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Part No. 06148SL (Rev. A)
Service Manual
ReelmasterR 5210/5410/5510/5610
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Reelmaster 5010 series: the 5210, 5410, 5510 and
5610.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals are
available on the internet at www.toro.com or by sending
complete Model and Serial Number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Minneapolis, MN 55420
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 INSTRUC-
TION. 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 re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company -- 2006, 2007
Reelmaster 5010 Series
Table Of Contents
Chapter 1 -- Safety
Safety Instructions 1 -- 2. . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking Instructions 1 -- 4. . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 1 -- 5. . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . .
KUBOTA WORKSHOP MANUAL: 05 SERIES 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 -- 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 -- 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 4 -- 54. . . . . . . . . . . . . . . . . . . . . . .
SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS REPAIR MANUAL
SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS SERVICE INSTRUCTIONS
PARKER TORQMOTORTM SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
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 Schematic 9 -- 5. . . . . . . . . . . . . . . . . . . . . . . .
Electrical Circuit Diagrams 9 -- 6. . . . . . . . . . . . . . . . . . .
Wire Harness Drawings 9 -- 10. . . . . . . . . . . . . . . . . . . .
Turf DefenderTM (Optional) Electrical Schematic 9 -- 16
SafetyProductRecords
andMaintenance
CuttingElectrical
System
Hydraulic
System
KubotaDiesel
Engine
GroomerChassis
Units
Foldout
Drawings
Reelmaster 5010 Series Page 1 -- 1 Safety
Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS 2. . . . . . . . . . . . . . . . . . . . . .
Before Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .
JACKING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 5. . . . . . . . . .
Safety
Reelmaster 5010 SeriesPage 1 -- 2Safety
Safety Instructions
Reelmaster machines meet or exceed safety standard
specifications when weights are installed according to
information in the Traction Unit Operator’s Manual. Al-
though hazard control and accident prevention are par-
tially dependent upon the design and configuration of
the machine, these factors are also dependent upon the
awareness, concern and proper training of the person-
nel involved in the operation, transport, maintenance
and storage of the machine. Improper use or mainte-
nance of the machine can result in injury or death. To re-
duce the potential for injury or death, comply with the
following safety instructions.
To reduce the potential for injury or death,
comply with the following safety instructions.
WARNING
Before Operating
1. Review and understand the contents of the Opera-
tor’s Manuals and Operator Training DVD before start-
ing and operating the machine. Become familiar with the
controls and know how to stop the machine and engine
quickly. A replacement Operator’s Manual is available
on the Internet at www.Toro.com or by sending the com-
plete model and serial number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Bloomington, Minnesota 55420--1196
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).
4. Since diesel fuel is highly flammable, handle it care-
fully:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove machine fuel tank cap while en-
gine 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 capssecure-
ly after refueling machine.
F. If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of spill-
age. 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 ma-
chine.
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 ade-
quate 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.
Reelmaster 5010 Series Page 1 -- 3 Safety
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 elimi-
nates the risk of the cutting units unexpectedly lowering
to the ground.
7. Do not park on slopes unless wheels are chocked or
blocked.
Maintenance and Service
1. Before servicing or making adjustments, lower cut-
ting 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 neara waterheat-
er or furnace.
4. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the hydraulic system.
5. Keep body and hands away from pin hole leaks in hy-
draulic 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 doc-
tor familiar with this form of injury or gangrene may re-
sult.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be re-
lieved by using all of the hydraulic controls (see Reliev-
ing 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. To 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. To assure safety and accuracy, check maximum
engine speed with a tachometer.
11.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 troubleshoot-
ing 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 de-
vices 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 Instruc-
tions in this section).
16.If major repairs are ever needed or assistance is de-
sired, 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 op-
timum 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.
Safety
Reelmaster 5010 SeriesPage 1 -- 4Safety
Jacking Instructions
When changing attachments, tires or perform-
ing 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 attach-
ments that may interfere with the safe and
proper raising of the machine. Always chock
or block wheels. Use jack stands or other ap-
propriate 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.
