Part No. 06148SL (Rev. C)
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.
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.
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. Additional copies of the Operator’s
Manual and Parts Catalog are available on the internet
at www.Toro.com.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
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, 2009, 2012
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Table Of Contents
Chapter 1 -- Safety
Chapter 5 -- Electrical System
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 4
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 2 -- Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 -- 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3
Chapter 6 -- Chassis
Chapter 3 -- Kubota Diesel Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 5
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 6
KUBOTA WORKSHOP MANUAL: 05 SERIES DIESEL
ENGINE
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 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
Chapter 8 -- Groomer
Grooming Performance . . . . . . . . . . . . . . . . . . . . . 8 -- 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 5
Chapter 9 -- Foldout Drawings
SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL
PISTON PUMPS SERVICE INSTRUCTIONS
PARKER TORQMOTORTM SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
EATON DELTA MOTORS PARTS AND REPAIR
MANUAL
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 -- 5
Electrical Circuit Diagrams . . . . . . . . . . . . . . . . . . . 9 -- 7
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 9 -- 12
Turf DefenderTM (Optional) Electrical Schematic 9 -- 18
SAUER--DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Rev. C
Reelmaster 5010 Series
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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 . . . . . . . . . . 4
Rev. B
Reelmaster 5010 Series
Page 1 -- 1
Safety
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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.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Review and understand the contents of the 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. Additional copies of the Operator’s Manual are
available on the internet at www.Toro.com.
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.
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.
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.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and PTO switch is OFF (disengaged).
E. Replace fuel tank and fuel container caps secure-
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.
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
2. Before starting the engine:
A. Apply the parking brake.
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.
B. Make sure the traction pedal is in NEUTRAL and
the PTO switch is OFF (disengaged).
5. Before getting off the seat:
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).
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
Safety
Page 1 -- 2
Reelmaster 5010 Series
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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.
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.
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 heat-
er or furnace.
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.
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.
14.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
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.
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).
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).
16.If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
7. Use care when checking or servicing the cutting
units. Wear gloves and use caution when servicing
them.
17.If welding on the machine is necessary, disconnect
the negative battery cable to prevent electrical system
damage.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
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.
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.
Reelmaster 5010 Series
Page 1 -- 3
Safety
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Jacking Instructions
CAUTION
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.
2
1
Figure 1
1. Front wheel
2. Front jacking point
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.
2
Rear End Jacking (Fig. 2)
1. Apply parking brake and chock both front tires to pre-
vent the machine from moving.
1
2. Place jack securely at the center of the rear axle un-
der the axle pivot bracket. Jack rear of machine off the
ground.
Figure 2
1. Axle center
2. Jack stand location
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 your Reelmaster.
If any decal becomes illegible or damaged, install a new
decal. Part numbers for decals are listed in your Part
Catalogs. Order replacement decals from your Autho-
rized Toro Distributor.
Rev. B
Safety
Page 1 -- 4
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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
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, 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.
Rev. B
Reelmaster 5010 Series
Page 2 -- 1
Product Records and Maintenance
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Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 -- 2
Reelmaster 5010 Series
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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.
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.
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.
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
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Inch Series Bolts and Screws
Figure 1
Metric Bolts and Screws
Figure 2
Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommen-
dation 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 recommen-
dation.
If the listed torque recommendation for a fastener is
from 76 to 94 ft--lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft--lb.
Offset wrench
Torque wrench
(effective length of
torque wrench)
A
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”.
B
(effective length of torque
wrench + offset wrench)
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”.
