Toro 5210, 5410, 5510, 5610 User Manual
ReelmasterR5210/5410/5510/5610
Preface
The purposeof this publication is to provide theservice
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Reelmaster 5010 series: the 5210, 5410, 5510 and
5610.
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.
Part No. 06148SL (Rev. C)
Service Manual
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: ANOTE willgive generalinformation aboutthe
correct operation, maintenance, service, testing or repair of the machine.
TheToroCompanyreserves the right to changeproduct
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give im portantinstructionswhichmust befollowedto prevent damage to systems or components on the
machine.
E The Toro Company -- 2006, 2007, 2009, 2012
This page is intentionally blank.
Reelmaster 5010 Series
Table Of Contents
SafetyProduct Records
Chapter 1 -- Safety
Safety Instructions 1 -- 2..........................
Jacking Instructions 1 -- 4.........................
Safety and Instruction Decals 1 -- 4................
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
General Information 3 -- 1........................
Specifications 3 -- 2..............................
Adjustments 3 -- 5...............................
Service and Repairs 3 -- 6........................
KUBOTAWORKSHOPMANUAL:05SERIES DIESEL
ENGINE
Chapter 4 -- Hydraulic System
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Hydraulic Schematics 4 -- 7.......................
Hydraulic Flow Diagrams 4 -- 8....................
Special Tools 4 -- 18.............................
Troubleshooting 4 -- 22...........................
Testing 4 - - 28...................................
Service and Repairs 4 -- 58.......................
SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS REPAIR MANUAL
SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS SERVICE INSTRUCTIONS
PARKER TORQMOTOR
TM
SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
EATON DELTA MOTORS PARTS AND REPAIR
MANUAL
SAUER--DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Chapter 5 -- Electrical System
General Information 5 -- 1........................
Electrical Diagrams 5 -- 1.........................
Special Tools 5 -- 2..............................
Troubleshooting 5 -- 4............................
Electrical System Quick Checks 5 -- 18.............
Adjustments 5 -- 20..............................
Component Testing 5 -- 23........................
Service and Repairs 5 -- 46.......................
Chapter 6 -- Chassis
Specifications 6 -- 2..............................
General Information 6 -- 2........................
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 -- 11...................
Service and Repairs 7 -- 14.......................
Chapter 8 -- Groomer
Grooming Performance 8 -- 2.....................
Troubleshooting 8 -- 3............................
Adjustments 8 -- 4...............................
Service and Repairs 8 -- 5........................
Chapter 9 -- Foldout Drawings
Hydraulic Schematics 9 -- 3.......................
Electrical Schematics 9 -- 5.......................
Electrical Circuit Diagrams 9 -- 7...................
Wire Harness Drawings 9 -- 12....................
Turf Defender
TM
(Optional) Electrical Schematic9 -- 18
and Maintenance
Engine
Kubota Diesel
System
Hydraulic
System
Cutting Electrical
Units
Reelmaster 5010 Series
Rev. C
Groomer Chassis
Foldout
Drawings
This page is intentionally blank.
Reelmaster 5010 Series
Table of Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 2.............................
Maintenance and Service 3....................
JACKING INSTRUCTIONS 4.....................
SAFETY AND INSTRUCTION DECALS 4..........
Chapter 1
Safety
Safety
Reelmaster 5010 Series Page 1 -- 1 Safety
Rev. B
Safety Instructions
Reelmaster machines meet or exceed safety standard
specifications when weights are installed according to
information in the T raction 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 re-
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.
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 PTO switch is OFF (disengaged).
duce the potential for injury or death, comply with the
following safety instructions.
WARNING
To reduce the potential for injury or death,
complywiththefollowingsafetyinstructions.
4. Since diesel fuel is highly 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 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.
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 and
the PTO switch is OFF (disengaged).
C. 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.
4. Do not touch engine, radiator or exhaust system
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:
A. Ensure that traction pedal is in NEUTRAL.
B. Lower and disengage cutting units and wait for all
movement to stop.
C. Set parking brake.
D. Stop engine and remove key from ignition switch.
Rev. B
Reelmaster 5010 SeriesPage 1 -- 2Safety
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.