CAUTION
Front End Jacking (Fig. 1)
1. Apply parking brake and chock both rear tires to pre-
vent the machine from moving.
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. The preferred method of lifting the rear end of the
machine is as follows:
A. Apply parking brake and chock both front tires to
prevent the machine from moving.
B. Secure a chain fall or hoist to the tie down rod on
the rear of the frame.
C. Lift rear of machine off the ground.
D. Position jack stands under the frame to support
the machine.
2. If the rear of the machine cannot be lifted as above:
A. Apply parking brake and chock both front tires to
prevent the machine from moving.
A. Place jack securely at the center of the rear axle
under the axle pivot bracket. Jack rear of machine off
the ground.
B. Position jack stands under the frame to support
the machine.
Figure 1
1. Front wheel 2. Front jacking point
1
2
Figure 2
1. Rear wheel
2. Tie down rod
3. Jack stand location
2
3
1
Reelmaster 5010 Series Page 1 -- 5 Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the traction unit and the cutting unitsof 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 Autho-
rized Toro Distributor.
Safety
Reelmaster 5010 Series Page 2 -- 1 Product Records and Maintenance
Chapter 2
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. . . . . . . . . . . . . . . . . . . . . . .
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, Op-
erator’s Manuals and Parts Catalogs for those options
at the end of this chapter.
Maintenance
Maintenance procedures and recommended service in-
tervals for your Reelmaster are covered in the Traction
Unit and Cutting Unit Operator’s Manuals. Refer to
those publications when performing regular equipment
maintenance.
ProductRecords
andMaintenance
0.09375
Reelmaster 5010 SeriesPage 2 -- 2Product Records and Maintenance
Equivalents and Conversions
Reelmaster 5010 Series Page 2 -- 3 Product 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 spe-
cified 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 Ser-
vice 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 en-
gagement, etc.
The standard method of verifying torque shall be per-
formed 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
Figure 1
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 2
Class 8.8 Class 10.9
Metric Bolts and Screws
ProductRecords
andMaintenance
Reelmaster 5010 SeriesPage 2 -- 6Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Thread Size
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
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 30 + 5 in--lb
No. 10 -- 24 UNC 38 + 7 in--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
Wheel Bolts and Lug Nuts
Thread Size 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)
Thread
Size
Threads per Inch
Baseline Torque*Size
Type A Type B
Baseline Torque*
No. 6 18 20 20 + 5 in--lb
No. 8 15 18 30 + 5 in--lb
No. 10 12 16 38 + 7 in--lb
No. 12 11 14 85 + 15 in--lb
*Hole size,materialstrength,materialthickness and fin-
ish must be considered when determining specific
torque values. All torque values are based on non--lubri-
cated fasteners.
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
Reelmaster 5010 Series Page 3 -- 1 Kubota Diesel Engine
Chapter 3
Kubota Diesel Engine
Table of Contents
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. . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS 6. . . . . . . . . . . . . . . . . . . . . .
Fuel System 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KUBOTA WORKSHOP MANUAL: 05 SERIES DIESEL
ENGINE
General Information
This Chapter gives information about specifications,
troubleshooting, testing and repair of the Kubota diesel
engine used in the Reelmaster 5010 Series of ma-
chines.
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 en-
gine service manual included at the end of this chapter.
However, the cost of the test equipment and the special-
ized 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 a parts list
is not available, be sure to provide your distributor with
the Toro model and serial number.
Traction Unit Operator’s Manual
The Traction Unit Operator’s Manual provides informa-
tion regarding the operation, general maintenance and
maintenance intervals for the Kubota diesel engine that
powers your Reelmaster machine. Refer to that publica-
tion for additional information when servicing the ma-
chine.
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.