TORQUE CONVERSION FACTOR = A / B
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Figure 3
Rev. B
Reelmaster 5010 Series
Page 2 -- 3
Product Records and Maintenance
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5 &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
Thread Size
in--lb
in--lb
N--cm
in--lb
15 + 2
N--cm
169 + 23
192 + 23
328 + 34
350 + 45
475 + 56
542 + 56
1130 + 113
1299 + 136
2260 + 282
2542 + 282
N--m
in--lb
23 + 3
N--cm
262 + 34
282 + 34
463 + 56
486 + 56
678 + 68
768 + 79
1582 + 169
1808 + 192
3390 + 339
3672 + 373
N--m
# 6 -- 32 UNC
# 6 -- 40 UNF
# 8 -- 32 UNC
# 8 -- 36 UNF
# 10 -- 24 UNC
# 10 -- 32 UNF
1/4 -- 20 UNC
1/4 -- 28 UNF
5/16 -- 18 UNC
5/16 -- 24 UNF
10 + 2
13 + 2
147 + 23
17 + 2
25 + 3
29 + 3
41 + 5
13 + 2
18 + 2
25 + 5
30 + 5
282 + 30
339 + 56
31 + 4
43 + 5
42 + 5
60 + 6
48 + 5
68 + 7
48 + 7
53 + 7
53 + 7
65 + 10
105 + 15
128 + 17
ft--lb
599 + 79
734 + 113
1186 + 169
1446 + 192
N--m
100 + 10
115 + 12
200 + 25
225 + 25
ft--lb
140 + 15
160 + 17
300 + 30
325 + 33
ft--lb
115 + 15
138 + 17
ft--lb
3/8 -- 16 UNC
3/8 -- 24 UNF
7/16 -- 14 UNC
7/16 -- 20 UNF
1/2 -- 13 UNC
1/2 -- 20 UNF
5/8 -- 11 UNC
5/8 -- 18 UNF
3/4 -- 10 UNC
3/4 -- 16 UNF
7/8 -- 9 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 5
58 + 7
17 + 2
18 + 2
24 + 3
35 + 4
47 + 5
50 + 6
68 + 8
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
29 + 3
29 + 3
39 + 4
55 + 6
75 + 8
77 + 8
104 + 11
142 + 15
163 + 16
285 + 28
325 + 33
508 + 52
569 + 58
813 + 81
904 + 89
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
115 + 12
203 + 20
230 + 24
359 + 37
407 + 41
583 + 61
644 + 65
105 + 11
120 + 12
210 + 21
240 + 24
375 + 38
420 + 43
600 + 60
667 + 66
32 + 4
53 + 7
72 + 9
85 + 9
65 + 10
75 + 10
93 + 12
115 + 15
140 + 20
155 + 25
88 + 12
95 + 15
140 + 20
165 + 25
225 + 25
260 + 30
119 + 16
129 + 20
190 + 27
224 + 34
305 + 34
353 + 41
150 + 15
170 + 18
265 + 27
300 + 30
430 + 45
475 + 48
7/8 -- 14 UNF
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 mini-
mum 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
Product Records and Maintenance
Page 2 -- 4
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws and Studs with
Thread Size
Regular Height Nuts
(Class 8 or Stronger Nuts)
(Class 10 or Stronger Nuts)
M5 X 0.8
M6 X 1.0
57 + 6 in--lb
96 + 10 in--lb
19 + 2 ft--lb
644 + 68 N--cm
1085 + 113 N--cm
26 + 3 N--m
78 + 8 in--lb
881 + 90 N--cm
1503 + 158 N--cm
38 + 4 N--m
133 + 14 in--lb
28 + 3 ft--lb
M8 X 1.25
M10 X 1.5
M12 X 1.75
M16 X 2.0
M20 X 2.5
38 + 4 ft--lb
52 + 5 N--m
54 + 6 ft--lb
73 + 8 N--m
66 + 7 ft--lb
90 + 10 N--m
225 + 23 N--m
440 + 45 N--m
93 + 10 ft--lb
229 + 23 ft--lb
450 + 46 ft--lb
126 + 14 N--m
310 + 31 N--m
610 + 62 N--m
166 + 17 ft--lb
325 + 33 ft--lb
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 + 10% of the
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Reelmaster 5010 Series
Page 2 -- 5
Product Records and Maintenance
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Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Recommended Torque
Thread Size
Thread Size
Recommended Torque**
65 + 10 ft--lb 88 + 14 N--m
Square Head
140 + 20 in--lb
215 + 35 in--lb
35 + 10 ft--lb
75 + 15 ft--lb
Hex Socket
73 + 12 in--lb
145 + 20 in--lb
18 + 3 ft--lb
7/16 -- 20 UNF
Grade 5
1/4 -- 20 UNC
5/16 -- 18 UNC
3/8 -- 16 UNC
1/2 -- 13 UNC
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.25
Class 8.8
50 + 10 ft--lb
M12 X 1.5
Class 8.8
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Threads per Inch
Size
Baseline Torque*
Thread Size
Baseline Torque*
20 + 5 in--lb
Type A Type B
No. 6 -- 32 UNC
No. 8 -- 32 UNC
No. 10 -- 24 UNC
1/4 -- 20 UNC
No. 6
No. 8
18
15
12
11
20
18
16
14
20 + 5 in--lb
30 + 5 in--lb
38 + 7 in--lb
85 + 15 in--lb
30 + 5 in--lb
38 + 7 in--lb
No. 10
No. 12
85 + 15 in--lb
110 + 20 in--lb
200 + 100 in--lb
5/16 -- 18 UNC
3/8 -- 16 UNC
*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
Product Records and Maintenance
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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.
