Toro 5210/5410/5510/5610 User manual

Part No. 06148SL (Rev. C)

Service Manual

ReelmasterR5210/5410/5510/5610

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. Additional copies of the Operator’s

Manual and Parts Catalog are available on the internet

at www.Toro.com.

TheToroCompanyreservestherighttochangeproduct

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: ANOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portantinstructionswhichmustbefollowedtopre-

vent damage to systems or components on the

machine.

EThe Toro Company -- 2006, 2007, 2009, 2012

Reelmaster 5010 Series

This page is intentionally blank.

Rev. C

Reelmaster 5010 Series

Table Of Contents

Chapter 1 -- Safety

Safety Instructions 1 -- 2..........................

Jacking Instructions 1 -- 4.........................

Safety and Instruction Decals 1 -- 4................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Kubota Diesel Engine

General Information 3 -- 1........................

Specifications 3 -- 2..............................

Adjustments 3 -- 5...............................

Service and Repairs 3 -- 6........................

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 -- 22...........................

Testing 4 -- 28...................................

Service and Repairs 4 -- 58.......................

SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL

PISTON PUMPS REPAIR MANUAL

SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL

PISTON PUMPS SERVICE INSTRUCTIONS

PARKER TORQMOTORTM SERVICE PROCEDURE

(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

EATON DELTA MOTORS PARTS AND REPAIR

MANUAL

SAUER--DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

Chapter 5 -- Electrical System

General Information 5 -- 1........................

Electrical Diagrams 5 -- 1.........................

Special Tools 5 -- 2..............................

Troubleshooting 5 -- 4............................

Electrical System Quick Checks 5 -- 18.............

Adjustments 5 -- 20..............................

Component Testing 5 -- 23........................

Service and Repairs 5 -- 46.......................

Chapter 6 -- Chassis

Specifications 6 -- 2..............................

General Information 6 -- 2........................

Service and Repairs 6 -- 4........................

Chapter 7 -- Cutting Units

Specifications 7 -- 2..............................

General Information 7 -- 3........................

Special Tools 7 -- 4..............................

Factors That Can Affect Cutting Performance 7 -- 8..

Set--Up and Adjustments 7 -- 11...................

Service and Repairs 7 -- 14.......................

Chapter 8 -- Groomer

Grooming Performance 8 -- 2.....................

Troubleshooting 8 -- 3............................

Adjustments 8 -- 4...............................

Service and Repairs 8 -- 5........................

Chapter 9 -- Foldout Drawings

Hydraulic Schematics 9 -- 3.......................

Electrical Schematics 9 -- 5.......................

Electrical Circuit Diagrams 9 -- 7...................

Wire Harness Drawings 9 -- 12....................

Turf DefenderTM (Optional) Electrical Schematic9 -- 18

SafetyProduct Records

and Maintenance

Cutting Electrical

System Hydraulic

System Kubota Diesel

Engine

Groomer Chassis

Units

Foldout

Drawings

Reelmaster 5010 Series

This page is intentionally blank.

Rev. B

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 4..........

Safety

Rev. B 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 safetyinstructions.

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. Additional copies of the Operator’s Manual are

available on the internet at www.Toro.com.

2. Keep all shields, safety devices and decals in place.

If a shield, safety device or decal is defective, illegible

or damaged, repair or replace it before operating the

machine. Also tighten any loose nuts, bolts or screws to

ensure machine is in safe operating condition.

3. Assure interlock switches are adjusted correctly so

engine cannot be started unless traction pedal is in

NEUTRAL and PTO switch is OFF (disengaged).

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 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.

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 near a water heat-

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

Rev. B Reelmaster 5010 SeriesPage 1 -- 4Safety

Jacking Instructions

When changing attachments, tires orperform-

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. Apply parking brake and chock both front tires to pre-

vent the machine from moving.

2. Place jack securely at the center of the rear axle un-

der the axle pivot bracket. Jack rear of machine off the

ground.

3. Position jack stands under the frame to support the

machine.

Figure 1

1. Front wheel 2. Front jacking point

1

2

Figure 2

1. Axle center 2. Jack stand location

2

1

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

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.......................

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.

Product Records

and Maintenance

0.09375

Reelmaster 5010 SeriesPage 2 -- 2Product Records and Maintenance

Equivalents and Conversions

Rev. B

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

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.

Example: The measured effective length of the torque

wrench (distance from the center of the handle to the

center of the square drive) is 18”.

The measured effective length of the torque wrench with

the offset wrench installed (distance from the center of

the handle to the center of the offset wrench) is 19”.

The calculated torque conversion factor for this torque

wrench with this offset wrench would be 18 / 19 = 0.947.

