastened to a machined cast iron bedbar with eight (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. 5 inch
and 7 inch reels are available in both 8 and 11 blade configurations.

Bedknife Adjustment: Dual screw assemblies allow
for precise bedknife adjustment. Adjustment detents
correspond to bedknife movement for each indexed position as follows:
0.0007 inch (0.018 mm) for 5 inch reel
0.0009 inch (0.022 mm) for 7 inch reel

Reel Bearings: Two (2) sealed, stainless steel ball
bearings support the reel shaft with inboard spacer for
protection.

Front and Rear Rollers: Greaseable through- shaft
front and rear rollers are used with these cutting units.
All rollers use the same heavy duty, stainless steel ball
bearings and seal package.

Reel Drive: The reel weldment shaft is a 1 5/16 inch
(33.3 mm) diameter tube with LH and RH drive inserts
threaded into both ends. The drive inserts for 5 inch reels have an internal eight (8) tooth spline. The drive inserts for 7 inch reels have an internal nine (9) tooth
spline.
Height- of- Cut (HOC): Cutting height is adjusted on
the front roller by two (2) vertical screws. Effective HOC
may vary depending on turf conditions, type of bedknife,
roller type and installed attachments.

Cutting Units

Cutting Unit Weight (without end weight):
8 Blade, 5 inch reel
90 lb. (41 kg)
11 Blade, 5 inch reel
93 lb. (42 kg)
8 Blade, 7 inch reel
118 lb. (54 kg)
11 Blade, 7 inch reel
121 lb. (55 kg)
Options: Refer to Cutting Unit Operator’s Manual for
available options for your Reelmaster cutting unit.

Page 7 - 2

Reelmaster 5010- H

General Information
Cutting Unit Operator’s Manual
The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for the cutting units on your Reelmaster machine. Additionally, if optional kits have been
installed on the cutting units (e.g. groomer, rear roller
brush), the installation instructions for the kit includes
set- up and operation information. Refer to those publications for additional information when servicing the
cutting units.

48 VDC Battery Disconnect

CAUTION

FRONT
1

The 48 VDC battery disconnect is attached to the right
frame rail under the operator seat (Fig. 2). Unplug the
disconnect to make sure that 48 VDC components do
not operate unexpectedly. Apply dielectric grease to the
contact surfaces of the battery disconnect and plug the
battery disconnect back in after service to the 48 VDC
system is completed.

Figure 2
2. 48V battery disconnect

Cutting
Units

1. RH frame rail

Reelmaster 5010- H

Page 7 - 3

Cutting Units

Special Tools
Order special tools for your Reelmaster from your Toro
Distributor. Some tools may have been supplied with
your machine or are available as Toro parts.

Gauge Bar Assembly
Toro Part Number: 108- 6715
Use gauge bar to verify height- of- cut adjustment. Also
used for adjustment of optional groomer.
Used for
groomer
adjustment

Used for Height- ofCut adjustment

Figure 3

Cutting Reel Shim
Toro Part Number: 125- 5611
The cutting reel shim (0.002”) is used to help parallel the
bedknife and cutting reel.

Figure 4

Cutting Performance Paper
Toro Part Number: 125- 5610
Cutting performance paper is used to test the cutting
reel performance after adjusting the reel to bedknife
clearance. 10 packs (30 strips per pack) of cutting performance paper are included in this part number.

Figure 5

Cutting Units

Page 7 - 4

Reelmaster 5010- H

Bedknife Screw Tool
Toro Part Number: TOR510880
This screwdriver- type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar.
IMPORTANT: To prevent damage to the bedbar, DO
NOT use an air or manual impact wrench with this
tool.
Figure 6

Handle Assembly
Toro Part Number: 29- 9100
For applying lapping compound to cutting units while
keeping hands a safe distance from the rotating reel.
Components for the handle assembly are available individually as follows:
Brush
36- 4310
Handle
29- 9080
Handle cap 2410- 18

Figure 7

Cutting Unit Kickstand
Toro Part Number: 119- 8010- 03

Cutting
Units

The cutting unit kickstand is used to prop up the rear of
the cutting unit during service. Use of this tool stabilizes
the cutting unit and prevents the bedbar adjusting
screws from resting on the work surface.

Figure 8

Reelmaster 5010- H

Page 7 - 5

Cutting Units

Spline Insert Tool
Toro Part Number: TOR4112 (8 tooth for 5 inch reels)
TOR4074 (9 tooth for 7 inch reels)
Use spline insert tool for rotating cutting reel when motor
is removed. Also use this tool for installation of threaded
inserts into cutting reel shaft.

Figure 9

Rear Roller Bearing and Seal Installation Tools
Toro Part Number: 115- 0803

Bearing Installation
Washer

This tool kit is used to assemble the cutting unit rollers.
Tools in this kit are also available individually as follows:
115- 0852 Inner Seal Tool
115- 0853 Bearing/Outer Seal Tool
107- 8133 Bearing Installation Washer

Bearing/Outer Seal
Tool

Inner Seal
Tool

Figure 10

Figure 11

Cutting Units

Page 7 - 6

Reelmaster 5010- H

Pulley Alignment Tool
Toro Part Number: 114- 5446
Use pulley alignment tool to verify alignment of groomer
and/or rear roller brush drive and driven pulleys.

Figure 12

Diameter/Circumference Measuring Tape
Toro Part Number: TOR6023
Spring steel measuring tape for accurately measuring
the circumference and outside diameter of cutting reel
and other spherical components. Tape calibration is in
fixed inch readings (no adjustments).

Figure 13

Turf Evaluator Tool
Toro Model Number: 04399
Many turf discrepancies are subtle and require closer
examination. In these instances, the Turf Evaluator
grass viewing tool is helpful. It can assist turf managers
and service technicians in determining causes for poor
reel mower performance and in comparing the effective
height- of- cut of one mowed surface to another. This
tool should be used with the Toro Guide to Evaluation
Reel Mower Performance and Using the TurfEvaluator
(Toro part no. 97931SL)

Reelmaster 5010- H

Page 7 - 7

Cutting
Units

Figure 14

Cutting Units

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.

Refer to the Cutting Unit’s Operator’s Manual for detailed cutting unit adjustment procedures. For cutting
unit repair information, refer to the Service and Repairs
section of this chapter.
NOTE: For additional information regarding cutting unit
troubleshooting, see Aftercut Appearance Troubleshooting Aid (Toro part no. 00076SL).

Factor

Possible Problem/Correction

Tire pressure

Check tire pressure of all traction unit tires. Adjust tire
pressure as necessary.

Engine speed

For best cutting performance and appearance, engine
should be run at maximum governed speed during
machine operation (use InfoCenter Display to check
engine speed).

Reel speed

All cutting reels must rotate at the same speed (within
100 rpm) (use InfoCenter Display to check reel speed).
All cutting units must have equal bedknife to reel and
height- of- cut adjustments.
Make sure that reel speed selection is correct (use
InfoCenter Display to check and adjust reel speed).

Reel bearing condition

Check reel bearings for wear and replace if necessary.
See Reel Assembly in the Service and Repairs section
of this chapter.

Bedknife to reel adjustment

Cutting Units

Check bedknife to reel contact daily. The bedknife
must have light contact across the entire reel. No
contact will dull the cutting edges. Excessive contact
accelerates wear of both edges. Quality of cut is
adversely affected by both conditions (see Bedknife to
Reel Adjustment in the Cutting Unit Operator’s
Manual).

Page 7 - 8

Reelmaster 5010- H

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. During this initial use, any burrs will be
removed from reel and bedknife which may create
improper reel to bedknife clearance and thus
accelerate wear. This practice of re- checking the reel
to bedknife contact after grinding will extend the
longevity of the sharpness of the edge of the reel and
the bedknife.

The most common cause of rifling is bedknife to reel
contact that is too tight.
Dull cutting edges must be corrected by grinding the
bedknife and cutting reel (see Preparing Reel for
Grinding in the Service and Repairs section of this
chapter).
A new bedknife must be ground flat (within 0.002”)
after installation to the bedbar. Backlapping may
be required to properly mate the reel and bedknife
after installation into the cutting unit.
NOTE: On cutting units equipped with optional
bedknives, slightly dull cutting edges may be corrected
by backlapping (see Backlapping in the Service and
Repairs section of this chapter).

Rear roller adjustment

Adjust the rear roller brackets to correct position
depending on the height- of- cut range and
aggressiveness of cut that is desired.
See Rear Roller Adjustment in the Cutting Unit
Operator’s Manual.

Height- of- cut

“Effective” or actual height- of- cut depends on the
cutting unit weight and turf conditions. Effective
height- of- cut will be different from the bench set
height- of- cut.
See Height- of- Cut Adjustment in the Cutting Unit
Operator’s Manual.
If the bedknife is incorrect for effective height- of- cut,
poor quality of cut will result.
See Cutting Unit Operator’s Manual for bedknife
options.

Stability of bedbar

Make sure bedbar pivot bolts are seated securely.
Check condition of the bushings in the side plates.
See Bedbar Removal and Installation in the Service
and Repairs section of this chapter.

Number of reel blades

Use correct number of reel blades for clip frequency
and optimum height- of- cut range.
Refer to Clip Chart in Traction Unit Operator’s Manual.

Reelmaster 5010- H

Page 7 - 9

Cutting Units

Cutting
Units

Proper bedknife selection for height- of- cut desired

Factor

Possible Problem/Correction

Cutting unit alignment and carrier frame ground
following

Check carrier frames and lift arms for damage, binding
conditions or bushing wear. Repair if necessary.

Roller condition and roller type

Make sure 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.

Turf compensation spring adjustment

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.

Cutting unit accessories

A variety of cutting unit accessories are available that
can be used to enhance aftercut appearance. Refer to
Cutting Unit Operator’s Manual for a listing of available
accessories.

Cutting Units

Page 7 - 10

Reelmaster 5010- H

Cutting
Units

This page is intentionally blank.

Reelmaster 5010- H

Page 7 - 11

Cutting Units

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.
Also, before installing, removing or working on
the cutting units, disconnect the cutting units
from the electrical power supply by separating
the 48 VDC battery disconnect (see 48 VDC Battery Disconnect in the General Information section of this chapter).

1. Adjust the bedknife parallel to the reel.
2. Determine desired height- of- cut range and install
rear roller mounting shim(s) accordingly.
3. Adjust the height- of- cut.
See Cutting Unit Operator’s Manual for cutting unit adjustment procedures for your Reelmaster.