KubotaDiesel
Engine
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Reelmaster 5010 SeriesPage 3 -- 2Kubota Diesel Engine
Specifications: Reelmaster 5210
Item Description
Make / Designation Kubota D1105, 4--stroke,
Liquid Cooled, OHV Diesel
Number of Cylinders 3
Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm)
Total Displacement 68.53 in3 (1123 cc)
Compression Ratio 22.0:1
Firing Order 1 (fan end) -- 2 -- 3 (flywheel end)
Dry Weight (approximate) 205 lb. (93 kg)
Fuel No. 2--D Diesel Fuel (ASTM D975)
Fuel Injection Pump Bosch MD Type Mini
Fuel Injector Nozzle Mini Nozzle (DNOPD)
Fuel Tank Capacity 14 U.S. Gallons (53 Liters)
Governor Centrifugal Mechanical
Low Idle Speed (no load) 1200 to 1300 RPM
High Idle Speed (no load) 3050 to 3250 RPM
Engine Oil API Classification CH--4, CI--4 or Higher
(see Traction Unit Operator’s Manual for viscosity recommendations)
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
Reelmaster 5010 Series Page 3 -- 3 Kubota 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
High Idle Speed (no load) 3050 to 3250 RPM
Engine Oil API Classification CH--4, CI--4 or Higher
(see Traction Unit Operator’s Manual for viscosity recommendations)
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
KubotaDiesel
Engine
Reelmaster 5010 SeriesPage 3 -- 4Kubota Diesel Engine
Specifications: Reelmaster 5610
Item Description
Make / Designation Kubota V1505, 4--stroke,
Liquid Cooled, OHV, Turbocharged Diesel
Number of Cylinders 4
Bore x Stroke 3.07” x 3.09“ (78 mm x 78.4 mm)
Total Displacement 91.4 in3 (1498 cc)
Compression Ratio 21.0:1
Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2
Dry Weight (approximate) 251 lbs (114 kg)
Fuel No. 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
High Idle Speed (no load) 3050 to 3250 RPM
Engine Oil API Classification CH--4, CI--4 or Higher
(see Traction Unit Operator’s Manual for viscosity recommendations)
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
Reelmaster 5010 Series Page 3 -- 5 Kubota Diesel Engine
Adjustments
Adjust Throttle Control
Proper throttle operation is dependent upon proper ad-
justment 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 con-
trol lever is in the FAST position.
3. If necessary, throttle control can be adjusted by loos-
ening 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.
Figure 1
1. Throttle cable
2. High speed screw
3. Speed control lever
4. Swivel
5. Cable clamp
2
1
3
4
5
KubotaDiesel
Engine

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Toro reelmaster 5510 mower service repair manual

  • 1. Part No. 06148SL (Rev. A) Service Manual ReelmasterR 5210/5410/5510/5610 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 5010 series: the 5210, 5410, 5510 and 5610. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUC- TIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available on the internet at www.toro.com or by sending complete Model and Serial Number to: The Toro Company Attn. Technical Publications 8111 Lyndale Avenue South Minneapolis, MN 55420 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 INSTRUC- TION. 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 re- pair of the machine. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company -- 2006, 2007
  • 2. Reelmaster 5010 Series Table Of Contents Chapter 1 -- Safety Safety Instructions 1 -- 2. . . . . . . . . . . . . . . . . . . . . . . . . . Jacking Instructions 1 -- 4. . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 5. . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . KUBOTA WORKSHOP MANUAL: 05 SERIES 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 -- 21. . . . . . . . . . . . . . . . . . . . . . . . . . . Testing 4 -- 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs 4 -- 54. . . . . . . . . . . . . . . . . . . . . . . SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON PUMPS REPAIR MANUAL SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON PUMPS SERVICE INSTRUCTIONS PARKER TORQMOTORTM SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES) 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 Schematic 9 -- 5. . . . . . . . . . . . . . . . . . . . . . . . Electrical Circuit Diagrams 9 -- 6. . . . . . . . . . . . . . . . . . . Wire Harness Drawings 9 -- 10. . . . . . . . . . . . . . . . . . . . Turf DefenderTM (Optional) Electrical Schematic 9 -- 16 SafetyProductRecords andMaintenance CuttingElectrical System Hydraulic System KubotaDiesel Engine GroomerChassis Units Foldout Drawings
  • 3. Reelmaster 5010 Series Page 1 -- 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2. . . . . . . . . . . . . . . . . . . . . . Before Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service 3. . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS 5. . . . . . . . . . Safety