Maintenance and Service
7. Do not park on slopes unless wheels are chocked or
blocked.
Safety
1. Before servicing or making adjustments, lower cutting units, stop engine, apply parking brake and remove
key from the ignition switch.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
4. 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 syst em, all pressure in the system must be relieved by using all of the hydraulic controls (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 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.
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.Do not overspeed the engine by changing governor
setting. T oassure safety and accuracy, check maximum
engine speed with a tachometer.
1 1.Shut engine off before checking or adding oil to the
crankcase.
12.Disconnect battery 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.
13.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.
14.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
15.When changing attachments, tires or performing
other service, use correct blocks, hoists and jacks.
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).
16.If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
17.If welding on the machine is necessary, disconnect
the negative battery cable to prevent electrical system
damage.
18.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 Series Page 1 -- 3 Safety
Jacking Instructions
CAUTION
When changing attachments, tires or performing other service, use correct blocks, hoists
and jacks. Make sure machine is parked on a
solid, level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and
proper raising of the machine. Always chock
or block wheels. Use jack stands or other appropriate load holding devices to support the
raised machine. 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
1
Figure 1
1. Front wheel 2. Front jacking point
2. Position jack securely 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
wheel as possible to support the machine.
Rear End Jacking (Fig. 2)
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. Position jack stands under the frame to support the
machine.
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.
2
1
Figure 2
1. Axle center 2. Jack stand location
Rev. B
Reelmaster 5010 SeriesPage 1 -- 4Safety
Product Records and Maintenance
Table of Contents
Chapter 2
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..........................
Product Records
Insert Operator’s Manuals and Parts Catalogs for your
Reelmaster at the end of this chapter. Additionally, if any
optional equipment or accessories have been installed
to your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options
at the end of this chapter.
Product Records
and Maintenance
Maintenance
Maintenance procedures and recommended service intervals for your Reelmaster are covered in the Traction
Unit and Cutting Unit Operator’s Manuals. Refer to
those publications when performing regular equipment
maintenance.
Reelmaster 5010 Series Page 2 -- 1 Product Records and Maintenance
Rev. B
Equivalents and Conversions
0.09375
Reelmaster 5010 SeriesPage 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 s hall 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 s imilar 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 ofan 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: 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”.
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
Torque wrenchOffset wrench
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Reelmaster 5010 Series Page 2 -- 3 Product Records and Maintenance
Rev. B
Figure 3
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
# 6 -- 32 UNC
# 6 -- 40 UNF
# 8 -- 32 UNC
# 8 -- 36 UNF
#10--24UNC
#10--32UNF
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 11 5 + 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
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
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.
Rev. B
Reelmaster 5010 SeriesPage 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 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 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm
M6 X 1.0 96 + 10 in--lb 1085 + 113 N - -c m 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: 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.
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.
10% ofthe
Product Records
and Maintenance
Reelmaster 5010 Series 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
Type A Typ e 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--lb X 11.2985 = N--cm N--cm X 0.08851 = 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
* Holesize, 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 SeriesPage 2 -- 6Product Records and Maintenance
Table of Contents
Chapter 3
Kubota Diesel Engine
GENERAL INFORMATION 1.....................
Traction Unit Operator’s Manual 1...............
Stopping the Engine (Reelmaster 5610) 1........
SPECIFICATIONS 2............................
Reelmaster 5210 2............................
Reelmaster 5410 and 5510 3...................
Reelmaster 5610 4............................
ADJUSTMENTS 5..............................
Adjust Throttle Control 5.......................
General Information
This Chapter gives information about specifications,
troubleshooting, testing and repair of the Kubota diesel
engine used in the Reelmaster 5010 Series of 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 service 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 REPAIRS 6......................
Fuel System 6................................
Air Cleaner 8.................................
Exhaust System 10...........................
Radiator 12..................................
Engine 14....................................
KUBOTA WORKSHOP MANUAL: 05 SERIES DIESEL
ENGINE
Service and repair parts for Kubota diesel engines are
supplied through your local Toro Distributor. If a parts list
is not available, be sure to provide your distributor with
the Toro model and serial number.
Engine
Kubota Diesel
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. Refer to that publication for additional information when servicing the machine.