The dual knob bedknife- to- reel adjustment system incorporated in this cutting unit simplifies the adjustment
procedure needed to deliver optimum mowing performance. The precise adjustment possible with this design gives the necessary control to provide a continual
self- sharpening action. This feature maintains sharp
cutting edges, assures good quality of cut and greatly
reduces the need for routine backlapping.
In addition, the rear roller positioning system allows for
various height-of-cut ranges and aggressiveness of cut
selections.

Cutting Units

Page 7 - 12

Reelmaster 5010- H

Leveling Rear Roller
The precision machined components of the cutting unit
frame keep the rear roller and cutting reel in alignment
(parallel). If the side plates are disassembled or as the
cutting reel wears, a limited amount of side plate adjustment is possible to make sure that the cutting unit is
properly aligned.

Cutting Unit with 7” Reel Shown

2
3

1. Place the assembled cutting unit on a surface plate.
2. Make sure that bedknife is properly adjusted to cutting reel.
1

NOTE: Cutting units with 5” diameter reel use two (2)
shoulder bolts to secure side plates to frame. Cutting
units with 7” diameter reel use three (3) shoulder bolts
to secure side plates to frame.
4. Loosen, but do not remove, shoulder bolts that secure the side plate to the frame opposite the side that is
not level (Fig. 15).

3
Figure 15
1. Bedbar
2. Bedbar adjuster

5. Adjust the position of the side plate to parallel the
rear roller and cutting reel. Then, tighten the shoulder
bolts to a torque from 27 to 33 ft- lb (37 to 44 N- m).

3. Shoulder bolt

4
5
1

6. After tightening the side plate, recheck the rear roller.
If necessary, loosen and adjust second side plate.
7. If rear roller is still not level after adjusting both side
plates, check to see if cutting reel is tapered (see Preparing Reel for Grinding in the Service and Repairs section of this chapter). If cutting reel is not tapered and rear
roller is not level, a 0.010” shim (part number 107- 4001)
is available to allow additional rear roller adjustment.
The shim would be used on one side of the rear roller
and should be installed between the rear roller bracket
and roller shim (Fig. 16).

Cutting
Units

3. Using the surface plate, check if rear roller is level to
cutting reel by using a 0.005” (0.13 mm) shim at each
end of rear roller. If the shim will pass under the roller at
one end but not the other, a frame adjustment should be
made.

8. After leveling rear roller, complete cutting unit set- up
and adjustment sequence.

Figure 16
1.
2.
3.
4.

Reelmaster 5010- H

Page 7 - 13

Rear roller assembly
Rear roller bracket
Carriage screw
Flange nut

5. Washer
6. Roller shim
7. 0.010” shim (if needed)

Cutting Units

Service and Repairs
Cutting Reel Motor
NOTE: If electrical problems exist with a cutting reel
motor, a fault should have occurred that would be indicated by a fault code on the InfoCenter Display. Before
considering that reel motor service work is necessary,
check for any existing fault codes that indicate problems
with a reel motor.

IMPORTANT: When performing service or maintenance on the cutting reel motors, take care to not
damage the motors or electrical connections.
For information on removal, installation and service of
the cutting unit motors, see Cutting Reel Motor and Cutting Reel Motor Service in the Service and Repairs section of Chapter 5 - Electrical System.
The cutting unit side plates (Fig. 19) have threaded inserts at the locations used for the cap screws that secure
the reel motor. Check the condition of the threaded inserts whenever the cutting reel motor is removed and replace inserts if damage is found. Inserts should be
torqued from 35 to 40 ft- lb (48 to 54 N- m) during installation.
For proper lubrication of the reel motor splines, a grease
fitting (item 3 in Fig. 19) must be installed in the cutting
unit side plate on the reel motor side of the cutting unit.
On the non- drive side plate, a set screw (item 4 in Fig.
19) should be installed so that it is flush with the side
plate surface.
NOTE: Refer to Figure 18 for correct placement of cutting unit reel motors and weights.

1
Figure 17
1. Cutting reel motor

2. Cap screw (2 used)

FRONT
Figure 18
1. Reel motor location

2. Weight location

35 to 40 ft- lb
(48 to 54 N- m)

3
1

Figure 19
1. Side plate (LH shown)
2. Threaded insert
3. Grease fitting

Cutting Units

Page 7 - 14

4. Set screw
5. Relief fitting

Reelmaster 5010- H

Backlapping

DANGER
TO AVOID PERSONAL INJURY OR DEATH:
D Never place hands or feet in the reel area
while the engine is running or if the 48 VDC battery pack is connected. Disconnect the cutting
units from the electrical power supply by separating the 48 VDC battery disconnect (see 48 VDC
Battery Disconnect in the General Information
section of this chapter).
D While backlapping, the reels may stall and
then restart.
D Do not attempt to restart reels by hand or foot.
D Do not adjust reels while the engine is
running or if the 48 VDC battery pack is connected.
D If a reel stalls, stop engine and separate the 48
VDC battery disconnect before attempting to
clear the reel.

Figure 20
1. Long handle brush

Cutting
Units

NOTE: Instructions and procedures on backlapping
are available in the Traction Unit Operator’s Manual and
the Toro General Service Training Book, Reel Mower
Basics (part no. 09168SL).

Reelmaster 5010- H

Page 7 - 15

Cutting Units

Bedbar Assembly
10
7

7” CUTTING REEL SHOWN
8
9

11
3
13

3
4

RIGHT

FRONT
Antiseize
Lubricant

Figure 21
1.
2.
3.
4.
5.

Bedbar assembly
Flange bushing (2 used)
Plastic washer (4 used)
Metal washer (2 used)
Bedbar pivot bolt (2 used)

6.
7.
8.
9.
10.

Lock nut (2 used)
Lock nut (2 used)
Compression spring (2 used)
Washer (2 used)
Bedbar adjuster screw (2 used)

Bedbar Removal (Fig. 21)
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. To prevent unexpected reel motor operation, disconnect motors from the electrical power supply by unplugging the 48 VDC battery disconnect (see 48 VDC
Battery Disconnect in the General Information section of
this chapter).

Cutting Units

11.
12.
13.
14.

Cutting unit frame
RH side plate
Cutting reel assembly
LH side plate

3. Remove the cutting unit from the machine. Use the
cutting unit kickstand to support the cutting unit (see
Special Tools in this chapter).
4. Loosen the lock nuts (item 7) on the end of each bedbar adjuster assembly until washer (item 9) is loose.
5. Loosen the lock nuts (item 6) on each bedbar pivot
bolt (item 5).

Page 7 - 16

Reelmaster 5010- H

6. Remove two (2) bedbar pivot bolts (item 5), two (2)
metal washers (item 4) and four (4) plastic washers
(item 3) from the cutting unit side plates.

CAUTION
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when handling the bedbar.
7. Remove bedbar assembly from cutting unit.
8. Inspect flange bushings (item 2) and rubber bushings in side plates for wear or damage. Remove bushings and replace if necessary.

6. Position a plastic washer (item 3) between bedbar
and each cutting unit side plate (Fig. 22).
7. Install the bedbar pivot bolt assemblies. Make sure
that plastic washers are not caught on the threads of the
pivot bolts. Tighten each bedbar pivot bolt from 27 to 33
ft- lbs (37 to 44 N- m).
8. Tighten both lock nuts (item 6) until outside metal
washer just stops rotating. Do not over tighten the lock
nuts as this can distort the side plates and affect reel
bearing adjustment. The plastic washer between the
bedbar and side plate should be loose.
9. Tighten the lock nut (item 7) on each bedbar adjuster
assembly until the adjuster spring is fully compressed,
then loosen lock nut 1/2 turn.
10.Adjust cutting unit (see Cutting Unit Operator’s
Manual).

Bedbar Installation (Fig. 21)
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. 22).

11. Install cutting unit to machine.
12.Plug the 48 VDC battery disconnect back in before
operating the machine.

2. If removed, install the flange bushings (item 2) with
flange facing outward. Apply antiseize lubricant to inside
of flange bushing.

Antiseize
Lubricant

3. Apply antiseize lubricant to the bedbar threads and
the shoulder area of each bedbar pivot bolt.
4. Slide one metal washer (item 4) and one plastic
washer (item 3) onto each bedbar pivot bolt.

CAUTION
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when handling the bedbar.

Reelmaster 5010- H

Figure 22
1.
2.
3.
4.

Page 7 - 17

Cutting unit sideplate
Rubber bushing
Flange bushing
Washer (plastic)

5.
6.
7.
8.

Washer (metal)
Bedbar
Bedbar pivot bolt
Lock nut

Cutting Units

Cutting
Units

5. Position bedbar into cutting unit. Make sure that the
top of each bedbar arm is between washer (item 9) and
adjuster screw flange (item 10).

Bedknife Replacement and Grinding

3
Antiseize
Lubricant

200 to 250 in- lb
(23 to 28 N- m)

Lightly Oil
Bedbar Surface

Figure 23
1.

Screw (8 used)

2. Bedbar

3. Bedknife

Bedknife Removal
1. Remove bedbar from cutting unit (see Bedbar Assembly in this section).
2. Remove screws from bedbar using a socket wrench
and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar
(Fig. 23).
Bedknife Installation
1. Use scraper to remove all rust, scale and corrosion
from bedbar surface. Lightly oil bedbar surface before
installing bedknife.
2. Make sure that screw threads in bedbar
(5/16- 18UNC- 2A) are clean. Apply antiseize lubricant
to the threads of new screws. Take care to keep antiseize lubricant from taper on screw heads.

Cutting Units

Page 7 - 18

Figure 24
Top Face
Top Angle

IMPORTANT: Do not use an impact wrench to tighten screws into the bedbar.
3. Use new screws to secure bedknife to bedbar. Install
all screws but do not tighten fully. Then, using a torque
wrench and bedknife screw tool, torque screws from
200 to 250 in- lb (23 to 28 N- m). Use a torquing pattern
working from the center toward each end of the bedknife
(Fig. 24).

Remove
Burr
Front
Face
Front Angle

Figure 25

Reelmaster 5010- H

4. After installing bedknife to bedbar, grind bedknife.
Bedknife Grinding
Since there can be variations in the mounting surface of
the bedbar, a new bedknife will not be perfectly flat after
it is installed to the bedbar. Because of this, it is necessary to grind a new bedknife after installing it to the bedbar. Follow the existing angle that was ground into the
bedknife and grind only enough to make sure the top
surface of the bedknife is true (Fig. 25).
IMPORTANT: When grinding the bedknife, be careful to not overheat the bedknife. Remove small
amounts of material with each pass of the grinder.
Also, clean and dress grinding stone often during
the grinding process.

