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Toro Reelmaster 5100-D, Service Manual

The Toro Reelmaster 5100-D is a top-of-the-line commercial lawn mower designed for precision and efficiency. With its powerful engine and advanced reel technology, it delivers superior cutting performance. Download the user manual for free at manualshive.com and learn how to maximize the potential of this exceptional machine.

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TurfDefender Leak Detector 

The TurfDefender

t 

is an electronic hydraulic fluid leak 

detection device that fits inside the hydraulic tank of your 
machine. It is a pressure based system which requires a 
sealed hydraulic tank to function properly. Very small 
changes to the oil level in the sealed tank result in a large 
movement of the leak detector’s internal float. The Turf-
Defender’s internal microprocessor analyzes the float 
movement and determines if there is a leak in the sys-
tem. 

D 

Turn ignition key to “ON” position start the sys-

tem. The system will reset itself whenever the igni-
tion key is moved to “OFF” position. Wait 5 seconds, 
then move key to “ON” position to restart the system. 

D 

When machine is started, the  alarm will give 

one short beep to indicate that everything is operat-
ing properly. If the alarm makes no noise at all, it 
should be checked by a mechanic. 

D 

If the  alarm gives 4 short beeps it means a sys-

tem problem has been detected and it should be 
checked by a mechanic. The 4 beep pattern will con-
tinue for approximately 1–1/2 minutes, then stop, un-
less the ignition key is moved to “OFF” position. 
Note: The low or high oil level 4 beep signal may oc-
cur if machine is started on a slope. Move machine to 
a level surface, move ignition key to “OFF” position, 
wait 5 seconds, then move key to “ON” position to re-
start the system. 

D 

If the  alarm gives a loud continuous beep while 

mowing and shuts off the cutting units, it means that 
a leak has been detected.  On the traction unit, the 
red light on the steering console will also blink indi-
cating the ECU has shut off the cutting units. 

Checking Leak Detector Operation 

The operation of the TurfDefender

t 

should be 

checked if any of the following conditions occur: 

a.  No beeps are heard when ignition switch is 
turned “ON”. 
b.  Any time the machine gives a series of 4 short 
beeps. 
c.  False alarms are observed. 

1.  Park machine on a level surface, stop the engine 
and engage the parking brake. 

2.  Open control panel cover. Locate leak detector 
harness loopback connector with hydraulic 
symbol tag. Carefully unplug loopback 
connector from harness connector. 
3.  Connect the Diagnostic ACE display connector to 
the correct harness loopback connector. Install TurfDe-
fender overlay decal (supplied with leak detector kit) 
onto  Diagnostic ACE (Fig. 8b). 

4.  Turn the key switch to the ON position, but do not 
start machine. 
Note: Red text on the overlay decal refers to inputs and 
green text refers to outputs. 
5.  The red “Inputs displayed” LED (Light Emitting 
Diode), on lower right column of the Diagnostic ACE, 
should be illuminated. If green “Outputs displayed” LED 
is illuminated, press and release the toggle button, on 
Diagnostic ACE, to change LED to “Inputs displayed”. 
Do not hold button down (Fig. 8b). 

If TurfDefender is functioning normally: 

1.  When the “Inputs displayed” LED is lit, the actual 
Float position (1 or 2  LED’s on left row) and “Oil level 
OK” LED – should be displayed (Fig. 8c). 

2.  Press toggle button until green “Outputs displayed” 
LED is lit. “Valve ON”, “data line” and ”self diagnos-
tic”LED’s should be lit steadily. “Alarm ON” LED may be 
displayed temporarily (about 5 seconds) (Fig. 8d). 

Note: If “data line” or ”self diagnostic” LED’s are blink-
ing, there is a problem in the system. 

If No beeps are heard: 

1.  Check alarm wires to make sure they are not dis-
connected, broken or “+” and “–” reversed. 

2.  Toggle “outputs displayed” on Diagnostic ACE dis-
play (Fig. 8d). 

D 

Alarm open circuit (LED blinking): Check / re-

place TurfDefender  alarm or wires. 

D 

Alarm short circuit (LED blinking): Check / re-

place TurfDefender  alarm or wires. 

If 4 beeps are heard: 

The most common cause for a 4 beep signal is from an 
improper oil level reading. Make sure machine is on a 
level surface when checking oil level. Since oil level will 
vary with temperature, it is best to check when cool. 

1.  When toggling “input”, a LED should display 
(Fig.  8c) any of the following problems diagnosed by the 
TurfDefender: 

D 

Oil level low: Position machine on a level surface

and fill to proper level.

D 

Oil level high: Position machine on a level sur

-

face and remove excess oil until proper level is at

-

tained.

D 

Oil too hot: Allow machine to cool and clean any

debris from oil cooler.

D 

Air leak in system: Assure tank cap is tight or

check for leak in tank.

Note: Only large air leaks can be detected by hand 
held Diagnostic ACE. A leakdown test is required to 
identify small air leaks. Consult your Authorized Toro 
Distributor for assistance. 

Troubleshooting 

Page 5 – 8.2  Rev. B 

Reelmaster 5100–D 

Summary of Contents for Reelmaster 5100-D

Page 1: ...complete Model and Serial Number of traction unit and cutting unit to The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARN ING or CAUTION PERSONAL SAFETY IN STRUCTION When you see this symbol carefully read the instructions that follow Failure to o...

Page 2: ...This page is blank ...

Page 3: ...ications 4 2 General Information 4 3 Hydraulic Schematic 4 6 Hydraulic Flow Diagrams 4 7 Special Tools 4 12 Troubleshooting 4 15 Testing 4 25 Adjustments 4 33 Transmission Repairs 4 35 Mowing Circuit Repairs 4 54 Hydraulic Reservoir and Filter 4 67 Chapter 5 Electrical System Wiring Schematics and Diagrams 5 2 Special Tools 5 5 Troubleshooting 5 7 Testing 5 18 Repairs 5 32 Chapter 6 Differential A...

Page 4: ...This page is blank ...

Page 5: ...erate the machine Do not allow adults to operate the machine without proper instruction Only trained operators who have read the Operator s Manual should operate the machine While Doing Maintenance Troubleshooting Testing Adjustments or Repairs 3 j Improper operation maintenance trou bleshooting testing adjustments or repairs ofthe machine can result in in ury or death To reduce the potential for ...

Page 6: ...se to a sand trap ditch creek or other hazard F Reduce speed when making sharp turns and turning on a hillside G Avoid sudden stops and starts 15 Traverse slopes carefully Do not start or stop sud denly when traveling uphill 16 Operator must be skilled and trained in how to drive on hillsides Failure to use caution on slopesor hills may cause loss of control and vehicle to tip or roll possibly res...

Page 7: ...os materials 30 If the engine must be running to perform an inspec tion or procedure use extreme caution Always use two people with the operator at the controls able to see the person doing the inspection or procedure Keep hands feet clothing and body away from cutting units and other moving parts 31 Do not overspeed the engine by changing governor setting 32 Shut engine off before checking or add...

Page 8: ...Safety Instructions Page 1 4 Reelmaster 5100 D ...

Page 9: ...00 D on the OPERATION AND SERVICE HISTORY REPORT form Use this information when referring to your ma chine TORQUE SPECIFICATIONS 3 Capscrew Markings and Torque Values U S 3 Capscrew Markings and Torque Values Metric 3 MAINTENANCE INTERVAL CHART 4 OPERATON AND SERVICE HISTORY REPORT Insert Operator s Manuals and Parts Manuals for your Reelmaster 5100 D at the end of this section Reelmaster 5100 D P...

Page 10: ...5 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 75...

Page 11: ...________________ ______ ________________ __________________________________ ______________________________ _____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________ _____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________ ___...

Page 12: ...Maintenance Interval Chart Maintenance Interval Chart Page 2 4 Rev A Reelmaster 5100 D ...

Page 13: ...5100 D AND 5300 D TORO Model and Serial Number __________ __________ Engine Numbers ____________________ Transmission Numbers ____________________ 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 a...

Page 14: ...ue Wheel Lug Nuts Level Service Air Filter Replace Electric Fuel Pump Filter Replace Fuel WaterSeparator Filter Inspect Traction Linkage Movement Torque Head and Adjust Valves D Check Engine RPM idle and full throttle Level Change Hydraulic Fluid Change Transmission Fluid Replace Transmission Filter Check Rear Wheel Toe in Rear Axle Service pack Rear Wheel Bearings 2WD E Level change Rear Axle Lub...

Page 15: ...ual Engine Noises 1 Unusual Operating Noises Transmission Oil Level Hydraulic System Oil Level Hydraulic Filter Indicator 2 Hydraulic Hoses for Damage Fluid Leaks Tire Pressure Instrument Operation Reel to Bedknife Adjustment Height of Cut Adjustment Cutting Units Shear Pin Lubricate All Grease Fittings 3 Touch up damaged paint 1 Check glow plugs and injector nozzles if hard starting excess smoke ...

Page 16: ...chnician A Service every 50 hours B Service every 100 hours C Service every 200 hours Check Battery Fluid Level Check Fan and Altenator Belt Tension Drain Moisture Hyd Tank Check Battery Cable Connections Replace Engine Oil Filter Drain Moisture Fuel Tank Lubricate All Grease Fittings Inspect Cooling System Hoses Check Reel Bearing Preload Change Engine Oil A Service required Torque Wheel Lug Nuts...

Page 17: ...ND INSTALLING THE ENGINE 44 TESTING 18 Removing the Engine 44 Glow Plug Test 18 Installing the Engine 45 Compression Test 19 CYLINDER HEAD OVERHAUL 46 Nozzle Tests 20 Cylinder Head Removal 46 Injection Pump Test 22 Cylinder Head Service 47 Injection Timing Test 23 Valve Guides 48 Fuel Pump Test 24 Valves 49 Thermostat Test 24 Valve Seats 49 PREPARATION FOR ENGINE REPAIR 25 Valve Springs 50 Cylinde...

Page 18: ... by Mitsubishi Heavy Indus tries 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 Figure 1a The engine model number is cast onto the injection pump side of the cylinder block Fig 1a Th...

Page 19: ...fications 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 Figure 2a Figure 2b Reelmaster 223 D 5100 D Page 3 3 Specifications ...

Page 20: ...______ ___ ______ ___ ______ ___ ______ _ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __...

Page 21: ...__________________________ ________________________________________________________________________________________________________________________ ________________________________ Engine Item Standard Specification Repair Limit Service Limit Governor Mechanical Centrifugal 50 Operating Speed no load 3200 rpm 0 rpm 50 Idle Speed no load 1700 rpm 0 rpm Compression 28 kg cm2 398 psi at 280 rpm 25 kg...

Page 22: ... Rod Type Bend and Twist Big End Thrust Clearance __ __ __ __ __ __ _ Connecting Rod Bearings Oil Clearance Undersize __ __ __ __ __ __ _ Crankshaft Type Bend End Play Journal O D Pin O D Finish Undersize Journal U S 0 25 mm 0 01 in Journal U S 0 50 mm 0 02 in Pin U S 0 25 mm 0 01 in Pin U S 0 50 mm 0 02 in __ __ __ __ __ __ _ Main Bearings Oil Clearance Undersize Standard Specification Solid Alum...

Page 23: ...__ __ __ __ __ __ __ __ _____ __ __ __ ____ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _____ __ __ __ ____ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _____ __ __ __ ____ Engine cont Item Camshafts Drive System Front Journal Journal to Cylinder Block Hole Clearance Cam Lobe Major Diameter both intake and exhaust Cam Lobe Major Diameter pump cam Tappets Outside Diameter Tappet to Cyl...

Page 24: ... __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Fuel System Item Fuel Pump Delivery Rate Fuel Injection Pump Model Injection Timing B T D C Nozzles Type Injection Start Pressure Standard Specification _ 225 cc 13 73 in 3 or more 15 sec 12V ND PFR NC 19 o 1 52 o at SS Throttle type 140 kg cm 2 1992 psi _ _ Repair Limit _ 19 o ...

Page 25: ...om pinion side No load Characteristics Cold Terminal Voltage 11 5V Current 100A or less Speed 3000 rpm or more Load Characteristics Terminal Voltage 7 7 V 11 5V Current torque 300A 0 98 kg m 6 7 ft lb or more 0 7 kg m 5 ft lb Speed 980 rpm or more Height of Brush 17 mm 0 67 in 6 mm 0 24 in Spring Pressure 3 kg 6 6 lb Commutator O D 38 7 mm 1 52 in 1 0 mm 0 4 in Depth of Commutator Undercut 0 5 mm ...

Page 26: ...__ ________________________________ ________________________________________________________________________________________________________________________ ________________________________ ________________________________________________________________________________________________________________________ ________________________________ ________________________________________________________...

Page 27: ...l Engine Compression Test Kit Diesel engine compression test kit Fig 5 0 1000 PSI Gauge allows testing ofdiesel engines to check general operating condition of engine Includes case guage with hose glow plug hole adapters and instructions Figure 5 Piston Pin Tool Piston pin tool Fig 6 is used to remove and install the wristpin without distorting thepiston Inludesanadapter for use with Mitsubishi an...

Page 28: ...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: ...1 NOTE There are two TDC positions compression and intake strokes At compression TDC the rocker arms will not move when the crankshaft pulley is rotated a small distance each way Compression TDC is where the valves are to be adjusted 6 Measure the valve clearance by using a thickness gauge inserted between the valve stem and rocker arm The correct valve clearance for both the intake and exhaust va...

Page 30: ...e should be atoperatingtemperature Make sure the parking brake is engaged 2 Open the hood 3 Loosen the lock nut on the high speed set bolt Fig 12 4 Adjust maximum engine speed to 3200 50 0 rpm by rotating the high speed set bolt Tighten the lock nut 5 Install a wire and lead seal on the high speed setbolt Idle Speed Adjustment NOTE Specified engine rpm is with no load on engine 1 Theengine should ...

Page 31: ...of motion of the throttle lever or governor lever 6 Tighten locknut on throttle lever pivot so 10 15 lb of force is required to move the throttle lever 2 1 Figure 13 1 Throttle lever2 Locknut 2 4 1 3 Figure 14 1 Governor lever 3 Throttle cable 2 Cap screw and nut 4 Throttle cable conduit Troubleshooting Giving Immediate attention to any indication of a prob Never make more that one adjustment at a...

