Toro 5010-H User Manual
Part No. 15212SL
Service Manual
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.
Reelmaster
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.
R
5010- H
E The Toro Company - 2015
This page is intentionally blank.
Reelmaster 5010- H
Table Of Contents
Chapter 1 - Safety
Safety Instructions 1 - 2..........................
Jacking Instructions 1 - 5.........................
Safety and Instruction Decals 1 - 6................
Chapter 2 - Product Records and Maintenance
Product Records 2 - 1...........................
Maintenance 2 - 1...............................
Equivalents and Conversions 2 - 2................
Torque Specifications 2 - 3.......................
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 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 TORQMOTOR
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER- DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
TM
SERVICE PROCEDURE
Chapter 5 - Electrical System
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 6 - Chassis
Specifications 6 - 2..............................
General Information 6 - 2........................
Special Tools 6 - 3..............................
Service and Repairs 6 - 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.......................
SafetyProduct Records
and Maintenance
Engine
Kubota Diesel
System
Hydraulic
System
Chassis
Reelmaster 5010- H
Cutting Electrical
Units
This page is intentionally blank.
Reelmaster 5010- H
Table Of Contents (Continued)
Chapter 8 - Groomer
General Information 8 - 2........................
Special Tools 8 - 3..............................
Grooming Performance 8 - 4.....................
Troubleshooting 8 - 5............................
Adjustments 8 - 7...............................
Service and Repairs 8 - 8........................
Chapter 9 - Foldout Drawings
Electrical Drawing Designations 9 - 2..............
Hydraulic Schematic 9 - 3........................
Electrical Schematic 9 - 4........................
Wire Harness Drawings 9 - 6.....................
GroomerFoldout
Drawings
Reelmaster 5010- H
This page is intentionally blank.
Reelmaster 5010- H
Table of Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 3.............................
Maintenance and Service 4....................
JACKING INSTRUCTIONS 5.....................
SAFETY AND INSTRUCTION DECALS 6..........
Chapter 1
Safety
Safety
Reelmaster 5010- H Page 1 - 1 Safety
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 uponthe
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.
Before Operating
WARNING
To reduce the potential for injury or death, comply with the following safety instructions.
1. Review and understand the contents of the Operator’ s Manuals and Operator Training DVD before starting and operating the machine. Become familiar withthe
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.
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).
4. Since fuel is flammable, handle it carefully:
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 fueltank 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- HPage 1 - 2Safety
While Operating
1. Sit on the seat when starting and operating the machine.
2. Before starting the engine:
A. Apply the parking brake.
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.
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.
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 T raction
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.
4. Do not touch engine, radiator, exhaust system or hydraulic components while engine is running or soonafter
it is stopped. These areas could be hot enough to cause
burns.
5. Before getting off the seat:
A. Ensure that traction pedal is in NEUTRAL.
B. Lower and disengage cutting units. Wait for all
movement to stop.
C. Apply parking brake.
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.
Safety
Reelmaster 5010- H Page 1 - 3 Safety
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).
7. Use care when checking or servicing the cutting
units. Wear appropriate gloves and use caution when
servicing them.
8. T o reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
13.Before installing, removing or working on 48 VDC
system components (e.g. cutting units, motor/generator), separatesystem 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.
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.
10.To assure safety and accuracy, check maximum engine speed.
1 1.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 themachine. 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.
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.
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.
Reelmaster 5010- HPage 1 - 4Safety
Jacking Instructions
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 attachmentsthat may interfere with the safeand 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.
Front End Jacking (Fig. 1)
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.
Safety
2
1
Figure 1
1. Front wheel 2. Front jacking point
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. T o 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 yourReelmaster.
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.
Reelmaster 5010- HPage 1 - 6Safety
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1.........................
MAINTENANCE 1..............................
EQUIVALENTS AND CONVERSIONS 2...........
Decimal and Millimeter Equivalents 2............