Bedknife Grinding Specifications (see Fig. 25)
Bedknife Top Angle

10o

Bedknife Front Angle

Extended Bedknife Front Angle

10o

0.250”
(6.4 mm)
1

1. Use Cutting Unit Operator’s Manual, Toro General
Service Training Book, Reel Mower Basics (part no.
09168SL) and grinder manufacturer’s instructions for
bedknife grinding information.
2. After grinding bedknife, check lead- in chamfer on
bedknife (see Cutting Unit Operator’s Manual).

0.060”
(1.5 mm)

Figure 26
1. Bedknife

2. Lead- in chamfer

3. After bedknife grinding is complete, install bedbar to
cutting unit (see Bedbar Assembly in this section).

Cutting
Units

NOTE: After grinding the reel and/or bedknife, check
the reel to bedknife contact again after cutting two (2)
fairways. During this initial use, any burrs will be removed from reel and bedknife which may create improper reel to bedknife clearance and thus accelerate wear.
This practice of re- checking the reel to bedknife contact
after grinding will extend the longevity of the sharpness
of the edge of the reel and the bedknife.

Reelmaster 5010- H

Page 7 - 19

Cutting Units

Bedbar Adjuster Service
Antiseize
Lubricant

14 to 16 ft- lb
(19 to 21 N- m)

Antiseize
Lubricant

4
3

7
6

1
9

15 to 20 ft- lb
(21 to 27 N- m)

RIGHT
FRONT

Figure 27
1.
2.
3.
4.

Bedbar assembly
Compression spring
Lock nut
Bedbar adjuster screw

Cutting Units

5.
6.
7.
8.

Keyed flange bushing (2 used)
Cap screw
Detent
Flat washer

Page 7 - 20

9.
10.
11.
12.

Lock nut
Bedbar adjuster shaft
Wave washer
Washer

Reelmaster 5010- H

Removal (Fig. 27)
1. Remove lock nut (item 3), compression spring (item
2) and washer (item 12) from bedbar adjuster screw
(item 4).
2. Remove bedbar (see Bedbar Assembly in this section).
NOTE: Inside threads in bedbar adjuster shaft (item 10)
are left- hand threads.
3. Unscrew bedbar adjuster screw (item 4) from the
bedbar adjuster shaft (item 10).
4. Remove bedbar adjuster shaft (item 10) from cutting
unit frame:
A. Remove lock nut and flat washer from adjuster
shaft.

2. If keyed flange bushings (item 5) were removed from
cutting unit frame, apply antiseize lubrication to bushing
bore in cutting unit frame. Align key on bushing to slot in
frame and slide bushing into frame.
3. Install bedbar adjuster shaft (item 10) to cutting unit
frame:
A. Slide wave washer onto bedbar adjuster shaft
and then slide adjuster shaft into keyed flange bushing in cutting unit frame.
B. Secure adjuster shaft with flat washer and lock
nut. Tighten lock nut to shoulder of adjuster shaft and
then torque lock nut from 15 to 20 ft- lb (21 to 27
N- m).
NOTE: Inside threads in bedbar adjuster shaft (item 10)
are left- hand threads.

B. Slide adjuster shaft and wave washer from cutting unit frame.

4. Apply antiseize lubricant to threads of bedbar adjuster screw (item 4) that fit into bedbar adjuster shaft (item
10). Thread bedbar adjuster screw into adjuster shaft.

5. Inspect keyed flange bushings (item 5) in cutting unit
frame and remove if necessary.

5. Install bedbar (see Bedbar Assembly in this section).

6. If detent (item 7) is damaged, remove it from cutting
unit side plate by removing the cap screw (item 6).
Installation (Fig. 27)

7. Adjust cutting unit (see Cutting Unit Operator’s
Manual).

Cutting
Units

1. If detent (item 7) was removed, secure detent to cutting unit side plate with cap screw. Torque cap screw
from 14 to 16 ft- lb (19 to 21 N- m).

6. Install washer (item 12), compression spring (item 2)
and lock nut (item 3) onto bedbar adjuster screw. Tighten the lock nut on each bedbar adjuster assembly until
the compression spring is fully compressed, then loosen
lock nut 1/2 turn.

Reelmaster 5010- H

Page 7 - 21

Cutting Units

Cutting Reel Assembly Removal and Installation

7” CUTTING REEL SHOWN
1
17

8
15

2
13

4
27 to 33 ft- lb
(37 to 44 N- m)

Antiseize
Lubricant
3

5
6

RIGHT

FRONT

Antiseize
Lubricant

10
11

Antiseize
Lubricant

Figure 28
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.

Lock nut (2 used)
RH side plate
LH side plate
Weight
Cap screw (2 used)
O- ring

13.
14.
15.
16.
17.
18.

Cutting reel assembly
Wire spring
Flange nut (3 used per side plate)
Shoulder bolt (3 used per side plate)
Cap screw (2 used)
O- ring

NOTE: This section provides the procedure for removing and installing the cutting reel assembly (cutting reel,
spline inserts, seals and bearings) from the cutting unit.
Refer to Reel Assembly Service later in this section for
information on replacing cutting reel seals and bearings.

Reel Assembly Removal (Fig. 28)

NOTE: Removal of the cutting reel requires removal of
the left side plate (item 9) from the cutting unit frame.
The right side plate (item 8) does not have to be removed from the frame.

Cutting Units

1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.

3. Remove the cutting unit from the machine and place
it on a flat work area.
Page 7 - 22
Reelmaster 5010- H

4. If cutting unit is equipped with a weight on LH side
plate, remove the two (2) flange nuts securing the
weight to the side plate and remove weight from the cutting unit. Remove and discard O- ring from weight.

7” CUTTING REEL

Antiseize
Lubricant
15 to 19 ft- lb
(20 to 25 N- m)

CAUTION
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when removing the cutting reel.

6. Remove the bedbar pivot bolt and washers from the
LH side plate. Note location of plastic and steel washers
for assembly purposes (see Bedbar Assembly in this
section).
7. Loosen fasteners that secure front and rear rollers to
LH side plate (see Front Roller and Rear Roller in this
section).
8. Remove cap screw and flat washer that secure rear
grass shield to LH side plate (Fig. 29 for 7” cutting units
or Fig. 30 for 5” cutting unit).

2
9
4

5
3

Loctite #242
27 to 33 ft- lb
(37 to 44 N- m)

4
7

Figure 29
1.
2.
3.
4.
5.

Carrier frame
Washer
Support tube
Frame spacer
Flat washer

6.
7.
8.
9.

Cap screw
Flange head screw
Rear grass shield
LH side plate

5” CUTTING REEL

Antiseize
Lubricant
15 to 19 ft- lb
(20 to 25 N- m)

9. Remove fasteners that secure frame spacer, washer(s) and carrier frame to LH side plate (Fig. 29 for 7” cutting units or Fig. 30 for 5” cutting unit). Note the number
of washers that exist between LH side plate and carrier
frame for assembly purposes.

10.Support cutting reel to keep it from shifting or falling.
NOTE: Side plates on 5” cutting reel attach to cutting
unit frame with two (2) shoulder bolts and flange nuts.
Side plates on 7” cutting reel use three (3) shoulder bolts
and flange nuts.

11. Remove shoulder bolts (item 8) and flange nuts (item
24) that secure the LH side plate to cutting unit frame.

12.Carefully remove the LH side plate from the reel
shaft, rollers, bedbar, carrier frame and cutting unit
frame. Locate and remove flat wire spring (item 14 in
Fig. 28).
13.Carefully slide the cutting reel assembly from the RH
side plate.

27 to 33 ft- lb
(37 to 44 N- m)

2
6

Figure 30
1.
2.
3.
4.
5.

14.Inspect and service cutting reel assembly (see Cutting Reel Assembly Service in this section).
Reelmaster 5010- H
Page 7 - 23

Carrier frame
Washer
Frame spacer
Flange head screw
Flange nut

6.
7.
8.
9.

LH side plate
Rear grass shield
Flat washer
Cap screw

Cutting Units

Cutting
Units

5. If cutting unit is equipped with an optional groomer or
rear roller brush, remove components for those options
from left hand side plate of cutting unit. See Service and
Repairs section of Chapter 9 - Groomer for information
on groomer disassembly. See Rear Roller Brush and
Rear Roller Brush Drive System in the Service and Repairs section of this chapter for information on rear roller
brush disassembly.

Reel Assembly Installation (Fig. 28)
1. Thoroughly clean side plates and other cutting unit
components. Inspect side plates for wear or damage
and replace if needed.

CAUTION

8. Apply antiseize lubricant to threads of cap screw that
secures rear grass shield to LH side plate (Fig. 29 for 7”
cutting units or Fig. 30 for 5” cutting unit). Install cap
screw and flat washer to secure rear grass shield to LH
side plate. Torque screw from 15 to 19 ft-lbs (20 to 25
N- m).
9. Secure the bedbar assembly to LH side plate (see
Bedbar Assembly in this section).

Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when installing the cutting reel.
2. Position the cutting unit on a flat work area. The rollers, bedbar, carrier frame and cutting unit frame should
be attached to RH side plate.
3. Apply a thin coat of antiseize lubricant to outside of
bearings on cutting reel.
4. Carefully slide the cutting reel assembly into the RH
side plate. Make sure that bearing is fully seated into
side plate.
5. Slide the LH side plate onto the cutting reel assembly, front roller and rear roller. Make sure that reel end
in RH side plate does not shift in position.
6. Install shoulder bolts (item 8) and flange nuts (item
24) that secure the LH side plate to the cutting unit
frame. Torque the shoulder bolts from 27 to 33 ft-lbs (37
to 44 N- m).
7. Secure carrier frame to LH side plate:

10.Secure front and rear rollers to LH side plate (see
Front Roller and Rear Roller in this section).
11. Adjust cutting unit (see Cutting Unit Operator’s
Manual).
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 the Set- Up and
Adjustments section of this Chapter).
12.If cutting unit is equipped with optional groomer or
rear roller brush, install components for those options to
left hand side plate of cutting unit. See Service and Repairs section of Chapter 9 - Groomer for information on
groomer assembly. See Rear Roller Brush and Rear
Roller Brush Drive System in the Service and Repairs
section of this chapter for information on rear roller
brush assembly.
13.Secure weight to cutting unit side plate with two (2)
cap screws. Torque screws from 27 to 33 ft-lbs (37 to
44 N- m).

A. For 7” cutting unit (Fig. 29), apply Loctite #242 (or
equivalent) to threads of flange head screw that secures support tube, frame spacer, removed washer(s) and carrier frame to LH side plate. Install screw
and torque screw from 27 to 33 ft-lbs (37 to 44
N- m).

14.Lubricate cutting unit grease fitting until grease
purges from relief valve in side plate with motor. Initial
greasing may require several pumps of a hand grease
gun.

B. For 5” cutting unit (Fig. 30), secure carrier frame,
frame spacer and removed washer(s) to LH side
plate with flange head screw and flange nut. Torque
screw from 27 to 33 ft-lbs (37 to 44 N- m).

