Toro Lawn Mower 5210 5410 5510 5610 User Guide

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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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  
Reelmaster 5010 Series  
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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  
Reelmaster 5010 Series  
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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  
Page 2 -- 6  
Reelmaster 5010 Series  
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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  
Page 3 -- 1  
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  
Page 3 -- 3  
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  
Reelmaster 5010 Series  
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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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Kubota Diesel Engine  
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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  
Page 3 -- 6  
Reelmaster 5010 Series  
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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  
Page 3 -- 7  
Kubota Diesel Engine  
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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  
Page 3 -- 8  
Reelmaster 5010 Series  
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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  
Page 3 -- 9  
Kubota Diesel Engine  
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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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Reelmaster 5010 Series  
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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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Kubota Diesel Engine  
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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  
Page 3 -- 12  
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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  
Page 3 -- 13  
Kubota Diesel Engine  
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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  
Page 3 -- 14  
Reelmaster 5010 Series  
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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)  
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Reelmaster 5010 Series  
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