Part No. 92796SL, Rev. C Service Manual Reelmaster 5100-D ® Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 5100-D REFER TO THE REELMASTER 5100-D TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chap ter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Table Of Contents Chapter 1 - Safety Chapter 5 - Electrical System Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Wiring Schematics and Diagrams. . . . . . . . . . . Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Safety Table of Contents While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs . . . . . . . . . . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The Reelmaster 5100-D was tested and certified by TORO for compliance with the B71.
8. Since diesel fuel is highly flammable, handle it carefully: C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill. A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. E. Wipe up any spilled fuel. While Operating G. Avoid sudden stops and starts. 9. Sit on the seat when starting and operating the machine. 15. Traverse slopes carefully.
While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs 22. Before servicing or making adjustments, stop the engine and remove the key from the ignition switch. 23. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 24. Frequently inspect all hydraulic line connectors and fittings. Make sure all hydraulic hoses and lines are in good condition before applying pressure to the system. 30.
Safety Instructions Page 1 - 4 Reelmaster® 5100-D
Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORDS. . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . . 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values - U.S. . . Capscrew Markings and Torque Values - Metric . MAINTENANCE INTERVAL CHART . . . . . . . . . . . .
Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals mm Fractions Decimals mm ___________________________________________________________________________________________________ 1/64 0.015625 1/32 ––––– 0.03125 3/64 0.046875 1/16 –––––––––––– 0.0625 5/64 0.078125 3/32 ––––– 0.9375 7/64 0.109275 1/8 ––––––––––––– 0.1250 9/64 0.140625 5/32 ––––– 0.15625 11/64 0.
Torque Specifications Use these torque values when specific torque values are not given. DO NOT use these values in place of specified values. Torque values listed are for lubricated threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S.
Maintenance Interval Chart Maintenance Interval Chart Page 2 - 4 Rev.
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for ® REELMASTER 223-D, 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 ___________________
REELMASTER® 223-D, 5100-D, and 5300-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Check Battery Fluid Level Check Battery Cable Connections Maintenance Interval & Service Every 50hrs Every Every Every 400hrs 100hrs 200hrs Every 800hrs Lubricate All Grease Fittings Change Engine Oil Inspect Air Filter, Dust Cup, and Baffle A Level Service † Check Fan and Altenator Belt Tension ‡ Replace Engine Oil Filter Inspect Cooling System Hoses B Level Service Drain Moi
REELMASTER® 223-D, 5100-D and 5300-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______ Daily Maintenance Check For Week Of _____________ Maintenance Check Item MON TUES WED THURS FRI SAT SUN _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS _____HRS Safety Interlock Operation Brake Operation Engine Oil & Fuel Level Cooling System Fluid Level Drain Water/Fuel Separator Air Filter/Pre-Cleaner Condition Radiator & Scr
A B C D E Other Service to perform (circle): ____________-____________ TORO I.D.
Chapter 3 Mitsubishi Diesel Engine Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication System . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor System . . . . . . . . . . . . . . . . . . . . .
Introduction Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section. The use of some specialized test equipment is explained, how ever, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at a qualified diesel engine repair facility. The engine is manufactured by Mitsubishi Heavy Indus tries Limited.
Specifications The illustrations (Figs. 2a and 2b) will give information about the general construction of the engine. Refer to the specifications listed in this section when performing tests on the engine or examining parts for wear. Some specifications are included in the service procedures later in this chapter.
General Item Specification __ ________________________________________________________________________________________ Make/Designation Mitsubishi L3E-61TG, overhead valve, vertical in-line, 4 cycle diesel ________________________________________________________________________________________________________________________________________________________ Combustion Chamber Swirl chamber type ______________________________________________________________________________________________________________
Engine Item Standard Specification Repair Limit Service Limit ___________________________________________________________________________________________ Governor Mechanical/Centrifugal ________________________________________________________________________________________________________________________ ________________________________ + 50 Operating Speed (no load) 3200 rpm – 0 rpm ________________________________________________________________________________________________________________________ _
Engine (cont.) Item Standard Specification Repair Limit Service Limit __ ________________________________________________________________________________________ Piston Type Material Piston Outside Diameter (skirt end) Piston to Cylinder Wall Clearance Oversize Protrusion from cylinder block top surface Solid Aluminum alloy 76 mm (2.99 in.) 0.3 mm (0.012 in.) 0.25, 0.50 mm (0.01, 0.02 in.) 0.9 mm (0.035 in.