16.Plug the 48 VDC battery disconnect back in before
operating the machine.

15.Install cutting unit to the machine.

C. After tightening flange head screw, check the
clearance between the carrier frame and side plate.
If clearance is more than 0.065” (1.7 mm), remove
flange head screw and position additional washer(s)
between carrier frame and side plate so that clearance is less than 0.065” (1.7 mm). Make sure that the
carrier frame pivots freely after assembly.

Cutting Units

Page 7 - 24

Reelmaster 5010- H

Cutting
Units

This page is intentionally blank.

Reelmaster 5010- H

Page 7 - 25

Cutting Units

Cutting Reel Assembly Service
4

6
7
1

7
Loctite #242
85 to 95 ft- lb
(115 to 128 N- m)
(Right Hand Threads)

6
5
4
3

RIGHT
Loctite #242
85 to 95 ft- lb
(115 to 128 N- m)
(Left Hand Threads)

FRONT

Figure 31
1. Cutting reel
2. Threaded insert (RH thread)
3. Bearing

4. Flocked seal
5. Special washer
6. Retaining ring

Disassembly of Cutting Reel (Fig. 31)
1. Remove threaded inserts (items 2 and 8) from cutting reel. The threaded insert with the groove on the face
has LH threads and is in end of reel shaft identified with
a groove that is just inside of reel spider (Fig. 32). Use
correct spline insert tool for insert removal (see Special
Tools in this chapter).
2. Slide bearings (item 3) from reel shaft.
3. Note orientation of flocked seals (item 4) for assembly purposes (flocked (red) side orientated toward bearing location). Remove flocked seals from reel shaft.
4. Note orientation of special washers (item 5) for assembly purposes (flat side toward bearing location).
Carefully drive special washers from reel shaft.

7. Reel shaft plug
8. Threaded insert (LH thread)

6. Discard removed components and replace during
cutting reel assembly.
Inspection of Cutting Reel (Fig. 31)
1. Check the threaded inserts for excessive wear or
distortion. Replace inserts if damage is evident.
2. Inspect the reel shaft as follows. If reel damage is detected, replace reel.
A. Check the reel shaft for bending and distortion by
placing the shaft ends in V- blocks.
B. Check the reel blades for bending or cracking.
C. Check the service limit of the reel diameter (see
Preparing a Reel for Grinding in this section).

5. If necessary, remove reel shaft plugs (item 7) from
reel shaft.
Page 7 - 26
Cutting Units

Reelmaster 5010- H

Assembly of Cutting Reel (Fig. 31)
4

1. If removed, install new reel shaft plugs into cutting
reel shaft. Plugs should be recessed into reel shaft from
1.370” to 1.630” (34.8 to 41.4 mm) (Fig. 33).

5
3

2. Install two (2) new retaining rings onto cutting reel
shaft. Make sure that the retaining rings are fully seated
into the grooves on the shaft.

1
2

3. Carefully drive special washers onto reel shaft with
beveled side of washers toward reel (flat side toward
bearing location). Installed washers should be tight
against retaining ring and should not wobble as the reel
is rotated.
IMPORTANT: The flocked seal should be installed
so the flocked (red) side of the seal is toward the
bearing location.
4. Slide flocked seals (flocked (red) side orientated toward bearing location) and bearings fully onto reel shaft.
Flocked seals and bearings should bottom on reel shaft
shoulder.

Figure 32
1. Cutting reel
2. Reel shaft groove
3. Insert with LH threads

NOTE: The threaded insert with the groove on the face
has LH threads and should be installed in end of reel
shaft identified with a groove that is just inside of reel spider (Fig. 32).

4. Groove on face
5. Insert with RH threads

2
1

5. Clean threads of threaded inserts and cutting reel
shaft. Apply Loctite #242 (or equivalent) to threads of inserts, thread inserts into reel shaft and torque from 85
to 95 ft-lb (115 to 128 N- m). Use correct spline insert
tool for insert installation (see Special Tools in this chapter).
6. Fill threaded insert splines with high temp Mobil
XHP- 222 grease or equivalent.
1.370” to 1.630”
(34.8 to 41.4 mm)

Figure 33
2. Reel shaft plug

Cutting
Units

1. Cutting reel shaft

Reelmaster 5010- H

Page 7 - 27

Cutting Units

Preparing Reel for Grinding
Three (3) types of cutting reel designs are used in cutting
units for Reelmaster 5010- H machines: scalloped radial reel, tapered radial reel and tapered forward swept
reel. The different types of individual reel blades are
shown in Figure 34. 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.

SCALLOPED RADIAL REEL

Before grinding a reel, make sure to identify the type of
reel design to make sure that grinding is correctly done.
NOTE: Before grinding a cutting reel, make sure that all
cutting unit components are in good condition. Depending on type of grinder used, faulty cutting unit components can affect grinding results.

TAPERED RADIAL REEL

NOTE: When grinding, be careful to not overheat the
cutting reel blades. Remove small amounts of material
with each pass of the grinder.
Follow reel grinder manufacturer’s instructions to grind
cutting reel to Toro specifications (see Reel Grinding
Specifications chart below). Additional reel grinding information can be found in your Cutting Unit Operator’s
Manual and the Toro General Service Training Book,
Reel Mower Basics (part no. 09168SL).
After completing the reel grinding process, adjust cutting unit (see Cutting Unit Operator’s Manual).

TAPERED FORWARD SWEPT REEL

2
1

Reel Grinding Specifications
Reel Diameter (New)
Service Limit Reel Diameter
Reel Shaft Diameter (OD)
Service Limit Reel Diameter Taper

5.060 in (128.5 mm) for 5” reel
7.060 in (179.3 mm) for 7” reel
4.500 in (114 mm) for 5”reel
6.600 in (168 mm) for 7” reel
1.313 in (33.3 mm)
0.010 in (0.25 mm) for both
5” and 7” reel (Fig. 35)

Blade Land Width

0.050 to 0.060 in (1.3 to 1.5 mm)

Blade Relief Angle

30o +/- 5o

Figure 34

NOTE: Relief grind of cutting reel blades is necessary
when blade land width exceeds 0.120” (3 mm).
NOTE: After grinding the reel and/or bedknife, check
the reel to bedknife contact again after cutting two (2)
fairways. During this initial use, any burrs will be removed from reel and bedknife which may create improper reel to bedknife clearance and thus accelerate wear.
This practice of re- checking the reel to bedknife contact
after grinding will extend the longevity of the sharpness
of the edge of the reel and the bedknife.

1. Blade land width

2. Blade relief angle

Reel Diameter Taper = D1 - D2

Figure 35
Cutting Units

Page 7 - 28

Reelmaster 5010- H

Cutting
Units

This page is intentionally blank.

Reelmaster 5010- H

Page 7 - 29

Cutting Units

Front Roller
Removal (Fig. 36)
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.

Loctite #242
Antiseize
Lubricant

2. Remove the cutting unit from the machine and place
on a level working surface. Use cutting unit kickstand
(see Special Tools in this chapter) to raise front roller
from work surface.

2
15 to 19 ft- lb
(20 to 26 N- m)
3

3. Loosen flange nut and cap screw securing the front
roller shaft to each front height- of- cut (roller) bracket.

4. On one of the height- of- cut (roller) brackets:

7
4

A. Remove flange lock nut and carriage screw that
secure bracket to the cutting unit side plate.
B. Remove the height- of- cut (roller) bracket from
the cutting unit.
5. Slide the front roller assembly from the remaining
height- of- cut (roller) bracket on the cutting unit.
6. If necessary, remove the second height- of- cut (roller) bracket from the cutting unit.
Installation (Fig. 36)
1. Place cutting unit on a level working surface and use
cutting unit kickstand (see Special Tools in this chapter)
to support cutting unit.
2. Inspect condition of cap screws (item 1) in both
height- of- cut (roller) brackets. Replace cap screw(s) if
necessary:
A. Place two (2) flat washers on cap screw and
thread flange lock nut onto cap screw to a position
0.750” (19 mm) from screw head.
B. Apply antiseize lubricant to cap screw threads
that will extend into height- of- cut (roller) bracket.
C. Thread cap screw into bracket.
NOTE: When assembling height- of- cut (roller) brackets to side plate, make sure that cap screw head and one
washer are above adjustment flange on side plate and
second washer and flange lock nut are below flange.

Loctite #242

Figure 36
1.
2.
3.
4.

Cap screw
Flat washer
Flange lock nut
HOC (roller) bracket

5.
6.
7.
8.

Carriage screw
Cap screw
Flange nut
Front roller assembly

4. Slide front roller shaft into bracket attached to the
cutting unit. Slide second height- of- cut (roller) bracket
onto the other end of roller shaft. Secure second bracket
to cutting unit side plate with carriage screw and flange
nut.
5. Apply Loctite #242 (or equivalent) to exposed
threads of cap screw (item 1) between flange of side
plate and position of flange lock nut (item 3) on cap
screw. Tighten flange lock nut on cap screw and then
loosen nut 1/4 to 1/2 turn. Cap screw should rotate freely
with little (if any) endplay after lock nut installation.
6. Apply Loctite #242 (or equivalent) to threads of two
(2) cap screws (item 6). Center front roller to the cutting
reel and secure in place with two (2) cap screws. Torque
cap screws from 15 to 19 ft- lb (20 to 26 N- m). Secure
cap screws with flange nuts.
7. Lubricate front roller grease fittings.
8. Adjust cutting unit (see Cutting Unit Operator’s
Manual).

3. If both front height- of- cut (roller) brackets were removed from cutting unit side plate, position one of the
brackets to side plate. Secure bracket to side plate with
carriage screw and flange lock nut.

Cutting Units

Page 7 - 30

Reelmaster 5010- H

Rear Roller
Removal (Fig. 37)

1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.

5
1

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.

3. Loosen two (2) flange nuts that secure the rear roller
shaft to each rear roller bracket.
4. On one of the rear roller brackets:
NOTE: On cutting units equipped with optional High
Height of Cut Kit, there will be additional roller shims
installed between rear roller bracket and cutting unit
side plate.

7
2

A. Remove flange nuts, washers and carriage
screws that secure rear roller bracket and roller
shims to the cutting unit side plate.

5. Slide the rear roller assembly from the remaining
rear roller bracket on the cutting unit.
6. If necessary, remove the second rear roller bracket
and roller shims from the cutting unit.
Installation (Fig. 37)
1. Place cutting unit on a level working surface.
NOTE: Refer to Cutting Unit Operator’s Manual for
number of roller shims required for various height of cut
settings.
NOTE: A 0.010” shim (part number 107- 4001) is available to allow for leveling of the rear roller (see Leveling
Rear Roller in the Set- up and Adjustments section of
this chapter). If necessary, this shim would be used on
one side of the rear roller and should be installed between the rear roller bracket and roller shim.