U.S. to Metric Conversions 2...................
TORQUE SPECIFICATIONS 3...................
Fastener Identification 3.......................
Using a Torque Wrench with an Offset Wrench 3..
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) 4...............
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Series) 5..............
Other Torque Specifications 6..................
Conversion Factors 6.........................
Chapter 2
Product Records
and Maintenance
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
Reelmaster 5010- HPage 2 - 2Product Records and Maintenance
Torque Specifications
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.
Fastener Identification
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.
Product Records
and Maintenance
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
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.
Example: Themeasuredeffectivelengthofthetorque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
Themeasuredeffectivelengthofthetorquewrenchwith
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
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.
(effective length of
torque wrench)
A
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
T orque wrenchOffset wrench
Thecalculatedtorqueconversionfactorforthistorque
wrench with this offset wrench would be 18 / 19 = 0.947.
Reelmaster 5010- H Page 2 - 3 Product Records and Maintenance
Figure 3
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
#6- 32UNC
#6- 40UNF 17 + 2 192 + 23 25 + 3 282 + 34
#8- 32UNC
#8- 36UNF 31 + 4 350 + 45 43 + 5 486 + 56
# 10 - 24 UNC
#10- 32UNF 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 + 11 3 115 + 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
3/8 - 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
Grade 1, 5 &
8withThin
Height Nuts
in- lb in- lb N- cm in- lb N- cm in- lb N- cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
ft- lb ft- lb N- m ft- lb N- m ft- lb N- m
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
15 + 2 169 + 23 23 + 3 262 + 34
29 + 3 328 + 34 41 + 5 463 + 56
42 + 5 475 + 56 60 + 6 678 + 68
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
3/8 - 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8
7/16 - 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 - 20 UNF 29 + 3 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: 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.
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- HPage 2 - 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Thread Size
M5 X 0.8 57 + 6in-lb 644 + 68 N- cm 78 + 8in-lb 881 + 90 N- cm
M6 X 1.0 96 + 10 in- lb 1085 + 11 3 N - cm 133 + 14 in- lb 1503 + 158 N- cm
M8 X 1.25 19 + 2ft-lb 26 + 3N-m 28 + 3ft-lb 38 + 4N-m
M10 X 1.5 38 + 4ft-lb 52 + 5N-m 54 + 6ft-lb 73 + 8N-m
M12 X 1.75 66 + 7ft-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: 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.
Regular Height Nuts
(Class 8 or Stronger Nuts)
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately +
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10% of the
Product Records
and Maintenance
Reelmaster 5010- H Page 2 - 5 Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
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 + 3ft-lb
1/2 - 13 UNC 75 + 15 ft- lb 50 + 10 ft- lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 + 5in-lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non- lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5in-lb
Threads per Inch
Typ e A Type B
Recommended Torque**
65 + 10 ft- lb 88 + 14 N- m
80 + 10 ft- lb 108 + 14 N- m
80 + 10 ft- lb 108 + 14 N- m
80 + 10 ft- lb 108 + 14 N- m
Baseline Torque*
No. 8 - 32 UNC 30 + 5in-lb
No. 10 - 24 UNC 38 + 7in-lb
1/4 - 20 UNC 85 + 15 in- lb
5/16 - 18 UNC 110 + 20 in- lb
3/8 - 16 UNC 200 + 100 in- lb
Conversion Factors
in-lbX11.2985=N-cm N-cmX0.08851=in-lb
ft- lb X 1.3558 = N- m N- m X 0.7376 = ft- lb
No. 8 15 18 30 + 5in-lb
No. 10 12 16 38 + 7in-lb
No. 12 11 14 85 + 15 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.