Engine (cont.) Item Standard Specification Repair Limit Service Limit _________________________________________________________________________________________ __ 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) Gear Ball bearing 27.37 mm (1.078 in.) 0.15 mm (0.006 in.) – 1.0 mm (– 0.0433 in.) 30 mm (1.224 in.) – 0.7 mm (– 0.028 in.
Fuel System Item Standard Specification Repair Limit Service Limit __ ________________________________________________________________________________________ Fuel Pump Delivery Rate 225 cc (13.73 in3) or more (15 sec., 12V) ________________________________________________________________________________________________ ______________________________ __________________________ Fuel Injection Pump Model Injection Timing (B.T.D.C.) ND-PFR-NC 19o ± 1.
Electrical System Item Standard Specification Repair Limit Service Limit _________________________________________________________________________________________ __ Starter Type Nominal Output Direction of Rotation No load Characteristics (Cold) Terminal Voltage Current Speed Load Characteristics Terminal Voltage Current (torque) Speed Height of Brush Spring Pressure Commutator O.D. Depth of Commutator Undercut Pinion Gap Thrust Gap Solenoid shift type 1.
Tightening Torque The Mitsubishi diesel engine has many bolts and capscrews of special materials and sizes. It is very important that special care be used to replace all bolts and capscrews in their proper location during assembly of the engine. The torque specifications in American Standard and Metric as listed below MUST be followed in order to have the assembled engine conform to the original specifications.
Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products). Some tools may be available from a local supplier. Filter Cleaner Filter cleaner (Fig. 3). Mix with water and use solution to wash the Donaldson air cleaner element. Figure 3 Diesel Engine Compression Test Kit Diesel engine compression test kit (Fig. 5). 0-1000 PSI Gauge allows testing of diesel engines to check general operating condition of engine.
Nozzle Tester Nozzle tester (Fig. 7). Tests condition and opening pressure of fuel injector nozzles. Figure 7 Nozzle Tester Adapter Nozzle tester adapter (Fig.8) is required to test the fuel injection nozzles.
Adjustments Valve Clearance Check the valve clearance after the first 50 hours of operation and every 400 hours of operation after that. 1. The engine must be cold when the valve clearance is checked. 2. Remove the air breather hose from the rocker cover. 3. Remove the rocker cover nuts and washers. Remove the rocker cover. 4. Tighten the cylinder head bolts to the proper torque. The rocker assembly must be removed before tighten ing the cylinder head bolts.
Engine Speed Adjustments Adjustments to the engine speed settings are not nor mally necessary unless the throttle linkage, injection pump, or governor mechanism have been repaired, rebuilt, replaced or are not operating correctly. Since there is no ignition system from which to power an electronic tachometer, a vibration-type tachometer must be used to set engine speed. High Speed Adjustment NOTE: Specified rpm is with no load on engine.
Throttle Linkage Adjustment 1. Loosen the capscrew and nut securing the throttle cable to the governor lever (Fig. 14) 2. Push the governor lever all the way back so it is contacting the high speed set screw. 3. Move the throttle lever (Fig. 13) to the maximum speed position (all the way forward). 4. Tighten the cap screw and nut securing the throttle cable to the governor lever. 1 5.
Troubleshooting Page 3 - 16 Reelmaster® 223-D/5100-D
Reelmaster® 223-D/5100-D Page 3 - 17 Troubleshooting
Testing Glow Plug Test CAUTION Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac cidental contact with the heated plug tip could cause personal injury. 1. Disconnect the wire lead(s) to the glow plug. 2. Remove the glow plug. 3. Inspect the glow plug for signs of a burnt glow plug end tube. Figure 15 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.
Compression Test Normal cylinder compression is 28 kg/cm2 (398 psi) at 280 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50o C (120o F). IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic” forces acting upon the piston and connecting rod. 1. Remove the glow plug lead wires and glow plugs from all three cylinders. 2. Insert the compression gauge adapter into the glow plug hole.