Figure 37
1.
2.
3.
4.

Rear roller assembly
Rear roller bracket
Carriage screw
Flange nut

5. Washer
6. Roller shim
7. 0.010” shim (if needed)

3. Slide rear roller shaft into the rear roller bracket attached to the cutting unit. Slide second rear roller bracket onto the other end of roller shaft. Secure second roller
bracket and shims to cutting unit side plate with two (2)
carriage screws, washers and flange nuts. Do not fully
tighten flange nuts.
4. Center rear roller to the cutting reel and secure in
place by tightening four (4) flange nuts.
5. Lubricate rear roller grease fittings.
6. Adjust cutting unit (see Cutting Unit Operator’s
Manual).

Cutting
Units

B. Remove the roller bracket and roller shims from
the rear roller and cutting unit.

2. If both rear roller brackets were removed from cutting
unit side plate, position brackets and roller shims to one
of the side plates. Install two (2) carriage screws and
flange nuts to retain bracket in position. Do not fully tighten flange nuts.

Reelmaster 5010- H

Page 7 - 31

Cutting Units

Roller Service
Disassembly (Fig. 38)
50 to 60 ft- lb
(68 to 81 N- m)

1. Remove bearing lock nut from each end of roller
shaft.

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

1
2

3. Carefully remove inner seal from both ends of roller
tube taking care to not damage tube surfaces.

4. Discard removed seals and bearings.

Loctite #242

5. Clean roller shaft and all surfaces on the inside of the
roller tube. Inspect components for wear or damage.
Also, carefully inspect seating surface and threads of
bearing lock nuts. Replace all damaged components.
Assembly (Fig. 38)

1. Install inner seals into roller tube making sure that
seal lip (and garter spring) faces end of tube. Use inner
seal tool (see Special Tools in this chapter) and soft face
hammer to fully seat seals against roller shoulder (Fig.
39). Apply a small amount of grease around the lip of
both inner seals after installation.

Figure 38
1.
2.
3.
4.

Roller tube
Roller shaft
Inner seal
Bearing

5. Outer seal
6. Bearing lock nut
7. Set screw

IMPORTANT: During assembly process, frequently
check that bearings rotate freely and do not bind. If
any binding is detected, consider component removal and reinstallation.
2. Install new bearing and outer seals into one end of
roller tube:
A. Position a new bearing into one end of roller tube.
Use bearing/outer seal tool (see Special Tools in this
chapter) with a soft face hammer to fully seat bearing
against roller shoulder (Fig. 40). After bearing installation, make sure that it rotates freely with no binding.

Figure 39
1. Roller tube
2. Inner seal

3. Inner seal tool

B. Apply a small amount of grease around the lip of
both outer seals.

3
4

C. Install first outer seal into roller tube making sure
that seal lip (and garter spring) faces end of tube.
Use bearing/outer seal tool (see Special Tools in this
chapter) and soft face hammer to lightly seat seal
against roller shoulder (Fig. 41). Make sure that
bearing still freely rotates after seal installation.
D. Using the same process, install second outer
seal making sure to not crush the installed outer seal.
Again, make sure that bearing still freely rotates.
Cutting Units

Figure 40
1. Roller tube
2. Inner seal

Page 7 - 32

3. Bearing
4. Bearing/outer seal tool

Reelmaster 5010- H

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. Install new bearing and outer seals into second end
of roller tube:

NOTE: After roller is installed to cutting deck, lubricate
roller grease fittings, rotate roller to properly distribute
grease in bearings and clean excess grease from roller
ends. A properly assembled roller should rotate with
less than 5 in- lbs (0.68 N- m) resistance.

A. Position a second new bearing to roller shaft and
tube. Position washer (see Special Tools in this
chapter) on bearing to allow pressing on both inner
and outer bearing races simultaneously.

B. Use washer and bearing/outer seal tool (see
Special Tools in this chapter) with a soft face hammer
to fully seat bearing (Fig. 42). After bearing installation, make sure that shaft freely rotates and that no
binding is detected. If necessary, lightly tap bearing
and/or shaft ends to align shaft and bearings. Remove washer from roller.
C. Apply a small amount of grease around the lip of
both outer seals.
D. Carefully install first outer seal into roller tube
making sure that seal lip (and garter spring) faces
end of tube. Use bearing/outer seal tool (see Special
Tools in this chapter) and soft face hammer to lightly
seat seal (Fig. 43). Make sure that shaft and bearings still freely rotate after seal installation.

Figure 41
1. Roller tube
2. Inner seal
3. Bearing

4. Outer seal
5. Bearing/outer seal tool

E. Using the same process, install second outer
seal making sure to not crush the installed outer seal.
Again, make sure that shaft and bearings still freely
rotate.
IMPORTANT: Make sure that all grease is removed
from shaft threads to prevent bearing lock nut loosening.

NOTE: If original bearing lock nut(s) are being used,
apply Loctite #242 (or equivalent) to threads of lock
nut(s).

Figure 42
1. Roller tube
2. Roller shaft
3. Inner seal

4. Bearing
5. Washer
6. Bearing/outer seal tool

6. Install bearing lock nut onto each end of the roller
shaft. Make sure that outer seals are not damaged during nut installation. Torque lock nuts from 50 to 60 ft- lb
(68 to 81 N- m).

5
6

7. If set screw was removed from either end of roller
shaft, apply Loctite #242 (or equivalent) to threads of removed set screw and install into roller shaft. Tighten set
screw until it bottoms in shaft and is recessed in shaft.
Figure 43
1. Roller tube
2. Roller shaft
3. Inner seal

Reelmaster 5010- H

Page 7 - 33

4. Bearing
5. Outer seal
6. Bearing/outer seal tool

Cutting Units

Cutting
Units

5. Thoroughly clean threads on both ends of roller
shaft.

Rear Roller Brush (Optional)

Grease
Seal Lip

22
21

20 to 25 in- lb
(2.3 to 2.8 N- m)

Antiseize
Lubricant

7
6

5
6

Grease
Seal Lip

11
12

RIGHT

Grease
Seal Lip

FRONT

2
8

27 to 33 ft- lb
(37 to 44 N- m)

9
13

Figure 44
1.
2.
3.
4.
5.
6.
7.
8.

Brush bearing housing (non- drive)
Brush bearing housing (drive)
O- ring
Roller brush shaft
Flange nut (4 used)
Mounting bracket (2 used)
Excluder seal (2 used)
Flat washer (4 used)

9.
10.
11.
12.
13.
14.
15.

Cap screw (4 used)
Spacer
Flat washer (for pulley alignment)
Driven pulley
Flange nut
Roller brush
Lock nut

NOTE: Drive components for the rear roller brush are
located on the opposite side of the cutting unit from the
cutting reel motor. Figure 44 shows components used
when the brush drive is on the left side of the cutting unit.
NOTE: The Installation Instructions for the rear roller
brush kit has detailed information regarding assembly
and adjustment. Use those Instructions along with this
Service Manual when servicing the rear roller brush.
Disassembly (Fig. 44)
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.

16.
17.
18.
19.
20.
21.
22.

J- bolt (2 used)
Grease fitting
Grease seal
Ball bearing
Grease fitting
Grease seal
Ball bearing

2. To prevent unexpected reel motor operation, disconnect motors from the electrical power supply by unplugging the 48 VDC battery disconnect (see 48 VDC
Battery Disconnect in the General Information section of
this chapter).
3. To remove roller brush from brush shaft:
A. Remove the non- drive brush bearing housing
(item 1) from cutting unit.
B. Slide excluder seal from roller brush shaft.
C. Remove lock nut and J- bolt from both ends of the
brush.
D. While rotating brush, slide brush from the shaft.

Cutting Units

Page 7 - 34

Reelmaster 5010- H

4. Disassemble roller brush components as necessary
using Figures 44 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

Assembly (Fig. 44)
1. If seals or bearings were removed from brush bearing housings, install new components noting proper orientation as shown in Figure 46.

B. Press bearing into bearing housing so that bearing contacts shoulder in housing bore.

20 to 25 in- lb
(2.3 to 2.8 N- m)

A. Pack bearings with high temp Mobil XHP- 222
grease (or equivalent) before installation.

Figure 45
1. Roller brush shaft
2. J- bolt

C. Install grease seals so that seal lips are positioned toward the brush location as shown in Fig. 46.
Press seals into housing so that seal contacts bore
shoulder.

3. Roller brush
4. Lock nut

2. If roller brush was removed from roller shaft, slide
brush onto shaft while rotating brush. Secure brush to
shaft with two (2) J- bolts and lock nuts. Make sure that
the J- bolts are installed with the threaded portion on the
outside of the brush (Fig. 45). Torque lock nuts from 20
to 25 in- lb (2.3 to 2.8 N- m).
3

3. Assemble roller brush components using Figure 44
as a guide noting the following items:
4

A. Apply coating of grease to lips of grease seals in
brush bearing housing before inserting brush shaft
into housing.
B. If driven pulley (item 12) was removed from roller
brush shaft, apply antiseize lubricant to splines of
pulley bore and slide pulley onto shaft. Install and
tighten flange nut until pulley is seated onto shaft and
then torque flange nut from 27 to 33 ft- lb (37 to 44
N- m). Use a ½ wrench on roller brush shaft flats to
prevent shaft from rotating when tightening nut.

Figure 46
1. Bearing
2. Inner grease seal
3. Outer grease seal

4. Housing (non- driven)
5. Housing (driven)

Cutting
Units

C. Position excluder seals on brush shaft so that
seals just touch bearing housings.
D. If driven pulley (item 12) was removed, check and
adjust alignment of drive and driven pulleys (see
Rear Roller Brush Drive System in this section).
4. Check that brush is parallel to rear roller with 0.060”
(1.5 mm) clearance to light contact with rear roller (Fig.
47). If contact is incorrect, brush operation will be adversely affected.
5. Lubricate grease fittings on brush housings until
grease purges past inboard seals. Wipe excess grease
from seals and fittings.
Reelmaster 5010- H

0.060” (1.5 mm)
Clearance to
Light Contact

2
Figure 47
1. Rear roller brush

Page 7 - 35

2. Rear roller

Cutting Units

Rear Roller Brush Drive System (Optional)

Loctite #242

15 to 19 ft- lb
(20 to 25 N- m)

2
4

6
9

10 to 15 ft- lb
(14 to 20 N- m)

10
6

2
Grease
Grommet ID

11
3

Loctite #242

RIGHT

13
15

14
6

15 to 19 ft- lb
(20 to 25 N- m)

20
18
8

17
16

Loctite #242

FRONT

22
6

12
35 to 40 ft- lb
(48 to 54 N- m)

Figure 48
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.
13.
14.
15.