Page 32: ...Troubleshooting Page 3 16 Reelmaster 223 D 5100 D ...

Page 33: ...Reelmaster 223 D 5100 D Page 3 17 Troubleshooting ...

Page 34: ... of a burnt glow plug end tube NOTE If the metal of the glow plug end is melted it is a sign of cylinder overheating See Engine Overheats in the Troubleshooting section of this chapter 4 Connect the positive battery terminal to the glow plug terminal and the negative battery terminal to the plug body Fig 15 If the glow plug glows red hot the glow plug is operating correctly 5 Replace any glow plug...

Page 35: ... Disconnectthe fuel stop solenoid electrical connector to prevent fuel delivery during the compression test Fig 17 This will prevent wash down of the cylinders and inaccurate readings 5 Crank the engine with the starter motor until you get a stable gauge reading 6 Normal compression is 28 32 kg cm2 398 455 psi If the pressure is less than 25 kg cm 2 356 psi it will be necessary to find the cause o...

Page 36: ...ine the pressure at which the nozzle opens and the fuel is sprayed 5 Verify that starting pressure is within the following limits Minimum starting pressure is 130 kg cm2 1850 psi Maximum starting pressure is 150 kg cm 2 2134 psi 6 Starting pressure can be adjusted by adding or re moving shims from the nozzle See Nozzle Service in the Fuel System Repairs section of this chapter A 0 1 mm shim will c...

Page 37: ...on the nozzle must effectively at omize the injected fuel 1 Operate the pump handle at a rate of 20 30 strokes per minute 2 Observe the injector nozzle spray The spray pattern should be finely atomized in a broad straight stream Fig 19 3 Ifthe nozzle fails tospray properly it must becleaned repaired or replaced See Nozzle Service in the Fuel System Repairs section of this chapter Figure 18 Figure ...

Page 38: ...he nozzle from the cylinder head C Connect the fuel delivery pipe to the nozzle as sembly so the tip of the nozzle is pointed away from the engine Tighten the fitting securely D Put the throttle control in the FAST position Turn the ignition key to the START position to crank the engine Observe the nozzle j The injection pump forces fuel from the noz zle under extremely high pressure Always point ...

Page 39: ...her push rod is tight rotate the engine crankshaft one full revolution and inspect the push rods again 5 Turn the ignition switch ON so the fuel pump will supply fuel through the injection pump and out the number one injection pipe 6 Rotate the engine crankshaft slowly in the normal direction until the flow from the number one injection pipe just stops This is the moment of actual injection timing...

Page 40: ...el pumped in during a 15 secondtimeinterval The standard pump rate isapproxi mately 8 ounces 225 cc in 15 seconds 4 If the fuel delivery rate is below the standard value the pump should be disassembled and checked See Fuel Pump Service in the Fuel System Repairs section of this chapter Thermostat Test Figure 22 If the engine overheats and a faulty thermostat is sus pected the thermostat should be ...

Page 41: ...r Cylinder and Cylinder Block Overhaul Before removing any parts disassembly or overhaul of the Mitsubishi engine it is very important to understand thenature andprobable cause ofthe problemthat made an overhaul necessary When the engine trouble is caused by worn cylinders rings or valves one or more of the following symptoms will occur 1 Low engine power and a decrease in compression pressure 2 I...

Page 42: ... by carefully moving around fan blades 5 Install new belt s 6 Connect drive shaft coupler to engine crankshaft pulley with two capscrews and lockwashers 7 Adjust belt tension Alternator belt Insert pry bar between alternator and engine and carefully pry alternator out until proper tension is achieved Belt should deflect 3 8 to 1 2 in when 22 lb of force is applied to belt midway between crankshaft...

Page 43: ...nd engine and pry out alternator Apply only enough pressure to get the correct belt tension 8 Hold the alternator in position afteryou getproper belt tension and tighten the alternatorbrace bolt Tighten the alternator support bolt For proper tension the belt should deflect 3 8 to 1 2 in when 22 lb of force is applied midway between alternator and crankshaft pul leys Starter Removal and Installatio...

Page 44: ...g the tie rod back and forth Fig 29 Stop screwing the solenoid into the engine when there is no free play in the tie rod 5 Turn the solenoid outward counterclockwise 1 4 to 1 2 turn There should be a small amount of free play in the injector pump control rack 0 01 0 03 in 0 3 0 7 mm IMPORTANT No free play in the control rack with the solenoid de energized plunger out may cause injection pump damag...

Page 45: ...switch threads When installing the switch make sure the sealant does not block the oil hole in the switch Figure 30 Thermostat Removal and Installation 1 Lower the coolant level to below the thermostat 2 Loosen the hose clamp and disconnect the hose from the water outlet fitting 3 Remove the water outlet fitting and gasket Fig 31 4 Replace the thermostatif necessary See Thermostat Test in the Test...

Page 46: ...s Replace as required Install the hoses on the water pump and tighten the hose clamps 8 Install the alternator water pump drive belt 9 Insert a pry bar between the alternator and engine and pry out alternator Apply only enough pressure to get the correct belt tension 10 Hold the alternator in position after you get proper belt tension and tighten the alternator brace bolt Tighten alternator the su...

Page 47: ...d The spring pulls on the governor lever to move the governor control rack and increase the fuel injection rate As engine speed increases the governor weight centrifugal force also increases until it is balanced with the governor spring force thus maintaining a constant engine speed 1 Sealing metal 2 Sealing wire 3 Speed adjustment screw 4 Governor weight assembly 5 Sliding shaft 6 Stopper 7 Gover...

Page 48: ...noid plunger allowing movement of the injection pump control rack 4 Push the tie rod forward only with only enough force to overcome the spring pressure and operate the speed control lever or throttle lever You should feel the governor lever under spring tension move the tie rod and control rack as the lever is operated 5 If the control rack does not move move correctly disconnect the tie rod from...

Page 49: ...llation B Install the levers and shafts After press fitting each grooved pin check the shaft for smooth opera tion C Install thegovernor springleverand speed control lever so there is a minimum play of angle between levers Fig 35 D The governor spring should not deflect more than 20 mm 0 8 in when installed 9 Inspect all parts for wear or damage and smooth operation 10 Reverse steps 1 4 to reassem...

Page 50: ...lt is adjusted to the correct engine speed of 3200 50 0 rpm See Adjusting Engine Speed in the Maintenance section of this chapter NOTE Specified rpm is with no load on engine 2 Operate the engine at high idle speed 3 Turn the torque spring set Fig 36 clockwise until engine speeddrops approximately50 rpmfromhighidle speed 4 From this position turn the back the torque spring set counterclockwise N t...

Page 51: ... until resistance to rotation is felt Lightly lock the screw in position with locknut 3 Set dial on spring scale to zero 0 Tighten spring case until a value of 970 10 0 grams is obtained Lock the spring case in that position with special nut 4 Temporarily loosen adjustment screw until to get a valueof 770 grams then retightenthescrew until a value of 970 10 0 grams is attained Lock the adjustment ...

Page 52: ... will begin to operate and force fuel outaround the screw loosened in step 2 Fuel will fill the filter bowl and then flow out around the screw When a solid stream of fuel flows out around the screw tighten the screw and turn the key switch OFF 4 Open the air vent screw on the fuel injection pump Fig 40 5 Turn the ignition key switch to the ON position The electric fuel pump will begin to operate a...

Page 53: ...pe connection 4 Tighten the pipe connector 5 Repeat steps 1 4 for the No 2 and No 3 injector nozzle and holder Figure 41 1 1 Fuel injector nozzle and holder 3 Fuel Pump Service The only serviceable parts of the fuel pump are the magnet filter and the gaskets on each end of the filter 1 Disconnect the fuel pump wires from the wiring har ness and ground connection 2 Disconnect the fuel hoses from th...

Page 54: ...mended to replace the pump IMPORTANT Clean the injection pump and the area near the injection pump before removing or servic ing it DO NOT spray water onto a hot injection pump Removing and Installing the Injection Pump 1 Remove the engine stop solenoid see Replacing and or Adjusting Engine Stop Solenoid in the External Engine Component Repair section of this chapter 2 Disconnect the fuel pipes fr...

Page 55: ...he plunger spring and upper seat 5 Remove the two screws securing the bracket to the pump housing Remove the control rack IMPORTANT DO NOT loosen the adjusting screws on the control rack for each cylinder If these parts are removed it is necessary to measure fuel injec tion quantity with a pump tester and cam box 7 Remove the sleeve and plunger Remove the plunger barrel upward from the pump housin...

Page 56: ...Fig 48 6 Push in the tappet roller assembly and install the stopper pin 7 Tighten the delivery valve holder to a torque of 3 5 3 9 Kgm 25 28 ft lb Install the holder stopper 9 Before installing the injection pump make sure the control rack slides smoothly with little resistance If the control rack binds it is assembled incorrectly or parts are dirty The pump must then be reassembled correctly and ...

Page 57: ...e Nozzle Tests in the Testing section of this chapter 3 Secure the nozzle holder in a vise that has aluminum orbrassjaw plates To preventdeformationdonotclamp the vise onto the retaining nut Fig 49 4 Remove the retaining nut shim washer spring pin and distance piece 6 Remove the nozzle assembly from the retaining nut If it is difficult to remove tap it lightly with a rubber or wooden mallet IMPORT...

Page 58: ...ece and pin into the retaining nut 2 Install the shim and pressure spring the body Assem ble the body to the retaining nut Put the nozzle holder in a vise Tighten the body and nut to a torque of 3 5 4 0 KgM 25 29 ft lb Fig 51 3 Test the nozzle for proper operation See Nozzle Tests in the Testing section of this chapter Nozzle Installation 1 Clean the nozzle holder fitting surface on the cylinder h...

Page 59: ...der to the frame and remove the fender 4 Disconnect fuel lines from fittings on top of fuel tank 5 Disconnect electrical wire from fuel gauge sender 6 Remove three capscrews flat washers and lock washers securing fuel tank to frame and remove fuel tank 7 Reverse steps 2 6 to install the fuel tank and tank base When installing the tank to the frame tighten the screws to a torque of 30 60 in lb Do n...

Page 60: ...0 Loosen hose clamp and remove fuel hose from injector pump Plug end of fuel line to prevent fuel leakage Loosen hose clamp and remove fuel return hose from rear fuel injector on engine 11 Disconnect and tag wires that attach to engine or engine components Alternator Starter motor and solenoid Ground cables Oil pressure switch Temperature gauge sender Thermoswitch Engine stop solenoid Glow indicat...

Page 61: ... with the correct oil Fill the cooling system with a 50 50 solution of ethylene glycol antifreeze and clean soft water Check for oil and coolant leaks and repair as necessary 3 Adjust throttle linkage See Throttle Linkage Adjust ment in the Adjustments section of this chapter Reelmaster 223 D 5100 D Page 3 45 Removing and Installing the Engine ...

Page 62: ...g lead wires 6 Remove the fuel injection pipes and return pipe 7 Remove the rocker cover and gasket 8 Loosen the rocker stay attaching bolts Remove the rocker assembly Fig 59 9 Loosen the cylinder head bolts Use the sequence shown in Figure 60 Remove the cylinder head assem bly including the intake and exhaust manifolds 10 Remove the cylinder head gasket Use a scraper tool to remove the cylinder h...

Page 63: ... cleaning 4 Remove all of the carbon deposits from the combus tion chamber using a scraper and wire brush 5 Clean the cylinder head thoroughly with solvent or degreasing solution and allow it to dry Inspect carefully for cracks 6 Remove all carbon deposits from the valve guide bores with a valve guide cleaner Use a valve guide bristle brush to remove loosened carbon deposits in the valve guide Pus...

Page 64: ...alve stem clearance Intake valve 0 10 mm 0 004 in Exhaust valve 0 15 mm 0 006 in 2 Use a valve guide removing mandrel with a pilot section to remove the valve guide Push the valve guide up from the bottom of the cylinder head 3 To install the new valve guide press it in from the top of the cylinder head using the valve guide mandrel Install the valve guide so the installed height is 13 5 14 5 mm 0...

Page 65: ...dications of incorrect contact Fig 66 Maximum valve sinkage 1 5 mm 0 06 in 2 The valveseat canbe resurfaced Fig 67 Resurface the valve seat so it contacts the mid portion of the valve face 3 After cutting new valve seats use lapping compound to lap the valve to the seat After lapping thoroughly clean the valve seat and valve areas to remove any traces of lapping compound 4 Put a lightcoat of Pruss...

Page 66: ...ocker arm stays spring and rocker arms from the shaft Fig 69 2 Inspect each rocker arm for wear at the valve tip and push rod contact surfaces Replace any worn or dam aged rocker arms 3 Inspect the rocker shaft for wear or damage Replace the rocker shaft if it is worn or damaged 4 Measure the rocker arm inside diameterand the shaft outside diameter Replace the shaft if the rocker arm to shaft clea...

Page 67: ...insert them in proper order into the valve guides Install the valve springs and valve retainers Compress the spring with a valve lifter then install the retainer lock IMPORTANT Be careful not to damage the spring and stem seal by over compressing the spring dur ing installation 6 Install the nozzle holders in the cylinder head and tighten to a torque of 5 0 6 0 KgM 36 43 ft lb 7 Install the glow p...

Page 68: ...stall the rocker arms spring and rocker arm stays on the rocker shaft Install the rocker shaft so the identification mark small drilled hole near the end of the shaft is at the front and facing the valve side Install the bolts through each stay and into the shaft Install the snap ring on each end of the shaft 12 Install the rocker arm and shaft assembly on the cylinder head Tighten the rocker arm ...

Page 69: ...y from the gear case See the Governor System Repairs section of this chapter 4 Remove the water pump See Water Pump Service in theExternal Engine Component Repair section ofthis chapter 5 Remove the alternator See Alternator Removal and Installation in the External Engine Component Repair section of this chapter 6 Remove the gear case assembly Fig 72 Figure 72 1 Bushings 5 Relief plunger 9 Oil pum...

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: ... governor bushings Fig 76 E Install the shaft spring and levers Press fit the expansion plug into the hole in the gear case Figure 74 9 Reverse steps 1 6 to reassemble the gear case Use new gaskets when assembling the gear case IMPORTANT Install a new front oil seal before in stalling the gear case Apply a thin coat of oil to the circumference and lip of the oil seal Figure 75 Figure 76 Reelmaster...