Nozzle Tests There are several tests to examine the condition of the injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. (See the Spe cial Tools section of this chapter.) 3. Allow pressure to dissipate before performing the test. 4. Operate the pump handle slowly and observe the gauge to determine the pressure at which the nozzle opens and the fuel is sprayed. 5.
amount of fuel may be present due to a previous chat tering test - this would be normal. If the fuel accumulates and drips down during the test (about ten seconds) the nozzle assembly is defective and must be replaced. Spray Test For proper combustion, the nozzle must effectively at 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).
Injection Pump Test D. Put the throttle control in the FAST position. Turn the ignition key to the START position to crank the engine. Observe the nozzle. Calibration of fuel delivery volumes, pressure and dis tribution between pump barrels should be performed by a professional diesel engine service shop. Special test fixtures and equipment are required. It is possible to determine if the fuel injection pump requires service through a process of elimination using other fuel system tests.
Injection Timing Test Injection timing can be adjusted by installing shims under the pump body. The timing is important because it determines when the fuel enters the combustion chamber. The most accurate method of timing is done with an electronic diesel timing tester (available from major tool supply companies). The following method is an initial setting for starting the machine. 1. Remove the number one injection pipe from both the pump and nozzle.
Fuel Pump Test 1. Turn the ignition switch to the ON position. Test for pump operation by listening for the pump oscillating sound, or by feeling for vibration which indicates the pump is operating. 2. If no pumping action occurs when the ignition switch is turned on, connect a 12 volt DC battery directly to the pump (Fig. 22). If the pump now operates, check for an electrical failure of the pump circuit, eg. fuses, connec tions, wires, etc. 3.
Preparation for Engine Repair 1. Before cleaning and disassembly, carefully check for problems that cannot be found after the engine has been cleaned or disassembled (e.g. oil leaks from cracked components, gaskets or loose fittings, dam aged air cleaner or breather hoses that could cause cylinder wear, etc.). Make a note of any problems that you find. 2. Clean or wash the engine exterior thoroughly before disassembly. engine oil to disassembled parts, as necessary to pre vent rust. 5.
External Engine Component Repair Fan Belt and Alternator Belt Replacement 1. Put machine on a level surface, engage parking brake, stop engine and remove key from ignition switch. Open hood. 1 2. Loosen locknut on belt tensioner lever (Fig. 24a). If replacing alternator belt, loosen bolt securing alternator brace to engine and bolt securing alternator to brace (Fig. 24b). 2 3. Remove two capscrews securing transmission drive shaft coupler to engine crankshaft pulley (Fig. 24c).
Alternator Removal and Installation 1. Disconnect the negative (–) cable from the battery. 2. Disconnect the wire from terminal “B” on the back of the alternator. 3. Disconnect the alternator wiring harness connector. 4. Loosen alternator brace bolt and alternator support bolt (Fig. 25). Push the alternator toward the engine and remove the belt. 5. Remove the alternator. 6. Reverse steps 1 - 5 to install the alternator.
Replacing and/or Adjusting Engine Stop Solenoid See Chapter 5 - Electrical System for information about testing the engine stop solenoid. An improperly adjusted stop solenoid can result in fail ure of the engine to stop when the key switch is turned off or could cause injection pump damage or malfunc tion. 7. Hold the solenoid body to prevent it from turning and tighten the nut against the engine to secure the adjust ment. Do not over tighten the nut.
Glow Plug Replacement Replace the glow plug(s) if they do not operate correctly. (See Glow Plug Test in the Testing section of this chap ter.) 3. Remove the glow plug. 4. Install a new glow plug. Tighten the glow plug to a torque of 11-14.5 ft-lb (1.5-2 KgM). 1. Remove the nut and lead wire. 5. Install the lead wire and nuts. 2. Clean the area around the glow plug. This will prevent dirt or other contamination from falling through the glow plug hole into the cylinder.
Water Pump Service 1. Drain the cooling system. 2. Remove the drive belt from the water pump and alternator. 3. Loosen the hose clamp and disconnect the hose from the water pump. 4. Remove the water pump (Fig. 32). 5. Check the water pump for cracks or leaks. Rotate the water pump shaft by hand. If the bearings do not rotate smoothly, or are noisy replace the water pump with a new water pump. There are no replaceable parts in the water pump. Figure 32 6.
Governor System Repairs Governor Operation The governor keeps the engine operating at a constant speed by balancing the centrifugal force acting on the governor weights and the governor spring tension. As the engine picks up speed, the governor weights open to move the sliding shaft forward. The shaft pushes on the governor lever to move the injector control rack and decrease the fuel injection rate.