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.

Figure 3

(effective length of

torque wrench)

TORQUE CONVERSION FACTOR = A / B

A

B

(effective length of torque

Torque wrenchOffset wrench

wrench + offset wrench)

Product Records

and Maintenance

Rev. B Reelmaster 5010 SeriesPage 2 -- 4Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

Grade 1, 5 &

8withThin

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)

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

# 6 -- 32 UNC

1

0

+

2

1

3

+

2

1

4

7

+

2

3

15 + 2169 + 23 23 + 3262 + 34

# 6 -- 40 UNF

10 + 213 + 2147 + 23

17 + 2192 + 23 25 + 3282 + 34

# 8 -- 32 UNC

1

3

+

2

5

+

5

2

8

2

+

3

0

29 + 3328 + 34 41 + 5463 + 56

# 8 -- 36 UNF

13 + 225 + 5282 + 30

31 + 4350 + 45 43 + 5486 + 56

#10--24UNC

1

8

+

2

3

0

+

5

3

9

+

5

6

42 + 5475 + 56 60 + 6678 + 68

#10--32UNF

18 + 230 + 5339 + 56

48 + 5542 + 56 68 + 7768 + 79

1/4 -- 20 UNC 48 + 753 + 7599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169

1/4 -- 28 UNF 53 + 765 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

3/8 -- 16 UNC 16 + 216 + 222 + 330 + 341 + 443 + 558 + 7

3/8 -- 24 UNF 17 + 218 + 224 + 335 + 447 + 550 + 668 + 8

7/16 -- 14 UNC 27 + 327 + 337 + 450 + 568 + 770 + 795 + 9

7/16 -- 20 UNF 29 + 329 + 339 + 455 + 675 + 877 + 8104 + 11

1/2 -- 13 UNC 30 + 348 + 765 + 975 + 8102 + 11 105 + 11 142 + 15

1/2 -- 20 UNF 32 + 453 + 772 + 985 + 9115 + 12 120 + 12 163 + 16

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89

NOTE: Reduce torque values listed in the table above

by 25% for lubricated fasteners. Lubricated fasteners

are defined as threads coated with a lubricant such as

engine oil or thread sealant such as Loctite.

NOTE: Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass.

The specific torque value should be determined based

on the fastener size, the aluminum or base material

strength, length of thread engagement, etc.

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.

Reelmaster 5010 Series Page 2 -- 5 Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

T

h

r

e

a

d

S

i

z

e

Class 8.8 Bolts, Screws and Studs with

R

e

g

u

l

a

r

H

e

i

g

h

t

N

u

t

s

Class 10.9 Bolts, Screws and Studs with

R

e

g

u

l

a

r

H

e

i

g

h

t

N

u

t

s

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

Regular Height Nuts

(Class 10 or Stronger Nuts)

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm

M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm

M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m

M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m

M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m

M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m

NOTE: Reduce torque values listed in the table above

by 25% for lubricated fasteners. Lubricated fasteners

are defined as threads coated with a lubricant such as

engine oil or thread sealant such as Loctite.

NOTE: Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass.

The specific torque value should be determined based

on the fastener size, the aluminum or base material

strength, length of thread engagement, etc.

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.

Product Records

and Maintenance

Reelmaster 5010 SeriesPage 2 -- 6Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws

T

h

r

e

a

d

S

i

z

e

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb

1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

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

S

i

z

e

Threads per Inch

B

a

s

e

l

i

n

e

T

o

r

q

u

e

*

Size

Type A Type B

Baseline Torque

*

No. 6 18 20 20 + 5in--lb

No. 8 15 18 30 + 5in--lb

No. 10 12 16 38 + 7in--lb

No. 12 11 14 85 + 15 in--lb

* Hole size, material strength, material thickness and 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.

Kubota Diesel

Engine

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

Kubota Diesel

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

Kubota Diesel

Engine

Reelmaster 5010 SeriesPage 3 -- 6Kubota Diesel Engine

Service and Repairs

Fuel System

Figure 2

1. Fuel cap

2. Bushing

3. Washer head screw (3 used)

4. Flange nut (3 used)

5. Clamp (3 used)

6. Return fitting

7. Suction fitting

8. Hose clamp

9. Hose clamp

10. Fuel tank

11. Grommet

12. Fuel gauge

13. Hose clamp

14. Draincock

15. Fuel hose

16. Return fuel hose

FRONT

RIGHT

12

11

10

5

2

6

2

7

14

5

3

9

8

1

13

4

3

15

16

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Toro 5210/5410/5510/5610 User manual

Toro 5210/5410/5510/5610 User manual

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