Page 1: Service Manual
Bloomington, MN 55420 portant instructions which must be followed to pre vent damage to systems or components on the The Toro Company reserves the right to change product machine. specifications or this publication without notice. © The Toro Company - 1992 - 1997, 2004...
Page 2 This page is blank.
Page 3: Table Of Contents
Table Of Contents Chapter 1 - Safety Chapter 5 - Electrical System Safety Instructions ......1 - 1 Wiring Schematics and Diagrams.
Page 4 This page is blank.
Page 5: Safety Instructions
While Operating......2 Safety Instructions The Reelmaster 5100-D was tested and certified by TORO for compliance with the B71.4-1990 specifica...
Page 6: While Operating
8. Since diesel fuel is highly flammable, handle it C. Do not smoke while handling fuel. carefully: D. Fill fuel tank outdoors and only to within an inch A. Use an approved fuel container. of the top of the tank, not the filler neck. Do not overfill.
Page 7 ARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS . For your pro ence to perform the job. Have it done by your Toro RESPIRATORY OR OTHER BODILY HARM tection: Distributor or a qualified tire service.
Page 8 ® Safety Instructions Page 1 - 4 Reelmaster 5100-D...
Page 9: Product Records
Record information about your Reelmaster 5100-D on Insert Operator’s Manuals and Parts Manuals for your the OPERATION AND SERVICE HISTORY REPORT Reelmaster 5100-D at the end of this section. form. Use this information when referring to your ma chine.
Page 10: Equivalents And Conversions
Equivalents and Conversions Decimal and Millimeter Equivalents ___ ________________ ______ ________________ __________________________________________________ Fractions Decimals Fractions Decimals ___ ________________ ______ ________________ __________________________________________________ 1/64 0.015625 — 0.397 33/64 0.515625 — 13.097 1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494 3/64 0.046875 —...
Page 11: Torque Specifications
Torque Specifications Use these torque values when specific torque values specified values. Torque values listed are for lubricated are not given. DO NOT use these values in place of threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S. Customary SAE Grade Number _____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________...
Page 12: Maintenance Interval Charts
Maintenance Interval Chart ® Page 2 - 4 Rev. A Maintenance Interval Chart Reelmaster 5100-D...
Page 13: Equipment Operation And Service History Report
Drive Axle(s) Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone __________________ See your TORO Distributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.
Page 14 REELMASTER® 223-D, 5100-D, and 5300-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Every 800hrs Check Battery Fluid Level Every 400hrs 200hrs 100hrs 50hrs Check Battery Cable Connections Lubricate All Grease Fittings Change Engine Oil A Level Service Inspect Air Filter, Dust Cup, and Baffle...
Page 15 REELMASTER® 223-D, 5100-D and 5300-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item...
Page 17 Chapter 3 Mitsubishi Diesel Engine Table of Contents INTRODUCTION ......2 Thermostat Removal and Installation ..29 SPECIFICATIONS .
Page 18: Introductions
Limited. Service and repair parts for Mitsubishi engines are supplied through TORO Distributors. Re pair parts may be ordered by TORO Part Number. If no parts list is available be sure to provide your dealer or distributor with the TORO Model Number and Serial Number.
Page 19: Specifications
Specifications The illustrations (Figs. 2a and 2b) will give information Refer to the specifications listed in this section when about the general construction of the engine. performing tests on the engine or examining parts for wear. Some specifications are included in the service procedures later in this chapter.
Page 20: General
General Item Specification ________________________________________________________________________________________ Make/Designation Mitsubishi L3E-61TG, overhead valve, vertical in-line, 4 cycle diesel ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ Combustion Chamber Swirl chamber type ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ Number of Cylinders...
Page 21: Engine
Engine Item Standard Specification Repair Limit Service Limit ___________________________________________________________________________________________ Governor Mechanical/Centrifugal ________________________________________________________________________________________________________________________ ________________________________ + 50 Operating Speed (no load) 3200 rpm – 0 ________________________________________________________________________________________________________________________ ________________________________ + 50 Idle Speed (no load) 1700 rpm – 0 ________________________________________________________________________________________________________________________ ________________________________ Compression 28 kg/cm (398 psi) at 280 rpm 25 kg/cm (356 psi)
Page 22 Engine (cont.) Item Standard Specification Repair Limit Service Limit ________________________________________________________________________________________ Piston Type Solid Material Aluminum alloy Piston Outside Diameter (skirt end) 76 mm (2.99 in.) Piston to Cylinder Wall Clearance 0.3 mm (0.012 in.) Oversize 0.25, 0.50 mm (0.01, 0.02 in.) Protrusion from cylinder block top surface 0.9 mm (0.035 in.)
Page 23: Lubrication System
Engine (cont.) Item Standard Specification Repair Limit Service Limit _________________________________________________________________________________________ Camshafts Drive System Gear Front Journal Ball bearing Journal to Cylinder Block Hole Clearance 0.15 mm (0.006 in.) Cam Lobe Major Diameter 27.37 mm (1.078 in.) – 1.0 mm (– 0.0433 in.) (both intake and exhaust) Cam Lobe Major Diameter (pump cam) 30 mm (1.224 in.)
Page 24: Fuel System
Fuel System Item Standard Specification Repair Limit Service Limit _________________________ ______________________________________________________________ Fuel Pump Delivery Rate 225 cc (13.73 in ) or more (15 sec., 12V) ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ _____ ___ ______ ___ ______ __ ______ ___ ______ Fuel Injection Pump...
Page 25: Electrical System
Electrical System Item Standard Specification Repair Limit Service Limit _________________________________________________________________________________________ Starter Type Solenoid shift type Nominal Output 1.6 kW - 12V Direction of Rotation Clockwise as viewed from pinion side No l oad Characteristics (Cold) Terminal Voltage 11.5V Current 100A or less Speed 3000 rpm or more Load Characteristics...
Page 26: Tightening Torque
Tightening Torque The Mitsubishi diesel engine has many bolts and of the engine. The torque specifications in American capscrews of special materials and sizes. It is very Standard and Metric as listed below MUST be followed important that special care be used to replace all bolts in order to have the assembled engine conform to the and capscrews in their proper location during assembly original specifications.
Page 27: Special Tools
Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products) . Some tools may be available from a local supplier. Filter Cleaner Filter cleaner (Fig. 3). Mix with water and use solution to wash the Donaldson air cleaner element.
Page 28 Nozzle Tester Nozzle tester (Fig. 7). Tests condition and opening pressure of fuel injector nozzles. Figure 7 Nozzle Tester Adapter Nozzle tester adapter (Fig.8) is required to test the fuel injection nozzles. Figure 8 ® Special Tools Page 3 - 12 Reelmaster 223-D/5100-D...
Page 29: Adjustments
Adjustments Valve Clearance Check the valve clearance after the first 50 hours of operation and every 400 hours of operation after that. 1. The engine must be cold when the valve clearance is checked. 2. Remove the air breather hose from the rocker cover. 3.
Page 30: Engine Speed Adjustments
Engine Speed Adjustments Adjustments to the engine speed settings are not nor mally necessary unless the throttle linkage, injection pump, or governor mechanism have been repaired, rebuilt, replaced or are not operating correctly. Since there is no ignition system from which to power an electronic tachometer, a vibration-type tachometer must be used to set engine speed.
Page 31: Troubleshooting
Throttle Linkage Adjustment 1. Loosen the capscrew and nut securing the throttle cable to the governor lever (Fig. 14) 2. Push the governor lever all the way back so it is contacting the high speed set screw. 3. Move the throttle lever (Fig. 13) to the maximum speed position (all the way forward).
Page 32 ® Troubleshooting Page 3 - 16 Reelmaster 223-D/5100-D...
Page 33 ® Reelmaster 223-D/5100-D Page 3 - 17 Troubleshooting...
Page 34: Testing
Testing Glow Plug Test CAUTION Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac cidental contact with the heated plug tip could cause personal injury. 1. Disconnect the wire lead(s) to the glow plug. 2.
Page 35: Compression Test
Compression Test Normal cylinder compression is 28 kg/cm (398 psi) at 280 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50 C (120 IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic”...
Page 36: Nozzle Tests
Nozzle Tests There are several tests to examine the condition of the 3. Allow pressure to dissipate before performing the test. injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. (See the Spe 4.
Page 37 amount of fuel may be present due to a previous chat tering test - this would be normal. If the fuel accumulates and drips down during the test (about ten seconds) the nozzle assembly is defective and must be replaced. Spray Test For proper combustion, the nozzle must effectively at...
Page 38: Injection Pump Test
Injection Pump Test Calibration of fuel delivery volumes, pressure and dis D. Put the throttle control in the FAST position. Turn tribution between pump barrels should be performed by the ignition key to the START position to crank the a professional diesel engine service shop.
Page 39: Injection Timing Test
Injection Timing Test Injection timing can be adjusted by installing shims pipe. If the slowest flow rate exceeds 1 drop in 5 under the pump body. The timing is important because seconds, repair of the pump should be considered. it determines when the fuel enters the combustion chamber.
Page 40: Fuel Pump Test
Fuel Pump Test 1. Turn the ignition switch to the ON position. Test for pump operation by listening for the pump oscillating sound, or by feeling for vibration which indicates the pump is operating. 2. If no pumping action occurs when the ignition switch is turned on, connect a 12 volt DC battery directly to the pump (Fig.
Page 41: Preparation For Engine Repair
Preparation for Engine Repair 1. Before cleaning and disassembly, carefully check for engine oil to disassembled parts, as necessary to pre problems that cannot be found after the engine has vent rust. been cleaned or disassembled (e.g. oil leaks from cracked components, gaskets or loose fittings, dam ...
Page 42: External Engine Component Repair
External Engine Component Repair Fan Belt and Alternator Belt Replacement 1. Put machine on a level surface, engage parking brake, stop engine and remove key from ignition switch. Open hood. 2. Loosen locknut on belt tensioner lever (Fig. 24a). If replacing alternator belt, loosen bolt securing alternator brace to engine and bolt securing alternator to brace (Fig.
Page 43: Alternator Removal And Installation
Alternator Removal and Installation 1. Disconnect the negative (–) cable from the battery. 2. Disconnect the wire from terminal “B” on the back of the alternator. 3. Disconnect the alternator wiring harness connector. 4. Loosen alternator brace bolt and alternator support bolt (Fig.