Stopping the Engine (Reelmaster 5610)
IMPORTANT: The engine used on the Reelmaster
5610 is turbo--charged. Before stopping the engine
after mowing or full load operation on Reelmaster
5610 machines, cool the turbo-charger by allowing
the engine to idle at low speed for 5 minutes.Failure
to do so may lead to turbo-charger trouble.
Reelmaster 5010 Series Page 3 -- 1 Kubota Diesel Engine
Specifications: Reelmaster 5210
Item Description
Make / Designation Kubota D1105, 4-- stroke,
Number of Cylinders 3
Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm)
Total Displacement 68.53 in3(1123 cc)
Compression Ratio 22.0:1
Firing Order 1 (fan end) -- 2 -- 3 (flywheel end)
Dry Weight (approximate) 205 lb. (93 kg)
Fuel No. 2--D Diesel Fuel (ASTM D975)
Fuel Injection Pump Bosch MD Type Mini
Fuel Injector Nozzle Mini Nozzle (DNOPD)
Fuel Tank Capacity 14 U.S. Gallons (53 Liters)
Governor Centrifugal Mechanical
Low Idle Speed (no load) 1200 to 1300 RPM
Liquid Cooled, OHV Diesel
High Idle Speed (no load) 3050 to 3250 RPM
Engine Oil API Classification CH--4, CI--4 or Higher
Oil Pump Gear Driven Trochoid Type
Crankcase Oil Capacity 4.0 U.S. Quarts (3.8 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
(see Traction Unit Operator’s Manual for viscosity recommendations)
Reelmaster 5010 SeriesPage 3 -- 2Kubota Diesel Engine
Specifications: Reelmaster 5410 and 5510
Item Description
Make / Designation Kubota V1505, 4-- stroke,
Liquid Cooled, OHV Diesel
Number of Cylinders 4
Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm)
Total Displacement 91.4 in3(1498 cc)
Compression Ratio 21.0:1
Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2
Dry Weight (approximate) 242 lbs (110 kg)
Fuel No. 2--D Diesel Fuel (ASTM D975)
Fuel Injection Pump Bosch MD Type Mini
Fuel Injector Nozzle Mini Nozzle (DNOPD)
Fuel Tank Capacity 14 U.S. Gallons (53 Liters)
Governor Centrifugal Mechanical
Low Idle Speed (no load) 1200 to 1300 RPM
Engine
Kubota Diesel
High Idle Speed (no load) 3050 to 3250 RPM
Engine Oil API Classification CH--4, CI--4 or Higher
Oil Pump Gear Driven Trochoid Type
Crankcase Oil Capacity 6.3 U.S. Quarts (6 Liters) with Filter
Cooling System Capacity (including reserve tank) 7 U.S. Quarts (6.6 Liters)
Starter 12 VDC 1.4 KW
Alternator/Regulator 12 VDC 40 Amp
(see Traction Unit Operator’s Manual for viscosity recommendations)
Reelmaster 5010 Series Page 3 -- 3 Kubota Diesel Engine
Specifications: Reelmaster 5610
Item Description
Make / Designation Kubota V1505, 4-- stroke,
Number of Cylinders 4
Bore x Stroke 3.07” x 3.09“ (78 mm x 78.4 mm)
Total Displacement 91.4 in3(1498 cc)
Compression Ratio 21.0:1
Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2
Dry Weight (approximate) 251 lbs (114 kg)
Fuel No. 2--D Diesel Fuel (ASTM D975)
Fuel Injection Pump Bosch MD Type Mini
Fuel Injector Nozzle Mini Nozzle (DNOPD)
Fuel Tank Capacity 14 U.S. Gallons (53 Liters)
Governor Centrifugal Mechanical
Low Idle Speed (no load) 1200 to 1300 RPM
Liquid Cooled, OHV, Turbocharged Diesel
High Idle Speed (no load) 3050 to 3250 RPM
Engine Oil API Classification CH--4, CI--4 or Higher
Oil Pump Gear Driven Trochoid Type
Crankcase Oil Capacity 5 U.S. Quarts (4.7 Liters) with Filter
Cooling System Capacity (including reserve tank) 10 U.S. Quarts (9.5 Liters)
Starter 12 VDC 1.4 KW
Alternator/Regulator 12 VDC 40 Amp
(see Traction Unit Operator’s Manual for viscosity recommendations)
Reelmaster 5010 SeriesPage 3 -- 4Kubota Diesel Engine
Adjustments
Adjust Throttle Control
Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is
operating properly.