Idler spring
Pivot washer
Drive belt
Idler pulley
Retaining ring
Bearing
Shoulder screw

NOTE: Drive components for the rear roller brush are
located on the opposite side of the cutting unit from the
cutting reel motor. Figure 44 shows components used
when the brush drive is on the left side of the cutting unit.
NOTE: The Installation Instructions for the rear roller
brush kit has detailed information regarding assembly
and adjustment. Use those Instructions along with this
Service Manual when servicing the rear roller brush.
Disassembly (Fig. 48)
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. To prevent unexpected reel motor operation, disconnect motors from the electrical power supply by unplugging the 48 VDC battery disconnect (see 48 VDC
Battery Disconnect in the General Information section of
this chapter).
Cutting Units

16.
17.
18.
19.
20.
21.
22.

Flange head screw
Drive pulley
Spacer
Flange bushing
Cover
Flange nut (2 used)
Set screw (top of cover only)

3. Remove cover (item 20) to access rear roller brush
drive components.
4. Remove roller brush drive components as necessary using Figure 48 as a guide.
5. Remove roller brush drive shaft if needed (Fig. 49):
A. Remove socket head screws that secure drive
housing to cutting unit side plate and remove housing from cutting unit.
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. 50).
B. Loosen and remove drive shaft from cutting reel.

Page 7 - 36

Reelmaster 5010- H

Assembly (Fig. 48)
85 to 95 ft- lb
(115 to 128 N- m)

1. Install drive shaft if it was removed (Fig. 49):
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. 50).

2
4

Loctite #242

A. Apply Loctite #242 (or equivalent) to threads of
drive shaft. Thread drive shaft into cutting reel and
torque from 85 to 95 ft- lb (115 to 128 N- m).
B. Make sure that O- ring is placed on inner flange of
drive housing.
C. Position housing to cutting unit side plate and secure to cutting unit with two (2) socket head screws.

3
1
4
5

NOTE: 5” CUTTING UNIT SHOWN

Figure 49
1. Drive housing
2. Drive shaft
3. O- ring

4. Socket head screw
5. Grommet

D. Make sure that grommet groove is correctly seated on flange in drive housing bore.
2. Assemble roller brush components using Figure 48
as a guide.

Drive Shaft
With RH Threads
(No Groove)

A. During assembly, apply Loctite #242 (or equivalent) to threads of fasteners and torque fasteners as
shown in Figure 48.
B. Apply a light coating of grease to inner diameter
of the grommet in drive bearing housing before installing brush plate.

Drive Shaft
With LH Threads
(With Groove)

C. Brush plate should be installed so that idler pulley
assembly is toward the bottom of the plate. Also, the
shoulder bolt (item 15) should not clamp the brush
plate to the drive housing during assembly.

Figure 50

D. When installing drive pulley (item 17), make sure
that tabs on pulley engage slot in drive shaft.

F. After drive belt installation, make sure that the
ribs on the belt are properly seated in the grooves of
both the drive and driven pulleys and that the belt is in
the center of the idler pulley.

Cutting
Units

E. Idler arm (item 7) should be free to rotate after assembly to brush plate. Make sure that idler spring is
installed so that it can rotate the idler arm and pulley
and apply tension to the drive belt.
2

3
Figure 51

1. Driven pulley
2. Drive pulley

Reelmaster 5010- H

Page 7 - 37

3. Straight edge

Cutting Units

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. 51).

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. 52).
C. If driven pulley was removed from roller brush
shaft, apply antiseize lubricant to splines of pulley
bore and slide pulley onto shaft. Install and tighten
flange nut until pulley is seated onto shaft and then
torque flange nut from 27 to 33 ft- lb (37 to 44 N- m).
Use a ½ wrench on roller brush shaft flats to prevent
shaft from rotating when tightening nut.

Antiseize
Lubricant
2

Figure 52
1. Flange nut
2. Driven pulley

3. Flat washer
4. Roller brush shaft

4. Check that brush is parallel to rear roller with 0.060”
(1.5 mm) clearance to light contact with rear roller. If contact is incorrect, brush operation will be adversely affected.
5. Install cover (item 20).There should not be a set
screw installed in the bottom of the cover.
6. Lubricate grease fittings on brush housings until
grease purges past inboard seals. Wipe excess grease
from seals and fittings.
7. Once all rear roller brush service is completed, plug
the 48 VDC battery disconnect back in before operating
the machine.

Cutting Units

Page 7 - 38

Reelmaster 5010- H

Groomer
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Groomer Kit Installation Instructions . . . . . . . . . . . 2
48 VDC Battery Disconnect . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 5
Groomer Reel Mechanical Problems . . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Groomer Height/Depth Adjustment . . . . . . . . . . . . 7
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Groomer Drive Assembly . . . . . . . . . . . . . . . . . . . . 8
Groomer Reel and Groomer Plate Assembly . . . 10
Groomer Reel Service . . . . . . . . . . . . . . . . . . . . . . 14
Height Adjuster Assembly . . . . . . . . . . . . . . . . . . . 16

Reelmaster 5010- H

Page 8 - 1

Groomer

Chapter 8

General Information
Groomer Kit Installation Instructions
The groomer kit installation instructions provides information regarding the installation, set- up and operation
of the optional groomer on your Reelmaster machine.
Refer to this publication for additional information when
servicing the groomer.

48 VDC Battery Disconnect

CAUTION

FRONT
1

Figure 1
1. RH frame rail

Groomer

Page 8 - 2

2. 48V battery disconnect

Reelmaster 5010- H

Special Tools
Groomer

Order Special Tools from your Toro Distributor. Some
tools may have been supplied with your machine or are
available as Toro parts.

Figure 2

Pulley Alignment Tool
Toro Part Number: 114- 5446
Use pulley alignment tool to verify alignment of groomer
drive and driven pulleys.

Figure 3

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- ofCut adjustment

Figure 4

Reelmaster 5010- H

Page 8 - 3

Groomer

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. READ AND UNDERSTAND THE GROOMER OPERATION INSTRUCTIONS BEFORE OPERATING OR TESTING GROOMER PERFORMANCE.
It is important to remember that factors affecting quality
of cut also affect grooming performance.
Variables That Affect the Use and Performance of
Groomers:
1. The growing season and weather conditions.
2. General turf conditions.
3. The frequency of grooming/cutting - number of cuttings per week and how many passes per cutting.
4. The height- of- cut.
5. The grooming depth.
6. The type of grass.
7. The amount of time that a groomer reel has been in
use on a particular turf area.
8. The amount of traffic on the turf.
9. The overall turf management program - irrigation,
fertilizing, weed control, coring, overseeding, sand
dressing, disease control and pest control.
10.Stress periods for turf - high temperatures, high humidity, unusually high traffic.

Groomer

Page 8 - 4

Reelmaster 5010- H

Groomer

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.

Failed groomer idler bearing(s) in
groomer side plate(s).

Replace faulty bearing(s).

Broken or damaged idler spring.

Replace spring.

The groomer drive belt is worn, bro- If the drive belt slips, it probably is
out of adjustment or worn.
ken or damaged.
Repair or replace drive belt if necessary. A broken or worn belt could
be the result of improper belt routing or seized bearings in groomer
assembly.

The turf is damaged or has uneven
grooming.

Reelmaster 5010- H

Grooming depth is too deep.

Change grooming depth.

Groomer drive shaft is loose in cutting reel.

Correctly tighten groomer drive
shaft. Replace drive shaft if threads
are faulty.

Groomer drive pulley square key is
damaged or missing.

Replace missing or damaged
square key.

Flange head screw that secures
groomer drive pulley is loose or
damaged.

Correctly tighten groomer drive pulley with existing flange head screw.
Replace screw if threads are faulty.

The groomer reel blades are bent,
damaged or missing.

Repair or replace blades if necessary.

The groomer reel shaft is bent or
damaged.

Replace groomer reel shaft.

Grooming depth is not equal on
both ends of groomer reel.

Adjust depth if necessary. Also,
check and adjust cutting unit set up
(level bedknife to reel, level rear
roller to reel, set height- of- cut,
etc.).

Page 8 - 5

Groomer

This page is intentionally blank.

Groomer

Page 8 - 6

Reelmaster 5010- H

Adjustments
Groomer

CAUTION
Never work on the groomer with the engine
running. Always stop the engine, remove the
key from the ignition switch and wait for all
machine movement to stop before working on
the groomer.
Also, before installing, removing or working on
the cutting units, disconnect the cutting units
from the electrical power supply by separating
the cutting unit power disconnect connector
(see 48 VDC Battery Disconnect in the General
Information section of this chapter).

Groomer Height/Depth Adjustment
NOTE: Grooming is performed above the soil level.
When adjusting groomer height/depth, groomer blades
should never penetrate the soil.
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.

6. Repeat step 5 on the opposite end of the groomer.
Then, recheck setting on the first side of groomer.
Height setting on both ends of groomer should be identical.
7. Plug the 48 VDC battery disconnect back in before
operating the machine.

3. Make sure rollers are clean and cutting unit is set to
the desired height- of- cut (see Cutting Unit Operator’s
Manual).
4. Place the groomer reel in the grooming (lowered)
position by rotating the quick- up levers toward the front
of the cutting unit (Fig. 5).
NOTE: Improper or over- aggressive 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 cautiously.
NOTE: Use the gauge bar assembly (see Special Tools
in this chapter) to determine groomer height.

Figure 5
1. Groomer height adjuster
2. Quick- up lever

3. Gauge bar assembly
4. Groomer height

5. Measure the distance from the lowest tip of the
groomer blade to the working surface. Turn groomer
height adjuster to raise or lower the groomer blade tip to
the desired height (Fig. 5).

Reelmaster 5010- H

Page 8 - 7

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.
Also, before installing, removing or working on
the cutting units, disconnect the electrical power supply by separating the 48 VDC battery disconnect (see 48 VDC Battery Disconnect in the
General Information section of this chapter).

Groomer Drive Assembly
22

7” CUTTING UNIT SHOWN

Antiseize
Lubricant
In Key Slot

21
3

27 to 33 ft- lb
(37 to 44 N- m)

6
5
4

17
1

15 10
Antiseize
Lubricant

19
8
7

16
14
13
12
11

75 to 90 in- lb
(8.5 to 10.1 N- m)

2
27 to 33 ft- lb
(37 to 44 N- m)

Loctite #242

Figure 6
1.
2.
3.
4.
5.
6.
7.
8.