Page 44: Replacing And/Or Adjusting Stop Solenoid
Replacing and/or Adjusting Engine Stop Solenoid See Chapter 5 - Electrical System for information about 7. Hold the solenoid body to prevent it from turning and testing the engine stop solenoid. tighten the nut against the engine to secure the adjust ment.
Page 45: Glow Plug Replacement
Glow Plug Replacement Replace the glow plug(s) if they do not operate correctly. 3. Remove the glow plug. (See Glow Plug Test in the Testing section of this chap ter.) 4. Install a new glow plug. Tighten the glow plug to a torque of 11-14.5 ft-lb (1.5-2 KgM).
Page 46: Water Pump Service
Water Pump Service 1. Drain the cooling system. 2. Remove the drive belt from the water pump and alternator. 3. Loosen the hose clamp and disconnect the hose from the water pump. 4. Remove the water pump (Fig. 32). 5. Check the water pump for cracks or leaks. Rotate the water pump shaft by hand.
Page 47: Governor System Repairs
Governor System Repairs Governor Operation The governor keeps the engine operating at a constant governor weights, thus maintaining constant engine speed by balancing the centrifugal force acting on the speed. governor weights and the governor spring tension. As the engine picks up speed, the governor weights open When the speed control lever is pulled toward high to move the sliding shaft forward.
Page 48: Governor Inspection
Governor Inspection A governor failure can cause engine starting failure, loss 4. Push the tie rod forward only with only enough force of engine speed control, or engine surging (hunting). to overcome the spring pressure and operate the speed Before removal and disassembly of the engine the control lever (or throttle lever).
Page 49: Governor Service
Governor Service 1. Remove the tie rod cover (Fig. 33). 2. Remove the tie rod clip and disconnect the tie rod from the injection pump control rack. 3. Disconnect the governor spring from the tension lever. 4. Remove the cover assembly. 5.
Page 50: Installation Of Torque Spring Set
Installation of Torque Spring Set IMPORTANT: Torque spring set adjustment has been done and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary. The torque spring set adjustment is very sensitive. Improper adjustment can vary fuel delivery to under power or over fuel the engine.
Page 51: Assembly Of Torque Spring Set
Assembly of Torque Spring Set If the torque spring set has been disassembled or parts replaced, reassemble and adjust the torque spring set using the following procedure. IMPORTANT: The torque spring set has been ad justed and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary.
Page 52: Fuel System Repairs
Fuel System Repairs When cleaning the engine, DO NOT spray water onto a tolerance parts of the fuel system can be easily dam hot injection pump. This could cause the fuel pump to aged by dirt. seize and be damaged. Wash fuel system parts in clean fresh diesel fuel.
Page 53: Bleeding Air From The Injectors
Bleeding Air From the Injectors This procedure should only be used if the fuel system has been purged of air. (See Bleeding the Fuel System in this section of the book.) 1. Loosen the pipe connection at the number one nozzle and holder assembly on the cylinder head (Fig.
Page 54: Injection Pump Service
5. Carefully remove the spring retainer from the end of the plunger tube (Fig. 43). Remove the washer, o-ring, valve, plunger spring and plunger. IMPORTANT: Be careful not to bend or deform the plunger tube while disassembling the fuel pump. If the plunger tube is bent, the fuel pump plunger will bind and the pump will need to be replaced.
Page 55 Injection Pump Disassembly 3. Remove the tappet roller and stopper pin. Remove the tappet and adjusting shim. IMPORTANT: Do not mix the delivery valves, deliv ery valve seats, plungers or plunger barrels from 4. Remove the lower seat from the plunger. Remove the one cylinder to another.
Page 56 Injection Pump Inspection Inspect the injection pump parts for proper operation, wear, corrosion, seizure, etc. (Fig. 47). Replace worn or damaged parts. Injection Pump Assembly 1. Insert the plunger barrel into the housing. 2. Install the delivery valve seat, gasket, delivery valve and valve spring.
Page 57: Nozzle Service
Nozzle Service IMPORTANT: When servicing the injection nozzles make sure that the engine and fuel delivery pipes are clean to prevent dirt from entering cylinder or nozzle. Do not mix components of one nozzle with the other. Nozzle Removal and Disassembly 1.
Page 58 Nozzle Inspection and Cleaning 1. Clean the inside and outside of the retaining nut in clean diesel fuel or kerosene to remove carbon or fuel deposits. Inspect the lower seating surface for rust or damage. The sealing area may be restored with emery cloth.
Page 59: Removing And Installing The Fuel Tank
Removing and Installing the Fuel Tank 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove the key from the ignition swtich. 2. Open drain fitting on bottom of fuel tank and drain fuel into a suitable container.
Page 60: Removing And Installing The Engine
Removing and Installing the Engine Removing the Engine 1. Put machine on a level surface, lower the cutting leakage. Loosen hose clamp and remove fuel return units, stop the engine, engage the parking brakes and hose from rear fuel injector on engine. remove key from ignition switch.
Page 61: Installing The Engine
Installing the Engine 1. To install the engine, perform steps 2 - 17 of Removing the Engine in reverse order. 2. Install a new engine oil filter. Fill engine with the correct oil. Fill the cooling system with a 50/50 solution of ethylene glycol antifreeze and clean, soft water.
Page 62: Cylinder Head Overhaul
Cylinder Head Overhaul Cylinder Head Removal 1. If the engine will not be removed from the traction unit, lower the coolant level in the engine. Loosen the hose clamp and remove the upper radiator hose from the thermostat housing. Disconnect the coolant bypass hose from the thermostat housing.
Page 63: Cylinder Head Service
Cylinder Head Service 1. Use a valve lifter tool to compress the valve spring (Fig. 61). To remove each valve retainer, depress the retainer against the valve spring and remove the re tainer lock (Fig. 62). Remove the valve retainer, spring and valve.
Page 64: Valve Guides
8. Use a straight edge and feeler gauge to check the flatness of the cylinder head lower surface (Fig. 63). Be sure to check the surface variation crosswise, length wise, and diagonally. If the variation in surface flatness exceeds (0.05 mm) 0.002 in. , the cylinder head or cylinder block must be replaced or resurfaced.
Page 65: Valves
Valves 1. Carefully clean each valve with a wire wheel to remove all carbon deposits. 2. Check the valve face and valve stem for excessive wear, damage, cracks or deformation. If any of these conditions exist, the valve must be replaced. It is possi ble to reface the valve if the valve head thickness (margin width) is not less than the service limit (Fig.65).
Page 66: Valve Springs
Valve Springs 1. Check the valve springs for rust, pitting, cracks or other damage. 2. Check the squareness of the valve spring by putting it upright on a level surface. Any spring that is 3 or more out of square must be replaced. 3.
Page 67: Cylinder Head Reassembly And Installation
Cylinder Head Assembly and Installation 1. Install the thermostat housing. Use a new gasket. valve springs and valve retainers. Compress the spring with a valve lifter, then install the retainer lock. 2. Install the intake and exhaust manifolds. Use new gaskets.
Page 68 8. Make sure that the cylinder head and cylinder block surfaces are clean. Put a new gasket on the cylinder head. Insert dowel pins into two cylinder head bolt holes to assist in mounting the head onto the block. Carefully put the cylinder head into position on the cylinder block.
Page 69: Cylinder Block Overhaul
Cylinder Block Overhaul NOTE: The engine must be removed from the traction Removing and Installing The Engine section of this unit chassis and put in an engine stand. (See the chapter.) Gear Case and Oil Pump 1. Remove the crankshaft pulley. 4.
Page 70 7. Check removed parts for wear or damage (Fig. 73). Replace parts as necessary. Figure 73 ® Cylinder Block Overhaul Page 3 - 54 Reelmaster 223-D/5100-D...
Page 71 8. Check the governor parts for wear or damage (Fig 74). Replace parts as necessary. A. Remove the expansion plug (Fig 75). Be careful to not scratch the gear case. B. Pull out the grooved pin. C. Remove the shaft, spring and levers. D.
Page 72: Timing Gears And Camshafts
Timing Gears and Camshafts 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the gear case (see Gear Case and Oil Pump in this section). 3. Remove the snap ring and remove the idle gear (Fig.
Page 73 6. Check the gears for incorrect tooth contact, wear and 7. Inspect the camshaft parts (Fig. 80). Replace any damage. Replace any gears that are badly worn or parts that are worn or damaged. damaged. Major diameter of cam: Injection pump cam: 29.3 - 30 mm (1.154 - 1.181 in.) Maximum idle gear bushing to shaft clearance: Valve cam: 26.37 - 27.37 mm (1.038 - 1.078 in.) 0.2 mm (0.008 in.)
Page 74 8. Before installing the camshafts and timing gears, turn the crankshaft to set the No. 1 cylinder to top dead center (TDC) of the compression stroke. Reverse steps 1 - 5 to install the camshafts and timing gears (Fig. 81). Figure 81 9.
Page 75: Piston And Connecting Rod
Piston and Connecting Rod 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the oil pan and gasket. 3. Remove the oil screen NOTE: Before removing the pistons, mark the number of the cylinder onto the top of each piston and on the side face of each connecting rod (on the large end).
Page 76 8. Measure the piston outside diameter (Fig. 84). (See Cylinder Block in this section). Maximum piston to cylinder wall clearance: 0.3 mm (0.012 in.) Figure 84 9. Use a thickness gauge to check the piston ring side clearance (Fig. 85). If the piston ring side clearance exceeds the service limit, the ring must be replaced.
Page 77 11. To remove the piston from the connecting rod press the piston pin from each piston. Use the piston setting tool (Fig. 87). IMPORTANT: Do not attempt to remove the piston pins by driving then out with a hammer. A stuck piston pin, requiring excessive pressure to remove, should be replaced.
Page 78 15.Install the piston rings. Each piston ring has different wooden block. Make sure the arrow mark on top of the shape. Make sure they are installed in the proper posi piston is facing toward the front of the engine. tion and with the ring gaps in the directions as illustrated (Fig.
Page 79: Crankshaft
Crankshaft 1. Perform steps 1 - 5 under Piston and Connecting Rod in this section. 2. Remove the flywheel. 3. Remove the rear oil seal case. 4. Remove the main bearing caps (Fig. 91). Keep each set of bearings together with its bearing cap. 5.
Page 80 6. Measure the crankshaft for “run-out” (bend). Mount the crankshaft in a pair of V-blocks (or live centers) and use a dial indicator to measure the run-out in the crank shaft (Fig. 103). The maximum allowable crankshaft run-out is 0.05 mm (0.002 in.). 7.
Page 81 10. Reverse steps 1 - 5 to install the crankshaft (Fig. 97). When installing the No. 1 and No. 4 bearing caps, apply sealant (Permatex No. 2 or equivalent) to the upper surface that meets with the cylinder block. 11. Use a dial indicator to measure the crankshaft end play.
Page 82: Cylinder Block