NOTE: The throttle cable swivel should be positioned
in the lowest hole in the speed control lever .
1. Move throttle control lever on control console to
FAST position.
2. Check position of the engine speed control lever on
fuel injection pump. The speed control lever should be
contacting the high speed screw when the throttle control lever is in the FAST position.
3. If necessary, throttle control can be adjusted by loosening cable clamp screw and repositioning control cable
until speed control lever contacts high speed screw
when the throttle control lever is in the FAST position.
Tighten cable clamp screw after adjustment has been
completed.
5
1. Throttle cable
2. High speed screw
3. Speed control lever
1
4
Figure 1
2
4. Swivel
5. Cable clamp
Engine
3
Kubota Diesel
Reelmaster 5010 Series Page 3 -- 5 Kubota Diesel Engine
Service and Repairs
Fuel System
8
15
7
2
1
12
11
RIGHT
FRONT
1. Fuel cap
2. Bushing
3. Washer head screw (3 used)
4. Flange nut (3 used)
5. Clamp (3 used)
6. Return fitting
16
6
9
2
3
5
13
14
4
3
10
3
5
4
Figure 2
7. Suction fitting
8. Hose clamp
9. Hose clamp
10. Fuel tank
11. Grommet
12. Fuel gauge
13. Hose clamp
14. Draincock
15. Fuel hose
16. Return fuel hose
Reelmaster 5010 SeriesPage 3 -- 6Kubota Diesel Engine
Fuel Tank Removal (Fig. 2)
DANGER
Because diesel fuel is highly flammable, use
caution when storing or handling it. Do not
smoke while filling the fuel tank. Do not fill fuel
tank while engine is running, when engine is hot
or when machine is in an enclosed area. Always
fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a
clean, safety--approved container and keep container cap in place. Use diesel fuel for the engine
only; not for any other purpose.
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.
To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of all contaminates and debris.
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.
NOTE: Before removing fuel hoses from tank fittings,
label hoses for assembly purposes.
4. Loosen hose clamps and disconnect fuel hoses from
suction (item 7) and return (item 6) fittings on the top of
the fuel tank.
5. Remove fuel tank using Figure 2 as a guide.
Fuel Tank Installation (Fig. 2)
1. Install fuel tank to frame using Figure 2 as a guide.
2. Correctly connect fuel hoses to suction (item 7) and
return (item 6) fittings on the top of the fuel tank. Secure
fuel hoses with hose clamps.
3. Make sure that fuel tank draincock is closed. Fill fuel
tank.
Engine
Kubota Diesel
Reelmaster 5010 Series Page 3 -- 7 Kubota Diesel Engine
Air Cleaner
REELMASTER 5410--D/5510--D SHOWN
7
11
RIGHT
FRONT
16
11
2
3
4
6
5
THREAD
SEALANT
1
13
11
12
9
15
12
10
14
11
8
12
1. Air cleaner assembly
2. Hex nut
3. Bolt
4. Spring
5. Indicator
6. Adapter
7. Hose
8. Hose
9. Mount bracket
10. Air cleaner stand
11. Ho se cla mp
NOTE: The models in the Reelmaster 5010 Series
have a very similar air cleaner system. The air cleaner
removal and installation procedure is the same for all
models.
Figure 3
12. Flange nut
13. Cap screw (2 used)
14. Flange head screw (4 used)
15. Flange head screw (2 used)
16. Air cleaner mounting band
Reelmaster 5010 SeriesPage 3 -- 8Kubota Diesel Engine
Removal (Fig. 3)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch. Raise hood.
2. Remove air cleaner components as needed using
Figures 3, 4 and 5 as guides.
3. See Traction Unit Operator’s Manual for air cleaner
service and maintenance procedures.
Installation (Fig. 3)
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 Figures 3, 4 and
5 as guides.