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.
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.
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.
Reelmaster 5010 Series
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Kubota Diesel Engine
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Specifications: Reelmaster 5210
Item
Description
Make / Designation
Kubota D1105, 4--stroke,
Liquid Cooled, OHV Diesel
Number of Cylinders
Bore x Stroke
3
3.07” x 3.09” (78 mm x 78.4 mm)
3
Total Displacement
Compression Ratio
Firing Order
68.53 in (1123 cc)
22.0:1
1 (fan end) -- 2 -- 3 (flywheel end)
205 lb. (93 kg)
Dry Weight (approximate)
Fuel
No. 2--D Diesel Fuel (ASTM D975)
Bosch MD Type Mini
Fuel Injection Pump
Fuel Injector Nozzle
Fuel Tank Capacity
Governor
Mini Nozzle (DNOPD)
14 U.S. Gallons (53 Liters)
Centrifugal Mechanical
Low Idle Speed (no load)
High Idle Speed (no load)
Engine Oil
1200 to 1300 RPM
3050 to 3250 RPM
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
Cooling System Capacity (including reserve tank)
Starter
4.0 U.S. Quarts (3.8 Liters) with Filter
5.5 U.S. Quarts (5.2 Liters)
12 VDC 1.4 KW
Alternator/Regulator
12 VDC 40 Amp
Kubota Diesel Engine
Page 3 -- 2
Reelmaster 5010 Series
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Specifications: Reelmaster 5410 and 5510
Item
Description
Make / Designation
Kubota V1505, 4--stroke,
Liquid Cooled, OHV Diesel
Number of Cylinders
Bore x Stroke
4
3.07” x 3.09” (78 mm x 78.4 mm)
3
Total Displacement
Compression Ratio
Firing Order
91.4 in (1498 cc)
21.0:1
1 (fan end) -- 3 -- 4 (flywheel end) -- 2
242 lbs (110 kg)
Dry Weight (approximate)
Fuel
No. 2--D Diesel Fuel (ASTM D975)
Bosch MD Type Mini
Fuel Injection Pump
Fuel Injector Nozzle
Fuel Tank Capacity
Governor
Mini Nozzle (DNOPD)
14 U.S. Gallons (53 Liters)
Centrifugal Mechanical
Low Idle Speed (no load)
High Idle Speed (no load)
Engine Oil
1200 to 1300 RPM
3050 to 3250 RPM
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
Cooling System Capacity (including reserve tank)
Starter
6.3 U.S. Quarts (6 Liters) with Filter
7 U.S. Quarts (6.6 Liters)
12 VDC 1.4 KW
Alternator/Regulator
12 VDC 40 Amp
Reelmaster 5010 Series
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Kubota Diesel Engine
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Specifications: Reelmaster 5610
Item
Description
Make / Designation
Kubota V1505, 4--stroke,
Liquid Cooled, OHV, Turbocharged Diesel
Number of Cylinders
Bore x Stroke
4
3.07” x 3.09“ (78 mm x 78.4 mm)
3
Total Displacement
Compression Ratio
Firing Order
91.4 in (1498 cc)
21.0:1
1 (fan end) -- 3 -- 4 (flywheel end) -- 2
251 lbs (114 kg)
Dry Weight (approximate)
Fuel
No. 2--D Diesel Fuel (ASTM D975)
Bosch MD Type Mini
Fuel Injection Pump
Fuel Injector Nozzle
Fuel Tank Capacity
Governor
Mini Nozzle (DNOPD)
14 U.S. Gallons (53 Liters)
Centrifugal Mechanical
Low Idle Speed (no load)
High Idle Speed (no load)
Engine Oil
1200 to 1300 RPM
3050 to 3250 RPM
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
Cooling System Capacity (including reserve tank)
Starter
5 U.S. Quarts (4.7 Liters) with Filter
10 U.S. Quarts (9.5 Liters)
12 VDC 1.4 KW
Alternator/Regulator
12 VDC 40 Amp
Kubota Diesel Engine
Page 3 -- 4
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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.
2
1. Move throttle control lever on control console to
FAST position.
5
1
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.