Cylinder Block Before cleaning check the cylinder block for coolant leaks, oil leaks or damage. Clean all parts to remove dirt, oil, carbon deposits and water scale. Check the cylinder block for cracks or other damage. Check the water jacket for water scale and rust. Replace the cylinder block if necessary.
Page 83 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......2 Test No. 2:Traction Circuit System Pressure . . . 27 GENERAL INFORMATION .
Page 84: Specifications
1250 psi (cracking) ________________________________________________________________________________________________________________________ ________________________________ Reel Motor (5) External gear type ________________________________________________________________________________________________________________________ ________________________________ Valve Block Toro, cartridge logic, elec./hyd. solenoid actuated Front reel circuit relief pressure 3000 psi Rear reel circuit relief pressure 2000 psi ________________________________________________________________________________________________________________________ ________________________________ Hydraulic Oil – Reel Drive & Steering (Fig. 2) Group 1 (for ambient temp.
Page 85: Hydraulic Oil
NOTE: A red dye additive for the hydraulic system oil is available in 2/3 oz. bottles. One bottle is sufficient for 4 to 6 gallons of hydraulic oil. Order Part No. 44-2500 from your Authorized Toro Distributor. Figure 2 1. Hydraulic reservoir cap ®...
Page 86 ® Specifications Page 4 - 2 .2 Reelmaster 5100-D...
Page 87: General Information
General Information 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 WARNING tions or mishandling during operation or maintenance. These conditions can cause damage or premature de Before disconnecting or performing any work terioration.
Page 88 SAE Straight Thread O-Ring Port (Non-adjustable) 1. Make sure both threads and sealing surfaces are free of burrs, n cks, scratches, or any foreign material. 2. A ways rep ace the O-ring seal when th s type of fitting shows signs of leakage. 3.
Page 89: Towing
Pushing or Towing If it becomes necessary to tow the machine, tow it forward only and at a speed no greater than 10 mph. IMPORTANT: If these towing limits are exceeded, severe damage to the hydrostatic transmission may occur. To tow a disabled machine: 1.
Page 90: Hydraulic Schematic
Hydraulic Schematic ® Rev. A Hydraulic Schematic Page 4 - 6 Reelmaster 5100-D...
Page 91: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Traction Forward The hydrostatic transmission is driven by a drive shaft An integral charge pump provides a constant supply of off the front of the engine crankshaft. Pushing the top of charge oil to the variable displacement pump and closed the traction pedal, rotates the variable displacement loop circuit for lubrication and to make up for oil that is pump swash plate to create a flow of oil.
Page 92: Lower Cutting Units / Mow
Lower Cutting Units / Mow The hydraulic pump that provides oil flow to the reel flow to solenoid valve “S8” and out to the front reel drive circuit is driven off the PTO output shaft of the motors. Valve “VS1” is adjusted by the electronic control hydrostatic transmission.
Page 93 System Pressure Solenoids Energized Low Pressure, Return or Case Drain Mow Front and Rear: S1, VS1, S2, VS2 Lower All Cutting Units: S6, S3, S4, S5 Oil Flow NOTE: Shown with VS1 and VS2 fully energized (maximum reel speed). 250 PSI Steering Cylinder to port D1 Rear Lift Cylinders...
Page 94: Backlap Front
Backlap (Front Shown) During “backlap”, the circuits operate the same as in the mode. To backlap the front cuttting units, solenoid “mow” mode except for the operation of solenoid valves valve “S1” is energized allowing pressure to build in the “S8”...
Page 95: Raise Cutting Units
Raise Cutting Units The “P1” pump circuit controls the raise and lower The return oil from the cylinders is directed back to tank function of all five cutting units. On the “P1” pump circuit, externally from the valve block. maximum system pressure is limited by relief valve “R1” which is set at 3000 PSI.
Page 96: Special Tools
NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) . So me to ols may be lis ted in the Reelmaster 5100-D Parts Catalog. Some tools may also be available from a local supplier. Seal Protector Slide protector over reel motor shaft before installing shaft seal to protect seal from damage.
Page 97 Hydraulic Pressure Test Kit Used to take various hydraulic pressure readings for diagnostic tests. Quick disconnect fittings provided at tach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each, 1,000, 5,000 and 10,000 PSI gauges.
Page 98 You must have o-ring face seal (ORFS) adapter fittings 4. HIGH PRESSURE GAUGE: High range gauge to for this tester to use it on the Reelmaster 5100-D. accommodate pressure beyond the capacity of the low pressure gauge, 0 - 5000.
Page 99: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys The charts that follow contain detailed information to tem is best diagnosed with the use of proper testing assist in troubleshooting. There may possibly be more equipment and a thorough understanding of the com than one cause for a machine malfunction.
Page 100: Transmission Operating Hot
Machine Travels Too Far Before Stopping When Traction Pedal is Released Cause Correction __________________________________________________________________________________________ Traction linkage out of adjustment. Adjust traction linkage. Transmission Operating Hot Cause Correction __________________________________________________________________________________________ Engine RPM too low. Adjust, use tachometer. ________________________________________________________________________________________________________________________ ________________________________ Transmission reservoir oil level too low. Fill to proper level.
Page 101: Loss Of Traction Power Or Unit Will Not Operate In Either Direction
Loss of Traction Power or Unit Will Not Operate In Either Direction Cause Correction _________________________________________________________________________________________ Engine RPM too low. Adjust, use tachometer. ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _______ ______ ___ ______ ___ ____...
Page 102: Front Reels Will Not Turn In Either Direction
Front Reels Will Not Turn in Either Direction Cause Correction ________________________________________________________________________________________ S1 not shifting. Do electrical diagnostics to make sure that voltage is being applied to S1 and that there is no electrical fault. See Chapter 5 - Electrical System. Do cartridge valve service procedure for valve S1.
Page 103: Front Reel(S) Turn Too Slow
Front Reel(s) Turn Too Slow Cause Correction _________________________________________________________________________________________ R1 bypassing. Check relief pressure at port G1 of valve block and adjust valve if necessary. Do cartridge valve service procedure for valve R1. Replace R1 with a new valve. _____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________ S7 partially shifted.
Page 104: Front Reels Turn Too Fast
Front Reels Turn Too Fast Cause Correction ________________________________________________________________________________________ VS1 not operating properly. Do electrical diagnostics to make sure that voltage is being applied to VS1 and that there is no electri cal fault. See Chapter 5 - Electrical System. Do cartridge service procedure for VS1.
Page 105: Front Reels Stop Under Load
Front Reels Stop Under Load Cause Correction _________________________________________________________________________________________ R1 bypassing. Check relief pressure at port G1 of valve block and adjust valve if necessary. Do cartridge valve service procedure for valve R1. Replace R1 with a new valve. _____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________ Internal leakage (by-passing oil) in reel motor.
Page 106: Cutting Unit(S) Will Not Raise
Cutting Unit(s) Will Not Raise Cause Correction ________________________________________________________________________________________ One-way variable orifice closed - center and rear Open speed control valve. cutting units only - see Hydraulic Schematics. _____________________________________________ ________________ ______ ________________ ______ ________________ ___________________________________ Engine RPM too low. Increase engine RPM to operating speed. _____________________________________________ ________________ ______ ________________ ______ ________________ ___________________________________ S7 not shifting.
Page 107: Cutting Units Raise, But Will Not Stay Up
Cutting Units Raise, But Will Not Stay Up Cause Correction _________________________________________________________________________________________ S6 energized (should only be energized during Do electrical diagnostics. See Chapter 5 - Electrical lower function). System. _____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________ S6 leaking down (not seating properly). Do cartridge valve service procedure for valve S6.
Page 108: Cutting Units Will Not Lower
Cutting Units Will Not Lower Cause Correction ________________________________________________________________________________________ S3, S4, or S5 not shifting (See Hydraulic Schemat Do electrical diagnostics to make sure that voltage ics to see which valve controls what lift cylinders.) is being applied to solenoid for affected circuit and that there is no electrical fault.
Page 109: Testing
Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.
Page 110: Test No. 1: Traction Circuit Charge Pressure
TEST NO. 1: Traction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Park the machine on a level surface, engage the parking brake and stop the engine. CAUTION To prevent possible personal injury from ro...
Page 111: Test No. 2:Traction Circuit System Pressure
TEST NO. 2: Traction Circuit System Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximate ly 10 minutes. 2. Before doing traction pressure test: A. Drive machine to an open area, lower cutting units, turn the engine off and engage the parking brake.
Page 112: Test No. 3: Front Mow/Lift Circuit Pressure
TEST NO. 3: Front Mow / Lift Circuit Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of hydraulic valve block.
Page 113: Test No. 4: Rear Mow Circuit Pressure
TEST NO. 4: Rear Mow Circuit Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. Set HOC Selector Knob, located under the instrument panel, to position A (full speed).
Page 114: Test No. 5: Reel Drive Pump Efficiency
TEST NO. 5: Reel Drive Pump Efficiency (Using Tester With Pressure and Flow Capabilities) 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine.
Page 115: Test No. 6: Reel Drive Circuit Flow
TEST NO. 6: Reel Drive Circuit Flow (Using Tester With Pressure and Flow Capabilities) 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine.
Page 116: Test No. 7: Reel Drive Motor Efficiency
TEST NO. 7: Reel Drive Motor Efficiency Reel drive motor efficiency can be tested by blocking outlet flow from the motor, then measuring flow from the motor case drain line. Use a graduated container, such as special tool TOR4077 to measure flow from the motor case drain line over a 15 second time period (Fig.
Page 117: Adjustments
Adjustments Traction Control Neutral Adjustment The machine must not “creep” when traction pedal is 7. Turn inner locknut clockwise until distance between released. If it does creep, an adjustment is required. inside of eye bolt loop and inside of spring anchor plate is shortened 1/8 inch, as shown in Figure 24A.
Page 118: Lift Circuit Variable Orifice Adjustment