A. If indicator and adapter were removed from air
cleaner housing, apply thread sealant to adapter before installing adapter and indicator to housing.
B. Make sure that vacuator valve is pointed down after assembly.
REELMASTER 5610--D
10
9
8
6
7
6
5
Figure 4
1. Air cleaner assembly
2. Mounting band
3. Adapter
4. Indicator
5. Hex nut
6. Hose clamp
7. Hose
11
8. Spacer
9. Hose
10. Hose
11. Ho se cla mp
12. Bolt
13. Spring
11
12
13
1
2
3
4
Engine
Kubota Diesel
4
1. Mounting band
2. Cover
3. Vacuator valve
5
1
Figure 5
2
3
4. Adapter
5. Indicator
Reelmaster 5010 Series Page 3 -- 9 Kubota Diesel Engine
Exhaust System
REELMASTER 5410--D/5510--D SHOWN
17
3
10
20
5
RIGHT
FRONT
1. Gasket
2. Lock washer (4 used)
3. Flange nut (4 used)
4. Cap screw (4 used)
5. Carriage screw (4 used)
6. Flange nut (4 used)
7. Lock washer
11
12
2
4
14
19
13
16
15
6
9
8. Cap screw
9. Isolator plate
10. Hex nut (2 used)
11. Cl amp
12. Flange nut (2 used)
13. Flat washer (2 used)
14. Cap screw (2 used)
6
12
7
8
4
16
13
14
Figure 6
2
1
18
5
15. Rubber hanger
16. Spacer (2 used)
17. Exhaust header
18. Support bracket
19. Tail pipe bracket
20. Muffler
NOTE: The models in the Reelmaster 5010 Series
have a very similar exhaust system. The exhaust system removal and installation procedure is the same for
all models.
Reelmaster 5010 SeriesPage 3 -- 10Kubota Diesel Engine
Removal (Fig. 6)
Installation (Fig. 6)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch. Raise hood.
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.
2. Remove exhaust system using Figure 6 as a guide.
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Place new muffler gasket on the exhaust manifold.
Install exhaust pipe to manifold and secure with four (4)
flange nuts.
IMPORTANT: Finger tighten all exhaust system fasteners before tightening so that there is no preload
on the exhaust system due to exhaust system assembly.
2. Install exhaust system to the engine using Figure 6
as a guide. Finger tighten all fasteners until all exhaust
system components have been installed. Then, fully
tighten fasteners to secure exhaust system.
Engine
Kubota Diesel
Reelmaster 5010 Series Page 3 -- 11 Kubota Diesel Engine
Radiator
2
3
11
28
38
2
1
20
4
29
13
10
34
23
24
33
8
21
5
16
13
26
16
13
25
16
1. Overflow bottle
2. Hose clamp (3 used)
3. Hose
4. Foam seal (2 used)
5. Foam seal (2 used)
6. Foam seal (2 used)
7. Oil cooler
8. Foam seal (2 used)
9. Flat washer (8 used)
10. Hose clamp (4 used)
11. Foam seal (2 used)
12. Flange nut (4 used)
13. Flange nut (22 used)
14. Oil cooler mount plate (2 used)
15. Oil cooler clamp (16 used)
6
22
40
12
27
5
16
30
16. Hose clamp (4 used)
17. Cap screw (4 used)
18. Clamp (2 used)
19. Cap screw (2 used)
20. Washer (4 used)
21. Radiator
22. Radiator frame
23. Reservoir bracket
24. Bracket
25. Hose
26. Hose
27. Fan shroud
28. Hose (2 used)
29. Rivet (2 used)
30. Flange head screw (9 used)
2
41
43
37
17
6
Figure 7
32
8
42
30
44
19
18
12
19
31
20
36
4
11
13
15
35
9
39
15
13
15
7
14
9
RIGHT
FRONT
31. Draw latch
32. Washer head screw (6 used)
33. Flange head screw
34. Lock nut
35. Cap screw (4 used)
36. Screen
37. Intake screen
38. Hose
39. Oil cooler bracket
40. Foam seal
41. Draincock
42. Radiator cap
43. Spacer (5 used)
44. Flange head screw (5 used)
NOTE: Three (3) radiators are used on Reelmaster
5010 series machines. Reelmaster 5410 and 5510 machines use the same radiator. Reelmaster 5210 and
5610 machines use different radiators. All models use
a similar procedure for radiator removal and installation.