Page 72: ...ove the injection pump camshaft A Remove the governor weight assembly Fig 33 B Remove camshaft rear cover Figure 77 C Remove the stopper bolt Fig 78 D Pull out the camshaft from the front of the cylinder block 5 To remove the valve camshaft A Pull the push rods and tappets out of the cylinder block B Remove the camshaft stopper bolt C Pull the camshaft out of the cylinder block Fig 79 Figure 78 Fi...

Page 73: ...etween gears in mesh 0 3 mm 0 012 in 7 Inspect the camshaft parts Fig 80 Replace any parts that are worn or damaged Major diameter of cam Injection pump cam 29 3 30 mm 1 154 1 181 in Valve cam 26 37 27 37 mm 1 038 1 078 in Push rod bend within 0 3 mm 0 012 in Tappet to cylinder block hole clearance 0 15 mm 0 006 in maximum Figure 80 Reelmaster 223 D 5100 D Page 3 57 Cylinder Block Overhaul ...

Page 74: ...enter TDC of the compression stroke Reverse steps 1 5 to install the camshafts and timing gears Fig 81 Figure 81 9 With the crankshaft set to No 1 cylinder TDC install the idle gear so the timing marks on all the gears are in alignment Fig 82 Figure 82 Cylinder Block Overhaul Page 3 58 Reelmaster 223 D 5100 D ...

Page 75: ...e the connecting rod end caps and bearings Fig 83 Keep these parts in cylinder number order so they can be reinstalledin the same cylinder Use a wood block to push the pistons and connecting rods up out from the bottom of the block Take care not to scratch the crankshaft pin and cylinder 6 Check each piston for wear signs of seizure or nicks Replace the piston if it is damaged 7 Thoroughly clean t...

Page 76: ...the service limit thering must bereplaced If theclearance still does not meet specifications with a new ring the piston must be replaced See the Specifications section of this chapter Figure 85 10 Measure the piston ring end gap Insert the ring into the least worn area of the cylinder by pushing it into place with the piston Fig 86 If the gap exceeds 1 5 mm 0 060 in the ring must be replaced Figur...

Page 77: ...emble the piston to the connecting rod press the piston pin into the set position Use the piston pin setting tool Fig 88 Make sure the identification mark of the rod and the arrow mark on the piston head are directed up Pin press fitting force 500 1500 kg 1100 3300 lb 14 Assemble each connecting rod and bearing to the crankshaft in proper order Use a feeler gauge to meas ure the side clearance bet...

Page 78: ...sembly into the cylinder block using a ring compressor and a wooden block Make sure the arrow mark on top of the piston is facing toward the front of the engine 17 Install the connecting rod bearings and end caps Make sure the notches on the bearings and connecting rod are aligned Tighten the end cap retaining bolts to a torque of 3 2 3 5 KgM 23 25 ft lb Figure 90 Cylinder Block Overhaul Page 3 62...

Page 79: ...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 Remove the crankshaft 6 Inspect the removed parts Repair or replace any worn or damaged parts Fig 92 Figure 91 Figure 92 Reelmaster 223 D 5100 D Page 3 63 Cylinder Block Overhaul ...

Page 80: ...its install a new bearing If installing the new bearing does not reduce the clearance to within service limits the crankshaft must be reground and oversize bearings installed Tightening Torque Main bearing cap bolt 5 0 5 5 KgM 23 25 ft lb Rod bearing cap nut 3 2 3 5 KgM 36 40 ft lb Crankpin oil clearance 0 15 mm 0 006 in Journal oil clearance 0 10 mm 0 004 in NOTE If using Plastigauge to measure t...

Page 81: ... dial indicator to measure the crankshaft end play If end play exceeds specifications replace all the main bearings Crankshaft end play 0 05 0 175 mm 0 002 0 007 in 12 Apply sealant Permatex No 2 or equivalent to the outside surface of the side seals Install the side seals with the radius towards the outside of the engine Fig 96 Figure 96 Figure 97 Reelmaster 223 D 5100 D Page 3 65 Cylinder Block ...

Page 82: ... 0 0004 in the cylinder must be rebored and oversized piston and rings installed IMPORTANT If one cylinder is rebored all cylinders must be rebored to the same specifications NOTE See the Specifications section of this chapter for oversize finishing sizes After machining install the piston and piston rings corresponding to the reworked cylinder size NOTE When the cylinder bore is worn a small amou...

Page 83: ...rating Hot 16 Filter Bypass Valve 40 Loss of Traction Power or Filter Bypass Reverse Flow Check Valve 41 Unit Will Not Operate In Either Direction 17 Charge Pump 42 No Cutting Units Operate 17 Transmission Removal and Installation 43 Front Reels Will Not Turn in Either Direction 18 Disassembly of Transmission 44 Front Reels Turn in Only One Direction Assembly of Transmission 49 Front Reel s Turn T...

Page 84: ...__________________________________________________________________________________________________________________ ________________________________ Specifications Item Description Transmission Sauer Sundstrand M25 U type System relief pressure 2WD units 2750 150 psi at 3250 RPM 4WD units 3200 150 psi at 3250 RPM Charge relief pressure 150 30 psi at 3250 RPM Cooler By pass pressure 70 10 psi Filter...

Page 85: ...mpatible with some brands of the other type of hydraulic oil If you always use Mobil products the two types ofoil are compatible and interchangeable IMPORTANT Use only types of hydraulic oils speci fied Other fluids could cause system damage NOTE A red dye additive for the hydraulic system oil is available in 2 3 oz bottles One bottle is sufficient for 4 to6 gallons ofhydraulic oil OrderPart No 44...

Page 86: ...Specifications Page 4 2 2 Reelmaster 5100 D ...

Page 87: ...ing of oil 4 Put the tube and nut squarely into position on the face seal endof the fittingandtighten the nut until fingertight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the correct flats from finger tight F F F T The markings on thenut and fitting body will verify thatthe connection has been tightened Size F F F T 4 1 4 in nominal hose or...

Page 88: ...h threads and sealing surfaces are free of burrs n cks scratches or any foreign materia F g 5 2 A ways rep acethe O ring seal when th s typeof fitting shows signs of leakage 3 Lubr cate the O r ng with a ght coat ng of o 4 Turn back the am nut as far as possible Make sure the back up washer s not loose and is pushed up as far as possible Step 1 5 Insta the f tting into the port and t ghten f nger ...

Page 89: ...mission to maintain its internal lubrication Severe damage to the hydro static transmission may occur 2 Attach a suitable chain strap or cable to the center of the front frame member Fig 7 3 Attach the other end of the towing device to a vehicle that is capable of towing the machine safely and at speeds below 10 mph 4 AN OPERATOR MUST BE ON THE MACHINE to steer it and keep the traction pedal fully...

Page 90: ...Hydraulic Schematic Rev A Hydraulic Schematic Page 4 6 Reelmaster 5100 D ...

Page 91: ...s through the relief valve to the low pressure side of the closed loop circuit An integral charge pump provides a constant supply of chargeoil to the variable displacement pumpand closed loop circuit for lubrication and to make up for oil that is lost due to internal leakage in the pump and motor Charge pump flow isdirected through the oil cooler then through the filter to the low pressure side of...

Page 92: ...d valve VS1 will direct part of the pump flow to tank while directing the remaining flow to solenoid valve S8 and out to the front reel motors Valve VS1 is adjusted bythe electronic control unit ECU with a variable duty cycle pulse width modu lated PWM voltage As the PWM duty cycle is in creased less oil is by passed to tank causing more oil to go to the reel motors When VS1 is fully energized no ...

Page 93: ...ximum reel speed 250 PSI Steering Cylinder to port D1 4 1 5 Rear Lift Cylinders Front Reel Motors Front Lift Cylinders 2 to port D2 3 M4 M5 S8 Variable Orifice Rear Reel Motors S3A S4A S5A M2 M3 VS1 S3 S5 S4 S1 Steering S9 Valve S6 G2 D2 P2 Control Valve Block S2 S7 VS2 R1 R2 3000 PSI 2000 PSI G1 Steering Pump P1 T D1 Pump Pump Figure 10 Reelmaster 5100 D Page 4 9 Rev A Hydraulic Flow Diagrams ...

Page 94: ...n solenoid valve S1 is energized variable solenoid valve VS1 will direct partof the pump flow to tank while directing the remaining flow to sole noid valve S8 and out to the front reel motors Return oil fromthemotors is directedto tank through valve S8 M5 M4 l Motors l i i li G1 P1 T G2 VS1 S1 S7 S3 S4 S5 S6 S9 S2 VS2 2 3 Pump 4 1 5 Orifice R1 R2 S8 Pump Pump Front Ree System Pressure Low Pressure...

Page 95: ...old the cutting units up in any position all of the solenoid valves are de energized Valve S6 is the load holding valve and this is the reason it is a poppet type valve The lift speed of No 1 front center and No 2 and 3 rear cutting units is regulated by one way variable orifices which are located in the hydraulic lines between the valve block and lift cylinders M4 System Pressure l M5 S3A S4A S5A...

Page 96: ... Protector Slide protector over reel motor shaft before installing shaft seal to protect seal from damage Apply a light coating of clean oil to seal protector to ease movement of seal over tool Use with seal installer tool Figure 13 Seal Installer Use installer and a small hammer to drive reel motor shaft seal into position in bore of reel motor body Use with seal protector tool Figure 14 Special ...

Page 97: ...nect 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 Use gauges as recommended in Testing section of this chapter Figure 15 Reelmaster 5100 D Page 4 13 Special Tools ...

Page 98: ...AUGE Low range gauge to provide accurate reading at low pressure 0 1000 psi This gauge has a protector valve which cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH PRESSURE GAUGE High range gauge to accommodate pressure beyond the capacity of the low pressure gauge 0 5000 5 FLOW METER This meter measures actual oil flow in the operat...

Page 99: ... be used again Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage The charts that follow contain detailed information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction All causes should be checked in the order in which they are listed on the charts Refer to the Testing section of this Chapter ...

Page 100: ..._________________________________________________________________________ ________________________________ 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 leve...

Page 101: ...__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _______ __ __ __ ____ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _______ __ __ __ ____ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _______ __ __ __ ____ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _______ __ __ __ ____ Loss of Traction Power or Unit Will Not Operate In Either Direction Cause Correction Engine R...

Page 102: ...nt Reels Will Not Turn in Either Direction Cause S1 not shifting Correction 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 Interchange S1 with S2 and check operation Re place S1 with a new valve if faulty R1 bypassing Check pressure at port G1 of valve...

Page 103: ...__ __ __ __ __ ___ __ __ __ __ __ __ ___ 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 Try operating lift circuit up and down a number of times Do cartridge valve service procedure for valve S7 S8 partially shift...

Page 104: ...age is being applied to VS1 and that there is no electri cal fault See Chapter 5 Electrical System Do cartridge service procedure for VS1 Interchange VS1 with VS2 and check operation Re place VS1 if faulty Front Reels Turn in Only One Direction Cause Correction S8 not shifting Do electrical diagnostics to make sure that voltage is being applied to S8 and that there is no electrical fault See Chapt...

Page 105: ...s 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 Excessive case drain flow may identify faulty motor Use hydraulic tester to perform reel motor efficiency test Repair or replace reel motor if faulty ...

Page 106: ...nter 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 Do electrical diagnostics to make sure that voltage is being applied to S7 and that there is no electrical fault See Chapter 5 Electrical System Test solenoid coil Replace if faulty See Chapter 5 Electrical System Oil viscosity too high run ma...

Page 107: ...utting 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 Replace S6 with a new valve if faulty Cutting Units Raise Too Fast or Too Slow Cause Correction One way variable orifice not properly adju...

Page 108: ... diagnostics to make sure that voltage is being applied to solenoid for affected circuit and that there is no electrical fault See Chapter 5 Elec trical System Do cartridge valve service procedure for valve in af fected circuit Interchange solenoid from affected circuit with an other similar valve S3 S4 or S5 and check opera tion Replace affected valve with a new valve if faulty Do electrical diag...

Page 109: ...essure can have sufficient force to penetrate skin and do serious dam age If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of in ury or gan grene may result WARNING 1 Thoroughly clean the machine before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hydraulic...

Page 110: ...r pressure is low check for restriction in pump intake line Inspect charge relief valve and valve seat Charge pressure can be adjusted by changing shim thickness behind the spring Check for sheared charge pump key Disassemble charge pump and check for internal damage or worn parts 6 Also take a gauge reading while operating the ma chine in forward and reverse Start the engine and put throttle at f...

Page 111: ...checked Fig 18 NOTE Test ports are 7 16 20 SAE O ring ports 4 Start the engine and move throttle to full speed approx 3200 RPM 5 Sit on seat and with brakes locked slowly depress the top of traction pedal While pushing top of traction pedal down look at pressure reading on gauge GAUGE READING Two wheel drive 2WD forward 2750 150 PSI Four wheel drive 4WD forward 3200 150 PSI Reverse 2WD and 4WD 275...

Page 112: ...d secure fitting 4 Sit on the seat and start the engine Move throttle to full speed approx 3200 RPM 5 While sitting on the seat pull Lower Mow Raise control leverbackto the RAISE position to lift the cutting units Hold the lever in the RAISE position while looking at the gauge GAUGE READING TO BE 3000 50 PSI NOTE Normal operating pressure when mowing is approximately 500 to 600 PSI per cutting uni...

Page 113: ...kof wood as shown in Figure 20b between cutting unit reel blades and front cross tube of left rear No 2 cutting unit to prevent reel from turning 5 Sit on the seat and start the engine Move throttle to full speed approx 3200 RPM Keep away from reels during test to prevent personal injury from rotating reel blades WARNING 6 While sitting on seat move Enable Disable switch to ENABLE Move Lower Mow R...

Page 114: ... will flow from the pump through the tester and into the valve block IMPORTANT The pump is a positive displacement type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 4 Make sure the parking brake is engaged Start the engine and move throttle to full speed approx 3200 RPM DO NOT engage the cutting units 5 While watching pressure gauges s...

Page 115: ...e person should sit on the seat and operate the machine while another person watches the gauges 6 Make sure the parking brake is engaged Start the engine and move throttle to full speed approx 3200 RPM Keep Cutting unit reels will rotate when lowered with Enable Disable switch in ENABLE posi tion away from reels during test to prevent personal injury from rotating reel blades Do not stand in front...