Lift Circuit Variable Orifice Adjustment Adjustable orifices are adjusted at the factory and should not require adjustment unless tampered with or in special situations. Opening valve increases lift speed. Closing valve slows lift speed. NOTE: Adjustment for special operating conditions should not require more than 1/2 turn of valve in either direction from initial adjustment.
Page 119: Transmission Repairs
Transmission Repairs Shaft Seal Replacement 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Disconnect the drive shaft from the transmission (Fig 27). 3. Remove retaining ring, then carefully remove seal from bore in charge pump cover (Fig.
Page 120: Transmission Control Linkage Removal
Transmission Control Linkage Removal 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Disconnect wiring harness from traction neutral switch (Fig. 29, 30). 3. Remove eybolt and extension spring. 4. Remove cotter pin and washer to disconnect traction control rod from pump control.
Page 121: Trunnion Seal Replacement
Trunnion Seal Replacement 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove control linkage from swashplate control shaft on transmission (see Transmission Control Removal). 3. Remove hex tapping screws retaining trunnion seal cover to transmission housing (Fig.
Page 122: Check And High Pressure Relief Valves
Check and High Pressure Relief Valves 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the check/high pressure relief valve hex plug (Fig 32). 3. Remove the valve cartridge assembly. Inspect the Machined groove valve and mating seat in the housing for damage or (reverse on y)
Page 123: Charge Pressure Relief Valve
Charge Pressure Relief Valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the charge relief valve hex plug (Fig. 33). 3. Remove the spring and poppet from the housing. 4.
Page 124: Heat Exchanger Bypass Valve
Heat Exchanger Bypass Valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the heat exchanger bypass valve hex plug (Fig. 34). 3. Remove the spring and poppet from the housing. 4.
Page 125: Filter Bypass Reverse Flow Check Valve
Filter Bypass Reverse Flow Check Valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the heat exchanger bypass valve hex plug (Fig. 36). 3. Remove the spring and poppet from the housing. 4.
Page 126: Charge Pump
Charge Pump 1. Park the machine on a level surface, lower cutting 10. Tighten the charge pump cover cap screws to a units, engage parking brake and stop the engine. torque of 27 to 37 ft-lb. 2. Remove the two (2) cap screws retaining the charge 11.
Page 127: Transmission Removal And Installation
Transmission Removal and Installation 1. Park machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the two (2) rear cutting units (see Chapter 8 - Cutting Units). 3. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of transmission and differential.
Page 128: Disassembly Of Transmission
Disassembly of Transmission Figure 41 The procedures on the following pages are for the During assembly of the transmission, all surfaces which c o mple te disa ss em bly an d re as se mbly o f the have relative motion between two parts should be transmission.
Page 129 1. Before performing major repairs on the transmission, remove external components as described in previous procedures. These include the following: Charge Check / High Pressure Relief Valves Charge Relief Valve Heat Exchanger Bypass Valve Filter Bypass Valve Filter Bypass Reverse Flow Check Valve Charge Pump 2.
Page 130 7. Lay transmission on its side and remove motor cylin der block assembly from the housing. Remove pump cylinder block assembly from pump shaft (Fig. 46). Figure 46 8. Remove the slipper guide and piston assemblies from cylinder blocks (Fig. 47). NOTE: Pump and motor cylinder block assemblies are identical.
Page 131 11. Use an 8-32 machine screw to remove motor shaft bearing retaining pin from housing (Fig. 50). Figure 50 12. Remove motor shaft from housing (Fig. 51). Figure 51 13. Press motor shaft out of bearings and spacer (Fig. 52). Figure 52 14.
Page 132 15. Slide pump shaft and bearing assembly from hous ing. Press shaft out of bearing (Fig. 54). 16. Remove hex tapping screws retaining trunnion seal cover and trunnion cover to housing (Fig. 55). Mark position of covers for reassembly. The trunnion seal cover assembly includes an o-ring, lip seal and trunnion bearing on the control side.
Page 133: Assembly Of Transmission
Assembly of Transmission 1. Clean and lightly oil parts before assembly. Tighten all threaded parts to recommended torque value. IMPORTANT: Most parts have critical, high toler ance surfaces. Use caution to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings and ports from damage and foreign material.
Page 134 7. Press ball bearing onto pump shaft. Install pump shaft and bearing assembly into housing (Fig. 62). Figure 62 8. Install PTO seal guide and o-ring into housing. Install spiral retaining ring (Fig. 63). Figure 63 9. Press inner bearing, spacer and outer bearing onto motor shaft (Fig.
Page 135 11. Install motor shaft bearing retaining pin into housing (Fig. 66). Figure 66 12. Install pipe plug over motor shaft bearing retaining pin and tighten to a torque of 6 to 9 ft-lb (Fig. 67). Figure 67 13. Coat thrust plates with petroleum jelly and install into housing and swashplate (Fig.
Page 136 15. Lay the transmission on its side and install cylinder block kits into the housing (Fig. 70). 16. Put the transmission housing on a work surface with the center section opening facing up. Figure 70 17. Install valve plate locating pins into center section (Fig.
Page 137 19. Install the two (2) alignment pins and install a new center section gasket onto the housing (Fig. 74). Figure 74 20. Install center section with valve plates onto trans mission housing (Fig. 75). IMPORTANT: Make sure all parts are properly aligned.
Page 138: Mowing Circuit Repairs
Mowing Circuit Repairs Valve Block Service 1. Before removing any parts from the valve block, park Diagrams to identify function of hydraulic lines and the machine on a level surface, engage the parking cartridges at each port location.) brake, lower the cutting units and stop the engine. Remove key from ignition switch.
Page 139: Cartridge Valve Service
Cartridge Valve Service 1. Clean valve block to prevent contamination when Cartridge Installation valve cartridge is removed. 1. Lubricate all o-rings with clean hydraulic oil. 2. Remove the cartridge valve from its port: 2. Carefully thread cartridge into the port by hand. Valve A.
Page 140: Cartridge Valve Identification
Cartridge Valve Identification NOTE: When troubleshooting hydraulic problems, keep in mind that is possible for some cartridge valves to be installed in the wrong ports, causing the system to malfunction. Solenoid valves in valve block must not be interchanged between ports, with the following exceptions: S1 and S2 are the same design and can be inter...
Page 141 Relief valves in the valve block cannot be interchanged Flow control cartridges are the same and can be inter between ports R1 and R2 because they have different changed between ports VS1 and VS2 (Fig. 85). internal parts and pressure settings (Fig. 84). Figure 84 Figure 85 Relief valves...
Page 142: Pump Removal And Installation
Pump Removal and Installation Removal 1. Park machine on a level surface, lower cutting units, engage parking brake and stop the engine. Remove key from ignition switch. 2. Raise seat and secure with prop rod to get access to pump (Fig. 91, 92). 3.
Page 143: Pump Repair
Pump Repair Figure 93 1. Gear plate (2) 11. Drive shaft 21. Dowel pin (2) 2. Dowel pin (2) 12. Idler shaft assembly 22. Oil seal 3. Cap screw (4) 13. Dowel pin (2) 23. Pump body assembly 4. Washer (4) 14.
Page 144 3. Secure the flange end of the pump (Fig. 88, Item 23) cover or plate assemblies as necessary. The bushings in a vise with the drive shaft (Item 24) pointing down. are not serviceable. 4. Remove the four (4) capscrews (Item 3) and washers 10.
Page 145: Reel Motor Removal And Installation
Reel Motor Removal and Installation 1. Disconnect hydraulic lines. Put caps or plugs on fittings and hoses to prevent contamination. Tag hydrau lic lines for proper reassembly. 2. Loosen motor mount nuts (Fig. 94). 3. Rotate motor clockwise so motor flanges clear studs and pull motor out.
Page 146: Reel Motor Shaft Seal Replacement
Reel Motor Shaft Seal Replacement 1. Remove reel motor (see Reel Motor Removal and Installation). 2. Plug ports and wash exterior of motor with cleaning solvent. Make sure parts and work area are clean. 3. Remove snap ring from motor (Fig. 95). 4.
Page 147: Reel Motor Repair
Reel Motor Repair Figure 96 1. Socket head screw (2) 6. Idler gear assembly 10. Body 2. Washer (2) 7. Drive shaft assembly 11. Spacer 3. Dowel pin (2) 8. Ring seal 12. Shaft seal 4. Cover 9. Load plate assembly 13.
Page 148: Lift Cylinder Removal And Installation
12. Apply hydraulic oil to inside of cover and assemble 14. Tighten the capscrews evenly in a crossing pattern the cover to the body, making sure none of the parts to a torque of 17 ft-lb. become displaced. Insert the capscrews and washers and hand tighten.
Page 149: Lift Cylinder Repair
Lift Cylinder Repair Figure 98 1. Barrel 5. O-ring seal 9. Head 2. Nut 6. Rod seal 10. Dust seal 3. Uni-ring seal 7. O-ring seal 11. Retaining ring 4. Piston 8. Back-up ring 12. Rod IMPORTANT: To prevent damage when clamping the cylinder barrel in a vise, clamp only on the pivot end.
Page 150 Figure 100 1. Barrel 5. O-ring seal 9. Head 2. Nut 6. Rod seal 10. Dust seal 3. Uni-ring seal 7. O-ring seal 11. Retaining ring 4. Piston 8. Back-up ring 12. Rod 5. Grasp the clevis end of the shaft and use a twisting A.Soak the seal rings in hot water.
Page 151: Flushing The Hydraulic System
Flushing The Hydraulic System IMPORTANT: Drain and refill reservoir, change oil 14. Shut off engine and check for hydraulic oil leaks. filter and flush hydraulic system if component fail Check oil level in hydraulic reservoir and add correct oil ure was severe or system is contaminated (oil ap ...
Page 152: Inspecting Reservoir Parts
Inspecting Reservoir Parts 1. Clean filler screen, suction screen and reservoir with clean solvent (Fig. 103). 2. Inspect reservoir for leaks, cracks or other damage. 3. Replace hoses or fittings if worn or leaking. 4. Replace breather with new part. Tighten mounting cap ...
Page 153 Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS ..... . 3 High Temperature Shut-Down Switch ..26 LOGIC CHART .
Page 154 ® Logic Chart Page 5 - 2 Reelmaster 5100-D...
Page 155: Wiring Schematics
Wiring Schematic (S/N Below 51001) ® Reelmaster 5100-D Page 5 - 3 Rev. B Wiring Schematic...
Page 156 Wiring Schematic (S/N 51001 – 59999) T–1143B Reelmaster 5100–D Wiring Schematic Page 5 – 3.1 Rev. B...
Page 157 Wiring Schematic (S/N 60001 & Up) T–2314A Wiring Schematic Reelmaster 5100–D Page 5 – 3.2 Rev. B...
Page 158 Wiring Schematic – Leak Detector 94–6345 BLK/BU OR/BLK Reelmaster 5100–D Wiring Schematic Page 5 – 4 Rev. B...
Page 159: Special Tools
Special Tools NOTE: Special tools may be ordered from: Some tools may bebe listed in the Reelmaster 5100-D Owatonna Tool Co. Parts Catalog or sold under Toro Model Numbers. Some 2013 4th Street, NW tools may also be available from a local supplier.
Page 160 When in “ ” mode, LED’s OUTPUTS DISPLAYED illuminate to show outputs turned on by the ECU. Diagnostic ACE Tool, Toro P/N 85-4750 RM5100-D/5300-D Overlay, V1.0, Toro P/N 85-4760 TurfDefender Overlay, V1.0, Toro P/N 94-5386 Figure 4 ®...
Page 161: Troubleshooting
The data log system records the actual state the source of the electrical problem. of machine inputs and outputs at the time of malfunction. Your Toro Distributor can then isolate the cause of the electrical problem. Quick Reference Troubleshooting Guide Controller Diagnostic Lamp 5.
