Toro Reelmaster 5100-D Manuals

Manuals and User Guides for Toro Reelmaster 5100-D. We have 2 Toro Reelmaster 5100-D manuals available for free PDF download: Service Manual, Manual

Toro Reelmaster 5100-D Service Manual

Toro Reelmaster 5100-D Service Manual (318 pages)

Brand: Toro | Category: Lawn Mower | Size: 9.68 MB

Table of Contents

Table of Contents

3
- Service Manual
  1
- Chapter 1 - Safety
  
  5
  - Safety Instructions
    5
    
    While Operating
    6
- Chapter 2 Product Records
  
  9
Chapter 3 Mitsubishi Diesel Engine

17
- Introductions
  18
  - Introduction
    18
- Specifications
  19
  - General
    20
    
    Engine
    21
    
    Lubrication System
    23
    
    Cooling System
    24
    
    Fuel System
    24
    
    Governor System
    24
    
    Electrical System
    25
    
    Tightening Torque
    26
- Special Tools
  27
- Adjustments
  29
  - Valve Clearance
    29
    
    Engine Speed Adjustments
    30
- Troubleshooting
  31
  - Throttle Linkage Adjustment
    31
- Testing
  34
  - Glow Plug Test
    34
    
    Compression Test
    35
    
    Nozzle Tests
    36
    
    Injection Pump Test
    38
    
    Injection Timing Test
    39
    
    Fuel Pump Test
    40
    
    Thermostat Test
    40
- Preparation for Engine Repair
  41
  - Cylinder and Cylinder Block Overhaul
    41
- External Engine Component Repair
  42
  - Alternator Belt Replacement
    42
    
    Alternator Removal and Installation
    43
    
    Starter Removal and Installation
    43
    
    Replacing And/Or Adjusting Stop Solenoid
    44
    
    Glow Plug Replacement
    45
    
    Oil Pressure Switch Replacement
    45
    
    Thermostat Removal and Installation
    45
    
    Water Pump Service
    46
- Governor System Repairs
  47
  - Governor Operation
    47
    
    Governor Inspection
    48
    
    Governor Service
    49
    
    Installation of Torque Spring Set
    50
    
    Assembly of Torque Spring Set
    51
- Fuel System Repairs
  52
  - Bleeding the Fuel System
    52
    
    Bleeding Air from the Injectors
    53
    
    Fuel Pump Service
    53
    
    Injection Pump Service
    54
    
    Nozzle Service
    57
    
    Removing and Installing the Fuel Tank
    59
- Removing and Installing the Engine
  60
  - Removing the Engine
    60
    
    Installing the Engine
    61
- Cylinder Head Overhaul
  62
  - Cylinder Head Removal
    62
    
    Cylinder Head Service
    63
    
    Valve Guides
    64
    
    Valve Seats
    65
    
    Valves
    65
    
    Rocker Arm and Rocker Shaft
    66
    
    Valve Springs
    66
    
    Cylinder Head Reassembly and Installation
    67
- Cylinder Block Overhaul
  69
  - Gear Case and Oil Pump
    69
    
    Timing Gears and Camshafts
    72
    
    Piston and Connecting Rod
    75
    
    Crankshaft
    79
    
    Cylinder Block
    82
Chapter 4 Hydraulic System

83
- Specifications
  84
  - Hydraulic Oil
    85
- General Information
  87
  - Hydraulic Hoses
    87
    
    Hydraulic Fitting Installation
    87
    
    Towing
    89
- Hydraulic Schematic
  90
- Hydraulic Flow Diagrams
  91
  - Traction Forward
    91
    
    Lower Cutting Units / Mow
    92
    
    Backlap Front
    94
    
    Raise Cutting Units
    95
- Special Tools
  96
- Troubleshooting
  99
  - Transmission Operates in One Direction Only
    99
    
    Traction Pedal Does Not Return to Neutral Properly
    99
    
    Transmission Jerky When Starting
    99
    
    Transmission Operating Hot
    100
    
    Loss of Traction Power or Unit will Not Operate in Either Direction
    101
    
    No Cutting Units Operate
    101
    
    Front Reels will Not Turn in Either Direction
    102
    
    Front Reel(S) Turn too Slow
    103
    
    Front Reels Turn in Only One Direction
    104
    
    Front Reels Turn too Fast
    104
    
    Front Reel Speed Erratic
    105
    
    Front Reels Stop under Load
    105
    
    Rear Cutting Unit Problems
    105
    
    Cutting Unit(S) will Not Raise
    106
    
    Cutting Units Raise too Fast or too Slow
    107
    
    Cutting Units Raise, but will Not Stay up
    107
    
    Cutting Units will Not Lower
    108
- Testing
  109
  - Test No. 1: Traction Circuit Charge Pressure
    110
    
    Test No. 2:Traction Circuit System Pressure
    111
    
    Test No. 3: Front Mow/Lift Circuit Pressure
    112
    
    Test No. 4: Rear Mow Circuit Pressure
    113
    
    Test No. 5: Reel Drive Pump Efficiency
    114
    
    Test No. 6: Reel Drive Circuit Flow
    115
    
    Test No. 7: Reel Drive Motor Efficiency
    116
- Adjustments
  117
  - Traction Control Neutral Adjustment
    117
  - Lift Circuit Variable Orifice Adjustment
    118
- Transmission Repairs
  119
  - Shaft Seal Replacement
    119
    
    Transmission Control Linkage Removal
    120
    
    Trunnion Seal Replacement
    121
  - Check and High Pressure Relief Valves
    122
    
