Toro Reelmaster 5100-D Service Manual page 83

Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . 3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC SCHEMATIC. . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 7
Traction Forward . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lower Cutting Units / Mow . . . . . . . . . . . . . . . . . 8
Backlap - Front . . . . . . . . . . . . . . . . . . . . . . . . . 10
Raise Cutting Units . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 15
Transmission Operates in One Direction Only . 15
Traction Pedal Does Not
Return to Neutral Properly . . . . . . . . . . . . . . . 15
Transmission Jerky When Starting . . . . . . . . . . 15
Transmission Operating Hot . . . . . . . . . . . . . . . 16
Loss of Traction Power or
Unit Will Not Operate In Either Direction . . . . 17
No Cutting Units Operate . . . . . . . . . . . . . . . . . 17
Front Reels Will Not Turn in Either Direction. . . 18
Front Reels Turn in Only One Direction . . . . . . . .
Front Reel(s) Turn Too Slow . . . . . . . . . . . . . . . 19
Front Reels Turn Too Fast. . . . . . . . . . . . . . . . . 20
Front Reels Turn in Only One Direction . . . . . . 20
Front Reels Stop Under Load . . . . . . . . . . . . . . 20
Front Reel Speed Erratic. . . . . . . . . . . . . . . . . . 21
Front Reels Stop or
Won't Stop During Backlap Only . . . . . . . . . 21
Rear Cutting Unit Problems . . . . . . . . . . . . . . . 21
Cutting Unit(s) Will Not Raise . . . . . . . . . . . . . . 22
Cutting Units Raise, But Will Not Stay Up . . . . . 23
Cutting Units Raise Too Fast or Too Slow . . . . . 23
Cutting Units Will Not Lower . . . . . . . . . . . . . . . 24
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Test No. 1: Traction Circuit Charge Pressure . . 26
®
Reelmaster 5100-D
Hydraulic System
Test No. 2:Traction Circuit System Pressure . . . 27
Test No. 3: Front Mow/Lift Circuit Pressure . . . . 28
Test No. 4: Rear Mow Circuit Pressure . . . . . . . 29
Test No. 5: Reel Drive Pump Efficiency . . . . . . . 30
Test No. 6: Reel Drive Circuit Flow . . . . . . . . . . 31
Test No. 7: Reel Drive Motor Efficiency
and Mow Circuit Relief Pressure . . . . . . . . . . 32
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Traction Control Neutral Adjustment . . . . . . . . . 33
Lift Circuit Variable Orifice Adjustment . . . . . . . 34
TRANSMISSION REPAIRS . . . . . . . . . . . . . . . . . . 35
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . 35
Transmission Control Linkage Removal . . . . . . 36
Trunnion Seal Replacement . . . . . . . . . . . . . . . 37
Check and High Pressure Relief Valves . . . . . . 38
Charge Pressure Relief Valve . . . . . . . . . . . . . . 39
Heat Exchanger Bypass Valve . . . . . . . . . . . . . 40
Filter Bypass Valve . . . . . . . . . . . . . . . . . . . . . . 40
Filter Bypass Reverse Flow Check Valve . . . . . 41
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Transmission Removal and Installation . . . . . . . 43
Disassembly of Transmission . . . . . . . . . . . . . . 44
Assembly of Transmission . . . . . . . . . . . . . . . . . 49
MOWING CIRCUIT REPAIRS . . . . . . . . . . . . . . . . 54
Valve Block Service . . . . . . . . . . . . . . . . . . . . . . 54
Cartridge Valve Service . . . . . . . . . . . . . . . . . . . 55
Cartridge Valve Identification . . . . . . . . . . . . . . . 56
Pump Removal and Installation . . . . . . . . . . . . . 58
Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Reel Motor Removal and Installation. . . . . . . . . 61
Reel Motor Shaft Seal Replacement . . . . . . . . . 62
Reel Motor Repair . . . . . . . . . . . . . . . . . . . . . . . 63
Lift Cylinder Removal and Installation . . . . . . . . 64
Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . 65
Flushing The Hydraulic System . . . . . . . . . . . . . 67
Inspecting Reservoir Parts . . . . . . . . . . . . . . . . 68
Page 4 - 1 Rev. A
Chapter 4
Table of Contents