Page 162 6. The diagnostic display will illuminate the LED asso If no output LED’s are flashing on and off, but the correct ciated with each of the inputs when that input switch is output LED’s do not illuminate, verify that the required closed.
Page 163 S/N 1. Turn Ignition key switch to OFF. 70001. Older machines can have new software installed. Contact your Toro Distributor for assistance. 2. Move the Backlap switch to the FRONT or REAR position.
Page 164 Install TurfDe- held Diagnostic ACE. A leakdown test is required to fender overlay decal (supplied with leak detector kit) identify small air leaks. Consult your Authorized Toro onto Diagnostic ACE (Fig. 8b). Distributor for assistance.
Page 165 3. Air leak in system. Check to make sure cap is se- (Fig. 8d) any of the following problems diagnosed by the curely on tank. Contact your local authorized Toro Dis- TurfDefender: tributor for further assistance with air leak problem.
Page 166 Diagnostic ACE Display Functions 1. Overlay decal (English shown) 2. “Inputs Displayed” LED (Red) “Outputs Displayed” LED (Green) 4. Toggle button Figure 8b Using “Inputs Displayed” (Red Text) 1. LED lit if oil level is too high 2. LED lit if oil level is OK 3.
Page 167: Starting Problems
Starting Problems Condition Possible Cause Correction _________________________________________________________________________________________ All electrical is dead, including Low battery charge. Charge battery. Replace battery if gauges. it will not hold a charge. Thermal circuit breaker No. 1 open. Find cause for open circuit breaker and correct. Circuit breaker will reset automatically after has cooled.
Page 168 Condition Possible Cause Correction ________________________________________________________________________________________ Nothing happens when start Faulty ignition (key) switch or Test switch and replace if faulty. attempt is made (control panel wiring. Correct wiring problem if lights and gauges DO operate necessary. with ignition key switch in ON position).
Page 169: General Run And Transport Problems
General Run and Transport Problems Condition Possible Cause Correction _________________________________________________________________________________________ Engine continues to run, but Engine fuel lever or run solenoid Check operation of run solenoid should not, when ignition key is stuck in “on” position. and adjust or replace if necessary. turned off.
Page 170 Condition Possible Cause Correction ________________________________________________________________________________________ Engine kills when traction pedal Seat lifting off seat switch. Instruct operator to sit back in is depressed. seat during operation. Check seat plate hinges and seat support pin and repair if faulty. Seat switch circuit open. Test seat switch and replace if faulty.
Page 171 Condition Possible Cause Correction _________________________________________________________________________________________ Cutting units run, but should not, Both the front reels down sensor Check front reels down sensor when raised and do not shut off and enable switch circuits are and enable switch and replace if with Enable/Disable switch.
Page 172 Condition Possible Cause Correction ________________________________________________________________________________________ Front cutting units do not operate Problem with solenoid S1. Test solenoid S1 and replace if in either direction (raise and faulty. lower function OK). Check wiring to S1 solenoid and repair if faulty. Problem with S7 solenoid. Check wiring to S7 solenoid and repair if faulty.
Page 173 Condition Possible Cause Correction _________________________________________________________________________________________ No cutting units lower. Lower - Mow switch circuit is open. Check for faulty Lower-Mow switch (joystick). Check Lower-Mow switch wiring and repair if faulty. Problem with solenoid S6. 5A SOL S3/S6 fuse open. If fuses burn out often, find and correct cause.
Page 174 Condition Possible Cause Correction ________________________________________________________________________________________ Rear (No. 2 and 3) cutting units Problem with solenoid S5. Test solenoid S5 and replace if will not raise/lower, but other faulty. cutting units raise and lower OK. Check wiring to solenoid S5 and repair if necessary.
Page 175 Verify Interlock System Operation The purpose of the interlock system is to prevent the be a malfunction in the interlock system. Use Diagnostic engine from cranking or starting unless the traction Display to help isolate problem and repair immediately. pedal is in the Enable/Disable switch is in If engine does not crank, proceed to step 4.
Page 176: Testing
Testing Testing of the electrical system has been greatly simpli fied by use of the ACE Diagnostic Display, Data Log system and ToroPC software. Before testing or replac CAUTION ing any electrical components, it is recommended that you verify electrical performance of the part(s) in ques When testing electrical components for con ...
Page 177: Electronic Control Unit (Ecu)
Electronic Control Unit (ECU) The Toro electronic control unit (ECU) senses the con dition of various switches, such as the seat switch, cutting unit down switches, traction neutral switch, etc., and directs power output to allow certain machine func...
Page 178: Traction (Neutral) Switch
Traction (Neutral) Switch The traction switch is a normally closed and opens when traction pedal is depressed in either direction. The switch is located on the right side of the hydrostatic transmission. IMPORTANT: The traction switch has three (3) ter minals.
Page 179: Lower-Mow/Raise Switches
Lower-Mow/Raise Switches (Joystick) The Lower-Mow/Raise Control has two (2) normally open (NO) switches, one for the Lower-Mow function and one for the Raise function. Each switch is normally open and closes when the joystick is moved (Fig. 15). Test each switch by disconnecting the wiring connector from the switch and connecting a continuity tester across the two terminals of the switch being tested.
Page 180: Backlap Switch
Backlap Switch The Backlap switch is a three-way switch (Fig. 17). Test the switch by disconnecting the wires and connecting a continuity tester across terminals of switch. With the switch OFF, the tester should show no continu ity across terminals 4 – 5 or 5 – 6. With the switch in the FRONT position (toward keyway), tester should show continuity across terminals 4 and 5.
Page 181: Glow Relay
Glow Relay To test the glow relay (Fig. 17), disconnect the relay wire connector and install a continuity tester between the relay terminals (terminals 30 and 87) (Fig. 19). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C.
Page 182: Fuel Stop (Etr) Solenoid
Fuel Stop (ETR) Solenoid ® The Reelmaster 5100-D has an energize-to-run (ETR) fuel stop solenoid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1. Disconnect the wire connector and remove the fuel stop solenoid from the engine (Fig.
Page 183: Indicator Lights And Gauges
Indicator Lights and Gauges Diagnostic Lamp Amp Light The diagnostic lamp should come on when the ignition The amp light should come on when the ignition key key switch is turned to the position. If the lamp is switch is in the position with the engine not running , it indicates that the electronic control unit ( ) is...
Page 184: High Temperature Shut-Down Switch
High Temperature Shut-Down Switch 1. Lower the coolant eve n the engine and remove the high temperature shut-down switch (Fig. 23). 2. Put the switch in a container of o l with a thermometer and heat the oil (Fig. 24). 3.
Page 185: Engine Oil Pressure Switch
Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If bulb is not on: 1. Disconnect wire from switch and touch wire to a good ground.
Page 186: Hydraulic Valve Block Solenoids
Hydraulic Valve Block Solenoids 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12 V.D.C is applied between leads.
Page 187: Checking Starter Pinion Gap
Checking Starter Pinion Gap 1. Install 12 volt battery between the “S” terminal and the starter body (Fig. 29). The pinion should protrude and stop. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. 2. Lightly push the pinion back and measure the return stroke (called pinion gap).
Page 188: Magnetic Switch (Solenoid) Attraction Test
Magnetic Switch (Solenoid) Attraction Test 1. Disconnect the wire from terminal “M” (Fig. 31). 2. Connect a 12 volt battery to the magnetic switch terminals “S” and “M”. The pinion must protrude. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. Figure 31 Magnetic Switch (Solenoid) Holding Test 1.
Page 189: Alternator Regulated Voltage Test
Alternator Regulated Voltage Test 1. Install an ammeter between the positive (+) terminal of the battery and terminal “B” of the alternator (Fig. 34). 2. Ground alternator terminal “L” through a voltmeter. 3. Note that the voltmeter shows 0 volts when the ignition key switch is in the OFF position.
Page 190: Repairs
Repairs IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery, dis connect both wire harness plugs from the electronic control unit and disconnect the terminal connector from the alternator to prevent damage to the electri cal system.
Page 191: Fuses
Fuses The electrical system is protected by fuses located under the control panel to the operator’s right (Fig. 38). NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continutiy tester, not visually.
Page 192: Traction (Neutral) Switch Replacement
Traction (Neutral) Switch Replacement 1. Remove the two wires that are connected to the traction switch (Fig. 39). 2. Have a helper push the traction pedal down into either the FORWARD or REVERSE position; this will take the switch arm tension off of the switch. Loosen two (2) screws and remove the switch.
Page 193: Electronic Control Unit (Ecu) Replacement
Electronic Control Unit (ECU) Replacement IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery, dis connect both wire harness connectors from the ECU and disconnect the terminal connector from the alternator to prevent damage to the electrical system.
Page 194: Solenoid Valve Coil Replacement
Solenoid Valve Coil Replacement 1. Park machine on a level surface, engage parking brake, lower the cutting units and turn engine OFF. 2. Disconnect solenoid electrical connector. 3. Remove nut from solenoid. 4. Remove solenoid coil. 5. Install new solenoid coil and secure with nut. Apply “Locktite 242"...
Page 195: Starter Service
Starter Service Disassembly and Inspection 6. Remove the cover, pry the snap ring out and remove the washer. 1. Remove the starter from the engine (see Starter Removal and Installation in the External Engine Com 7. Unscrew the bolts and remove the center bracket. As ponent Repair section of Chapter 4 - Mitsubishi Diesel the bracket is removed, washers for pinion shaft end Engine).
Page 196 Break and short circuit Wear and chipping One-way mechanism Bear ing: Pl ay, noise, and rough rotation Insulat on Break and short c rcu Bearing: Play, noise, and rough rotation Figure 45 10. Check the magnetic switch for continuity between terminals “S”...
Page 197 11. Put the armature on a growler tester to check for a shorted armature (Fig. 47). A burned commutator bar is an indication of a shorted armature. With the growler turned on, put a thin strip of steel or a hacksaw blade on the armature as it is slowly rotated.
Page 198 Assembly and Adjustment of Starter Gear justing 1. Reverse steps 1 - 10 under Disassembly and Inspec Washer tion and also following the following instructions: Washer Snap 2. Set the pinion shaft end play (thrust gap) to 0.5 mm ring (0.02 in.) or less by inserting an adjusting washer be...