Page 116: ...nder the instrument panel to position A full speed Make sure Backlap switch is OFF tion test to prevent personal injury from rotating Cutting unit reels will rotate when lowered with Enable Disable switch in ENABLE posi Keep away from cutting units during reel blades Do not stand in front of the ma chine CAUTION 6 Sit on the seat and start the engine Move throttle to full speed approx 3200 RPM Mov...

Page 117: ...e machine to the shop floor Test drive the machine to make sure it does not creep Neutral Return Spring Adjustment 1 On a large flat open area drive the machine at full throttle and full traction speed 2 Remove foot from traction pedal and measure dis tance required for machine to come to a stop 3 If distance required to stop is greater than 18 feet 5 5 meters an adjustment is required 4 To adjust...

Page 118: ...tment Front Center Initial Adjustment Fig 25 This adjustment affects the front center No 1 cutting unit only Loosen set screw Turn valve clockwise to fully closed position Turn valve counterclockwise open 2 1 2 turns Secure adjustment by tightening set screw Rear Initial Adjustment Fig 26 Loosen set screw Turn valve clockwise to fully closed position Turn valve counterclockwise open 2 1 4 turns Se...

Page 119: ... pump cover new seal and shaft for damage Inspect sealing area on shaft for rust wear or contamination Polish seal area on shaft if necessary 5 Use a seal installer tool or wrap spline end of shaft with thin plastic to prevent damage to seal lip during installation Lubricate inside diameter of new seal with petroleum jelly 6 Press new seal into charge pump cover being certain the seal is perpendic...

Page 120: ... to disas semble transmission control assembly 6 Remove four 4 capscrews securing traction plate to transmission housing Remove transmission control as sembly from transmission 7 Reverse steps 2 6 to install transmission control linkage 8 Do traction control neutral adjustment see Adjust ments section of this chapter 1 3 4 5 2 Figure 29 1 Traction neutral switch 4 Capscrew locknut 2 Extension spri...

Page 121: ...sary 7 Using an arbor press press seal into position from inside of seal cover until it bottoms out in its bore Be careful not to damage the seal 8 Install o ring onto seal cover and retain with petro leum jelly 9 Use a seal installer tool or wrap end of swashplate control shaft with thin plastic to prevent damage to seal during installation 10 Slide seal cover assembly over swashplate control sha...

Page 122: ...to the special plug with its largerdiametertoward the plug and snap the valve cartridge into position in the plug NOTE The forward and reverse valves are different The seating surface of the reverse check high pres sure relief valve has a machined groove in it Fig 32 Installing the reverse check high pressure relief valve in the wrong port may cause performance problems 5 Reinstall the valve cartr...

Page 123: ...d when reassembling the parts unless shims need to be added or removed to adjustthe pressure setting 5 Inspect the poppet and mating seat in the end cap for damage or foreign material 6 Reinstall the poppet spring and plug with shims and o ring into the housing Tighten the plug to a torque of 30 to 70 ft lb 7 Before starting the engine check the oil level in the differential housing andadd thecorr...

Page 124: ...evel again Check the transmission for leaks 1 Figure 34 1 Heat exchanger bypass valve Filter 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 35 3 Remove the spring and poppet from the housing 4 Do not interchange parts with another valve The spring used in the heat exchanger bypass...

Page 125: ...y 0 3 lb to compress it to a length of 1 28 in 5 Inspect the poppet and mating seat in the end cap for damage or foreign material 6 Reinstall the poppet spring and plug with shims and o ring into the housing Tighten the plug to a torque of 30 to 70 ft lb 7 Before starting the engine check the oil level in the differential housing andadd thecorrectoil as necessary Start the engine and let it run fo...

Page 126: ...ricate the geroter assembly with clean hydraulic oil Install the geroter assembly into the charge pump cover Install the o ring and retain with petroleum jelly IMPORTANT Correct charge pump installation to match engine rotation is determined by the position of thecharge pumpcoveron the transmission hous ing To prevent damage to transmission from lack of replenishing oilfrom charge pump the flat on...

Page 127: ...lower it out of the machine Fig 40 NOTE If the machine is going to be stored until trans mission is repaired or replaced cover hole in support plate with weatherproof tape to prevent contamination of the reservoir 9 Leave support plate installed and auxiliary pump installed on support plate 10 Remove retaining ring and remove pinion gear from transmission output shaft 11 Remove filter from transmi...

Page 128: ... foreign materials and chemi cals Protect all sealing surfaces and open cavities from damage and foreign material During assembly of the transmission all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubricated during start up Itis recommended that all gaskets o rings and seals be replaced Ligh...

Page 129: ...will cause the center section to separate from the housing 3 Remove center section from housing Fig 43 IMPORTANT The pump and motor cylinder blocks may stick to the valve plates and center section Be careful to prevent damage to the sealing surfaces 4 Remove gasket and two 2 alignment pins from housing Figure 42 Figure 43 5 Carefully remove valve plates from center section Fig 44 Itmay be necessar...

Page 130: ...ocks Fig 47 NOTE Pump and motor cylinder block assemblies are identical To avoid mixing wearpatterns donotmixparts between pump and motor cylinder block assemblies Figure 47 9 Use an o ringpickor wire to remove thrust platesfrom swashplate and housing Fig 48 Figure 48 10 Use an internal hex wrench to remove pipe plugover motor shaft bearing retaining pin Fig 49 Figure 49 Transmission Repairs Page ...

Page 131: ... 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 Remove spiral retaining ring and remove PTO seal guide with o ring from the housing Fig 53 Figure 53 Reelmaster 5100 D Page 4 47 Transmission Repairs ...

Page 132: ... Replace all parts having unusual or excessive wear or discoloration If scratches which can be felt with a pencil lead can be found on bronze surface of valve plates or running surface of cylinder blocks polish or replace the parts Inspect needle bearings in center section If replace Figure 55 ment is necessary remove shaft needle bearings using a suitable puller Do not damage valve plate surface ...

Page 133: ...andoverswashplate trunnion Fig 59 NOTE The trunnion bearings are pressed into the cover assemblies so the split in each bearing will be located closest to the center section Figure 59 4 Use an arbor press to press a new seal into trunnion seal cover Outer face of seal should be pressed flush with outer surface of seal cover Be careful not to damage the seal 5 Install trunnion seal cover with o rin...

Page 134: ...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 64 Figure 64 10 Install motor shaft assembly into housing Fig 65 Figure 65 Transmission Repairs Page 4 50 Reelmaster 5100 D ...

Page 135: ...hplate Fig 68 The thrust plates are reversible Figure 68 14 Assemble each cylinder block kit by installing piston assemblies into the slipper guide Lubricate pistons and cylinder block bores Install assembled guide and pis tons into cylinder block by inserting pistons into cylinder block bores Fig 69 The pistons and bores are not selectively fitted so no specific piston and bore orienta tion is re...

Page 136: ...valve plates with petroleum jelly to hold them in position and install valve plates onto center section with their bronze faces visible Fig 72 The notch on each valve plate must engage its locating pin Figure 72 NOTE Donotinterchange pump andmotor valve plates when assembling transmission The pump plate can be identified by the grooves on one side of the ports Fig 73 The motor valve plate has no g...

Page 137: ...sing approximately 1 8 in Figure 75 21 Install the six 6 screws that retain the center section to the housing and torque evenly to 33 to 41 ft lb Fig 76 22 Rotate the pump and motor shafts to make sure transmission is assembled correctly When properly assembled a maximum torque of 3 5 ft lb should be required to turn either shaft 23 Assemble the following components as described in previous proced...

Page 138: ... valve block can be removed A Disconnect solenoid electrical connecters B Disconnect hydraulic lines Put caps or plugs on disconnected hoses and fittings to prevent contami nation C Remove four 4 capscrews from bottom of valve block and lift valve block out of machine Solenoid Wire Identification Solenoid Power Wire Color VS1 Orange Black VS2 Orange White 1 Pink Blue 2 Brown White 3 Orange Blue 4 ...

Page 139: ...ts to clean cartridge valve Submerge the valve in clean mineral sprits and use a probe to push the internal spool in and out 20 to 30 times to flush out contamination Mineral spirits does not affect the O ring material particles as fine as talcom powder can affect the operation of high pressure hydraulic valves Cartridge Installation 1 Lubricate all o rings with clean hydraulic oil 2 Carefully thr...

Page 140: ...d Fig 79 S3 S4 and S5 are the same design and can be interchanged Fig 80 S7 S8 and S9 are the same design and can be interchanged Fig 82 valve Note poppet Figure 81 Solenoid valve S6 Note position 2 way pilot operated poppet valve normally closed of holes in cage Figure 79 Solenoid valves S1 and S2 Figure 82 2 way spool valve normally open Solenoid valve S7 S8 and S9 4 way 2 position spool valve N...

Page 141: ...n 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 2 1 Figure 84 Figure 85 Relief valves Flow control solenoid valves R1 3000 PSI 1 VS1 R2 2000 PSI 2 VS2 Reelmaster 5100 D Page 4 57 Mowing Circuit Repairs ...

Page 142: ...leeve on transmission output shaft 3 Install transmission coupling on pump shaft and install pump on to transmission adapter Secure pump and transmission adapter to support plate with two 2 capscrews and lock washers 4 Replacehydraulic filterand fill hydraulic reservoir with new hydraulic oil 5 Disconnect fuel stop solenoid electrical connector on engine to prevent engine from starting Prime the h...

Page 143: ...move valve ad turn adjuster clockwise to increase pressure and coun juster Item 28 spring Item 27 and ball Item 26 terclockwise to decrease pressure See Steering Valve and Steering Pump Test in Chapter 7 Steering and 2 Remove gasket Item 29 from cap Brakes 3 Inspect ball for burrs or roughness Inspect relief Pump Service valve bore and seat in cover If the bore or seat is damaged the cover must be...

Page 144: ...scoring nicks and other damage Check the bushings in the plate assemblies Items 15 and 25 and cover assembly Item 5 for excessive wear or scoring Replace the cover or plate assemblies as necessary The bushings are not serviceable 10 Replace load plates if excessively worn or scored Replace gears in sets if scored or worn excessively 11 Apply oil to inside of gearplates and bushings Apply grease or...

Page 145: ...s to preventcontamination Taghydrau 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 4 Reverse steps 1 3 to reinstall motor 1 2 Figure 94 1 Motor 2 Motor mount nuts Reelmaster 5100 D Page 4 61 Mowing Circuit Repairs ...

Page 146: ... may also be removed by punching two holes in face of seal 180o apart installing metal screws and pulling seal out by grasping the screws IMPORTANT Do not try to pry the seal out of the motor This usually damages the shaft sealbore and mounting hub area so oil will leak past the seal 7 Remove and discard shaft seal and spacer 8 Clean seal bore and shaft on motor so it is free of any foreign materi...

Page 147: ...th to retain timing Pump efficiency may be affected if the teeth are not installed in the same position during reassembly IMPORTANT To prevent damage to load plates dur ingmotoroperation do not mark gearswitha punch or scribe 6 Be careful when disassembling The needle bearings may be of the loose grease retained type Pack these with general purpose grease toretain them forreassem bly It isrecommen...

Page 148: ...n switch 2 To prevent contamination of hydraulic system during removal thoroughly clean exterior of cylinder and fit tings 3 Disconnect hydraulic lines from cylinder and put caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 4 Remove retaining ring and thrust washer from one side of cylinder pin on each end of cylinder 5 Remove cylinder pin ...

Page 149: ...ore mounting in the vise 1 After removing the cylinder pump the oil out of the cylinder into a drain pan by SLOWLY moving the cylin der s piston in and out of the cylinder bore 2 Plug the ports and wash the outside of the cylinder with cleaning solvent 3 Mount the cylinder in a vise so the shaft end of the cylinder is tilted up slightly Do not close the vise so Figure 99 firmly that the barrel cou...

Page 150: ...install the two piece Uni ring piston seal 9 Head 10 Dust seal 11 Retaining ring 12 Rod A Soak the seal rings in hot water The hot water will soften the rings allowing then to stretch over the piston B Apply clean hydraulic oil to the black inner ring and Install the ring into the seal groove on the piston C Apply clean hydraulic oil to the purple outer ring and install the ring into the same groo...

Page 151: ...amage 6 Disconnect fuel stop solenoid electrical connector to prevent engine from starting 7 Turn ignition key switch to engage starter for ten 10 seconds to prime pump Repeat this procedure again 8 Connect fuel stop solenoid electrical connector 9 Start engine and let idle at low speed for minimum of two 2 minutes 10 Increase engine speed to high idle for minimum of one 1 minute under no load 11 ...

Page 152: ...age 3 Replace hoses or fittings if worn or leaking 4 Replace breather with new part 6 7 1 5 3 2 4 8 9 10 Tighten mounting cap screws to a torque of 30 to 60 in lb Figure 103 1 Filler screen 6 Cap 2 Suction strainer 7 Dipstick 3 Reservoir 8 Grommet 3 4 Drain plug 9 Washer 3 5 Breather 10 Capscrew 3 Mowing Circuit Repairs Page 4 68 Rev A Reelmaster 5100 D ...

Page 153: ...lenoid Holding Test 30 TESTING 18 Magnetic Switch Solenoid Return Test 30 Ignition Key Switch 18 Alternator Regulated Voltage Test 31 Electronic Control Unit ECU 19 Alternator Output Test 31 Seat Switch 19 REPAIRS 32 Traction Neutral Switch 20 Battery Service 32 Cutting Unit Down Switches 20 Fuses 33 Lower Mow Raise Switches 21 Traction Neutral Switch Replacement 34 Enable Disable Switch 21 Electr...

Page 154: ...Logic Chart Page 5 2 Reelmaster 5100 D ...

Page 155: ...Wiring Schematic S N Below 51001 Rev B Reelmaster 5100 D Page 5 3 Wiring Schematic ...

Page 156: ...WHITE YELLOW WHITE REELS ENABLE DISABLE SWITCH FRONT REELS DOWN SENSOR VIOLET RED RED YELLOW GREEN TAN GREEN WHITE VIOLET BROWN BLACK WHITE PINK BLACK YELLOW BLACK ORANGE BLACK C A B ORANGE WATER TEMP SENSOR 3B 1P 1R 1D 2S 1C 8S BLACK RED 9S BROWN WHITE VS1 VS2 ORANGE BLACK ORANGE WHITE ORANGE BLUE YELLOW BLACK BLACK 2L 1A 1J 1K 1L 1M COMMUNICATION PORT BLACK PINK WHITE M VCC 10A 3A 10A 4A 10A 1A ...