Governor Inspection A governor failure can cause engine starting failure, loss of engine speed control, or engine surging (hunting). Before removal and disassembly of the engine the following inspections are recommended: 1. Stop the engine, lower the implement and engage the parking brake. Open the engine hood. 2. Remove the governor tie rod cover (Fig. 28). 3. While holding the stop lever (Fig.
Governor Service 1. Remove the tie rod cover (Fig. 33). 2. Remove the tie rod clip and disconnect the tie rod from the injection pump control rack. 3. Disconnect the governor spring from the tension lever. 4. Remove the cover assembly. 5. Removing the levers: A. To remove the levers, pull out the grooved pins from the governor lever, stop lever and speed control lever. Figure 35 B. Loosen the bolts securing the levers and shafts. 6. Installing the levers: A. Coat the o-rings with oil before installation.
Installation of Torque Spring Set IMPORTANT: Torque spring set adjustment has been done and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary. The torque spring set adjustment is very sensitive. Improper adjustment can vary fuel delivery to under power or over fuel the engine. 1. Engage the parking brake. Make sure the high speed set bolt is adjusted to the correct engine speed of 3200 +50– 0 rpm (See Adjusting Engine Speed in the Maintenance section of this chapter).
Assembly of Torque Spring Set If the torque spring set has been disassembled or parts replaced, reassemble and adjust the torque spring set using the following procedure. IMPORTANT: The torque spring set has been ad justed and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary. The torque spring set adjustment is very sensitive. Improper adjustment can vary fuel delivery to under power or over fuel the engine. 1. Assemble the torque spring set as shown in Fig ure 37.
Fuel System Repairs When cleaning the engine, DO NOT spray water onto a hot injection pump. This could cause the fuel pump to seize and be damaged. When working on the fuel system, ALWAYS make sure that the equipment and work area is clean. The close tolerance parts of the fuel system can be easily dam aged by dirt. Wash fuel system parts in clean fresh diesel fuel. If parts are removed for a period of time, store them in contain ers of clean diesel fuel to prevent corrosion. Bleeding the Fuel System 1.
Bleeding Air From the Injectors This procedure should only be used if the fuel system has been purged of air. (See Bleeding the Fuel System in this section of the book.) 1. Loosen the pipe connection at the number one nozzle and holder assembly on the cylinder head (Fig. 41). 2. Move the throttle control to the FAST position. 1 3. Turn the ignition key to the START position to crank the engine and pump fuel to the nozzles.
5. Carefully remove the spring retainer from the end of the plunger tube (Fig. 43). Remove the washer, o-ring, valve, plunger spring and plunger. IMPORTANT: Be careful not to bend or deform the plunger tube while disassembling the fuel pump. If the plunger tube is bent, the fuel pump plunger will bind and the pump will need to be replaced. 6. Install the plunger (valve side out), plunger spring, valve, o-ring, washer and spring retainer. Make sure the plunger operates freely. 7.
3. Remove the tappet roller and stopper pin. Remove the tappet and adjusting shim. Injection Pump Disassembly IMPORTANT: Do not mix the delivery valves, deliv ery valve seats, plungers or plunger barrels from one cylinder to another. These are parts are “matched sets”. Handle these parts carefully. Place the parts in a container of clean diesel fuel to pre vent corrosion. 1. Remove the stopper holder. Remove the delivery valve holder (Fig. 46). 2. Remove the valve spring, delivery valve and o-ring.
Injection Pump Inspection Inspect the injection pump parts for proper operation, wear, corrosion, seizure, etc. (Fig. 47). Replace worn or damaged parts. Injection Pump Assembly 1. Insert the plunger barrel into the housing. 2. Install the delivery valve seat, gasket, delivery valve and valve spring. Install the o-ring on the delivery valve holder. Temporarily tighten the delivery valve holder. 3. Insert the control rack. Insert the sleeve. Align the match mark on the rack with that on the pinion (sleeve).
Nozzle Service IMPORTANT: When servicing the injection nozzles make sure that the engine and fuel delivery pipes are clean to prevent dirt from entering cylinder or nozzle. Do not mix components of one nozzle with the other. Nozzle Removal and Disassembly 1. Disconnect the injection pipes and fuel return pipe. 2. Remove the injector nozzle from the cylinder head. NOTE: Further disassembly of the nozzle is not required for the nozzle to be tested. (See Nozzle Tests in the Testing section of this chapter.) 3.