4
3
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
Reelmaster 5010 Series
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Service and Repairs
Fuel System
8
15
12
11
7
2
1
6
10
9
2
16
3
5
3
5
4
13
14
3
RIGHT
4
FRONT
Figure 2
1. Fuel cap
7. Suction fitting
12. Fuel gauge
13. Hose clamp
14. Draincock
2. Bushing
8. Hose clamp
9. Hose clamp
10. Fuel tank
3. Washer head screw (3 used)
4. Flange nut (3 used)
5. Clamp (3 used)
6. Return fitting
15. Fuel hose
11. Grommet
16. Return fuel hose
Kubota Diesel Engine
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Fuel Tank Removal (Fig. 2)
DANGER
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
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 die-
sel fuel before starting the engine. Store fuel in a
clean, safety--approved container and keep con-
tainer cap in place. Use diesel fuel for the engine
only; not for any other purpose.
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.
Check Fuel Lines and Connections
4. Loosen hose clamps and disconnect fuel hoses from
suction (item 7) and return (item 6) fittings on the top of
the fuel tank.
Check fuel lines and connections periodically as recom-
mended in the Traction Unit Operator’s Manual. Check
lines for deterioration, damage, leakage or loose con-
nections. Replace fuel hoses, clamps and connections
as necessary.
5. Remove fuel tank using Figure 2 as a guide.
Fuel Tank Installation (Fig. 2)
Drain and Clean Fuel Tank
1. Install fuel tank to frame using Figure 2 as a guide.
Drain and clean the fuel tank periodically as recom-
mended 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 ex-
tended period.
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.
To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of all contaminates and debris.
Reelmaster 5010 Series
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Air Cleaner
REELMASTER 5410--D/5510--D SHOWN
7
11
3
11
4
6
5
16
THREAD
SEALANT
2
1
13
9
11
12
15
10
12
14
RIGHT
11
8
FRONT
12
Figure 3
1. Air cleaner assembly
2. Hex nut
7. Hose
8. Hose
9. Mount bracket
10. Air cleaner stand
11. Hose clamp
12. Flange nut
13. Cap screw (2 used)
3. Bolt
14. Flange head screw (4 used)
15. Flange head screw (2 used)
16. Air cleaner mounting band
4. Spring
5. Indicator
6. Adapter
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.
Kubota Diesel Engine
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Removal (Fig. 3)
REELMASTER 5610--D
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch. Raise hood.
10
11
12
13
11
9
2. Remove air cleaner components as needed using
Figures 3, 4 and 5 as guides.
1
2
3
8
6
3. See Traction Unit Operator’s Manual for air cleaner
service and maintenance procedures.
7
6
4
5
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
are in good condition and are properly secured dur-
ing 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 be-
fore installing adapter and indicator to housing.
Figure 4
1. Air cleaner assembly
2. Mounting band
3. Adapter
8. Spacer
9. Hose
10. Hose
11. Hose clamp
12. Bolt
13. Spring
B. Make sure that vacuator valve is pointed down af-
ter assembly.
4. Indicator
5. Hex nut
6. Hose clamp
7. Hose
1
2
4
5
3
Figure 5
1. Mounting band
2. Cover
3. Vacuator valve
4. Adapter
5. Indicator
Reelmaster 5010 Series
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Exhaust System
17
REELMASTER 5410--D/5510--D SHOWN
3
11
10
1
6
18
20
2
4
14
19
13
12
7
5
16
8
2
5
4
15
16
13
RIGHT
14
6
9
12
FRONT
Figure 6
1. Gasket
8. Cap screw
15. Rubber hanger
16. Spacer (2 used)
17. Exhaust header
18. Support bracket
19. Tail pipe bracket
20. Muffler
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
9. Isolator plate
10. Hex nut (2 used)
11. Clamp
12. Flange nut (2 used)
13. Flat washer (2 used)
14. Cap screw (2 used)
NOTE: The models in the Reelmaster 5010 Series
have a very similar exhaust system. The exhaust sys-
tem removal and installation procedure is the same for
all models.
Kubota Diesel Engine
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Removal (Fig. 6)
Installation (Fig. 6)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch. Raise hood.
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Place new muffler gasket on the exhaust manifold.
Install exhaust pipe to manifold and secure with four (4)
flange nuts.
CAUTION
IMPORTANT: Finger tighten all exhaust system fas-
teners before tightening so that there is no preload
on the exhaust system due to exhaust system as-
sembly.
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and ex-
haust system to cool before working on the ex-
haust system.
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.