Page 157: ...E 2A BROWN RED RED WHITE 85 4400 SOLID STATE CONTROLLER RED BLUE 2K YELLOW BLUE ORANGE RED PINK BLUE BROWN WHITE YELLOW WHITE REELS ENABLE DISABLE SWITCH FRONT REELS DOWN SENSOR VIOLET RED RED YELLOW GREEN TAN GREEN WHITE VIOLET BROWN BLACK WHITE PINK BLACK YELLOW BLACK ORANGE BLACK C A B ORANGE WATER TEMP SENSOR 3B 1P 1R 1D 2S 1C 8S BLACK RED 9S BROWN WHITE VS1 VS2 ORANGE BLACK ORANGE WHITE ORANG...

Page 158: ... W BLK W RED Y BLK Y RED ALARM YELLOW BLK OR GN WT BLK BLK BU TURF DEFENDER LOOPBACK I D DECAL OR BLK BLK RED 94 6345 LEAK DETECTOR 2D 1B 3B 2C 1E 2E 1C 3C 2A 2F 1F VALVE Reelmaster 5100 D Page 5 4 Rev B Wiring Schematic TURF DEFENDER COMMUNICATION PORT AND LOOPBACK CONNECTOR Wiring Schematic Leak Detector ...

Page 159: ...l circuits The high imped ance internal resistance of a digital meter will ensure that excess current is not allowed through the meter Excess current can cause damage to a circuit that is not designed to carry it Figure 1 Inductive Ammeter AC DC Current Transducer Hall Effect Use this tool connected to a Digital multimeter for doing current draw tests This tool can be useful when check ing glow pl...

Page 160: ...ns of the machine When in INPUTS DISPLAYED mode LED s on the display illuminate to show input switches that are closed When in OUTPUTS DISPLAYED mode LED s 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 Special Tools Page 5 6 Rev B Reelmaster 5100 D ...

Page 161: ...or is not attached 2 Diagnostic light is burned out 3 ECU is not powered on 4 ECU is not functioning correctly Check electrical connections input fuses and diagnos tic light to find malfunction Make sure loop back con nector is secured to wire harness connector Diagnostic ACE TM Display Use diagnostic display tool to verify correct electrical function of the machine and to locate electrical malfun...

Page 162: ... NOT start engine Put input switches in required position to allow desired functions to occur as defined by Logic Chart on page 4 The appropriate output LED s should illuminate to indicate that the ECU is turning on that function If any output LED is FLASHING ON and OFF this indicates and electrical problem with that OUTPUT To reset a flashing LED turn the key switch OFF then back ON Ifno output L...

Page 163: ...ostic ACE for the playback of the re tained fault in the ECU memory The problem circuit will be flashing Clearing Fault Memory Once a fault is repaired it must be must be cleared from the ECU memory so any future fault can then be stored 1 Turn Ignition key switch to OFF 2 Move the Backlap switch to the FRONT or REAR position 3 Move the Enable Disable switch to the ENABLE position 4 Move the Lower...

Page 164: ...he Diagnostic ACE display connector to the correct harness loopback connector Install TurfDe fender overlay decal supplied with leak detector kit onto Diagnostic ACE Fig 8b 4 Turn the key switch to the ON position but do not start machine Note Red text on the overlay decal refers to inputs and green text refers to outputs 5 The red Inputs displayed LED Light Emitting Diode on lower right column of...

Page 165: ...ging air out of system Normal maneuvering should not cause this condition 3 Air leak in system Check to make sure cap is se curely on tank Contact your local authorized Toro Dis tributor for further assistance with air leak problem 4 To check for a system problem install hand held Diagnostic ACE toggle input output and check for any problems previously discussed Note The system will reset itself w...

Page 166: ...em air leak has been detected 6 One or two LED s lit displaying relative position of the Turfdefender s internal float b 7 7 Inputs Displayed LED ON Red Normal Operation a Oil Level OK LED lit b 1 or 2 LED s lit on left column Figure 8c Using Outputs Displayed Green Text Normal Operation a Valve ON LED lit steadily b Self Diagnostic LED lit steadily c DATA LINE LED lit steadily d Alarm ON LED lit ...

Page 167: ...heck fuse and replace if fuse is open If fuses burn out often find and correct cause NOTE If auxillary lights are added this fuse must be replaced with a 15A fuse Faulty key switch wiring Repair wiring Faulty key switch Test key switch and replace if necessary Starter solenoid clicks but starter Low battery charge Charge battery Replace battery if will not crank If solenoid clicks it will not hold...

Page 168: ...ary Start relay faulty Test relay and replace if necessary Wiring between start relay and Check wiring and repair if starter faulty necessary Start solenoid faulty Test start solenoid and replace if necessary Engine starts but dies when Run solenoid out of adjustment Adjust run solenoid ignition key switch is released from start position Run solenoid faulty Replace run solenoid Run solenoid wiring...

Page 169: ...tch Engine continues to run but Seat switch circuit is closed Check seat plate hinges and seat should not when traction pedal is support pin and repair if faulty engaged with no operator on seat Check for water soaked seat cushion Test seat switch and replace if faulty Check seat switch wiring and repair if faulty Traction neutral switch circuit Check traction neutral switch closed adjustment and ...

Page 170: ... faulty Seat switch circuit open Test seat switch and replace if faulty Check seat switch wiring and repair if faulty Battery does not charge Alternator belt slipping Adjust belt tension Faulty wiring Check and repair wiring Malfunctioning alternator Repair or replace alternator Faulty battery Replace battery Cutting Unit Operation Problems Condition Possible Cause Correction Cutting units remain ...

Page 171: ...ould not Enable Disable switch circuit Test Enable Disable switch and when lowered with Enable closed replace if faulty Disable switch in disable position Check Enable Disable switch wiring and repair if faulty No cutting units operate in either Seat lifting off seat switch Instruct operator to sit back in direction raise and lower seat during operation function OK Check seat plate hinges and seat...

Page 172: ...ulty lower function OK Check wiring to S2 solenoid and repair if necessary Hydraulic problem See Troubleshooting section of Chapter 4 Hydraulic System Cutting units operate but speed Problem with solenoid VS1 or VS2 Test solenoid VS1 front cutting is either too slow or too fast and only front or rear cutting units will units or VS2 rear cutting units is not regulated by changing the be affected an...

Page 173: ...solenoid coil Check S6 solenoid wiring and repair if faulty Hydraulic problem See Troubleshooting section of Chapter 4 Hydraulic System No cutting units raise Raise switch circuit open Test for faulty Raise switch joystick Check Raise switch wiring and repair if faulty Problem with S7 solenoid Test solenoid S7 and replace if faulty Check wiring to solenoid S7 and repair if necessary Hydraulic prob...

Page 174: ... raise and lower OK Check wiring to solenoid S5 and repair if necessary Hydraulic problem See Troubleshooting section of Chapter 4 Hydraulic System Front cutting units do not Problem with solenoid S8 Test solenoid S8 and replace if backlap but run forward instead faulty Check wiring to solenoid S8 and repair if necessary Hydraulic problem See Troubleshooting section of Chapter 4 Hydraulic System F...

Page 175: ...oblem and repair immediately If engine does not crank proceed to step 4 4 Sit on seatandstartengine Position theENABLE DIS ABLE switch in ENABLE Move the LOWER MOW RAISE control forward to turn the cutting units ON Rise off the seat slowly The cutting units should stop If cutting units stop the switch is operating correctly Proceed to step 5 If cutting units do not stop there is a malfunction in t...

Page 176: ...r before doing a continuity check When testing electrical components for con tinuity with a volt ohm meter or continuity tester make sure that power to the circuit has been disconnected CAUTION NOTE Electrical troubleshooting of any 12 Volt power connection can also be performed through voltage drop tests without disconnection of the component Ignition Key Switch The ignition key switch has three ...

Page 177: ...nt damage to the electrical system 1 Figure 11 1 Electronic control unit ECU Seat Switch The seat switch is a proximity type normally open NO reed switch thatcloses when the operator is on theseat With the operator on the seat the magnet on the bottom of the seat activates the reed switch causing it to close and complete the circuit 1 Raise the seat to get access to the seat switch wiring connecto...

Page 178: ... section of this chapter for replacement and adjustment procedures 1 Figure 13 1 Traction neutral switch Cutting Unit Down Switch The cutting unit down switch is a normally open NO reed switch located on the left front lift arm that closes when the lift arm is in the lowered position As the lift arm is lowered a magnet in the lift arm causes the reed switch to close and complete the circuit 1 Disc...

Page 179: ...n the neutral position there should be no continuity across the terminals Lower Mow Switch With the engine turned off move the joystick toward the rear then allow it to return to neutral while watching the continuity tester There should be indications that the switch is opening and closing With the joystick in the neutral position there should be no continuity across the terminals Enable Disable S...

Page 180: ... Wire color Figure 17 1 Not used 2 Not used 1 Backlap switch 3 Start relay 3 Not used 2 Glow relay 4 Blue 5 Black 6 White Start Relay To test the start relay Fig 17 disconnect the relay wire connector and install a continuity tester between the relay terminals terminals 30 and 87 Fig 18 The relay should make and break continuity at terminals 30 and 87 as 12 V D C is connected and disconnected to t...

Page 181: ...d 87 as 12 V D C is connected and disconnected to terminal 85 with terminal 86 connected to ground 85 86 30 87 RED WHITE ORANGE RED Figure 19 Battery 1 Use a volt ohm meter to measure the voltage be tween the battery terminals 2 If the voltage is less than 12 3 Volts D C the battery should be charged NOTE Regulated voltage will increase to 13 5 Volts when the engine is running Figure 20 Reelmaster...

Page 182: ...tion Replace the fuel stop solenoid if it fails any of the above tests See Replacing and or Adjusting Stop Solenoid in the External Engine Component Repair section of Chapter 3 Engine To Test While Connected to Wire Harness 1 Remove the governor tie rod cover so you can observe the solenoid plunger 2 Hold the manual fuel stop lever back to prevent fuel delivery Turn the key switch to the START pos...

Page 183: ... closes during operation oil pressure below 7 psi 0 5 kg cm2 Test the lamp by disconnecting the wires and applying 12 V D C between the lamp wiring terminals Amp Light The amp light should come on when the ignition key switch is in the RUN position with the engine not running or if the charging circuit is not operating properly during operation Test the lamp by disconnecting the wires and applying...

Page 184: ...e Figure 23 CAUTION 1 High temperature shut down switch 2 Temperature gauge sender Figure 24 Temperature Gauge Sender 1 Lower the coolant level in the engine and remove the temperature gauge sender Fig 23 2 Put the switch in a container of oil with a thermometer and heat the oil Fig 25 3 With an Ohm meter connected as shown the follow ing resistance readings should be indicated 90 5 117 5 ohm at 1...

Page 185: ...engine oil pressure switch port Startengine and check for 30 psi minimum at 1500 rpm If engine pressure is good replace switch If engine pressure is low DO NOT operate the engine Fuel Gauge Sender 1 Disconnect wire and remove the fuel gauge sender from the fuel tank 2 Install an ohm meter between the terminal and base 3 With arm completely down empty position resis tance should be 240 260 ohms 4 W...

Page 186: ...s not retract after replacing solenoid coil replace the valve NOTE To to a quick test without removing solenoid valve hold a screwdriver to top of affected valve When solenoid is energized screw driver should be attracted to valve stem due to magnetism from energized sole noid This test will not identify a sticking valve spool Resistance specifications 20 Watt solenoid 7 2 Ohms 28 Watt solenoid 5 ...

Page 187: ...hown Fig 30 Poor contact between brushes and commutator 2 When terminals S and B are connected the pinion should protrude and the starter should run smoothly Terminal voltage 11 5V Current 100 A broken brush springs wornbrushes high insulation between commutator bars High internal resistance poor connections dam aged leads dirty commutator or open field circuit Shorted fields Speed 3000 rpm No Loa...

Page 188: ...netic switch terminal S and the starterbody Pull outthe pinion fully The pinion must remain at that position even when released IMPORTANT Never apply battery voltage to the starter for longer than 10 seconds Figure 32 Magnetic Switch Solenoid Return Test 1 Disconnect the wire from terminal M Fig 33 2 Connect a 12 volt battery to the magnetic switch terminal M and the starterbody Pull outthepinion ...

Page 189: ...l accessories OFF Ammeter below 5 A Regulated voltage will decrease slightly as alternator temperature increases Regulated voltage 13 5 V Alternator Output Test Figure 34 1 Disconnect the battery ground cable 2 Install an ammeter between the positive terminal of the battery and terminal B of the alternator Fig 35 3 Ground alternator terminal B through a voltmeter 4 Connect the battery ground cable...

Page 190: ... plates Fig 37 If the level is low but above the plates inside the battery add water so the level is to the bottom of the cap tubes If the level is below the plates add water only until the plates are covered and then charge the battery After charging fill the battery to the proper level o o a Do not charge a frozen battery because it can explode and cause injury Let the battery warm to 60 F 15 5 ...

Page 191: ...ty It is recommended that you check for faulty fuses with a continutiy tester not visually The electrical system is also equipped with thermal circuit breakers The thermal circuit breakers automat ically reset when allowed to cool 1 Figure 39b S N 51001 59999 Figure 38 1 Fuses Figure 39a Figure 39c S N Below 51001 S N 60001 Up Reelmaster 5100 D Page 5 33 Rev B Repairs ...

Page 192: ...d to the COMMON terminal and one wire is connected to the NORMALLY OPEN NO terminal IMPORTANT The traction switch has three 3 ter minals If the two 2 wires are not connected to the COMMON and NORMALLY OPEN NO termi nals the engine willbe unable to startand the safety interlock circuit will not function properly If the wires are not correctly installed to the switch the engine could start with the ...

Page 193: ...event damage to the electrical system 1 Stop the engine 2 Remove nuts securing ECU to frame 3 Loosen nuts on wiring connectors with a 1 4 nut driver then disconnect wiring connectors from ECU Fig 40 4 Remove ECU 5 To install ECU connect wiring connectors to ECU then tighten nuts on wiring connectors Secure ECU to frame with nuts removed in step 2 2 1 Figure 40 1 Electronic control unit ECU 2 Wirin...