Page 199: Alternator Service
Alternator Service Disassembly and Inspection 4. Put the rotor in a vise. Remove pulley nut and pull off the pulley and spacer. 1. Remove the alternator from the engine (see Alterna tor Removal and Installation in the External Engine 5. Pull the rotor assembly from the front bracket. Component Repair section of Chapter 4 - Mitsubishi Diesel Engine).
Page 200 Deformation Break and and damage short circuit Wear and roughness Wear Crack and damage Break and short circuit Wear to limit line Figure 52 9. Check each diode in the rectifier for conduction (Fig. 53). Connect an ohm meter across the lead wire and diode case.
Page 201 11. Check for continuity between a slip ring and shaft (core) (Fig. 55). Replace the field coil if there is continuity. Figure 55 12. Check for continuity between lead wires of the stator coil (Fig. 56). Replace the stator coil if there is no continuity.
Page 202 Assembly of Alternator 1. Reverse steps 1 - 8 under Disassembly and Inspec tion and also following the following instructions: 2. The rear bearing has an eccentric groove. Install the snap ring so its projection fits in the deepest part of the groove.
Page 203: Speedometer Sensor Installation
Speedometer Sensor Installation To install speedometer sensor: 1. If axle cover plate was not removed, go to step 9. 2. Lubricate and install O-ring into plate. 3. Apply silicone sealant to face of plate where it will contact cover. 4. Install plate to inside face of cover, then install cap screw and lockwasher through cover into plate.
Page 204: Reel Speed Sensor Installation
Reel Speed Sensor Installation Reel speed sensors are located on the left front and left rear cutting units. 1. Thread reel speed sensor into sensor holder until dimension shown in Figure 60 is attained. Lock adjust ment with two (2) jam nuts. 2.
Page 205 Reel Speed Sensor Installation Reel speed sensors are located on the left front and left rear cutting units. 1. Install magnet on end of reel shaft through opening in end of counterweight. Install magnet so counterbore faces towards end of reel shaft and smooth side faces out.
Page 206 ® Repairs Page 5 - 48 Rev. A Reelmaster 5100-D...
Page 207: Introduction
Chapter 6 Differential Axle Table of Contents INTRODUCTION ......1 Axle Shaft Disassembly TORQUE SPECIFICATIONS ....2 and Wheel Bearing Service .
Page 208: Special Tools
0.00 to 0.005 in. Special Tools NOTE: Order special tools from the TORO SPECIAL Catalog for your Toro equipment. Some tools may also TOOLS AND APPLICATIONS GUIDE (COMMERCIAL be available from a local supplier. PRODUCTS) . Some tools may be listed in the Parts...
Page 209: Repairs
Repairs Axle Removal and Installation 1. Put machine on a level surface, lower cutting units, 7. Remove the cotter pin and clevis pin to disconnect stop the engine and remove key from ignition switch. the brake cable from brake actuating lever on each Block rear wheels to prevent machine from moving.
Page 210: Axle Shaft Disassembly And Wheel Bearing Service
Axle Shaft Disassembly and Wheel Bearing Service NOTE: When servicing the bearing and seal area of the axle shaft, it is recommended that you replace hex head screws and flange nuts with socket head screws (94 6934), washers (94-6936) and nuts (94-6935). See Figure 18.
Page 211 4. Remove the inner axle shaft seal (Fig. 8). Discard the seal and replace with a new one at the time of assembly. Figure 8 5. Center punch the outside of the retaining ring (Fig. 9). Figure 9 6. Drill a 1/4 inch hole (approximate) into the outside of the retainer ring to a depth of about 3/4 the thickness of the ring (Fig.
Page 212 7. After drilling, put a chisel in position across the hole and strike sharply to break the ring. Replace with a new ring at time of reassembly (Fig. 11). WARNING Wear protective safety goggles when break ing the retaining ring. Personal injury could result from flying metal particles.
Page 213 11. Slide a new retaining ring on the axle shaft and support the shaft and ring in a suitable press (Fig. 14). Press the retaining ring firmly against the bearing. Figure 14 12. Put a light coating of No. 1 Permatex on the outside diameter of a new grease seal (surface that contacts the axle housing).
Page 214: Differential And Housing Disassembly
13. Assemble the bearing retainer bolts to the axle housing. Apply a .0625 in. (16 mm) bead of gasket material to flange on end of axle housing, then install the axle shaft assembly into the axle housing. Be careful not to damage the, oil seal and bearing. Line up the holes of the brake assembly and oil seal.
Page 215 2. Remove the four bearing cap screws and remove the caps. Place the caps in a safe place to avoid damaging their machined surfaces (Fig. 20). The bearing caps are marked for identification. The letters or numbers are in horizontal and vertical posi tions.
Page 216 5. Do not remove the bearings from the differential case unless bearing failure is evident. It is recommended that whenever bearings are removed (regardless of usage) they must be replaced with new ones. Remove the case side bearing with a puller as shown (Fig. 23). Figure 23 6.
Page 217 8. To remove the side gears and pinion mate gears, rotate the side gears. This will allow the pinion mate gears to turn to the opening of the case (Fig. 26). Remove the pinion mate gears and the spherical washers behind the gears. Figure 26 9.
Page 218 11. Before pressing pinion out of housing: If unit was equipped with an expansion plug (removed in step 10), remove the snap ring and shim from the end of the pinion (Fig. 29). If unit is equipped with a pinion coupler for 4WD (no expansion plug), nut, pinion spacer and pinion coupler (Fig.
Page 219 13. Clamp the inner pinion bearing with a universal bearing remover (Fig. 32). Position the unit in a press and carefully push the drive pinion out of the bearing. DO NOT allow the pinion to drop on the floor - damage will result.
Page 220: Differential And Housing Reassembly
Differential and Housing Reassembly 1. Inspect the differential parts for damage before assembling. A. If any bearings are damaged they must be replaced with new ones. B. Check the ring, pinion, and spur gear for abnormal wear and damage; replace worn components. C.
Page 221 Ring and Pinion Set Rings gears and pinions are supplied in matched sets only. Matching numbers are etched on both the pinion and ring gear (Fig. 37). The mounting distance from the bottom of the differen tial bearing bores to the button end of the pinion is 1.210 in.
Page 222 4. Install a new inner bearing cup using a press plate of proper diameter. Reuse the original shims or use new shims of the same thickness. Push the bearing cup into the housing until it bottoms against the housing (Fig. 38). Figure 38 5.
Page 223 7. Support the drive pinion in a suitable press (Fig. 41). Figure 41 8. Install the outer pinion spacer with the chamfer towards the pinion splines and install the new outer pinion bearing cone (Fig. 42). Figure 42 9. With a hollow press sleeve of proper diameter, press on the outer bearing cone race until the drive pinion seats in the carrier and a slight drag is noticed when the gear is rotated by hand (2-13 in.-lb.
Page 224 10. Install the shim and snap ring onto the end of the pinion shaft. Use the thickest shim possible which will permit installation of the snap ring (Fig. 44). Limit the end play to 0.000 - 0.005 inch (0.000 - 0.127 mm). Figure 44 11.
Page 225 13. Place the differential case in a vise as shown (Fig. 47). Apply grease to new side gear thrust washers and hubs of the side gears. Apply grease to new pinion mate spherical washers and pinion mate gears. Place the side gears and thrust washers in the case. Install the pinion gears while holding the side gears in place.
Page 226 16. Put the ring gear onto the differential case and start the new capscrews into the gear with your fingers. Tighten the screws, alternating back and forth across the gear to allow the gear to be pulled evenly into place. Tighten the cap screws to a torque of 45 - 65 ft-lb (6.2 - 9.0 KgM) (Fig.
Page 227 19. Using a dial indicator, check the ring gear backlash in three equally spaced points. Ring gear backlash should be .003 - .007 inch (.076 - .178 mm) and must not vary more than .002 in. between points checked (Fig. 53). If the backlash is not in this range, move the shims which are located beneath the differential bearings, from one side to the other until the correct backlash is attained.
Page 228 Drive Side Coast Side Heel Heel Backlash correct. Thicker pinion position shims required. Figure 55 Drive Side Coast Side Heel Heel Backlash correct. Thinner pinion position shims required. Figure 56 Drive Side Coast Side Heel Heel Backlash incorrect. Thinner pinion position shim re quired.
Page 229 Gear Pattern Movements Summary 1. Decreasing backlash moves the ring gear closer to the pinion. Drive pattern (convex side of gear) moves lower and toward the toe. Coast pattern (concave side of gear) moves slightly higher and toward the heel. 2.
Page 230 ® Repairs Page 6 - 24 Reelmaster 5100-D...
Page 231 Chapter 7 Steering And Brakes Table of Contents INTRODUCTION ......2 REPAIRS ....... . 11 SCHEMATICS .
Page 232: Introduction
Introduction Power Steering The power steering valve is enclosed in the steering tower at the front of the traction unit. As the steering wheel is turned, the steering valve meters hydraulic fluid to the double-acting steering cylinder on the rear axle and turns the wheels.
Page 233: Schematics
Power Steering Schematics FROM PUMP When the steering wheel is turned to the right (Fig. 3), STEERING VALVE the control valve within the steering valve shifts to close the “AUX” port. This directs oil supplied by the steering pump to the metering section of the steering valve. As the steering wheel is turned, system oil is metered out port “RT”...
Page 234: Specifications
Specifications Item Specification ________________________________________________________________________________________ Front wheel lug nut torque 45 to 55 ft-lb ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ Rear wheel lug nut torque 30 to 35 ft-lb ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ Steering cylinder bolt torque...
Page 235: Troubleshooting
Troubleshooting Problem Possible Causes _________________________________________________________________________________________ Steering Wander Tire pressure incorrect or unequal left to right. Loose or worn steering linkage. Improperly adjusted or worn rear wheel bearings. Rear wheels out of alignment; toe-in / toe-out. Internal leakage of steering cylinder. _____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________ Poor or No Returnability (Recovery)
Page 236 Problem Possible Causes ________________________________________________________________________________________ Steering Wheel Lash (Free Movement) Steering wheel loose on column. Steering linkage loose or worn. Steering valve loose at mounting. Air in hydraulic system. Internal leakage in hydraulic cylinder. _____________________________________________ ________________ ______ ________________ ______ ________________ ___________________________________ Excessive Heat in Hydraulic System Undersized replacement hose or tube line.
Page 237: Testing
Testing Steering Valve and Pump Tests 1. Make sure the hydraulic oil is at normal operating 11. If flow is lower than 3.5 GPM or a pressure of 1000 temperautre by operating the machine for approxi PSI cannot be obtained, check for restriction in pump mately 5 minutes.
Page 238: Steering Cylinder Internal Leakage Test
Steering Cylinder Internal Leakage Test 1. Engage the parking brake, and lower the cutting units to the floor. 2. Turn the steering wheel all the way to the left (coun terclockwise) so the steering cylinder rod is extended all the way. 3.