2. Remove exhaust system using Figure 6 as a guide.
Reelmaster 5010 Series
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Radiator
11
28
20
38
2
1
2
4
13
3
10
29
31
19
40
22
6
18
34
12
23
43
24
33
5
19
39
8
44
21
20
15
36
12
4
37
17
11
35
9
13
13
15
7
42
32
8
15
16
13
14
9
30
RIGHT
26
16
13
FRONT
6
27
16
2
25
16
41
5
30
Figure 7
1. Overflow bottle
2. Hose clamp (3 used)
3. Hose
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
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)
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)
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)
14. Oil cooler mount plate (2 used)
15. Oil cooler clamp (16 used)
NOTE: Three (3) radiators are used on Reelmaster
5010 series machines. Reelmaster 5410 and 5510 ma-
chines 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.
Kubota Diesel Engine
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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.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot cool-
ant can escape and cause burns.
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.
Ethylene--glycol antifreeze is poisonous. Dis-
pose of coolant properly, or store it in a properly
labeled container away from children and pets.
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.
3. Drain coolant from radiator.
6. Connect upper and lower radiator hoses to radiator
and secure with clamps.
A. Slowly remove radiator cap from the radiator.
B. Place drain pan below the radiator draincock lo-
cated on the bottom of the radiator. Make sure that
drain pan is large enough to holdcooling systemcon-
tents (see Specifications in this Chapter).
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.
C. Loosen draincock and allow coolant to drain from
radiator.
9. Lower hood. Install screen to rear of machine.
4. Remove screen from machine.
5. Disconnect radiator hoses (upper and lower) from
the radiator.
REELMASTER 5610
6
6. Loosen hose clamp and remove overflow hose from
radiator fill opening.
5
3
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.
1
8. Remove five (5) flange head screws and flange nuts
that secure air intake screen (item 37) to machine. Re-
move screen and foam seal (item 42). Locate and re-
trieve five (5) spacers (item 43).
2
5
4
5
9. Remove flange head screws and flange nuts that se-
cure fan shroud and radiator to radiator frame. Position
fan shroud away from the radiator.
6
10.Carefully pull radiator assembly from the machine.
Plug radiator and hose openings to prevent contamina-
tion.
6
11.Inspect all foam seals placed between radiator, fan
shroud and radiator frame. Replace damaged foam
seals.
Figure 8
1. Radiator (RM 5610)
2. Fan shroud
3. Radiator frame
4. Flange head screw
5. Flange head screw
6. Flange nut
Installation (Fig. 7)
1. Remove plugs placed in radiator and hose openings
during the removal procedure.
2. Carefully position radiator assembly to the radiator
support. Position fan shroud to the radiator.
Reelmaster 5010 Series
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Engine
34 to 42 ft--lb
(47 to 56 N--m)
3
11
26
18
19
24
20
16
25
2
7
17
10
23
14
15
1
5
4
7
23
25
5
13
4
26
22
9
9
6
23
5
2
27
12
27
8
21
4
RIGHT
9
FRONT
Figure 9
1. Engine assembly
10. Fan spacer
19. Spring washer
20. Hex nut
2. Cap screw (12 used)
3. Temperature sender
11. Cap screw (4 used)
12. Lock washer
13. Lock washer
14. Pulley
21. Cap screw
4. Engine mount (4 used)
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
5. Cap screw (2 used per mount)
6. Snubbing washer (4 used)
7. Cap screw (4 used)
15. V -belt
16. Flat washer (4 used)
17. Cooling fan
18. Flat washer
8. Flange nut (4 used)
9. Lock nut (2 used per mount)
NOTE: The engine removal and installation procedure
is similar for all models in the Reelmaster 5010 Series.
Kubota Diesel Engine
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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
1
2
3. Disconnect negative (--) and then positive (+) battery
cables from the battery.
CAUTION
Figure 10
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot cool-
ant can escape and cause burns.
1. Throttle cable end
2. Swivel
3. Cable clamp
Ethylene--glycol antifreeze is poisonous. Dis-
pose of coolant properly, or store it in a properly
labeled container away from children and pets.
4. Drain coolant from radiator (see Radiator Removal
in this section).
3
5. Remove air cleaner from machine (see Air Cleaner
Removal in this section).
1
6. Remove exhaust system from machine (see Ex-
haust System Removal in this section).
2
7. Remove throttle cable from injector pump (Fig. 10):
Figure 11
A. Remove cap screw that secures throttle cable
end to swivel in speed control lever.
1. Fuel return hose
2. Fuel supply hose
3. Fuel/water filter
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:
1
2
A. Loosen clamps and remove upper and lower ra-
diator hoses from the engine.