Flange nut (2 used)
Groomer cover
Groomer drive belt
Flange head screw
Drive pulley
Square key
Lock nut
Retaining ring

Groomer

9.
10.
11.
12.
13.
14.
15.
16.

Ball bearing (2 used)
Idler pulley
Flange nut
Drive pulley
Washer (for pulley alignment)
Spacer
Groomer drive shaft
Groomer weight

Page 8 - 8

17.
18.
19.
20.
21.
22.
23.

Screw (2 used)
Flange nut (2 used)
Grommet
Set screw
Groomer plate
Pivot hub
Idler plate

Reelmaster 5010- H

Disassembly (Fig. 6)
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
2. To prevent unexpected reel motor operation, disconnect motors from the electrical power supply by unplugging the 48 VDC battery disconnect (see 48 VDC
Battery Disconnect in the General Information section of
this chapter).
NOTE: If cutting unit is equipped with powered rear roller brush, removal of roller brush components will be
necessary to replace groomer drive belt (see Rear
Roller Brush (Optional) in the Service and Repairs section of Chapter 7 - Cutting Units).
NOTE: When removing groomer cover, groomer
weight does not have to be removed from cover.
3. Remove two (2) flange nuts that secure groomer
cover, then remove cover.

NOTE: To prevent cutting reel from turning when installing drive pulley, block cutting reel with piece of wood.
3. If drive pulley (item 5) was removed, apply antiseize
lubricant to key slot in shaft. Place square key into shaft
slot. Slide drive pulley onto shaft and secure with flange
head screw. Torque screw from 27 to 33 ft- lb (37 to 44
N- m).
4. 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 13 in Figure 6) between pulley and pulley spacer. Do not use idler pulley
to check pulley alignment.
5. Install drive belt to drive pulley, idler pulley and driven
pulley observing correct belt routing (Fig. 7). Make sure
that groomer drive belt is above idler pulley after belt installation and also that the ribs on drive belt are seated
in grooves in each pulley.
6. Install groomer cover and secure with two (2) flange
nuts.
7. Plug the 48 VDC battery disconnect back in before
operating the machine.

4. Remove groomer drive belt tension by pivoting idler
plate and pulley using a wrench on pulley nut. Slip
groomer drive belt off pulleys. Carefully release idler
plate and pulley.
5. As needed, remove drive pulley (item 5), driven pulley (item 12) and idler pulley (item 10) using Figure 6 as
a guide.
1

NOTE: See Groomer Plate Assembly in this section for
information on removing and installing groomer plate
(item 21), pivot hub (item 22) or idler plate (item 23).
Assembly (Fig. 6)
1. If idler pulley (item 10) was removed, make sure that
bearings are in good condition before installing pulley.
Slide pulley assembly onto idler plate shaft and secure
with flange nut. Torque flange nut from 75 to 90 in- lb
(8.5 to 10.1 N- m).

2
Figure 7
1. Drive pulley
2. Driven pulley

3. Straight edge

NOTE: To prevent groomer shaft from turning when
installing driven pulley, use wrench on groomer shaft
flats.
2. If driven pulley (item 10) was removed, make sure
that spacer and washer(s) are on groomer shaft. Apply
antiseize lubricant to splines of drive pulley, slide pulley
onto groomer shaft and secure with flange nut. Torque
flange nut from 27 to 33 ft- lb (37 to 44 N- m).
Reelmaster 5010- H

Page 8 - 9

Groomer

NOTE: The groomer drive is located on the opposite
side of the cutting unit from the cutting reel motor. Figure
6 shows components used when the groomer drive is on
the left side of the cutting unit.

Groomer Reel and Groomer Plate Assembly

7” CUTTING UNIT SHOWN

Loctite #242
85 to 95 ft- lb
(115 to 128 N- m)

20
24
18

Antiseize
Lubricant

17 to 21 ft- lb
(23 to 28 N- m)

Loctite #242
13
6

15
7

Antiseize
Lubricant

22
Antiseize
Lubricant

20
12

Antiseize
Lubricant

RIGHT
FRONT

27 to 33 ft- lb
(37 to 44 N- m)

Loctite #242
85 to 95 ft- lb
(115 to 128 N- m)

13
16

8
10

Figure 8
1.
2.
3.
4.
5.
6.
7.
8.

Groomer reel
Pulley spacer
Washer (for pulley alignment)
Driven pulley
Flange nut
Excluder seal (2 used)
O- ring
Idler plate

9.
10.
11.
12.
13.
14.
15.
16.

Extension spring
Retaining ring
Socket head screw (2 used per hub)
Pivot hub (drive side)
O- ring (1 used per hub)
Groomer plate (drive side)
Groomer shim
Groomer drive shaft

NOTE: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel motor.
Figure 8 shows components used when the groomer
reel drive is on the left side of the cutting unit.
Removal (Fig. 8)
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch. Remove cutting unit from machine.
NOTE: If cutting unit is equipped with powered rear roller brush, removal of roller brush components will be
necessary to service groomer plate assemblies (see
Rear Roller Brush (Optional) in the Service and Repairs
section of Chapter 7 - Cutting Units).
Groomer

17.
18.
19.
20.
21.
22.
23.
24.

Pivot hub (non- drive side)
Groomer plate (non- drive side)
Reel threaded insert
Shoulder bolt
LH ball joint rod
Spacer
RH ball joint rod
Spacer

2. To remove groomer plate (item 14) from groomer
drive side of cutting unit:
A. Remove groomer belt cover, groomer drive belt,
drive pulley and driven pulley from cutting unit (see
Groomer Assembly in this section).
B. Slide washer(s) (item 3) and pulley spacer (item
2) from groomer shaft.
C. Remove shoulder bolt (item 20) that secures
quick- up ball joint rod to drive side groomer plate.
Locate and retrieve spacer from between ball joint
rod and groomer plate.
D. Disconnect idler extension spring (item 9) from
stud on groomer plate.

Page 8 - 10

Reelmaster 5010- H

DRIVE SIDE GROOMER PLATE

F. Remove pivot hub with attached idler plate assembly from cutting unit.
G. Support groomer shaft to prevent it from falling.
Carefully slide drive side groomer plate from groomer shaft and cutting unit. Remove groomer shim
(item 15).

14 to 18 ft- lb
(19 to 24 N- m)

Groomer

E. Remove two (2) socket head screws (item 11)
that secure pivot hub to cutting unit side plate.

1
5

3. Carefully pull the groomer reel from the non- drive
side groomer plate assembly.
4. To remove groomer plate (item 18) from groomer
non- drive side of cutting unit:
A. Remove shoulder bolt (item 20) that secures
quick- up ball joint rod to non- drive side groomer
plate. Locate and retrieve spacer from between ball
joint rod and groomer plate.
B. Remove two (2) socket head screws (item 11)
that secure pivot hub to cutting unit side plate.

Figure 9
1. Groomer plate
2. Bushing
3. Seal

4. Bearing
5. Groomer stud
6. Grease fitting

NON- DRIVE SIDE GROOMER PLATE

C. Remove pivot hub from cutting unit.
D. Support groomer shaft to prevent it from falling.
Carefully slide non- drive side groomer plate from
groomer shaft and cutting unit.

2
1

5. Inspect seals, bearings and bushings in groomer
plates. Remove and discard damaged components.

NOTE: See Groomer Reel Service in this section for information about groomer reel disassembly and assembly.

Installation (Fig. 8)

Figure 10

1. If seals, bearings or bushing was removed from either of the groomer plates, install new components noting proper orientation as shown in Figures 9, 10 and 11.

1. Groomer plate
2. Bushing
3. Seal

4. Bearing
5. Grease fitting

A. Press bushing into groomer plate until the bushing contacts the shoulder in the groomer plate bore.

B. Pack bearings with grease before installation.
C. Press bearings into groomer plate so that bearings contact shoulder in groomer plate bore.
D. Install grease seals so that seal lips are positioned toward the groomer blade location. Seals
should be flush with surface of groomer plate.
E. If groomer studs were removed from drive side
groomer plate and studs are being reinstalled, apply
Loctite #242 (or equivalent) to threads of studs. New
studs have patchlock on threads. Install studs into
groomer plate and torque from 14 to 18 ft- lb (19 to
24 N- m).
Reelmaster 5010- H

Figure 11
1. Drive side groomer plate
2. Non- drive groomer plate

Page 8 - 11

3. Bearing
4. Grease seal

Groomer

2. If removed, install groomer plate (item 18) to groomer non- drive side of cutting unit:
A. Position non- drive side groomer plate to cutting
unit side plate.
B. Slide O- ring onto pivot hub and then apply antiseize lubricant onto pivot hub flange. Position pivot
hub to groomer plate and cutting unit.
C. Secure pivot hub to cutting unit side plate with two
(2) socket head screws (item 11). Make sure that
groomer plate rotates freely after installation.
D. Apply antiseize lubricant to shoulder area of
shoulder bolt that secures quick- up ball joint rod to
non- drive side groomer plate and apply Loctite #242
(or equivalent) to threads of shoulder bolt. Position
spacer between ball joint rod and groomer plate. Install shoulder bolt and torque from 17 to 21 ft- lb (23
to 28 N- m).

E. Apply antiseize lubricant to shoulder area of
shoulder bolt that secures quick- up ball joint rod to
drive side groomer plate and apply Loctite #242 (or
equivalent) to threads of shoulder bolt. Position
spacer between ball joint rod and groomer plate. Install shoulder bolt and torque from 17 to 21 ft- lb (23
to 28 N- m).
F. Slide pulley spacer (item 2) and washer(s) (item
3) onto groomer shaft.
G. Install drive pulley, driven pulley and groomer
drive belt to cutting unit (see Groomer Assembly in
this section). Make sure that fasteners are correctly
torqued. Also, make sure that drive and driven pulley
alignment is checked and adjusted if necessary. Install groomer belt cover.

3. Make sure that O- ring (item 7) is on groomer reel
shaft and is lightly greased. Also, apply a light coat of
grease to lip of seal in installed groomer plate.
4. Make sure that excluder seals (item 6) and lightly
greased O- ring (item 7) are positioned on groomer
shaft. The excluder seal lips should be toward the end
of the groomer shaft. Apply a film of grease onto excluder seal lips.

5. Carefully slide the groomer reel into the non- drive
side groomer plate assembly taking care to not damage
seals in groomer plate assembly.
6. Carefully install groomer plate (item 14) to groomer
drive side of cutting unit:
A. Apply a light coat of grease to lips of seals in
groomer plate.

2
Figure 12
1. Drive pulley
2. Driven pulley

B. Position groomer shim to cutting unit side plate.
Carefully position drive side groomer plate onto
groomer shaft and slide to cutting unit.