Page 239: Adjustments
Adjustments Rear Wheel Toe-in Adjustment The rear wheels should have 0 to 1/8 of an inch toe-in when they are pointed straight ahead. To check toe-in, measure the center-to-center distance, at axle height, in front and rear of steering tires. If toe-in is not within specifications, an adjustment is required.
Page 240: Brake Adjustment
Brake Adjustment Adjust the service brakes when there is more that one 1/2 to 1 in. free travel inch of “free travel” of the brake pedals. Free travel is the distance the brake pedal moves before braking resistance is felt (Fig. 11). Adjust where brake cables connect to bottom of brake pedals.
Page 241: Repairs
Repairs Steering Wheel Removal and Installation Removing the Steering Wheel Remove the cover from the steering wheel hub. Re move the locknut that secures the steering wheel to the shaft (Fig. 15). Pull the steering wheel off the shaft. NOTE: It may be necessary to use a jaw-type puller to remove the steering wheel from the steering shaft.
Page 242: Rear Axle Bushing Service
Rear Axle Bushing Service The rear axle must be held in place snugly by the axle 5. Use a drift punch and hammer to drive both bushings pin. Excessive movement of the axle, which is charac out of the axle. Clean the inside of the axle pivot tube to terized by erratic steering, usually indicates worn bush...
Page 243 7. Connect the tie rod end to the spindle bracket with 8. Install the lock nut and cap screw to secure the one (1) nut. Tighten the nut to a torque of 25 - 33 ft-lb. steering cylinder rod end to the steering pivot. Tighten Install the jam nut and tighten against the other nut to the nut to 130 to 150 ft-lb.
Page 244: Rear Wheel Spindle Bushing Service
Rear Wheel Spindle Bushing Service The rear wheel spindles must fit snugly in the rear axle. 7. Use a punch and hammer to drive both bushings out Excessive movement of the spindle in the axle indicates of the axle tube. Clean the inside of the axle tube to that the bushings are probably worn and must be re ...
Page 245: Front Wheel Bearing Service
Figure 17 1. Rear axle 5. Tie rod 9. Thrust washer 2. Steering cylinder 6. Wheel spindle 10. Bushing 3. Capscrew 7. Snap ring 11. Thrust washer 4. Rear axle pin 8. Shim washer Front Wheel Bearing Service See Axle Shaft Disassembly and Wheel Bearing Serv ice in the Repairs section of Chapter 6 - Differential.
Page 246: Rear Wheel Bearing Service
Rear Wheel Bearing Service Disassemble, clean, repack and adjust the rear wheel wear, pitting or other noticeable damage. Replace worn bearings after each 500 hours of operation or once a or damaged parts. year. Use No. 2 general purpose lithium base grease containing E.P.
Page 247 Adjusting Rear Wheel Bearings 1. Remove dust cap from end of wheel spindle. Also remove cotter pin retaining slotted nut in place (Fig. 18). 2. Rotate the wheel by hand and tighten the slotted nut (Fig. 19) until the bearing binds SLIGHTLY. Then, loosen the nut until the nearest slot and hole in the spindle line up.
Page 248: Steering Cylinder Removal And Installation
Steering Cylinder Removal and Installation 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 2. Disconnect the hydraulic hoses from the steering cylinder. Put caps or plugs on all the fittings and hoses to prevent contamination.
Page 249: Steering Cylinder Service
Steering Cylinder Service IMPORTANT: To prevent damage to rod or barrel, 8. Remove all seals and O-rings. clamp vise on pivot ends only. DO NOT clamp against smooth rod surface. 9. Wash parts in a safe solvent. Dry parts with com pressed air.
Page 250: Brake Shoe Replacement
Brake Shoe Replacement CAUTION CAUTION The brake linings contain asbestos fibers. Wear a face shield when removing brake re Breathing dust containing asbestos fibers turn spring (Fig. 22). The spring is under ten may be hazardous to your health and may sion and could possibly slip during removal.
Page 251: Steering Valve Removal And Installation
Steering Valve Removal and Installation 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 2. Remove the front center cutting unit (see Repairs section of Chapter 8 - Cutting Units). 3.
Page 252: Steering Valve Service
Steering Valve Service Before Disassembly When disassembling any of the parts, use a clean work bench. Wash all parts in solvent and dry them with compressed air. DO NOT wipe them dry with a cloth of paper as lint and dirt may remain. Keep each part separate to prevent nicks and burrs.
Page 253 Disassembly of Steering Valve 1. To avoid distorting or damaging the steering valve, do not clamp it directly into a vise. Clamp a service assem bly fixture securely in a vise (Fig. 25). Put the steering valve, input shaft first, into the service assembly fixture. Attache the steering valve to the fixture with four (4) 5/16-24 UNF nuts (Fig.
Page 254 4. Grasp the port cover assembly (four plates bonded together) and lift it from the unit. Remove and discard the four o-rings and seal ring (Fig. 29). Figure 29 5. Remove the loosened plug and o-ring assembly from the port cover. Be ready to catch the steel check ball as it falls from its cavity (Fig.
Page 255 11. Remove the valve ring (Fig. 32). Remove and dis card the two seal rings (Fig. 33). The valve ring should be free of nicks and scoring. Figure 32 Figure 33 12. Remove the valve plate by lifting it from the isolation manifold (Fig.
Page 256 14. Remove three springs from the isolation manifold pockets (Fig. 35). NOTE: The unit has two different length spring sets. the set you have just removed from the isolation manifold is 1/2 in. (13 mm) long. Keep this spring set separate from the set removed from the port manifold.
Page 257 18. Remove the two alignment pins that align the port manifold, valve ring and isolation manifold (Fig. 38). Figure 38 19. Remove the isolation manifold (four plates bonded together) (Fig. 39). 20. Inspect the ground surfaces of the isolation mani fold.
Page 258 22. Remove the drive link from the unit (Fig. 41). 23. Inspect each end of the drive link. the four crowned contact surfaces should not be worn or scored. Replace if wear or scoring is evident. Figure 41 24. Remove the metering ring and discard the two seal rings (Fig.
Page 259 26. Remove and discard the commutator seal from the commutator cover (Fig. 44). Figure 44 27. Remove the eleven hex socket head screws, that hold the metering package together (Fig. 45). Use a 3/32 in. allen wrench. Inspect the screws for thread and socket damage and replace as necessary.
Page 260 30. Remove the commutator ring (Fig. 47). Inspect for cracks, burrs and scoring. IMPORTANT: Handle the commutator ring with care, as it is easily broken. Figure 47 31. Remove the commutator from the rotor (Fig. 48). IMPORTANT: To prevent damage, DO NOT use a screwdriver to remove the commutator.
Page 261 34. Remove the drive link spacer (Fig. 50). Replace it if it grooved or worn. 35. With the rotor set lying on the drive plate, the rotor should rotate and orbit freely within the stator. The commutator side of the stator face must be free of grooves or scoring.
Page 262 39. Inspect the thrust bearing side of the drive plate (Fig. 53) for brinelling (dents) or spalling (flaking). The flat sides of the input shaft engagement hole should not be grooved or worn. If any of these conditions in steps 38 and 39 are present, the drive plate must be replaced.
Page 263 43. Remove the upper cover plate (four plates bonded together) (Fig. 56). Inspect the upper cover plate. You should notice some polishing due to the action of the seal. The plate should be free of brinelling (dents) or spalling (flaking). If it is damaged, the upper cover plate must be replaced.
Page 264 47. Remove the washer and upper cover & jacket (Fig. 59). NOTE: The retaining plate and upper cover & jacket are a matched set. If either part is worn or damaged, both must be replaced. Figure 59 48. Inspect the bushing at the top of the cover & jacket for wear or damage.
Page 265 50. Remove the nuts holding the four bolts to the fixture, and remove the bolts (Fig. 62). Check the bolt threads for wear or damage. Figure 62 ® Reelmaster 223-D/5100-D/5300-D Page 7 - 35 Repairs...
Page 266 Assembly of Steering Valve Replace all seals and o-rings with new ones. Make sure the seals and o-rings remain seated correctly when components are assembled. Before assembling the steering valve, wash all parts in clean solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain.
Page 267 3. Put the upper cover and jacket on the four bolts with the jacket tube pointing down through the hole in fixture (Fig. 66). Make sure the square shoulder of the bolts engage the square holes in the upper cover. 4.
Page 268 8. Apply clean multi-purpose grease to the face of the upper cover plate, input shaft and face seal (Fig. 70). Figure 70 9. Assemble the seal back-up ring and face seal onto the seal spacer (Fig. 71). Figure 71 10. Install the face seal, back-up ring and spacer assem bly over the end of the input shaft and onto the upper cover plate (Fig.
Page 269 11. Put the drive plate on a clean lint-free surface with the eleven tapped holes facing up. Put the rotor set on top of the drive plate with the five pin holes facing up. Rotate the stator until the eleven hex socket head screw relief slots are aligned with the tapped holes in the drive plate (Fig.
Page 270 14. Align the five holes and press the five alignment pins in place (Fig. 76). IMPORTANT: Make sure the five alignment pins are pressed below the surface of the commutator. Figure 76 15. Put a few drops of oil into each recess in the commutator (Fig.
Page 271 17. Put the commutator cover on top of the commutator ring with the flat surface towards the commutator (Fig. 79). Align the screw holes in the cover, with the screw holes in the drive plate. Figure 79 18. Screw the eleven hex socket head cap screws loosely into the metering package (Fig.
Page 272 20. Put another piece of the 0.007 in. (0.18 mm) shim stock between the drive plate and each of the three pieces of shim stock already in place. Lift the metering ring and metering package and remove the wood block. Push the metering package and shims into the metering ring until the drive plate and shims are at least flush with the metering ring (Fig.
Page 273 22. Insert the LARGE tang of the drive link into the slot in the rotor (Fig. 85). IMPORTANT: An incorrect (reversed) assembly of the drive link will prevent the assembly of the hex drive. Figure 85 23. Grasp the drive link and rotate the metering package by hand to make sure the parts do not bind (Fig.
Page 274 25. Put the bearing spacer onto the face of the upper cover plate (Fig. 88). Figure 88 26. Lightly grease the roller thrust bearing and put it on the upper cover plate, inside the bearing spacer (Fig. 89). Figure 89 27.
Page 275 28. Put the metering package, drive plate side first, into the metering ring (Fig. 91). Revolve the input shaft or metering package until the hole in the drive plate en gages the end of the input shaft and the drive plate is seated on the thrust bearing.
Page 276 31. Put two alignment pins into the metering ring (Fig. 94). Figure 94 32. Stack the isolation manifold (4 plates bonded to gether) onto the metering ring, aligning the grooves on the side of the manifold with the grooves on the side of the upper cover plate (Fig.
Page 277 34. Put the three 1/2 in. (13 mm) springs into the spring pockets of the isolation manifold (Fig. 97). NOTE: Two different length springs are used in the unit. Be sure to use the 1/2 in. (13 mm) length springs during this part of the assembly.