    Charge Pressure Relief Valve
    123
    
    Heat Exchanger Bypass Valve
    124
  - Filter Bypass Valve
    124
    
    Filter Bypass Reverse Flow Check Valve
    125
  - Charge Pump
    126
    
    Transmission Removal and Installation
    127
  - Disassembly of Transmission
    128
    
    Assembly of Transmission
    133
- Mowing Circuit Repairs
  138
  - Valve Block Service
    138
    
    Cartridge Valve Service
    139
    
    Cartridge Valve Identification
    140
    
    Pump Removal and Installation
    142
  - Pump Repair
    143
  - Reel Motor Removal and Installation
    145
  - Reel Motor Shaft Seal Replacement
    146
  - Reel Motor Repair
    147
    
    Lift Cylinder Removal and Installation
    148
    
    Lift Cylinder Repair
    149
- Inspecting Reservoir Parts
  152
Chapter 5 Electrical System

153
- Wiring Schematics
  155
- Special Tools
  159
- Troubleshooting
  161
  - Quick Reference Troubleshooting Guide
    161
    
    Starting Problems
    167
    
    General Run and Transport Problems
    169
- Testing
  176
  - Ignition Key Switch
    176
    
    Electronic Control Unit (ECU)
    177
    
    Seat Switch
    177
    
    Cutting Unit down Switches
    178
    
    Traction (Neutral) Switch
    178
    
    Enable/Disable Switch
    179
    
    Lower-Mow/Raise Switches
    179
    
    Backlap Switch
    180
    
    Start Relay
    180
    
    Battery
    181
    
    Glow Relay
    181
    
    Fuel Stop (ETR) Solenoid
    182
    
    Indicator Lights and Gauges
    183
    
    High Temperature Shut-Down Switch
    184
    
    Temperature Gauge Sender
    184
    
    Engine Oil Pressure Switch
    185
    
    Fuel Gauge Sender
    185
  - Hydraulic Valve Block Solenoids
    186
  - Checking Starter Pinion Gap
    187
  - Starter No-Load Test
    187
    
    Magnetic Switch (Solenoid) Attraction Test
    188
  - Magnetic Switch (Solenoid) Holding Test
    188
    
    Magnetic Switch (Solenoid) Return Test
    188
  - Alternator Regulated Voltage Test
    189
    
    Alternator Output Test
    189
- Repairs
  190
  - Battery Service
    190
    
    Fuses
    191
    
    Traction (Neutral) Switch Replacement
    192
  - Electronic Control Unit (ECU) Replacement
    193
  - Solenoid Valve Coil Replacement
    194
    
    Starter Service
    195
    
    Alternator Service
    199
    
    Speedometer Sensor Installation
    203
  - Reel Speed Sensor Installation
    204
Chapter 6 Differential Axle

207
- Introduction
  207
- Torque Specifications
  207
- Chapter 7 - Steering and Brakes
  
  208
  - Special Tools
    208
    
    Axle Removal and Installation
    209
    
    Repairs
    209
    
    Axle Shaft Disassembly and Wheel Bearing Service
    210
    
    Differential and Housing Disassembly
    214
    
    Differential and Housing Reassembly
    220
Chapter 7 Steering and Brakes

231
- Introduction
  232
- Schematics
  233
- Special Tools
  234
- Specifications
  234
- Troubleshooting
  235
- Testing
  237
  - Steering Valve and Pump Tests
    237
    
    Steering Cylinder Internal Leakage Test
    238
- Adjustments
  239
  - Rear Wheel Toe-In Adjustment
    239
    
    Brake Adjustment
    240
- Repairs
  241
  - Steering Wheel Removal and Installation
    241
  - Rear Axle Bushing Service
    242
  - Steering Pivot Bushing Service
    242
  - Rear Wheel Spindle Bushing Service
    244
  - Front Wheel Bearing Service
    245
  - Rear Wheel Bearing Service
    246
  - Steering Cylinder Removal and Installation
    248
  - Steering Cylinder Service
    249
  - Brake Shoe Replacement
    250
  - Steering Valve Removal and Installation
    251
  - Steering Valve Service
    252
Chapter 8 Cutting Units

283
- Specifications
  284
- Special Tools
  285
- Troubleshooting
  287
  - Factors that Can Affect Quality of Cut
    287
- Set-Up and Adjustments
  289
  - Adjustment Summary and Check List
    289
  - Set up and Adjustments
    289
  - Reel Bearing Service and Adjustment
    290
  - Bedknife to Reel Adjustment
    291
  - Front Roller Adjustment
    292
  - Height of Cut Adjustment
    293
  - Shield Height Adjustment
    294
  - Top Bar Adjustment
    295
- Lift Arm down Pressure Adjustment
  296
- Repairs
  297
  - Cutting Unit Removal and Installation
    297
- Reel Lapping
  298
- Bedbar Removal and Installation
  300
- Bedknife Replacement
  301
- Preparing Reel for Grinding
  301
- Reel Removal and Bearing Replacement
  302
- Lift Arm Spring Replacement
  303
- Specifications
  306
- General Information
  307
  - Four-Matic 4WD
    307
  - Over-Running Clutch Operation
    307
- Adjustments
  308
  - Rear Wheel Toe-In
    308
- Chapter 9 Drive Shaft Service
  
  309
  - Rear Axle Removal and Installation
    312
    
    Axle Repair
    313
- Repairs
  309

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Toro Reelmaster 5100-D Manual

Toro Reelmaster 5100-D Manual (38 pages)

Using the Diagnostic ACE

Brand: Toro | Category: Lawn Mower | Size: 1.19 MB

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