3. Straight edge

1
2

C. Slide O- ring onto pivot hub and then apply antiseize lubricant onto pivot hub flange. Position pivot
hub with attached idler plate assembly to cutting unit
side plate and secure with two (2) socket head
screws (item 11). Make sure that groomer shim has
not shifted and that groomer plate rotates freely after
installation.
D. Connect extension spring (item 9) to stud on
groomer plate. Make sure that spring is in the stud
groove and that spring hook is positioned toward the
drive pulley location.

Groomer

Figure 13
1. Groomer plate
2. Excluder seal

Page 8 - 12

3. Groomer reel

Reelmaster 5010- H

8. Check groomer reel height and mower height- of- cut
settings. Adjust as needed.

Reelmaster 5010- H

9. Lubricate groomer bearings.
10.Install cutting unit back on machine.
NOTE: After greasing groomer bearings, operate
groomer for thirty (30) seconds, stop machine and wipe
excess grease from groomer shaft and seals.

Page 8 - 13

Groomer

7. Check that excluder seals just touch groomer plate
assembly (Fig. 13). Reposition excluder seals on
groomer shaft if needed. Excluder seal ID should be located on groomer shaft surface that is recessed slightly.

Groomer Reel Service

Figure 14
1. Groomer shaft
2. Lock nut (2 used)
3. Spacer (thick) (41 used)

4. Spacer (thin) (2 used)
5. Groomer blade (40 used)

Inspect groomer reel blades frequently for damage and
wear. Straighten bent blades with a pliers. Either replace
worn blades or reverse the blades to put the sharpest
blade edge forward (Fig. 15). Blades that are rounded
to the midpoint of the blade tip must be reversed or replaced for best groomer performance.

6. Broomer brush (5 used)
7. Broomer strap (4 used)

Disassembly (Fig. 14)
1. Remove groomer reel from cutting unit (see Groomer Reel in this section).
GROOMER
ROTATION

2. Remove excluder seals from groomer reel.
3. If groomer reel is equipped with broomer kit, remove
straps and broomer brushes from reel.
4. Remove lock nut from either end of the shaft.

Figure 15
1. Groomer blade
2. Sharp edge

5. Remove spacers and blades from groomer shaft. If
needed, remove second lock nut from shaft.

3. Dull (rounded) edge

CENTERED ON SHAFT

Assembly (Fig. 14)
1. Install lock nut on drive end of groomer shaft. Place
thick spacer, thin spacer and then first blade on shaft.
2. Alternately install thick spacers and blades making
sure that all blades are separated by a spacer.

3. When all blades have been installed, place thin
spacer and final thick spacer on shaft and then thread
second lock nut onto the shaft. Center blades on shaft
with lock nuts.

1.
2.
3.
4.

Groomer

4 5

Figure 16

Page 8 - 14

Groomer reel shaft
Groomer blade (40 used)
Thick spacer (41 used)
Thin spacer (2 used)

5. Lock nut (2 used)
6. Excluder seal
7. O- ring groove

Reelmaster 5010- H

4. Using wrench on shaft flats to prevent shaft from
turning, torque second lock nut from 375 to 425 in- lb
(43 to 48 N- m). After torquing lock nut, spacers should
not be free to rotate and groomer blades should be centered on shaft.

5. If groomer reel is equipped with broomer kit, position
broomer brushes to reel blades and secure with straps.
Straps should be wrapped around the groomer assembly as shown in Figure 17 and 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
1

6. Apply a film of grease onto excluder seal lips and
slide seals onto groomer shaft. Excluder seal ID should
be located on groomer shaft surface that is recessed
slightly.
7. Install O- ring on non- drive end of groomer shaft.

Groomer

Figure 17
1. Groomer shaft

2. Broomer strap

8. Install groomer reel back on cutting unit (see Groomer Reel in this section).
9. Check groomer reel height and mower height- of- cut
settings. Adjust as needed.
10.Lubricate groomer bearings.
11. Install cutting unit back on machine.
NOTE: After greasing groomer bearings, operate
groomer for thirty (30) seconds, stop machine and wipe
excess grease from groomer shaft and seals.

Reelmaster 5010- H

Page 8 - 15

Groomer

Height Adjuster Assembly
7” CUTTING UNIT SHOWN
18
17
19

17 to 21 ft- lb
(23 to 28 N- m)

Antiseize
Lubricant
12
11
10
9
8
7
13

6
5

RIGHT
FRONT

4
30 to 40 in- lb
(3.4 to 4.5 N- m)

1
15

Loctite #242

Figure 18
1.
2.
3.
4.
5.
6.
7.
8.

Groomer plate (drive side)
Shoulder bolt
Ball joint rod
Jam nut
Compression spring
Flange head screw
LH lower ramp
External snap ring

9.
10.
11.
12.
13.
14.
15.
16.

LH upper ramp
Bushing
Flat washer
Groomer adjuster
Detent spring
Washer head screw
Spacer
Groomer plate (non- drive side)

NOTE: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic
motor. Figure 18 shows components used when the
groomer reel drive is on the left side of the cutting unit.
Disassembly (Fig. 18)
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

17.
18.
19.
20.
21.
22.
23.
24.

RH lower ramp
RH upper ramp
Cap screw
Spacer
Spacer
Roll pin
Groomer plate
Lock nut

2. To prevent unexpected reel motor operation, disconnect motors from the electrical power supply by unplugging the 48 VDC battery disconnect (see 48 VDC
Battery Disconnect in the General Information section of
this chapter).
3. Disassemble height adjuster as needed using Figure
18 as a guide.
4. Clean all height adjuster components and inspect for
wear or damage. Replace all worn or damaged components.

Page 8 - 16

Reelmaster 5010- H

Assembly (Fig. 18)
5” CUTTING UNIT
FRONT

NOTE: On 7” cutting units, the ball joint rod on the cutting unit motor side is longer that the ball joint rod used
on the groomer drive side of the cutting unit. On 5” cutting units, the ball joint rods are identical.
A. If bushing (item 10) was removed from upper
ramp, press new bushing into housing fully to the
shoulder in the bore.

Groomer

1. Assemble height adjuster using Figure 18 as a guide
noting the following items:

1.320” to 1.440”
(3.4 to 3.6 mm)

B. If jam nuts (item 4) were removed from ball joint
rod, apply antiseize lubricant to threads of rod where
jam nuts will be positioned. Install jam nuts so that
distance from top of ball joint rod to bottom of lower
nut is from 3.190” to 3.310” (8.1 to 8.4 cm).
C. Apply antiseize lubricant to threads of ball joint
rod before installing groomer adjuster (item 12) onto
rod.
D. If detent spring (item 13) was removed, secure
detent spring to upper ramp with washer head screw.
Torque screw from 30 to 40 in- lb (3.4 to 4.5 N- m).
2. Apply antiseize lubricant to shoulder area of shoulder bolt that secures ball joint rod to groomer plate and
apply Loctite #242 (or equivalent) to threads of shoulder
bolt. Position spacer between ball joint rod and groomer
plate. Install shoulder bolt and torque from 17 to 21 ft- lb
(23 to 28 N- m).

Figure 19
1. Groomer handle
2. Compression spring

3. Upper jam nut

7” CUTTING UNIT
FRONT

1.320” to 1.440”
(3.4 to 3.6 mm)

3. Check groomer reel height and adjust as needed.
4. After groomer height has been adjusted, adjust location of jam nuts so compression spring length is from
1.320” to 1.440” (3.4 to 3.6 mm) when the groomer
handle is in the disengaged position (handle toward rear
of cutting unit) (shown in Fig. 19 For 5” cutting unit and
Fig. 20 For 7” cutting unit).
5. Plug the 48 VDC battery disconnect back in before
operating the machine.
Figure 20
1. Groomer handle
2. Compression spring

Reelmaster 5010- H

Page 8 - 17

3. Upper jam nut

Groomer

This page is intentionally blank.

Groomer

Page 8 - 18

Reelmaster 5010- H

Chapter 9

Foldout Drawings
Table of Contents

Reelmaster 5010- H

2
3
4

Foldout
Drawings

ELECTRICAL DRAWING DESIGNATIONS . . . . . . .
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . .
WIRE HARNESS DRAWINGS
Main Wire Harness Drawing . . . . . . . . . . . . . . . . . .
Main Wire Harness Diagram . . . . . . . . . . . . . . . . . .
Seat Wire Harness Drawing . . . . . . . . . . . . . . . . . .
Seat Wire Harness Diagram . . . . . . . . . . . . . . . . . .

6
7
8
9

Page 9 - 1

Foldout Drawings

Electrical Drawing Designations
The following abbreviations are used for wire harness
colors on the electrical schematics and wire harness
drawings in this chapter.
ABBREVIATION

COLOR

BLACK

BR or BN

BROWN

BLUE

GREEN

GRAY

ORANGE

PINK

R or RD

RED

TAN

VIO

VIOLET

W or WH

WHITE

Y or YE

YELLOW

Numerous harness wires used on Reelmaster machines include a line with an alternate color. These wires
are identified with the wire color and line color with either
a / or _ separating the color abbreviations listed above
(e.g. R/BK is a red wire with a black line, OR_BK is an
orange wire with a black line).
NOTE: The electrical harness drawings in this chapter
identify both the wire color and the wire gauge. For example, 16 BK on a harness diagram identifies a 16
gauge wire that has a black insulator.
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).

Foldout Drawings

Page 9 - 2

Reelmaster 5010- H

LIFT
CONTROL
MANIFOLD

POWER
STEERING
VALVE

Reelmaster 5010- H
Hydraulic Schematic
Page 9 - 3

Reelmaster 5010- H
Electrical Schematic
All relays and solenoids
are shown as de- energized.
All ground wires are black.

Page 9 - 4

NOTE: REFER TO ELECTRICAL DRAWING
DESIGNATIONS IN THIS CHAPTER FOR
WIRE COLOR ABBREVIATIONS.

This page is intentionally blank.

Page 9 - 5

Reelmaster 5010- H
Main Wire Harness Drawing
Page 9 - 6

NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE
SIZE AND WIRE COLOR. REFER TO ELECTRICAL
DRAWING DESIGNATIONS IN THIS CHAPTER
FOR ADDITIONAL INFORMATION.

Reelmaster 5010- H
Main Wire Harness Diagram
Page 9 - 7

NOTE CLOCK POSITION

Reelmaster 5010- H
Seat Wire Harness Drawing
Page 9 - 8

NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE
SIZE AND WIRE COLOR. REFER TO ELECTRICAL
DRAWING DESIGNATIONS IN THIS CHAPTER
FOR ADDITIONAL INFORMATION.

Reelmaster 5010- H
Seat Wire Harness Diagram
Page 9 - 9

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