Nozzle Inspection and Cleaning 1. Clean the inside and outside of the retaining nut in clean diesel fuel or kerosene to remove carbon or fuel deposits. Inspect the lower seating surface for rust or damage. The sealing area may be restored with emery cloth. 2. Remove carbon or lacquer deposits from the nozzle by cleaning in clean diesel fuel or kerosene. Stubborn deposits can be removed with a brass wire brush. IMPORTANT: Do not use a steel brush, steel wool, etc.
Removing and Installing the Fuel Tank 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove the key from the ignition swtich. 2. Open drain fitting on bottom of fuel tank and drain fuel into a suitable container. 1 3. Remove six capscrews securing the fender 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.
Removing and Installing the Engine Removing the Engine 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. Allow engine and ra diator to cool. 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: 2. Open hood. Disconnect hood stop cable from frame. Lower hood. Remove left and right hinge plates.
Installing the Engine 1. To install the engine, perform steps 2 - 17 of Removing the Engine in reverse order. 2. Install a new engine oil filter. Fill engine with the correct oil. Fill the cooling system with a 50/50 solution of ethylene glycol antifreeze and clean, soft water. 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).
Cylinder Head Overhaul Cylinder Head Removal 1. If the engine will not be removed from the traction unit, lower the coolant level in the engine. Loosen the hose clamp and remove the upper radiator hose from the thermostat housing. Disconnect the coolant bypass hose from the thermostat housing. 2. Remove plug from left side of cylinder block to drain the coolant from head and cylinder block. 3. Remove the muffler. 4.
Cylinder Head Service 1. Use a valve lifter tool to compress the valve spring (Fig. 61). To remove each valve retainer, depress the retainer against the valve spring and remove the re tainer lock (Fig. 62). Remove the valve retainer, spring and valve. Keep each valve and other parts for each cylinder separate so they can be reinstalled in the same cylinder. 2. Examine each valve for burning, pitting, heavy carbon deposits or wear.
8. Use a straight edge and feeler gauge to check the flatness of the cylinder head lower surface (Fig. 63). Be sure to check the surface variation crosswise, length wise, and diagonally. If the variation in surface flatness exceeds (0.05 mm) 0.002 in. , the cylinder head or cylinder block must be replaced or resurfaced. Figure 63 Valve Guides 1. Use a micrometer and a small hole gauge to check the valve guide to valve stem clearance.
Valves 1. Carefully clean each valve with a wire wheel to remove all carbon deposits. 2. Check the valve face and valve stem for excessive wear, damage, cracks or deformation. If any of these conditions exist, the valve must be replaced. It is possi ble to reface the valve if the valve head thickness (margin width) is not less than the service limit (Fig.65). If the margin of the resurfaced valve is less than the service limit, replace the valve. Minimum valve head thickness (margin width): 0.5 mm (0.
Valve Springs 1. Check the valve springs for rust, pitting, cracks or other damage. 2. Check the squareness of the valve spring by putting it upright on a level surface. Any spring that is 3o or more out of square must be replaced. 3. Measure the spring free length. Any spring that has a free length of 39.3 mm (1.55 in.) or less must be replaced. 4. Over a period of time, valve springs can lose some of their tension. The spring must be replaced if the tension is less than the service limit. (Fig.
Cylinder Head Assembly and Installation 1. Install the thermostat housing. Use a new gasket. valve springs and valve retainers. Compress the spring with a valve lifter, then install the retainer lock. 2. Install the intake and exhaust manifolds. Use new gaskets. 3. Make sure the valve guides are properly installed (Fig. 64). 4. Install new valve stem seals onto the valve guides (Fig. 70). DO NOT install used seals. 5.
8. Make sure that the cylinder head and cylinder block surfaces are clean. Put a new gasket on the cylinder head. Insert dowel pins into two cylinder head bolt holes to assist in mounting the head onto the block. Carefully put the cylinder head into position on the cylinder block. Remove the dowel pins. Insert the cylinder head bolts. IMPORTANT: Do not put any sealant on the cylinder head gasket. 9. Tighten the cylinder head bolts in the order shown in Figure 71.