Removal (Fig. 7)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Raise the hood.
Reelmaster 5010 SeriesPage 3 -- 12Kubota Diesel Engine
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
3. Drain coolant from radiator.
3. Secure fan shroud and radiator to radiator frame with
removed flange head screws and flange nuts. Make
sure that at least .250” (6.4 mm) clearance exists at all
points between shroud opening and fan.
4. Position coolant reservoir and brackets to the fan
shroud. Secure reservoir to fan shroud and radiator
frame with two (2) flange head screws and flange nuts.
5. Place spacers (item 43) into holes in foam seal (item
42). Position foam seal and air intake screen (item 37)
to radiator frame. Secure screen to machine with five (5)
flange head screws and flange nuts.
A. Slowly remove radiator cap from the radiator.
B. Place drain pan below the radiator draincock located on the bottom of the radiator. Make sure that
drain pan is large enough to hold cooling system contents (see Specifications in this Chapter).
C. Loosen draincock and allow coolant to drain from
radiator.
4. Remove screen from machine.
5. Disconnect radiator hoses (upper and lower) from
the radiator.
6. Loosen hose clamp and remove overflow hose from
radiator fill opening.
7. Remove two (2) flange head screws and flange nuts
that secure coolant reservoir and brackets to fan
shroud. Carefully position reservoir and brackets away
from the fan shroud.
8. Remove five (5) flange head screws and flange nuts
that secure air intake screen (item 37) to machine. Remove screen and foam seal (item 42). Locate and retrieve five (5) spacers (item 43).
6. Connect upper and lower radiator hoses to radiator
and secure with clamps.
7. Connect overflow hose to radiator fill opening and
secure with hose clamp.
8. Make sure radiator draincock is closed (threaded out
fully). Fill radiator with coolant.
9. Lower hood. Install screen to rear of machine.
6
1
2
REELMASTER 5610
5
3
5
4
Engine
Kubota Diesel
9. Remove flange head screws and flange nuts that secure fan shroud and radiator to radiator frame. Position
fan shroud away from the radiator.
10.Carefully pull radiator assembly from the machine.
Plug radiator and hose openings to prevent contamination.
6
5
6
1 1.Inspect all foam seals placed between radiator, fan
shroud and radiator frame. Replace damaged foam
seals.
Installation (Fig. 7)
1. Remove plugs placed in radiator and hose openings
1. Radiator (RM 5610)
2. Fan shroud
3. Radiator frame
Figure 8
4. Flange head screw
5. Flange head screw
6. Flange nut
during the removal procedure.
2. Carefully position radiator assembly to the radiator
support. Position fan shroud to the radiator.
Reelmaster 5010 Series Page 3 -- 13 Kubota Diesel Engine
Engine
34 to 42 ft--lb
(47to56N--m)
3
26
11
18
24
25
19
20
16
2
7
17
23
14
10
15
5
4
1
7
23
25
5
13
26
9
6
27
8
21
23
5
2
12
27
4
22
9
4
RIGHT
FRONT
1. Engine assembly
2. Cap screw (12 used)
3. Temperature sender
4. Engine mount (4 used)
5. Cap screw (2 used per mount)
6. Snubbing washer (4 used)
7. Cap screw (4 used)
8. Flange nut (4 used)
9. Lock nut (2 used per mount)
10. Fan spacer
11. Cap screw (4 used)
12. Lock washer
13. Lock washer
14. Pulley
15. V --belt
16. Flat washer (4 used)
17. Cooling fan
18. Flat washer
NOTE: The engine removal and installation procedure
is similar for all models in the Reelmaster 5010 Series.
9
Figure 9
19. Spring washer
20. Hex nut
21. Cap screw
22. Spacer (4 used)
23. Engine bracket (4 used)
24. Diode assembly
25. Lock washer (12 used)
26. Engine wire harness
27. Negative battery cable
Reelmaster 5010 SeriesPage 3 -- 14Kubota Diesel Engine
Removal (Fig. 9)
1. Park machine on a level surface, lower cutting units,
stop engine and remove key from the ignition switch.