Page 194: ...ivalent to threads on end of stem tube before installing nut Tighten nut to a torque of 15 in lb Over tightening may damage the solenoid or cause the solenoid valve to malfunction 1 Figure 41 6 Connect electrical wiring connector 1 Solenoid Solenoid Wire Identification Solenoid Power Wire Color 1 Pink Blue 2 Brown White 3 Orange Blue 4 Yellow Black 5 Yellow White 6 Orange Red 7 Yellow Blue 8 Black...

Page 195: ...crew the bolts and remove the center bracket As the bracket is removed washers for pinion shaft end play adjustment will come off 8 Pull out the reduction gear lever and leverspring from the front bracket 9 Pry the snap ring out on the pinion side and pull out the pinion and pinion shaft 10 Remove the ball bearings from each end of the armature with a bearing puller The bearing that is press fitte...

Page 196: ...u Insulat on One way mechanism Bearing Play noise and rough rotation Figure 45 10 Check the magnetic switch for continuity between terminals S and M and between terminals S and body Fig 46 If there is continuity or zero ohm is indicated replace the magnetic switch Figure 46 Repairs Page 5 38 Reelmaster 5100 D ...

Page 197: ...rough polish the commutator with fine 00 or 000 sandpaper DO NOT use emery cloth Item Standard Service Limit Commutator O D 38 7 mm 1 52 in 1 0 mm 0 4 in Depth of Undercut 0 5 mm 0 02 in 0 2 mm 0 008 in 13 Checkthe brushes Fig 48 Replaceif wornbeyond the service limit Check the brush spring tension Re place the springs if tension is less than the service limit Check for insulation between the posi...

Page 198: ... the center bracket B Measure end play by moving the pinion shaft in and out If end play exceeds 0 5 mm 0 02 in increase the number of adjusting washers 3 Putgreaseon thefollowingparts wheneverthe starter has been overhauled Armature shaft gear and reduction gear All bearings Bearing shaft washers and snap rings Bearing sleeves Pinion Sliding part of lever IMPORTANT Never put grease on terminals b...

Page 199: ...too far causing damage to the windings 4 Put the rotor in a vise Remove pulley nut and pull off the pulley and spacer 5 Pull the rotor assembly from the front bracket 6 Unsolder the stator core lead wires Remove the stator assembly IMPORTANT To prevent damage to the diodes heat the stator core lead wires only long enough to re move 7 Disconnect the capacitor from terminal B 8 Loosen the screws sec...

Page 200: ...ss the lead wire and diode case The diode is normal if its resistance is large in one direction and small in the reverse direction If there is equal resistance in both directions the diode is damaged Replace the rectifier assembly if a diode is damaged Figure 53 10 Check the field coil for continuity between the slip rings Fig 54 If there is no continuity replace the field coil Figure 54 Repairs P...

Page 201: ...inuity Figure 55 12 Check forcontinuity between lead wires ofthe stator coil Fig 56 Replace the stator coil if there is no continuity Figure 56 13 Check for continuity between each lead wire and stator core Fig 57 Replace the stator coil if there is continuity Figure 57 Reelmaster 5100 D Page 5 43 Repairs ...

Page 202: ...st part of the groove 3 When installing a new rear bearing press fit the bearing with its groove facing the slip ring side 4 Heat the rear bracket when press fitting the rear bearing into the bracket Figure 58 IMPORTANT Puta wire through the smallholeinthe rear bracket to lift the brushes before installing the rotor to the rear bracket Fig 58 Remove the wire after the rotor is installed Repairs Pa...

Page 203: ...t 8 Install plate and cover assembly to axle assembly using silicone sealant to seal cover to axle then install eight 8 screws to secure cover 9 Lubricate and install O ring if not done in step 2 above 10 Insert sensor into hole in cover with hole in sensor going over long machine screw and push sensor in until it contacts axle gear 11 Thread jam nut out until is contacts sensor Turn jam nut one m...

Page 204: ...maximum torque of 5 ft lb IMPORTANT Over tightening capscrew securing magnet will damage magnet and cause sensor to malfunction 5 Install cap plug into end of counterweight 6 Route front sensor wire across carrier frame cross tube up the pull arm and connect to wiring harness above front cutting unit lift cylinders Figure 60 7 Route rear sensor wire across carrier frame cross 1 Counterweight 2 Sen...

Page 205: ...h magnet thenbacksensor out one 1 turn Tighten jam nut to hold sensor in position 4 Route front sensor wire across carrier frame cross tube up the pull arm and connect to wiring harness above front cutting unit lift cylinders 5 Route rear sensor wire across carrier frame cross tube up the pull arm and connect to wiring harness connector near engine fuel stop ETR solenoid 5 Use cable ties to secure...

Page 206: ...Repairs Page 5 48 Rev A Reelmaster 5100 D ...

Page 207: ...outside ends of the axle shafts The entire drive line of the axle assembly is made of alloy steel The axle has a die cast aluminum housing that also serves as the hydraulic oil reservoir Power is transmitted from the transmission output gear to the pinion spur gear The pinion spur gear transmits power directly to the differential drive gears to turn the axles and the wheels The differential axle h...

Page 208: ...______ ________________________________________________________________________________________________________________________ ________________________________ ________________________________________________________________________________________________________________________ ________________________________ Specifications Item Specification Front wheel lug nut torque 45 to 55 ft lb Front to ...

Page 209: ...isconnect speedometer sensor wire connector 9 Put a jack or blocking under differential to hold it in place Remove cap screws and lock nuts securing axle mounting pads to frame Carefully lower differential axle and pull it out from under traction unit 10 To install axle reverse steps 1 9 Apply silicone sealant between axle housing and transmission sup port Leave axle mounting pad nuts loose Instal...

Page 210: ...loosen the brake shoes by turning the star wheel inside the brake drum assemb ly See Chapter 7 Steering and Brakes Figure 5 2 Line up the hole in the axle shaft flange and remove the backing plate nuts which hold the axle shaft assemb ly to the axle housing Use a 1 2 inch socket wrench Fig 6 Figure 6 3 Pull out the axle shaft and brake assembly Fig 7 NOTE Bearing races and retainer ring are cement...

Page 211: ... 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 10 IMPORTANT Drilling completely through the retainer ring could damage the shaft Figure 10 Reelmaster 5100 D Page 6 5 Repairs ...

Page 212: ...personnel away during this procedure WARNING 8 Inspect the shaft for possible damage Fig 12 Inspect the sealing surface of the hub and shaft Replace it if the seal has grooved the surface more that 1 64 inch 0 4 mm 9 Put a new grease seal brake assembly and a new grease packed bearing in that order onto the axle shaft Figure 11 Figure 12 10 Press the assembly until the bearing is firmly seated aga...

Page 213: ... 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 Install the new seal to a depth of 1 218 in into the housing Fig 15 16 After the seal has been assembled put grease on the lip of the seal Figure 15 1 218 seal installation depth Figure 16 Reelmaster 5100 D Page 6 7 Repairs ...

Page 214: ...uts Fig 18 If installing socket head screws tighten the nuts to a torque of 16 20 ft lb 2 3 Kgm If reinstalling hex head screws tighten the nuts to a torque of 37 45 ft lb 5 6 Kgm IMPORTANT Hold the socket head screw or hex head screw when tightening the nut to prevent the head from turning into the tube radius Figure 17 l Nut 94 6935 Washer 94 6936 Socket Hd Screw 94 6934 Ho d socket head screw a...

Page 215: ...ooden devices i e hammer handles under the dif ferential case and pry firmly upward The bearing cups must be kept with their mating cones Fig 21 4 Remove the ring gear cap screws Using a hard wooden block and a hammer drive the ring gear off of the differential case Be prepared to protect the ring gear when removing it from the differential case this will avoid damage of the ring gear teeth Fig 22...

Page 216: ...as shown Fig 23 Figure 23 i i j 6 Put the case in a v se Drive the lock pin out of the pinion shaft F g 24 Use a small drift punch as shown To prevent personal in ury always wear a face shield or safety goggles when striking a drift punch with a hammer WARNING Figure 24 7 While supporting the differential in a vise drive the pinion mate shaft from the differential with a long drift punch Fig 25 Fi...

Page 217: ... the eight side cover capscrews Remove the the side cover from the carrier assembly Fig 27 Clean the gasket material from the mating surfaces before reassembly Figure 27 10 If unit has an expansion plug remove it by driving a pointed punch through the plug about 3 8 inch 10 mm from the outer edge When the hole is large enough insert a large screwdriver through it and pry the plug outward Fig 28 Fi...

Page 218: ...nch 3 mm piece of steel or a screwdriver blade under the edge of the spur gear This will prevent the spur gear from cocking and possibly cracking the housing Fig 30 When the pinion is close to being pressed completely out of the bearing reach under the housing and catch the pinion in your hand to prevent any damage to the pinion Figure 29 Figure 30 Removing the drive pinion releases the spur gear ...

Page 219: ...e of the proper size against the cup Press the cup out of the housing Fig 33 15 Position the front housing on a press bed with the bearing saddles resting on the press bed Protect the bearing saddles with a strip of wood if the press bed is rough Insert a press plate of the proper size and press the bearing cup toward the inside of the housing Retain the shims located under the bearing cup Fig 34 ...

Page 220: ...of the axle assembly D Inspect the differential case for wear in the side gear and pinion mate area Replace the case if its machined areas are scored or if the pinion mate shaft fits loosely in the bore 2 Press the inner pinion bearing onto the pinion drive gear Support the bearing on the inner cup of the bearing ONLY WHEN INSTALLING Fig 35 3 Put the front housing on a press Using a press plate pu...

Page 221: ...pinion is etched 3 this pinion would require 0 003 in less than a pinion etched 0 This means that by removing shims the mounting distance of the pinion is increased to 1 213 in which is just what 3 indicates Or if a pinion is etched 3 we would want to add 0 003 in shims the mounting distance of the the pinion was decreased to 1 207 in which is just what a 3 etching indicates If a new gear set is b...

Page 222: ...n set is used to establish the proper amount of shims required prior to installing the pinion gear see page 15 The final pinion position will be verified by using the gear contact pattern method as described on page 21of this chapter 6 Insert the spur gear into the front housing with the chamfered area of the center spline toward the drive pinion Install the drive pinion with a soft mallet to enga...

Page 223: ...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 torque to rotate Fig 43 If the drag is to severe tap the pinion shaft with a soft mallet until the drag is reduced Figure 43 Reelmaster 5100 D Page 6 17 Repairs ...

Page 224: ...ll bead of Permatex No 2 or silicone sealant to the outer edge of the carrier bore Install the expansion plug or seal if equipped with pinion coupler for 4WD into carrier until plug or seal seats firmly in carrier bore Fig 45 Figure 45 12 Install the spur gear cover Use Permatex No 2 or silicone sealant when installing the cover Tighten the capscrews to a torque of 25 40 in lb Fig 46 Figure 46 Rep...

Page 225: ...s and pinion gears line up with the holes of the case If the gears cannot be rotated by hand install one of the axle shafts into the side gear spline and use a pipe wrench to turn the shafts Figure 47 14 Install the pinion shaft Grease the shaft to aid assembly Be sure the hole in the pinion shaft lines up with the hole in the differential case Fig 48 Figure 48 15 Assemble the lock pin Drive the p...

Page 226: ...rential bearing Shims are available in 003 005 010 and 030 inch sizes Fig 51 18 Assemble new differential bearing cups to differen tial bearing cones Seat differential assembly with drive gear on proper side of carrier into carrier bearing crad les NOTE The Reelmaster 223 D 5100 D 5300 D applica tion requires that the ring gear teeth face toward the spur gear cover The bearing cradles are designed...

Page 227: ...sh required to bring the gears into specification For example if the backlash needed to be changed by 004 inch the shim pack should be changed by 006 inch as a starting point High backlash is corrected by moving the ring gear closer to the pinion Low backlash is corrected by moving the ring gear away from the pinion These corrections are made by switching shims from one side of the differential ca...

Page 228: ...Toe Figure 55 Backlash correct Thinner pinion position shims required Drive Side Heel Toe Coast Side Heel Toe Figure 56 Backlash incorrect Thinner pinion position shim re quired Adjust backlash to match Drive Side Heel Toe Coast Side Heel Toe Figure 57 Repairs Page 6 22 Rev A Reelmaster 5100 D ...

Page 229: ...es the pinion closer to the ring gear Drive pattern moves deeper on the tooth flank contact and slightly toward the toe Coast pattern moves deeper on the tooth and toward the heel 4 Thinner pinion position shim with backlash constant moves the pinion further from the ring gear Drive pattern moves toward the top of the tooth face contact and toward the heel Coast pattern moves toward the top of the...

Page 230: ...Repairs Page 6 24 Reelmaster 5100 D ...

Page 231: ...dle Bushing Service 14 TESTING 7 Front Wheel Bearing Service 15 Steering Valve and Pump Tests 7 Rear Wheel Bearing Service 16 Steering Cylinder Internal Leakage Test 8 Steering Cylinder Removal and Installation 18 ADJUSTMENTS 9 Steering Cylinder Service 19 Rear Wheel Toe In Adjustment 9 Brake Shoe Replacement 20 Brake Adjustment 10 Steering Valve Removal and Installation 21 Steering Valve Service ...

Page 232: ...d and retracted the steering wheel will not return to its original position after making a turn NOTE The steering system will operate with the engine off if necessary with increased effort Figure 1 Brakes The Reelmaster 5100 D is equipped with 7 inch di ameter x 1 3 4 inch wide mechanical drum brakes on the front wheels Fig 2 Two pedals are used to control the brakes When used separately the pedal...

Page 233: ...tionary the control valve within the steering valve shifts back to neutral Fig 4 allowing system oil to flow through the steering valve and out the AUX port back to reservoir Oil in the rest of the steering circuit is then trapped Right Turn STEERING CYLIN STEERING VALVE FROM PUMP Figure 3 Neutral FROM STEERING CYLIN STEERING VALVE PUMP When the steering valve is turned to the left Fig 5 oil is me...

Page 234: ..._ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Specifications Item Specification Front wheel lug nut torqu...