B. At injector pump, loosen hose clamp and discon-
nect supply fuel hose from the injector pump fitting
(Fig. 11).
C. Loosen hose clamp and disconnect fuel return
hose from front injector body (Fig. 11).
Figure 12
D. Plug disconnected hoses and engine openings to
prevent leakage and contamination. Positiondiscon-
nected hoses away from engine.
1. Negative battery cable
2. Harness ground
Reelmaster 5010 Series
Page 3 -- 15
Kubota Diesel Engine
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9. Disconnect hydraulic transmission drive shaft from
engine (see Hydraulic Transmission Drive Shaft Re-
moval in the Service and Repairs section of Chapter 4
-- Hydraulic System). Support drive shaft away from en-
gine.
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.
2. Make sure that all parts removed from the engine
during maintenance or rebuilding are installed to the en-
gine.
10.Disconnect wire harness connectors from the follow-
ing engine components:
NOTE: Before disconnecting wire harness connectors,
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).
label all electrical leads for assembly purposes.
A. Alternator connector and stud.
B. Oil pressure switch located near the engine oil fil-
ter.
4. Install engine to machine.
C. Connector, fusible link connector and positive
battery cable from the starter motor.
A. Attach short section of chain between lift tabs lo-
cated on each end of the cylinder head
D. High temperature shut down switch and temper-
ature sender located on the water pump housing.
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.
E. Fuel stop solenoid on injector pump.
F. Negative battery cable and harness ground from
injector pump (Fig. 12).
CAUTION
G. Glow plug strip.
One person should operate lift or hoist while
another other person guides the engine into the
machine.
11.Remove engine from machine:
A. Attach short section of chain between lift tabs lo-
cated on each end of the cylinder head.
IMPORTANT: Make sure to not damage the engine,
fuel hoses, hydraulic lines, electrical harness, ra-
diator, battery or other parts while installing the en-
gine.
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. Lower engine to the machine frame. Make sure
fastener holes of the engine brackets are aligned
with the holes in the engine mounts.
C. Remove fasteners that secure the engine (with
brackets) to 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.
CAUTION
One person should operate lift or hoist while
another person guides the engine out of the ma-
chine.
5. Connect hydraulic transmission drive shaft to engine
(see Hydraulic Transmission Drive Shaft Installation in
the Service and Repairs section of Chapter 4 -- Hydrau-
lic System).
IMPORTANT: Make sure to not damage the engine,
fuel hoses, hydraulic lines, electrical harness, ra-
diator, battery or other parts while removing the en-
gine.
6. Connect all wire harness connectors to correct en-
gine components.
D. Raise engine and remove toward front of machin-
e.
12.If necessary, remove engine brackets from engine.
Kubota Diesel Engine
Page 3 -- 16
Reelmaster 5010 Series
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7. Remove plugs installed in hoses during disassem-
bly. Connect hoses to the engine:
9. Install air cleaner (see Air Cleaner Installation in this
section).
A. Connect fuel supply and fuel return hoses to en-
gine fittings (Fig. 11). Secure with hose clamps.
10.Install exhaust system to machine (see Exhaust
System Installation in this section).
B. Connect upper and lower radiator hoses to the
engine. Secure with hose clamps.
11.Add coolant to radiator.
12.Check engine oil level and adjust if needed.
8. Connect throttle cable to injector pump (Fig. 10):
A. Route throttle cable to injector pump on engine.
13.Connect positive (+) and then negative (--) battery
cables to the battery.
B. Install the throttle cable end into the swivel in
speed control lever. Secure cable end with cap
screw.
14.Bleed fuel system.
15.Close hood.
C. Position cable under cable clamp.
D. Adjust throttle control (see Adjust Throttle Con-
trol in the Adjustments section of this chapter).