Chock wheels to keep the machine from moving.
2. Open hood.
3. Disconnect negative (--) and then positive (+) battery
cables from the battery.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
3
1. Throttle cable end
2. Swivel
2
Figure 10
3. Cable clamp
1
Engine
Kubota Diesel
4. Drain coolant from radiator (see Radiator Removal
in this section).
5. Remove air cleaner from machine (see Air Cleaner
Removal in this section).
6. Remove exhaust system from machine (see Exhaust System Removal in this section).
7. Remove throttle cable from injector pump (Fig. 10):
A. Remove cap screw that secures throttle cable
end to swivel in speed control lever.
B. Loosen throttle cable clamp and remove cable
from clamp. Slide throttle cable end from swivel.
C. Position throttle cable away from the engine.
8. Disconnect hoses from engine:
A. Loosen clamps and remove upper and lower radiator hoses from the engine.
B. At injector pump, loosen hose clamp and disconnect supply fuel hose from the injector pump fitting
(Fig. 11).
1. Fuel return hose
2. Fuel supply hose
3
1
2
Figure 11
3. Fuel/water filter
1
2
C. Loosen hose clamp and disconnect fuel return
hose from front injector body (Fig. 11).
D. Plug disconnected hoses and engine openings to
prevent leakage and contamination. Position discon-
1. Negative battery cable 2. Harness ground
Figure 12
nected hoses away from engine.
Reelmaster 5010 Series Page 3 -- 15 Kubota Diesel Engine
9. Disconnect hydraulic transmission drive shaft from
engine (see Hydraulic Transmission Drive Shaft Removal in the Service and Repairs section of Chapter 4
-- Hydraulic System). Support drive shaft away from engine.
Installation (Fig. 9)
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.
10.Disconnect wire harness connectors from the following engine components:
NOTE: Before disconnecting wire harness connectors,
label all electrical leads for assembly purposes.
A. Alternator connector and stud.
B. Oil pressure switch located near the engine oil filter.
C. Connector, fusible link connector and positive
battery cable from the starter motor.
D. High temperature shut down switch and temperature sender located on the water pump housing.
E. Fuel stop solenoid on injector pump.
F. Negative battery cable and harness ground from
injector pump (Fig. 12).
G. Glow plug strip.
1 1.Remove engine from machine:
2. Make sure that all parts removed from the engine
during maintenance or rebuilding are installed to the engine.
3. If engine 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. Install engine to machine.
A. Attach short section of chain between lift tabs located on each end of the cylinder head
B. Connect a hoist or chain fall at the center of the
short section of chain. Apply enough tension on the
short chain so that the engine can be supported.
CAUTION
One person should operate lift or hoist while
another other person guides the engine into the
machine.
A. Attach short section of chain between lift tabs located on each end of the cylinder head.
B. Connect a hoist or chain fall at the center of the
short section of chain. Apply enough tension on the
short chain so that the engine will be supported.
C. Remove fasteners that secure the engine (with
brackets) to the engine mounts.
CAUTION
One person should operate lift or hoist while
another person guides the engine out of the machine.
IMPORTANT: Make sure to not damage the engine,
fuel hoses, hydraulic lines, electrical harness, radiator, batteryor other partswhile removing the engine.
D. Raise engine and remove toward front of machine.
IMPORTANT: Make sure to not damage the engine,
fuel hoses, hydraulic lines, electrical harness, radiator, batteryor other parts while installing the engine.
C. Lower engine to the machine frame. Make sure
fastener holes of the engine brackets are aligned
with the holes in the engine mounts.
D. Insert cap screw down through each engine
bracket and mount. Place spacer, snubbing washer
and then flange nut on four (4) cap screws. Tighten
fasteners to secure engine to engine mounts.
5. Connect hydraulic transmission drive shaft to engine
(see Hydraulic Transmission Drive Shaft Installation in
the Service and Repairs section of Chapter 4 -- Hydraulic System).
6. Connect all wire harness connectors to correct engine components.
12.If necessary, remove engine brackets from engine.
Reelmaster 5010 SeriesPage 3 -- 16Kubota Diesel Engine
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