Page 235: ... 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 Improper rear wheel alignment toe in Steering linkage binding Low tire pressure Steering column bin...

Page 236: ... 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 Kinked or severely bent hose or tube line Restricted oil cooler Restricted recentering of steering valve control va...

Page 237: ...inst the right stop 8 Release the steering wheel Flow should be approximately3 gpmwhen the steer ing wheel is released If flow does not return to approximately 3 gpm when the steering wheel is released the control valve within the steering valve may be sticking 9 Repeat steps 7 and 8 turning the steering wheel in the opposite direction Steering Pump Flow and Relief Pressure Test 10 While watching ...

Page 238: ...revent contamination 5 With the engine OFF continue turning the steering wheel to the left counterclockwise with the cylinderrod completely extended and observe the open fitting onthe steering cylinder If oil comes out of the fitting while turning the steering wheel to the left the steering cylin der has internal leakage and must be repaired or re placed NOTE DO NOT turn the steering wheel to the ...

Page 239: ...oe in is not within specifications an adjustment is required 1 Rotate the steering wheel so the rear wheels are straight ahead 2 Loosen the jam nuts on both tie rods Adjust both tie rods until center to center distance at front of rear wheels is 0 1 8 of an inch less than at the rear of the wheels Fig 9 1 3 When toe in is correct tighten jam nuts against tie Figure 9 rods Fig 9 1 Tie rods Reelmast...

Page 240: ... be adjusted Before adjusting the star nut loosen brake cable nuts to prevent unnecessary strain on the cables 4 Loosen do not remove the five 5 wheel lug nuts 5 Jack up machine until front wheel is off the floor Use jack stands or block machine to prevent it from falling accidentally 6 Remove wheel nuts and slide wheel off the studs Rotate the brake drum until adjusting slot is at the top and cen...

Page 241: ...ering shaft IMPORTANT DO NOT hit the steering shaft with a hammer This could damage the steering valve com ponents Installing the Steering Wheel 1 Use the steering wheel to put the rear wheels in the straight ahead position Figure 15 2 Slide the steering wheel onto the steering shaft 1 Steering wheel 4 Screw 2 Jam nut 5 Foam seal 3 Secure the steering wheel in place with the jam nut 3 Cap Fig 10 T...

Page 242: ...ove dirt and grease Inspect the pin for wear or damage and replace as necessary 8 Mount the axle to the frame with the axle pin The washer s must be positioned between the rear end of the pivot tube and the frame see the NOTE after step 3 Secure the axle pin in place with the cap screw 9 Remove the jackstands and lower the machine to the floor 10 Install the hydraulic hoses to the steering cylinde...

Page 243: ... tighten against the other nut to the nut to 130 to 150 ft lb secure tie rod end 9 Lubricate the bushings through the grease fitting on the steering pivot 3 6 5 4 1 12 2 11 10 8 13 7 9 Figure 16 1 Rear axle 6 Axle bushings 11 Washer 2 Steering cylinder 7 Steering pivot 12 Cylinder spacer 3 Lock nut 8 Tie rod 13 Steering pivot bushings 4 Rear axle pin 9 Wheel spindle 5 Washer 10 Snap ring Reelmaste...

Page 244: ...e spindle and wheel assembly out of the axle tube to expose the bushings 7 Use a punch and hammer to drive both bushings out of the axle tube Clean the inside of the axle tube to remove any dirt and foreign material 8 Apply grease to the inside and outside of the new bushings Use an arborpress to install the bushings into the top and bottom of the axle tube The bushings must be flush with the axle...

Page 245: ...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 Reelmaster 223 D 5100 D 5300 D Page 7 15 Repairs ...

Page 246: ...f the wheel hub Check the bearing cups for wear pitting or other noticeable damage Replace worn or damaged parts 6 If bearing cups were removed from the wheel hub press them into the hub until they seat against the shoulder 7 Pack both bearings with grease Install one bearing into the cup on inboard side of the wheel hub Lubricate the inside of the new lip seal and press it into the wheel hub IMPO...

Page 247: ... nut until the nearest slot and hole in the spindle line up Reinstall the cotter pin to retain the slotted nut in place NOTE The correct end play of the adjusted assembly is 002 005 inches 3 Remove jack stands or blocks and lower machine to floor 4 Put a coating of grease on the inside of the dust cap Install dustcap on the end ofthe wheel spindle Fig 18 Figure 19 1 1 Cotter pin and slotted nut Re...

Page 248: ... cap screw securing the rod end of the cylinder to the steering pivot Fig 20 4 Remove the lock nut cap screw and spacer securing the barrel end of the cylinder to the rear axle 5 Remove the cylinder 6 Reverse steps 2 5 to install the steering cylinder Tighten the cap screw and nut securing the rod end of the cylinder to the steering pivot to 130 150 ft lb 7 After installing the cylinder bleed the ...

Page 249: ...ng it counterclockwise 7 Remove piston Slide head off of piston rod 8 Remove all seals and O rings 9 Wash parts in a safe solvent Dry parts with com pressedair DO NOTwipe them drywitha cloth or paper as lint and dirt may remain 10 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace entire cylinder if barrel is damaged Inspect head rod and piston for evi...

Page 250: ...n spring Fig 22 by prying the end of the spring up and over its retaining boss Use a brake spring pliers or flat blade screwdriver Wear a face shield when removing brake re turn spring Fig 22 The spring is under ten sion and could possibly slip during removal CAUTION 4 Remove brake lever retainers cotter pins with a slip joint pliers 5 Pull strut and lever from brake shoes Remove brake shoes by sl...

Page 251: ...ttings and hoses to prevent contamination NOTE Toease reassembly tag each hoseandtube line to show their correct position on the steering valve 5 Remove the steering wheel 6 Remove the clamp securing the steering column to the steering tower 7 Remove four 4 nuts and washers securing steering valve to steering tower 8 Carefully move hydraulic lines to the side and pull steering valve and column out...

Page 252: ...um force necessary and maximumcare when separatingorassembling the com ponents The steering valve has several components that are of brazed laminate construction These components have plates and parts bonded together permanently to form an integral component that cannot be disassembled Disassemblethe steering valve onlyto the extent shown in this book IMPORTANT Do not force or abuse closely fitted...

Page 253: ...he relative positions of the alignment grooves on the side of the components in the assembly The relative alignment groove positions on the compo nents must be maintained at reassembly Fig 24 Figure 25 Figure 26 2 Use a slot type screwdriver or screwdriver socket to loosen the plug assembly one turn counterclockwise Fig 27 Do not remove the plug assembly Figure 27 3 Remove the four nuts from the p...

Page 254: ...t you have just removed from the port manifold are 3 4 in 19 mm long Keep this set of three springs separate from the next set of three springs to be re moved 9 Inspect the springs for bent or distorted coils If a spring is broken or deformed all six springs in the unit should be replaced 10 Inspectthe ground surfaces ofthe port manifold You should notice a normal polished pattern due to the rotat...

Page 255: ...2 Remove the valve plate by lifting it from the isolation manifold Fig 34 13 Inspect the slot edges and ground surfaces If the valve plate shows nicks or scoring or the edges are not sharp it must be replaced NOTE The valve ring and valve plate are a matched set and must be replaced as a set Figure 34 Reelmaster 223 D 5100 D 5300 D Page 7 25 Repairs ...

Page 256: ...gs for bent or distorted coils If a spring is broken or deformed all six springs in the unit must be replaced Fig 36 16 Remove the hex drive assembly from the drive link Fig 37 17 The pin in the hex drive assembly should not show wear and must be firmly pressed in place the sides of the hex and slot should not have grooves or scoring if the hex drive assembly shows signs of this type of wear it mu...

Page 257: ...e to the rotation of the valve plate and on the opposite side a normal polished pattern due to the action of the commutator cover and commutator seal The holes and edges should be free of nicks The manifold surfaces should be free of nicks or scoring If the manifold has developed any of these conditions it must be replaced 21 Remove the two isolation manifold metering ring alignment pins Fig 40 Fi...

Page 258: ...and discard the two seal rings Fig 42 If the metering ring bore is scored it should be replaced Figure 42 25 The metering package components are held to gether with eleven hex socket head screws Lift the metering package from the assembly and put it on a clean surface Fig 43 IMPORTANT Do not clamp the metering package in a vise as this could damage the components Figure 43 Repairs Page 7 28 Reelma...

Page 259: ...ch Inspect the screws for thread and socket damage and replace as necessary Figure 45 28 Lift the commutator cover from the metering pack age Fig 46 29 Inspect the ground surfaces of the commutator cover You should notice a normal polishedpatterndue to the rotation of the commutator If the cover has nicks burrs or scoring it must be replaced Figure 46 Reelmaster 223 D 5100 D 5300 D Page 7 29 Repai...

Page 260: ...manent assembly that cannot be disassembled Inspect the ground sur faces of the commutator The holes and edges should be free of nicks The ground surfaces should be free of scoring The edges should be sharp NOTE The commutator and commutator ring are a matched set If either is worn or damaged the set must be replaced IMPORTANT Five alignment pins connect the com mutatortotherotorwitha slipfit Care...

Page 261: ...e rotor lobe directly across from the rotor lobe tip being measured see pointer in Fig 51 mustbe centered between stator lobes during the measurement A rotor and stator that exceeds the maximum allowable tip clearance must be replaced Max rotor to stator tip clearance 0 003 in 0 08 mm 37 Remove the rotor set from the drive plate The drive plate side of the rotor set also must be free of grooves or...

Page 262: ... back up ring and face seal spacer from the upper cover plate Fig 54 Discard the face seal and back up ring Keep the metal spacer Figure 54 41 Remove the thrust bearing and bearing spacer from the upper cover plate Fig 55 42 Inspect the thrust bearing for brinelling dents or spalling flaking if either exists or if one or more of the rolls are lost or broken replace the bearing assembly Replace the...

Page 263: ...aking If it is damaged the upper cover plate must be replaced Figure 56 44 Slide the seal from the jacket tube Fig 57 If the seal is worn or damaged it must be replaced Figure 57 45 Remove the input shaft and snap ring sliding it out of the upper cover end of the assembly Fig 58 46 Inspect the input shaft serrations threads and flats for grooves wear or damage Figure 58 Reelmaster 223 D 5100 D 530...

Page 264: ...cket for wear or damage If bushing replacement is neces sary put the upper cover jacket in a vise Use a pliers or punch to straighten the crimped areas on the bushing end of the jacket tube Fig 60 IMPORTANT Hold the steering tube in a soft jaw vise Be careful not to damage the steering tube 49 Use a bearing pullerto remove the bushing Fig 61 Figure 59 Figure 60 Figure 61 Repairs Page 7 34 Reelmast...

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: ...e the assembly to the fixture but loose enough to turn the bolts and facilitate stacking of components 2 If the bushing was removed from the upper cover and jacket for replacement press a new bushing into the upper end of the jacket tube with the recessed end of the bushing toward the jacket tube Use an arbor press or the wood handle end of a hammer Fig 64 Push the bushing down until it is 0 1 in ...

Page 267: ...r plate Figure 66 5 Install the snap ring onto the input shaft if it was removed Fig 67 6 Slide the input shaft into the upper cover end of the upper cover jacket and through the bushing until the retaining ring bottoms against the washer Make sure the washer bottoms against the retainer plate recessed face and the retainer plate seats against the end of the jacket tube Fig 68 Figure 67 Figure 68 ...

Page 268: ...e 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 theface seal back upringand spacerassem bly over the end of the input shaft and onto the upper cover plate Fig 72 Figure 72 Repairs Page 7 38 Reelmaster 223 D 5100 D 5300 D ...

Page 269: ...ts are aligned with the tapped holes in the drive plate Fig 73 Figure 73 12 Apply a small amount ofclean multi purpose grease to the spacer and insert it into the drive slot in the rotor Fig 74 The grease will aid in retaining the spacer during other assembly procedures Figure 74 13 Put the commutator on top of the rotor Be sure the correct surface Fig 75 is towards the rotor Figure 75 Reelmaster ...

Page 270: ...sed below the surface of the commutator Figure 76 15 Put a few drops of oil into each recess in the commutator Fig 77 Figure 77 16 Put the commutator ring either side up on top of the stator Fig 78 Align the commutator ring screw recesses with the stator screw slots Figure 78 Repairs Page 7 40 Reelmaster 223 D 5100 D 5300 D ...

Page 271: ...t two procedures are a method of achieving the concentricity 19 Put the metering ring on a hard flat surface Put the assembled metering packageinto themeteringringwith the commutator cover down so the drive plate is par tially out of the metering ring Fig 81 A suitable wood block under the metering package will hold it in this position Put one piece of 0 007 in 0 18 mm shim stock approximately 0 5...

Page 272: ...late is on the flat surface Be sure the cap screws are loose enough to allow the commutator ring and drive plate to align themselves concentrically in the metering ring bore Gradually tighten the eleven cap screws following the sequence shown in Figure 83 at least twice until a final torque of 11 13 in lb 1 24 1 47 Nm is reached Fig 83 and 84 Remove the metering package and shims from the metering...

Page 273: ...ply clean multi purpose grease to the metering ring seal ring Put the seal ring into position in the metering ring seal groove opposite to the end with the alignment pin holes Stack the metering ring into place over the four bolts with the seal ring towards the upper cover plate Make sure an alignment pin hole on the metering ring is in line with and on the same side as the alignment groove on the...

Page 274: ...hrust bearing and put it on the upper cover plate inside the bearing spacer Fig 89 Figure 89 27 Inspect the exposed face of the drive plate making sure it is clean and lint free Apply a small amount of clean multi purpose grease on the drive plate Fig 90 Figure 90 Repairs Page 7 44 Reelmaster 223 D 5100 D 5300 D ...

Page 275: ...ckage will be below the surface of the metering ring Figure 91 29 Apply clean multi purpose grease on the new com mutator seal and put it into the commutator cover seal groove Fig 92 The rubber portion the softer side of the seal with the yellow mark must be put into the seal groove Figure 92 30 Apply clean multi purpose grease to the metering ring seal ring Put the seal ring into the metering rin...

Page 276: ...de of the manifold with the grooves on the side of the upper cover plate Fig 95 Align the alignment pin holes with the alignment pins in the metering ring The isolation manifold surface without the recessed slots must be toward the metering ring Figure 95 33 Install two alignment pins into the isolation manifold Fig 96 Figure 96 Repairs Page 7 46 Reelmaster 223 D 5100 D 5300 D ...