Reelmaster 5010 Series
Page 3 -- 17
Kubota Diesel Engine
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Kubota Diesel Engine
Page 3 -- 18
Reelmaster 5010 Series
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Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Traction Unit Operator’s Manual . . . . . . . . . . . . . . . 3
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3
Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 4
Relieving Hydraulic System Pressure . . . . . . . . . . 6
Traction Circuit Component Failure . . . . . . . . . . . . 6
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 8
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lift Circuit: Raise Cutting Units . . . . . . . . . . . . . . . 12
Lift Circuit: Lower Cutting Units . . . . . . . . . . . . . . . 14
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 22
General Hydraulic System Problems . . . . . . . . . . 22
Traction Circuit Problems . . . . . . . . . . . . . . . . . . . . 23
Mow Circuit Problems . . . . . . . . . . . . . . . . . . . . . . . 24
Lift Circuit Problems . . . . . . . . . . . . . . . . . . . . . . . . 25
Steering Circuit Problems . . . . . . . . . . . . . . . . . . . 26
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Traction Circuit Relief Valve (R3) and (R4)
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 58
General Precautions for Removing and Installing
Hydraulic System Components . . . . . . . . . . . . . 58
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 59
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 60
Filtering Closed--Loop Traction Circuit . . . . . . . . . 61
Hydraulic System Start--up . . . . . . . . . . . . . . . . . . 62
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 64
Hydraulic Pump Drive Shaft . . . . . . . . . . . . . . . . . 66
Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . . 68
Piston (Traction) Pump Service . . . . . . . . . . . . . . 72
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 74
Front Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . 76
Motor Service (Parker) . . . . . . . . . . . . . . . . 80
Wheel
Wheel Motor Service (Eaton) . . . . . . . . . . . . . . . . 81
Mow Control Manifold . . . . . . . . . . . . . . . . . . . . . . . 82
Mow Control Manifold Service . . . . . . . . . . . . . . . 84
Lift Control Manifold . . . . . . . . . . . . . . . . . . . . . . . . 88
Lift Control Manifold Service . . . . . . . . . . . . . . . . . 90
CrossTraxTM AWD (Optional Kit) Manifold . . . . . . 92
CrossTraxTM AWD (Optional Kit) Manifold
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cutting Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cutting Reel Motor Service . . . . . . . . . . . . . . . . . . 98
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . 104
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 106
Steering Control Valve Service . . . . . . . . . . . . . . 108
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Steering Cylinder Service . . . . . . . . . . . . . . . . . . 112
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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)
EATON DELTA MOTORS PARTS AND REPAIR
MANUAL
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Traction Circuit Charge Pressure Test . . . . . . . . . 32
Gear Pump (P3) Flow Test . . . . . . . . . . . . . . . . . . 34
Front Wheel Motor Efficiency Test . . . . . . . . . . . . 36
Piston (Traction) Pump Flow Test . . . . . . . . . . . . . 38
Relief Valve (R1) and (R2) Pressure Test . . . . . . 40
Gear Pump (P1) and (P2) Flow Test . . . . . . . . . . 42
Reel Drive Motor Efficiency Test . . . . . . . . . . . . . . 44
Reel Drive Motor Cross--Over Relief Pressure
Test (Reelmaster 5510 and 5610) . . . . . . . . . . . 46
Lift Relief Valve (R6) Pressure Test . . . . . . . . . . . 48
Gear Pump (P4) Flow Test . . . . . . . . . . . . . . . . . . 50
Lift Cylinder Internal Leakage Test . . . . . . . . . . . . 52
Steering Relief Valve (R10) Pressure Test . . . . . 54
Steering Cylinder Internal Leakage Test . . . . . . . 56
SAUER--DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Reelmaster 5010 Series
Page 4 -- 1
Hydraulic System (Rev. C)
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Specifications
Item
Description
Piston (Traction) Pump
Maximum Pump Displacement (per revolution)
Sauer--Danfoss, LPV Closed Circuit Axial Piston Design
2.14 Cubic Inches (35 cc)
Gear Pump
Casappa 4 section, positive displacement gear type pump
0.50 Cubic Inches (8.3 cc)
Section P1/P2 Displacement (per revolution) (RM 5210 & 5410)
Section P1/P2 Displacement (per revolution) (RM 5510 & 5610)
Section P3 Displacement (per revolution) (all models)
Section P4 Displacement (per revolution) (all models)
0.66 Cubic Inches (10.8 cc)
0.37 Cubic Inches (6.1 cc)
0.24 Cubic Inches (3.9 cc)
Charge Circuit Relief (R5) Pressure
200 PSI (14 bar)
Traction Circuit Relief Pressure: Forward (R3) and Reverse (R4)
Front Wheel Motors (see NOTE below)
3625 PSI (250 bar)
Parker orbital rotor motor, TG Series
Eaton geroler motor, Delta Series
Rear Wheel Motors (if equipped)
Parker orbital rotor motor, TL Series
Mow Circuit Relief Pressure
Rear Mow Circuit (R1)
Front Mow Circuit (R2)
2500 PSI (172 bar)
3500 PSI (241 bar)
Cutting Unit Motor (RM 5210 & RM 5410)
Displacement (per revolution)
Sauer--Danfoss gear motor
0.73 Cubic Inches (12 cc)
Cutting Unit Motor (RM 5510 & RM 5610)
Displacement (per revolution)
Cross Over Relief Valve Pressure
Bosch gear motor
1.18 Cubic Inches (19.3 cc)
1500 PSI (103 bar)
Steering Valve
Sauer--Danfoss Steering Unit, Type OSPMS
1000 PSI (69 bar)
Steering Circuit Relief (R10) Pressure
Lift Circuit Relief (R6) Pressure
2000 PSI (138 bar)
Lift Circuit Lower Relief (R7) Pressure
Hydraulic Filter (Transmission and Steering Circuits)
Hydraulic Filter (Mow and Lift Circuits)
500 PSI (34 bar)
Spin--on Cartridge Type with 50 PSI (3.4 bar) Relief in Adapter
Spin--on Cartridge Type with 50 PSI (3.4 bar) Relief in Adapter
(filter adapter includes filter change indicator)
Hydraulic Oil
See Traction Unit Operator’s Manual
11 U.S. Gallons (41.6 L)
Hydraulic Reservoir Capacity
NOTE: Machines produced with serial number below
311000600 were produced with Parker brand front
wheel motors. Machines with serial number above
311000600wereproducedwithEatonbrandfrontwheel
motors. If Parker brand wheel motors have been re-
placed, the replacement wheel motors may have been
Eaton brand.