Cylinder Block Overhaul NOTE: The engine must be removed from the traction unit chassis and put in an engine stand. (See the Removing and Installing The Engine section of this chapter.) Gear Case and Oil Pump 1. Remove the crankshaft pulley. 2. Remove the fuel injection pump. (See Injection Pump Service in the Fuel System Repairs section of this chapter.) 3. Disconnect the governor spring from the tension lever. Remove the governor cover assembly from the gear case.
7. Check removed parts for wear or damage (Fig. 73). Replace parts as necessary.
8. Check the governor parts for wear or damage (Fig 74). Replace parts as necessary. A. Remove the expansion plug (Fig 75). Be careful to not scratch the gear case. B. Pull out the grooved pin. C. Remove the shaft, spring and levers. D. If necessary replace the 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.
Timing Gears and Camshafts 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the gear case (see Gear Case and Oil Pump in this section). 3. Remove the snap ring and remove the idle gear (Fig. 77). 4. To remove 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.
6. Check the gears for incorrect tooth contact, wear and damage. Replace any gears that are badly worn or damaged. 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.) Maximum idle gear bushing to shaft clearance: 0.2 mm (0.008 in.) Push rod bend: within 0.3 mm (0.012 in.) Maximum backlash between gears in mesh: 0.3 mm (0.012 in.
8. Before installing the camshafts and timing gears, turn the crankshaft to set the No. 1 cylinder to top dead center (TDC) of the compression stroke. Reverse steps 1 - 5 to install the camshafts and timing gears (Fig. 81). Figure 81 9. 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).
Piston and Connecting Rod 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the oil pan and gasket. 3. Remove the oil screen NOTE: Before removing the pistons, mark the number of the cylinder onto the top of each piston and on the side face of each connecting rod (on the large end). When the piston and connecting rod is removed be careful to prevent damage to the piston or bearing surfaces. 4.
8. Measure the piston outside diameter (Fig. 84). (See Cylinder Block in this section). Maximum piston to cylinder wall clearance: 0.3 mm (0.012 in.) Figure 84 9. Use a thickness gauge to check the piston ring side clearance (Fig. 85). If the piston ring side clearance exceeds the service limit, the ring must be replaced. If the clearance still does not meet specifications with a new ring the piston must be replaced. (See the Specifications section of this chapter.) Figure 85 10.
11. To remove the piston from the connecting rod press the piston pin from each piston. Use the piston setting tool (Fig. 87). IMPORTANT: Do not attempt to remove the piston pins by driving then out with a hammer. A stuck piston pin, requiring excessive pressure to remove, should be replaced. 12. Check for bending or distortion of the connecting rod. The service limit for bend and distortion is 0.15 mm (0.006 in.). Replace the connecting rod if damaged or out of specification. 13.
15.Install the piston rings. Each piston ring has different shape. Make sure they are installed in the proper posi tion and with the ring gaps in the directions as illustrated (Fig. 90). 16. Insert the piston and connecting rod assembly 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.
Crankshaft 1. Perform steps 1 - 5 under Piston and Connecting Rod in this section. 2. Remove the flywheel. 3. Remove the rear oil seal case. 4. Remove the main bearing caps (Fig. 91). Keep each set of bearings together with its bearing cap. 5. Remove the crankshaft. 6. Inspect the removed parts. Repair or replace any worn or damaged parts (Fig. 92).
6. Measure the crankshaft for “run-out” (bend). Mount the crankshaft in a pair of V-blocks (or live centers) and use a dial indicator to measure the run-out in the crank shaft (Fig. 103). The maximum allowable crankshaft run-out is 0.05 mm (0.002 in.). 7. Check the crank journals and crankpins for damage, out of round wear or tapering wear. The diameter of each crankpin or main journal should be measured at two places, “1" and ”2", in two directions, “A” and “B” (Fig. 104). Main journal diameter: 42.
10. Reverse steps 1 - 5 to install the crankshaft (Fig. 97). When installing the No. 1 and No. 4 bearing caps, apply sealant (Permatex No. 2 or equivalent) to the upper surface that meets with the cylinder block. 11. Use a dial indicator to measure the crankshaft end play. 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.