Reelmaster 5010- HPage 2 - 6Product Records and Maintenance
Table of Contents
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
Chapter 3
Kubota Diesel Engine
Engine
Kubota Diesel
Reelmaster 5010- H Page 3 - 1 Kubota Diesel Engine
Specifications
Item Description
Make / Designation Kubota Model D1105- E4B: 4- Cycle, 3 Cylinder,
Number of Cylinders 3
Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm)
Total Displacement 68.5 in3(1123 cc)
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
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
Water Cooled, Tier 4 Diesel Engine
Low or Ultra Low Sulfur Content
High Idle Speed (no load) 3000 RPM
Engine Oil API CH- 4, CI- 4 or higher
Engine Oil V iscosity 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.
Reelmaster 5010- HPage 3 - 2Kubota Diesel Engine
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.
Traction Unit Operator’s Manual
The T raction 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
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.
Engine
Kubota Diesel
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
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.
1
1. RH frame rail 2. 48V battery disconnect
2
Figure 1
FRONT
Reelmaster 5010- H Page 3 - 3 Kubota Diesel Engine
Service and Repairs
Air Cleaner Assembly
3
5
3
7
1
10
8
9
11
12
13
14
6
2
3
12
16
17
15
30 to 40 in- lb
(3.4 to 4.5 N- m)
Thread
Sealant
3
4
30 to 40 in- lb
(3.4 to 4.5 N- m)
RIGHT
FRONT
1. Diesel engine
2. Air cleaner assembly
3. Hose clamp (4 used)
4. Air intake hose
5. Air intake hose
6. Service indicator
Figure 2
7. Indicator adapter
8. Shoulder bolt
9. Nut
10. Compression spring
11. Air cle aner mounting band
12. Flange nut (6 used)
12
13. Flange head screw (2 used)
14. Cap screw (2 used)
15. Flange head screw (2 used)
16. Air cleaner bracket
17. Air cleaner stand
Reelmaster 5010- HPage 3 - 4Kubota Diesel Engine
Removal (Fig. 2)
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.
12 to 15 in- lb
(1.4 to 1.6 N- m)
2
3. See Traction Unit Operator’s Manual for air cleaner
service and maintenance procedures.
Installation (Fig. 2)
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
arein good condition and are properly secured during assembly.
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).
B. Make sure that evacuator valve on air cleaner assembly is pointed down after assembly.
1
1. Air cleaner assembly
2. Service indicator
3
Thread
Sealant
Engine
Kubota Diesel
4
Figure 3
3. Indicator adapter
4. Evacuator valve
C. T orque 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
Exhaust System
11
12
13
14
15
16
RIGHT
FRONT
17
5
3
4
9
14
2
1
8
6
7
10
1. Diesel engine
2. Exhaust muffler
3. Clamp
4. Hex nut (2 used)
5. Flange nut (4 used)
6. Carriage bolt (4 used)
Figure 4
7. Bellhousing
8. Tailpipe bracket
9. Flange head screw
10. Flange nut
11. Exhaust header
12. Flange nut (4 used)
13. Exhaust gasket
14. Flange head screw (6 used)
15. Muffler guard
16. Washer head screw (2 used)
17. Muffler bracket
Reelmaster 5010- HPage 3 - 6Kubota Diesel Engine
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.
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.
3. Adjust muffler guard (item 15) on frame so there is
⅜” (9.5 mm) clearance between exhaust tailpipe and
guard in all directions.
4. After all exhaust components have been installed,
lower and secure hood.
D
C
B
A
Engine
Kubota Diesel
E
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.
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.
F
Figure 5
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
Fuel System
RIGHT
FRONT
9
12
17
16
15
18
7
6
8
19
12
4
3
5
3
14
20
2
1
11
10
1. Fuel tank
2. Fuel tank cap
3. Screw (7 used)
4. Strap
5. Sender cover
6. Hose clamp
7. Fuel supply hose
8. Hose clamp
9. Fuel return hose
10. Clamp (2 used)
11. Flange head screw (2 used)
12. Flange nut (3 used)
13. Draincock
14. Hose clamp
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.
