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Reelmaster 5100-D
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 (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
Equivalents and Conversions
10
Torque Specifications
11
Maintenance Interval Charts
12
Equipment Operation and Service History Report
13
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 (38 pages)
Using the Diagnostic ACE
Brand:
Toro
| Category:
Lawn Mower
| Size: 1.19 MB
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