Cylinder Block Before cleaning check the cylinder block for coolant leaks, oil leaks or damage. Clean all parts to remove dirt, oil, carbon deposits and water scale. Check the cylinder block for cracks or other damage. Check the water jacket for water scale and rust. Replace the cylinder block if necessary. Measure each cylinder bore size in six locations (Fig. 98). The standard bore diameter is 76 mm (2.9921 in.).
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fitting Installation . . . . . . . . . . . . . . . Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SCHEMATIC. . . . . . . . . . . . . . . . . . . HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . Traction Forward . . . . . . . . . . . .
Specifications Item Description __________________________________________________________________________________________ Transmission System relief pressure 2WD units 4WD units Charge relief pressure Cooler By-pass pressure Filter By-pass pressure Oil filter Sauer-Sundstrand M25, U-type 2750 ± 150 psi at 3250 RPM 3200 ± 150 psi at 3250 RPM 150 ± 30 psi at 3250 RPM 70 ± 10 psi 70 ± 10 psi Screw-on type _____________________________________________________________________________________________________
Hydraulic Oil The hydraulic system was initially filled at the factory with Mobil 424 oil. Two groups of hydrauic oil are specified to allow optimal operation of the machine in a wide range of tempera tures encountered. The group 1 oil are a multi-viscosity hydraulic oil which allows operation at lower temperatures without the in creased viscosity, which is associated with straight vis cosity oils.
Specifications Page 4 - 2 .
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi tions or mishandling during operation or maintenance. These conditions can cause damage or premature de terioration. Some hoses, such as reel motor hoses, are more susceptible to these conditions than others. In spect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O-Ring Port (Non-adjustable) 1. Make sure both threads and sealing surfaces are free of burrs, ni cks, scratches, or any foreign material. 2. Al ways repl ace the O-ring seal when thi s type of fitting shows signs of leakage. 3. Lubricate the O-ring with a li ght coating of oil. O-Ring 4. Install the fitting into the port and tighten it down full length until finger tight (Fig. 4). 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Figure 4 Size 4 (1/4 in.
Pushing or Towing If it becomes necessary to tow the machine, tow it forward only and at a speed no greater than 10 mph. IMPORTANT: If these towing limits are exceeded, severe damage to the hydrostatic transmission may occur. 1 To tow a disabled machine: 1. Loosen and remove capscrews securing drive shaft to engine drive coupler. Loosen capscrews clamping drive shaft to transmission (Fig. 6). Remove drive shaft.
Hydraulic Schematic Hydraulic Schematic Page 4 - 6 Rev.
Hydraulic Flow Diagrams Traction Forward The hydrostatic transmission is driven by a drive shaft off the front of the engine crankshaft. Pushing the top of the traction pedal, rotates the variable displacement pump swash plate to create a flow of oil. This oil is directed to the fixed displacement motor which turns the differential input shaft to drive the front wheels.
Lower Cutting Units / Mow The hydraulic pump that provides oil flow to the reel drive circuit is driven off the PTO output shaft of the hydrostatic transmission. This oil flow enters a control valve block which directs the oil flow to perform the functions of reel drive and cutting unit lift and lower. The valve block consists of two individual control cir cuits. Each circuit is supplied by its own pump section – “P1” and “P2”.
System Pressure Solenoids Energized Low Pressure, Return or Case Drain Mow Front and Rear: Lower All Cutting Units: Oil Flow S1, VS1, S2, VS2 S6, S3, S4, S5 NOTE: Shown with VS1 and VS2 fully energized (maximum reel speed).
Backlap (Front Shown) mode. To backlap the front cuttting units, solenoid valve “S1” is energized allowing pressure to build in the front reel circuit. When solenoid valve “S1” is energized, variable solenoid valve “VS1” will direct part of the pump flow to tank, while directing the remaining flow to sole noid valve “S8” and out to the front reel motors. Return oil from the motors is directed to tank through valve “S8”.
Raise Cutting Units The return oil from the cylinders is directed back to tank externally from the valve block. The “P1” pump circuit controls the raise and lower function of all five cutting units. On the “P1” pump circuit, maximum system pressure is limited by relief valve “R1” which is set at 3000 PSI. System pressure on the “P1” side can be measured at Port “G1”. To hold the cutting units up in any position, all of the solenoid valves are de-energized.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). So me to ols may be lis ted in the Reelmaster 5100-D Parts Catalog. Some tools may also be available from a local supplier. Seal Protector Slide protector over reel motor shaft before installing shaft seal to protect seal from damage. Apply a light coating of clean oil to seal protector to ease movement of seal over tool. Use with seal installer tool.