Page 278 37. To install the valve plate correctly, first carefully study Figures 93 and 94 for positioning of the valve plate spring slots and other cavities in relation to the spring and spring recesses on the isolation manifold. Be sure to use the alignment grooves on the side of the isolation manifold for orientation.
Page 279 39. Put the port manifold (three plates bonded together), valve side up, in a clean surface. Install three 3/4 in. springs into the spring pockets (Fig. 103). Figure 103 40. Apply a few drops of oil to the valve plate. Align the grooves on the side of the port manifold with the grooves on the side of the isolation manifold and assemble the port manifold with the springs toward the valve plate...
Page 280 42. Apply clean multi-purpose grease to the four o-rings and seal ring. Put the new o-rings and seal ring into their proper location in the port cover (Fig. 106). Figure 106 43. Align a groove on the side of the port cover with the grooves on the side of the port manifold and put the port cover into position (Fig.
Page 281 44. Install the lock nuts onto the bolts. Tighten each nut gradually until resistance is felt (Fig. 108). Tighten to a torque of 20 - 24 ft-lb (27 - 33 Nm) in the sequence shown (Fig. 109). Figure 108 Figure 109 45.
Page 282 46. Apply a small amount of clean multi-purpose grease on the lip of the seal. Install the seal onto the jacket tube and input shaft (Fig. 111). 47. Make a final inspection of the relative groove posi tions on the side of the unit (Fig. 24). Components of the steering valve with alignment grooves, must be assem ...
Page 283 Chapter 8 Cutting Units Table of Contents SPECIFICATIONS ......2 Lock-up Roller Adjustment....13 SPECIAL TOOLS .
Page 284: Specifications
Specifications Height of Cut: Bedknife To Reel Adjustment: Bedknife adjusts 5 Blade: 1/2 to 3/4 in. against reel, with opposed screw adjustment on each 8 Blade: 1/4 to 5/8 in. end of bedbar. Roller Adjustment: Bedknife Screw Torque: 200 in-lb. Front: Fixed Rear: Screw adjustable with bolt clamp lock Reel Splined Drive Nut Torque: 40 to 60 ft-lb.
Page 285: Special Tools
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS) . Some tools may be listed in the Reelmas ter Parts Catalog. Some tools may also be available from a local supplier. Plastic Plug Insert plug in cutting unit bearing housing in place of reel motor when sharpening or grinding the reel.
Page 286 Bedknife Screw Tool Fits Toro bedknife attaching screws. Use with torque wrench to secure bedknife to bedbar. With clean bedbar threads and new screws, tighten to a torque of 200 in-lb. NOTE: Remove all rust, scale and corrosion from bed ...
Page 287: Troubleshooting
Troubleshooting There are a number of factors that can contribute to the machine. It is important to remember that the lower unsatisfactory quality of cut, some of which may be turf the height of cut, the more critical these factors are. See conditions.
Page 288 Factor Possible Problem/Correction 7. Bedknife to reel contact. Check bedknife to reel contact daily and adjust as nec essary. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected.
Page 289: Set-Up And Adjustments
Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW Weekly Checks THIS SUMMARY AND CHECK LIST. Study this infor mation and refer to it often to get maximum life and 1. Check reel bearing adjustment and bearing condition. performance from the cutting units.
Page 290: Reel Bearing Service And Adjustment
Reel Bearing Service and Adjustment 1. Adjust the bedknife so it is not in contact with the reel. 2. Reel bearing drag should be 4 to 7 in-lb. This can be measured with a torque wrench (Fig. 5). If bearing drag does not meet above specification, adjust the reel bear...
Page 291: Bedknife To Reel Adjustment
Bedknife To Reel Adjustment IMPORTANT: For adjusting bedknife to reel, use a 3/8 in. open end wrench that is 3 to 6 in. in length. A longer wrench will provide too much leverage and may cause distortion of the adjustment screw mounting plate or bedbar breakage.
Page 292: Front Roller Adjustment
Front Roller Adjustment Loosen four (4) capscrews holding front roller brackets. Push roller towards the rear, then hold in position and tighten capscrews. Make sure roller has not changed position. NOTE: When securing front roller brackets, tighten fastener on inside of cutting unit frame so posi tion of roller bracket does not change.
Page 293: Height Of Cut Adjustment
Height Of Cut Adjustment NOTE: Effective height of cut in the turf can be affected by lift arm down pressure adjustment and turf condi tions, such as grass type, grass density, and amount of thatch. 1. Do bedknife to reel adjustment and front roller adjust ment before adjusting height of cut.
Page 294: Shield Height Adjustment
Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket or for desired front discharge when not using baskets. 1. Set cutting unit in normal cutting position. 2. Loosen capscrews and nuts securing shield to each side-plate, adjust shield to correct height and tighten fasteners (Fig.
Page 295: Top Bar Adjustment
Top Bar Adjustment Adjust top bar to make sure clippings are cleanly dis charged from reel area: 1. Loosen screws securing top bar (Fig. 15). Insert 0.060 inch feeler gauge between top of reel and bar and tighten screws. Make sure bar and reel are equal dis tance apart across complete reel.
Page 296: Lift Arm Down Pressure Adjustment
Lift Arm Down Pressure Adjustment The down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf condi tions. Increased down pressure will help keep the cut ting units on the ground when mowing at higher speeds and helps maintain a uniform height of cut in rough conditions or in areas of thatch build up.
Page 297: Repairs
Repairs Cutting Unit Removal and Installation Remove cutting unit from traction unit before doing adjustments or repairs. 1. Remove basket from cutting unit. 2. Disconnect chain from cross tube on each rear cutting unit (Fig. 17). Figure 17 1. Lock up chain 3.
Page 298: Reel Lapping
Reel Lapping DANGER Reel may stall while backlapping. Do not at- tempt to restart reels by hand or ad ust while backlapping. Stop engine and turn H.O.C. knob one position toward “A”. 1. Put the machine on a clean, level surface, lower cutting units, stop the engine, engage the parking brakes, move the enable/disable switch to DISABLE...
Page 299 8. Apply lapping compound with long-handled brush supplied with machine (Fig. 23). Never use a short handled brush. 9. If reel to be backlapped turns too slowly, or erratically, stop engine and turn H.O.C. knob one position toward “A”. Repeat steps 5 – 8. Position “P” will provide the slowest speed for backlapping.
Page 300: Bedbar Removal And Installation
3. Bedknife adjusting screws NOTE: For proper grinding of bedknife follow proce 4. Front roller brackets dures in the Toro publication “Sharpening Reel & Rotary 5. Counterbalance end cap Mowers”, Form No. 80-300-PT. 5. Reverse steps 1 - 4 to install the bedbar.
Page 301: Bedknife Replacement
3. Bedknife adjusting screws sides. 4. Front roller brackets 5. Counterbalance end cap For proper grinding of reel, follow procedures in the Toro publication “Sharpening Reel & Rotary Mowers, Form No. 80-300-PT. 3. Install bedbar. After grinding, assemble cutting unit and do all adjustments.
Page 302: Reel Removal And Bearing Replacement
Reel Removal and Bearing Replacement 1. Remove front and rear roller assemblies. Remove bedbar. Remove carrier frame. 2. Remove counterbalance end cap (Fig. 28). Remove large bearing adjustment nut from left hand end of reel shaft (Fig. 28) and special spline nut from opposite end of reel shaft.
Page 303: Lift Arm Spring Replacement
Lift Arm Spring Replacement 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. 2. Remove floor plate in front of seat to get access to front springs or open hood to get access to rear springs.
Page 304 ® Repairs Page 8 - 22 Reelmaster 223-D/5100-D/5300-D...
Page 305 Chapter 9 4WD Rear Axle Table of Contents SPECIFICATIONS ......2 REPAIRS ....... . . 5 GENERAL INFORMATION .
Page 306: Specifications
Specifications Item Specification ________________________________________________________________________________________ Lubricant (Fig. 1, 2, 3) SAE 80W90 gear lube ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ Rear wheel toe-in 1/8 inch ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ Wheel nut torque...
Page 307: General Information
General Information Four-Matic 4WD Over-Running Clutch Operation A drive shaft connected to the front axle provides power for the rear 4WD drive axle. The drive shaft tor the rear Locked 49 RPM axl e in c o r porat es an OVER-RUNNING (ROLLER) Unlocked CLUTCH THAT TRANSMITS POWER ONLY IN THE FOR-...
Page 308: Adjustments
Adjustments Rear Wheel Toe-in (Fig. 7) 1. Measure center–to–center distance (at axle height) at front and rear of steering tires. Front measurement must be 1/8 in. less than rear measurement. 2. To adjust, loosen clamps at both ends of tie rod. 3.
Page 309: Repairs
Repairs Drive Shaft Service ± ″ 0.34 0.03 ″ MAX Arrow end of roller 0.040 clutches must face 6-bolt flange end of clutch housing (toward rear axle) Detail A Detail B Apply Never-seeze 110 - 120 ft-lb (L.H. thread) Apply Apply Never-seeze Loctite...
Page 310 0.34 ± 0.03″ ″ MAX Arrow end of roller 0.040 utches must face 6-bolt f ange end of utch housing (toward rear axle) Detail A Detail B Apply Never-seeze 110 - 120 ft-lb (L.H. thread) Apply Apply Never-seeze Loctite gure 9 6.
Page 311 If bracket (Item 3) was not removed: 5. Tighten two (2) capscrews (Item 19) and locknuts (Item 6) to secure yoke to shaft. Slide bearing assembly onto traction shaft. Loosely mount bearing support (Item 5) to bracket (Item 3) Do steps 6 - 9 only if traction shaft (Item 31) was with three (3) carriage bolts (Item 1) and locknuts removed: (Item 6).
Page 312: Rear Axle Removal And Installation
Rear Axle Removal and Installation Apply Loctite 0.318″ 0.018″ 0.032″ ″ 0.018 45 - 55 ft-lb Figure 10 1. Remove drive shaft (see Drive Shaft Service). 6. Remove capscrew (Item 4) from pin (Item 44). Re move pin (Item 44) from axle support, allowing axle to 2.
Page 313: Axle Repair
Rear Axle Repair Before disassembling axle, remove hydraulic cylinder (Fig. 9, Item 28), cylinder support (Item 17), tie rod tube and clamp assembly (Item 12) and steering arms (Items 46, 31). Disassembly 1. Remove drain plugs (Fig. 11) and let oil drain out into containers.
Page 314 Apply Loctite 16 - 20 ft-lb 20 - 24 ft-lb Shim for backlash adjustment Measure backlash here: 0.003 - 0.01″ Shim for bevel gear to pinion contact adjustment Tighten to pre-load bearings. Pinion shaft should rotate with 2.0 - 5.5 in-lb torque 16 - 20 ft-lb Figure 12 2.
Page 315 6 - 8 ft-lb 12 - 20 ft-lb Apply Loctite 12 - 20 ft-lb Figure 13 Assembly E. Tighten bolts (Item 1, 35) to a torque of 16 - 20 ft-lb (220-280 Kg-Cm). 1. Use new gaskets and seals when reassembling axle. 3.
Page 316 B. Assemble knuckle pin (Item 20) and knuckle case medium strenght Loctite on capscrews (Item 28) (Item 38) to match knuckle arm (Item 8) with knuckle securing cover (Item 26). pin. Fasten capscrew (Item 10) temporarily (will be removed to fill with lubricant). F.
Page 317 This page is blank.

Toro Reelmaster 5100-D Service Manual

Table of Contents

Chapter 1 - Safety

Chapter 2 Product Records

Chapter 3 Mitsubishi Diesel Engine

Chapter 4 Hydraulic System

Chapter 5 Electrical System

Chapter 6 Differential Axle

Chapter 7 - Steering and Brakes

Chapter 7 Steering and Brakes

Chapter 8 Cutting Units

Chapter 9 Drive Shaft Service

Quick Links

Service Manual

Chapters

Troubleshooting

Related Manuals for Toro Reelmaster 5100-D

Summary of Contents for Toro Reelmaster 5100-D