  • 4. Reelmaster 5010 SeriesPage 1 -- 2Safety Safety Instructions Reelmaster machines meet or exceed safety standard specifications when weights are installed according to information in the Traction Unit Operator’s Manual. Al- though hazard control and accident prevention are par- tially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the person- nel involved in the operation, transport, maintenance and storage of the machine. Improper use or mainte- nance of the machine can result in injury or death. To re- duce the potential for injury or death, comply with the following safety instructions. To reduce the potential for injury or death, comply with the following safety instructions. WARNING Before Operating 1. Review and understand the contents of the Opera- tor’s Manuals and Operator Training DVD before start- ing and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. A replacement Operator’s Manual is available on the Internet at www.Toro.com or by sending the com- plete model and serial number to: The Toro Company Attn. Technical Publications 8111 Lyndale Avenue South Bloomington, Minnesota 55420--1196 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). 4. Since diesel fuel is highly flammable, handle it care- fully: A. Store fuel in containers specifically designed for this purpose. B. Do not remove machine fuel tank cap while en- gine 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 capssecure- ly after refueling machine. F. If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spill- age. 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 ma- chine. 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 ade- quate 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.
  • 5. Reelmaster 5010 Series Page 1 -- 3 Safety 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 elimi- nates the risk of the cutting units unexpectedly lowering to the ground. 7. Do not park on slopes unless wheels are chocked or blocked. Maintenance and Service 1. Before servicing or making adjustments, lower cut- ting 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 neara waterheat- er or furnace. 4. Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition be- fore applying pressure to the hydraulic system. 5. Keep body and hands away from pin hole leaks in hy- draulic 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 doc- tor familiar with this form of injury or gangrene may re- sult. 6. Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be re- lieved by using all of the hydraulic controls (see Reliev- ing 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. To 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. To assure safety and accuracy, check maximum engine speed with a tachometer. 11.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 troubleshoot- ing 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 de- vices 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 Instruc- tions in this section). 16.If major repairs are ever needed or assistance is de- sired, 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 op- timum 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. Safety
  • 6. Reelmaster 5010 SeriesPage 1 -- 4Safety Jacking Instructions When changing attachments, tires or perform- ing 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 attach- ments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or other ap- propriate 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. CAUTION Front End Jacking (Fig. 1) 1. Apply parking brake and chock both rear tires to pre- vent the machine from moving. 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. The preferred method of lifting the rear end of the machine is as follows: A. Apply parking brake and chock both front tires to prevent the machine from moving. B. Secure a chain fall or hoist to the tie down rod on the rear of the frame. C. Lift rear of machine off the ground. D. Position jack stands under the frame to support the machine. 2. If the rear of the machine cannot be lifted as above: A. Apply parking brake and chock both front tires to prevent the machine from moving. A. Place jack securely at the center of the rear axle under the axle pivot bracket. Jack rear of machine off the ground. B. Position jack stands under the frame to support the machine. Figure 1 1. Front wheel 2. Front jacking point 1 2 Figure 2 1. Rear wheel 2. Tie down rod 3. Jack stand location 2 3 1
  • 7. Reelmaster 5010 Series Page 1 -- 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and the cutting unitsof 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 Autho- rized Toro Distributor. Safety
  • 8. Reelmaster 5010 Series Page 2 -- 1 Product Records and Maintenance Chapter 2 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. . . . . . . . . . . . . . . . . . . . . . . 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, Op- erator’s Manuals and Parts Catalogs for those options at the end of this chapter. Maintenance Maintenance procedures and recommended service in- tervals for your Reelmaster are covered in the Traction Unit and Cutting Unit Operator’s Manuals. Refer to those publications when performing regular equipment maintenance. ProductRecords andMaintenance