13
Figure 6
15. Cap screw
16. Flat washer
17. Bumper
18. Fuel sender cap
19. Fuel sender
20. Gasket
Check Fuel Lines and Connections
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.
Reelmaster 5010- HPage 3 - 8Kubota Diesel Engine
IMPORTANT: Follow all local codes and regulations when recycling or disposing waste fuel.
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.
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 fuelin 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).
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).
A. If fuel sender was removed from fuel tank, make
sure that fuel fittings on sender are orientated at 90
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.
2. Correctly connect supply (item 7) and return (item 9)
fuel hoses to fittings on the top of thefuel 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
2
o
Engine
Kubota Diesel
NOTE: Before removing fuel hoses from tank fittings,
label hoses for assembly purposes.
IMPORTANT: T o 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.
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).
o
90
FRONT
1. Fuel sender
2. Fuel supply fitting
3
Figure 7
3. Fuel return fitting
Reelmaster 5010- H Page 3 - 9 Kubota Diesel Engine
Radiator Assembly
11
6
14
12
13
15
9
2
1
2
10
21
3
28
18
8
2
26
20
25
4
10
23
5
27
7
17
16
24
7
22
10
29
31
19
30
30 to 40 in- lb
(3.4 to 4.5 N- m)
1. Coolant reservoir
2. Hose clamp (3 used)
3. Hose
4. Foam seal (2 used)
5. Oil cooler
6. Hose
7. Hose clamp (4 used)
8. Foam seal (2 used)
9. Radiator cap
10. Flange nut (14 used)
11. Rear screen
Figure 8
12. Foam seal
13. Spacer (5 used)
14. Flange head screw (5 used)
15. Air intake screen
16. Draincock
17. Foam seal (2 used)
18. Radiator
19. Radiator frame
20. Reservoir bracket
21. Reservoir bracket
RIGHT
FRONT
22. Upper radiator hose
23. Lower radiator hose
24. Fan shroud
25. Flange head screw
26. Lock nut
27. Flange head screw (9 used)
28. Foam seal (2 used)
29. Foam seal (2 used)
30. Mount plate (2 used)
31. Washer head screw (6 used)
Reelmaster 5010- HPage 3 - 10Kubota Diesel Engine
Removal (Fig. 8)
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.
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.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
30 to 40 in- lb
(3.4 to 4.5 N- m)
RIGHT
FRONT
2
1. Fan shroud
2. Air cleaner intake hose
3. Hose clamp
3
4
30 to 40 in- lb
(3.4 to 4.5 N- m)
Figure 9
4. Generator intake hose
5. Hose clamp
1
5
Engine
Kubota Diesel
Ethylene- glycol antifreeze is poisonous. Dispose of coolant properly, orstore 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).
IMPORTANT: Follow all local codes and regulations when recycling or disposing engine coolant.
7. Disconnect air cleaner and motor/generator intake
hoses from fan shroud (Fig. 9).
8. Disconnect radiator hoses (upper and lower) from
the radiator.
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.
1 1.Carefully raise radiator assembly (radiator, fan
shroud, coolant reservoir and radiator frame) from the
machine.
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.
2. Remove plugs placed in radiator and hose openings
during the removal procedure.
3. Install all removed components to radiator frame using Figure 8 as a guide.
4. Carefully lower radiator assembly with radiator, fan
shroud, coolant reservoir and radiator frame to the machine frame.
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).
Reelmaster 5010- H Page 3 - 11 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).
9. Make sure radiator draincock is closed (threadedout
fully).
12.Carefully position and install oil cooler to radiator
frame. Rotate clamps to secure oil cooler to radiator
frame.
13.Install 12 volt battery (see 12 VDC Battery Service
in the Serviceand Repairs sectionof Chapter5 - Electrical System).
10.Fill radiator and coolant reservoir with coolant.
1 1.Lower and secure hood.
14.Install and latch rear screen.
Reelmaster 5010- HPage 3 - 12Kubota Diesel Engine
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