Page 277: ...nment pins with the seal ring facing the isolation manifold Fig 98 IMPORTANT Be sure the seal ring is seated cor rectly after the valve ring is assembled 36 Put the hex drive assembly pin side up through the hole in the isolation manifold Fig 99 the slot in the hex drive must be engaged with the SMALLtang of the drive link Turn the input shaft to assist the engagement NOTE Ifthe hex drive does not...

Page 278: ...it Fig 100 must be placed over the spring and spring recess in the isolation manifold at the top 12 o clock position as shown Fig 100 and 101 Adjust the valve plate position radially to centralize the spring slotsover the springs and the springrecesses in the isolation manifold IMPORTANT The unit will not function if the valve plate is not positioned on the isolation manifold exactly as shown in F...

Page 279: ...the valve plate Fig 104 Be careful not to pinch a spring during installation The two alignment pins in the valve plate will engage the holes in the port manifold The pin on the hex drive assembly must engage the center hole in the port manifold 41 Install a new o ring on the plug Insert the check ball hole in the port cover Be sure the ball is seated in the bottom of the check ball hole Turn the p...

Page 280: ...rings and seal ringinto 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 107 Figure 107 Repairs Page 7 50 Reelmaster 223 D 5100 D 5300 D ...

Page 281: ...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 Tighten the plug to atorqueof 8 12ft lb 11 16 Nm Fig 110 Figure 110 Reelmaster 223 D 5100 D 5300 D Page 7 51 Repairs ...

Page 282: ...side of the unit Fig 24 Components ofthe steering valve with alignment grooves must be assem bled so that their alignment grooves are positioned as illustrated for the valve to function correctly Fig 24 Disassemble and correct the assembly if necessary 48 Remove the four nuts holding the unit to the fixture and remove the unit Fig 112 Figure 111 Figure 112 Repairs Page 7 52 Reelmaster 223 D 5100 D...

Page 283: ...AND ADJUSTMENTS 7 Reel Lapping 16 Adjustment Summary and Check List 7 Bedbar Removal and Installation 18 Reel Bearing Service and Adjustment 8 Bedknife Replacement 19 Bedknife To Reel Adjustment 9 Preparing Reel For Grinding 19 Front Roller Adjustment 10 Reel Removal and Bearing Replacement 20 Height Of Cut Adjustment 11 Lift Arm Spring Replacement 21 Shield Height Adjustment 12 Top Bar Adjustment...

Page 284: ...ith bolt clamp lock Bedknife To Reel Adjustment Bedknife adjusts against reel with opposed screw adjustment on each end of bedbar Bedknife Screw Torque 200 in lb Reel Splined Drive Nut Torque 40 to 60 ft lb Reel Bearing Rolling Torque 4 to 7 in lb with no end play Figure 1 Specifications Page 8 2 Reelmaster 223 D 5100 D 5300 D ...

Page 285: ... tools may also be available from a local supplier Plastic Plug Insert plug in cutting unit bearing housing in place ofreel motor when sharpening or grinding the reel Figure 2 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly Figure 3 Reelmaster 223 D 5100 D 5300 D Page 8 3 Special Tools ...

Page 286: ...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 bar surface before installing bedknife DO NOT use an air impact wrench with this tool Figure 4 Special Tools Page 8 4 Reelmaster 223 D 5100 D 5300 D ...

Page 287: ...hapter 4 Hydraulic System 3 Cutting unit down pressure adjustment Down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf conditions Increased down pressure will help keep the cutting 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 Make sure all springs have th...

Page 288: ...tive height of cut depends on cutting unit down pressure adjustment and turf conditions 10 Rear roller scraper adjustment Set scraper to 1 32 in clearance from roller 11 Stability of bedbar Make sure bed bar pivot bolts are securely seated maximum 40 ft lb Make sure opposing bedknife adjustment screws are tight To prevent distortion of adjustment screw mount ing plate and to prevent damage to bedb...

Page 289: ... settings shown on REEL SPEED SETTINGS graph for number of reel blades 5 or 8 and desired ground speed see Operator s Manual and decal on machine under seat plate NOTE Reel speed settings may require fine tuning from initial adjustmentfor optimum cuttingperformance Weekly Checks 1 Checkreel bearingadjustmentand bearing condition 2 Make sure bed bar pivot bolts are securely seated maximum 40 ft lb ...

Page 290: ...f the reel shaft with asmall hammer until endplay ofthe reel shaft can be felt NOTE If reel bearings will not hold adjustment during operation loosen adjustment nut tighten reel shaft spline nut on right hand end of reel shaft to a torque of 40 to 60 ft lb then adjust reel bearings 3 Tighten reel bearing adjustment nut until there is no reel shaftend play then tighten an additional 1 16 to 1 8 tur...

Page 291: ... the bottom adjustment screws are secured at both ends of cutting unit 3 After adjustment check to see if reel can pinch paper when inserted from the front and cut paper when in serted at a right angle Fig 9 It should be possible to cut paper with minimum contact between the bedknife and reel blades Should excessive reel drag be neces sary to cut paper more than 7 in lb it will be necessary to eit...

Page 292: ...old 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 1 Figure 10 1 Roller bracket Set Up and Adjustments Page 8 10 Rev A Reelmaster 223 D 5100 D 5300 D ...

Page 293: ...n each height of cut adjusting bolt 4 Set head of screw on gauge bar to desired height of cut Height of cut measurement is from face of bar to under side of screw head 5 Put bar across front and rear rollers Turn height of cut adjustment bolt until underside of screw head en gages bedknife cutting edge IMPORTANT Do step 5 on each end of bedknife Tighten height of cut adjustment bolt locknuts and h...

Page 294: ...s conditions clippings fly over top of baskets or raised to allow for heavy wet grass conditions clippings build up on rear edge of basket Opening Rear Shield When mowing in conditions in which an excessive amount of clippings is being removed rear discharge may be desirable Opening the rear shield will allow direct discharge of clippings to prevent cutting the clippings again 1 Loosen locking bol...

Page 295: ...el for optimum per formance and should be adjusted whenever shield height is adjusted or whenever reel is sharpened on a reel grinder Lock up Roller Adjustment Adjust lock up rollers so they contact the lock up lever on each rear lift arm and support the cutting units when fully raised Fig 15a The cutting units should have approximately 3 8 to 5 8 in vertical travel when meas ured at the rear roll...

Page 296: ...and remove key from ignition switch 2 Remove floor plate in front of seat and open the hood to get access to all five 5 springs j Springs are under tension Use caution when ad usting CAUTION 3 Put an open end wrench on hex shaft of spring bracket NOTE Because wrench can be moved only a limited distance it may be necessary to use a second wrench to hold hex shaft while re positioning other wrench f...

Page 297: ...the motor clockwise so motor flanges clear studs and pull motor off of cutting unit 1 2 Figure 18 1 Reel drive motor 2 Mounting nuts 4 Remove capscrew lock washer flat washer and thrust washer from cutting unit mounting shaft Fig 19 5 Pull cutting unit off mounting shaft 6 Reverse steps 1 5 to install cutting unit 3 2 1 Figure 19 1 Cutting unit mounting shaft 2 Carrier tube frame pivot tube 3 Caps...

Page 298: ...cklapping Stop engine and turn H O C knob one position toward A Figure 21 1 Height of cut H O C selector knob 6 Move backlap switch to either FRONT or REAR to select with reels are to be backlapped DANGER To avoid personal injury make sure you are clear of cutting units before proceeding 7 Move enable disable switch to ENABLE Move lower mow raise lever forward to start backlapping operation 1 Figu...

Page 299: ...o OFF lower seatand tighten both locking bolts securely Wash all lapping compound off cutting units Do cutting unit reel to bedknife adjust ment as necessary IMPORTANT If the backlap switch is not returned to OFF position after backlapping the cutting units will not raise or function properly IMPORTANT If the cutting units are removed for backlapping such as when bedknives are replaced the reel sp...

Page 300: ... at each end of cutting unit Remove the bedbar by rotating it away from the reel NOTE For proper grinding of bedknife follow proce dures in the Toro publication Sharpening Reel Rotary Mowers Form No 80 300 PT 5 Reverse steps 1 4 to install the bedbar IMPORTANT When installing bedbar be sure to assemble rear roller brackets UNDER arms of bed bar IMPORTANT Securely seat the 2 bedbar pivot bolts to a...

Page 301: ...Adjustment in the Adjustments section of this chapter 1 Remove bedbar see Bedbar Removal and Installation NOTE Some reel grinders may require rear roller as sembly be mounted to the cutting unit for propersupport in reel grinder Rear roller MUST be parallel to reel shaft to remove taper when grinding 2 If necessary remove front roller assembly A Remove locknuts securing front roller brackets to si...

Page 302: ...t of side plates and reel assembly can be removed as soon as bearing housings are disassembled from side plates 5 Before installing reel install new special machine screws and washers from inside of frame to secure bearing housing 6 If necessary install new bearings and seals A Remove outer seal in counterbalance weight bearing cup bearing cone and inner seal B Bearing housing must be completely f...

Page 303: ... distance it may be necessary to use a second wrench to hold hex shaft while re positioning other wrench for further rotation of hex shaft 4 Remove capscrew and locknut securing retaining bracket while rotating hex shaft to relieve spring ten sion then rotate hex shaft to completely relieve spring tension 5 Remove spring 6 Install new spring 7 Use an open end wrench to move spring bracket to desir...

Page 304: ...Repairs Page 8 22 Reelmaster 223 D 5100 D 5300 D ...

Page 305: ...IONS 2 REPAIRS 5 GENERAL INFORMATION 3 Drive Shaft Service 5 TM Four Matic 4WD Rear Axle Removal and Installation 8 Over Running Clutch Operation 3 Axle Repair 9 ADJUSTMENTS 4 Rear Wheel Toe in 4 Reelmaster 223 D 5100 D 5300 D Page 9 1 Table of Contents ...

Page 306: ..._ ___ ______ ___ ______ ___ ______ ___ ______ _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Specifications Item Specification Lubricant Fig 1 2 3 SAE 80W90 gear lube Rear wheel toe in 1 8 inch Wheel nut torque 45 55 ft lb 1 2 1 Figure 1 Figure 3 Right hand end of axle shown 1 Drain plugs 1 Check plugs ...

Page 307: ...ment of the traction unit slows This causes the rear axle pinion speed to slow down As soon as the rear axle pinion is Figure 4 turning the same speed as the drive shaft the roller clutch will engage and power will be transmitted from the drive shaft to the rear wheels four wheel drive Fig 4 1 Rear axle pinion shaft Figure 5 1 Over running clutch When the traction unit is turning the rear wheels s...

Page 308: ...f 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 Rotate tie rod to move front of tire inward or outward 4 Tighten tie rod clamps when adjustment is correct 1 Figure 7 1 Tie rod Adjustments Page 9 4 Reelmaster 223 D 5100 D 5300 D ...

Page 309: ...ecuring cou pling to axle shaft Slide coupling off of shaft 4 Loosen two 2 capscrews and locknuts securing end Clutch Service 1 To disassemble clutch remove six 6 capscrews Item 17 and lockwashers Item 16 Remove axle coupling Item 15 from clutch housing Item 23 2 Remove retaining ring Item 21 Clutch housing Item 23 along with thrust washers Item 14 roller clutches Item 22 and seals Item 13 can now...

Page 310: ... securing bearing Item 5 to bracket Item 3 Remove three 3 carriage bolts Item 1 and bearing Item 5 3 Remove traction shaft from differential axle pinion coupler by rotating it clockwise gure 9 Installing Traction Shaft Item 31 1 Apply medium strength Loctite or equivalent to threads of pinion coupler on rear of differential axle 2 Thread traction shaft Item 31 left hand thread onto pinion coupler ...

Page 311: ...ws Item 19 and locknuts Item 6 to secure coupling to shaft 4 Slide yoke end Item 7 of drive shaft onto traction shaft spline Item 31 Item 6 to secure yoke to shaft Do steps 6 9 only if traction shaft Item 31 was removed 6 Block front tires and jack up rear wheels of machine until there is approximately one inch clearance between rear tires and the ground SECURELY BLOCK FRAME 7 Using an open end to...

Page 312: ...n hoses and fittings to prevent contamination of Install washers Items 14 15 43 between axle and hydraulic system axle support 3 Loosen rear wheel capscrews Item 39 Item 14 qty 2 is 0 018 thick Item 15 is 0 318 thick Item 43 is 0 032 thick 4 Block fronttiresand jackuprearof machine until there is approximately one inch clearance between rear tires Apply medium strength locktite to capscrew Item 4 ...

Page 313: ...nder 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 1 Figure 11 1 Drain plugs Reelmaster 223 D 5100 D 5300 D Page 9 9 Repairs ...

Page 314: ...haft Item 35 and bevel gear Item 5 C Remove capscrews Item 10 securing knuckle arm Item 8 to knuckle case Item 28 Pull off knuckle arm toward upper side and pull off case toward bottom D Remove capscrews Item 13 and remove bear ing retainer Item 15 Remove bevel gear Item 18 and knuckle pin Item 20 5 Disassemble differential case Fig 12 A Remove bolts Item 35 and remove bearing case Item 33 and pin...

Page 315: ...t tooth contact of bevel gear Item 6 to pinion Item 30 Use shims Item 29 to make good contactwith lightloadbetween bevel gear and pinion Fig 13 D After adjusting tooth contact use shims Item 5 to make backlash 0 003 0 01 in 0 08 0 25 mm Check backlash through plug hole Item 26 with a dial indicator E Tighten bolts Item 1 35 to a torque of16 20 ft lb 220 280 Kg Cm 3 Assemble knuckle assembly Fig 13...

Page 316: ...8 Note that top two 2 capscrews Item 39 securing cover Item 30 are a shorter length E Install bevel gear Item5 toknucklepinandinstall cover Item 26 to knuckle case Item 38 Use medium strenght Loctite on capscrews Item 28 securing cover Item 26 F Evenly tighten capscrews Item 28 39 securing covers to a torque of 12 20 ft lb 170 280 Kg Cm 4 Install axle on machine see Rear Axle Removal and Installat...

Page 317: ...This page is blank ...

Page 318: ...Commercial Products The Toro Company ...

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