  • 9. 0.09375 Reelmaster 5010 SeriesPage 2 -- 2Product Records and Maintenance Equivalents and Conversions
  • 10. Reelmaster 5010 Series Page 2 -- 3 Product 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 spe- cified 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 Ser- vice 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 en- gagement, etc. The standard method of verifying torque shall be per- formed 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 Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8.8 Class 10.9 Metric Bolts and Screws ProductRecords andMaintenance
  • 11. Reelmaster 5010 SeriesPage 2 -- 6Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size 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 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 30 + 5 in--lb No. 10 -- 24 UNC 38 + 7 in--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 Wheel Bolts and Lug Nuts Thread Size 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) Thread Size Threads per Inch Baseline Torque*Size Type A Type B Baseline Torque* No. 6 18 20 20 + 5 in--lb No. 8 15 18 30 + 5 in--lb No. 10 12 16 38 + 7 in--lb No. 12 11 14 85 + 15 in--lb *Hole size,materialstrength,materialthickness and fin- ish must be considered when determining specific torque values. All torque values are based on non--lubri- cated fasteners. 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
  • 12. Reelmaster 5010 Series Page 3 -- 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents 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. . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS 6. . . . . . . . . . . . . . . . . . . . . . Fuel System 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 10. . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KUBOTA WORKSHOP MANUAL: 05 SERIES DIESEL ENGINE General Information This Chapter gives information about specifications, troubleshooting, testing and repair of the Kubota diesel engine used in the Reelmaster 5010 Series of ma- chines. 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 en- gine service manual included at the end of this chapter. However, the cost of the test equipment and the special- ized 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 a parts list is not available, be sure to provide your distributor with the Toro model and serial number. Traction Unit Operator’s Manual The Traction Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the Kubota diesel engine that powers your Reelmaster machine. Refer to that publica- tion for additional information when servicing the ma- chine. 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. KubotaDiesel Engine
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  • 14. Reelmaster 5010 SeriesPage 3 -- 2Kubota Diesel Engine Specifications: Reelmaster 5210 Item Description Make / Designation Kubota D1105, 4--stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.53 in3 (1123 cc) Compression Ratio 22.0:1 Firing Order 1 (fan end) -- 2 -- 3 (flywheel end) Dry Weight (approximate) 205 lb. (93 kg) Fuel No. 2--D Diesel Fuel (ASTM D975) Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle (DNOPD) Fuel Tank Capacity 14 U.S. Gallons (53 Liters) Governor Centrifugal Mechanical Low Idle Speed (no load) 1200 to 1300 RPM High Idle Speed (no load) 3050 to 3250 RPM Engine Oil API Classification CH--4, CI--4 or Higher (see Traction Unit Operator’s Manual for viscosity recommendations) 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
  • 15. Reelmaster 5010 Series Page 3 -- 3 Kubota 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 High Idle Speed (no load) 3050 to 3250 RPM Engine Oil API Classification CH--4, CI--4 or Higher (see Traction Unit Operator’s Manual for viscosity recommendations) 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 KubotaDiesel Engine
  • 16. Reelmaster 5010 SeriesPage 3 -- 4Kubota Diesel Engine Specifications: Reelmaster 5610 Item Description Make / Designation Kubota V1505, 4--stroke, Liquid Cooled, OHV, Turbocharged Diesel Number of Cylinders 4 Bore x Stroke 3.07” x 3.09“ (78 mm x 78.4 mm) Total Displacement 91.4 in3 (1498 cc) Compression Ratio 21.0:1 Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2 Dry Weight (approximate) 251 lbs (114 kg) Fuel No. 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 High Idle Speed (no load) 3050 to 3250 RPM Engine Oil API Classification CH--4, CI--4 or Higher (see Traction Unit Operator’s Manual for viscosity recommendations) 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
  • 17. Reelmaster 5010 Series Page 3 -- 5 Kubota Diesel Engine Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper ad- justment 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 con- trol lever is in the FAST position. 3. If necessary, throttle control can be adjusted by loos- ening 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. Figure 1 1. Throttle cable 2. High speed screw 3. Speed control lever 4. Swivel 5. Cable clamp 2 1 3 4 5 KubotaDiesel Engine