Hydraulic System (Rev. C)
Page 4 -- 2
Reelmaster 5010 Series
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General Information
Traction Unit Operator’s Manual
The Traction Unit Operator’s Manual provides informa-
tion regarding the operation, general maintenance and
maintenance intervals for your Reelmaster machine.
Refer to that publication for additional information when
servicing the machine.
Check Hydraulic Fluid
The hydraulic system on Reelmaster 5010 series ma-
chines is designed to operate on high quality hydraulic
fluid. The hydraulic system reservoir holds approxima-
tely 11 gallons (41.6 liters) of hydraulic fluid. Check lev-
elofhydraulic fluiddaily. SeeTraction UnitOperator’s
Manual for fluid level checking procedure and hydraulic
oil recommendations.
1
Figure 1
1. Hydraulic reservoir cap
Towing Traction Unit
IMPORTANT: If towing limits are exceeded, severe
damage to the piston (traction) pump may occur.
If it becomes necessary to tow or push the machine, tow
or push at a speed below 3 mph (4.8 kph), and for a very
short distance. If the machine needs to be moved a con-
siderable distance, machine should be transported on a
trailer. The piston (traction) pump is equipped with a by-
passvalvethatneedstobeloosened fortowing orpush-
ing (Fig. 2). See Traction Unit Operator’s Manual for
Towing Procedures.
2
1
Figure 2
1. Piston (traction) pump
2. Bypass valve
Reelmaster 5010 Series
Page 4 -- 3
Hydraulic System (Rev. C)
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Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage condi-
tionsormishandlingduringoperation andmaintenance.
Theseconditionscancausedamageorprematuredete-
rioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
WARNING
Before disconnecting or performing any work
on hydraulic system, relieve all pressure in
system. Stop engine; lower or support all cut-
ting units.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint on the hose.
Use two wrenches; hold the hose straight with one
wrench and tighten the hose swivel nut onto the fitting
with the other wrench.
Keepbodyandhandsawayfrompinholeleaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands,
to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgi-
cally removed within a few hours by a doctor
familiar with this type of injury. Gangrene may
result from such an injury.
Hydraulic Fitting Installation
O--Ring Face Seal
Nut
Body
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches or any foreign material.
Sleeve
2. Make sure the O--ring is installed and properly
seated in the groove. It is recommended that the O--ring
be replaced any time the connection is opened.
Seal
3. Lubricate the O--ring with a light coating of oil.
4. Put the tube and nut squarely into position on the
face seal end of the fitting and tighten the nut until finger
tight.
Figure 3
5. Mark the nut and fitting body. Hold the body with a
wrench.Useanotherwrenchtotightenthenuttothecor-
rect Flats From Finger Tight (F.F.F.T.). The markings on
the nutand fittingbody willverify thatthe connectionhas
been tightened.
Final
Position
Mark Nut
and Body
Size
F.F.F.T.
Initial
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
0.75 + 0.25
0.75 + 0.25
0.75 + 0.25
1.00 + 0.25
0.75 + 0.25
0.75 + 0.25
Extend Line
Position
Finger Tight
After Proper Tightening
Figure 4
16 (1 in.)
Hydraulic System (Rev. C)
Page 4 -- 4
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