Hydraulic Pressure Test Kit Used to take various hydraulic pressure readings for diagnostic tests. Quick disconnect fittings provided at tach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each, 1,000, 5,000 and 10,000 PSI gauges. Use gauges as recommended in Testing section of this chapter.
Hydraulic Tester (With Pressure and Flow Capabilities) Figure 16 You must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Reelmaster 5100-D. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit. 4.
Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
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.
Loss of Traction Power or Unit Will Not Operate In Either Direction Cause Correction _________________________________________________________________________________________ __ Adjust, use tachometer. Engine RPM too low. ________________________________________________________________________________________________________________________________________________________ Drive shaft disconnected or damaged. Repair or replace drive shaft.
Front Reels Will Not Turn in Either Direction Cause Correction __ ________________________________________________________________________________________ S1 not shifting. Do electrical diagnostics to make sure that voltage is being applied to S1 and that there is no electrical fault. See Chapter 5 - Electrical System. Do cartridge valve service procedure for valve S1. Interchange S1 with S2 and check operation. Re place S1 with a new valve if faulty.
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.
Front Reels Turn Too Fast Cause Correction __ ________________________________________________________________________________________ VS1 not operating properly. Do electrical diagnostics to make sure that voltage is being applied to VS1 and that there is no electri cal fault. See Chapter 5 - Electrical System. Do cartridge service procedure for VS1. Interchange VS1 with VS2 and check operation. Re place VS1 if faulty.
Front Reels Stop Under Load Cause Correction _________________________________________________________________________________________ __ Check relief pressure at port G1 of valve block and adjust valve if necessary. R1 bypassing. Do cartridge valve service procedure for valve R1. Replace R1 with a new valve.
Cutting Unit(s) Will Not Raise Cause Correction __ ________________________________________________________________________________________ One-way variable orifice closed - center and rear cutting units only - see Hydraulic Schematics. Open speed control valve. ________________________________________________________________________________________________________________________________________________________ Engine RPM too low. Increase engine RPM to operating speed.
Cutting Units Raise, But Will Not Stay Up Cause Correction _________________________________________________________________________________________ __ S6 energized (should only be energized during lower function). Do electrical diagnostics. See Chapter 5 - Electrical System. ________________________________________________________________________________________________________________________________________________________ S6 leaking down (not seating properly).
Cutting Units Will Not Lower Cause Correction __ ________________________________________________________________________________________ S3, S4, or S5 not shifting (See Hydraulic Schemat ics to see which valve controls what lift cylinders.) Do electrical 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.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Tools section in this Chapter.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2.
TEST NO. 1: Traction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 1 2. Park the machine on a level surface, engage the parking brake and stop the engine. CAUTION To prevent possible personal injury from ro tating drive shaft, engine must be OFF before attempting to connect gauge. If gauge has a hose attached, be careful to route hose so it will not contact the drive shaft. Figure 17 1.
TEST NO. 2: Traction Circuit System Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximate ly 10 minutes. 2. Before doing traction pressure test: A. Drive machine to an open area, lower cutting units, turn the engine off and engage the parking brake. 1 2 B. If testing forward function, connect a chain to the rear frame tie-down brackets. Connect the other end of the chain to an immovable object and remove all slack from the chain.
TEST NO. 3: Front Mow / Lift Circuit Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2 2. Lower cutting units, engage parking brake and stop the engine. 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of hydraulic valve block. Install a 5000 PSI gauge with extension hose onto quick disconnect fitting in port G1 (Fig. 19).
TEST NO. 4: Rear Mow Circuit Pressure 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. Set HOC Selector Knob, located under the instrument panel, to position A (full speed). Make sure Backlap switch is OFF. 1 3. Raise seat to get access to hydraulic test fittings. Remove access cover from in front of hydraulic valve block.
TEST NO. 5: Reel Drive Pump Efficiency (Using Tester With Pressure and Flow Capabilities) 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 1 3 3. With the engine off and cutting units lowered, install tester in series between pressure hose and valve block fitting for suspected bad pump section (Fig. 21). Make sure the tester flow control valve is OPEN.
TEST NO. 6: Reel Drive Circuit Flow (Using Tester With Pressure and Flow Capabilities) 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 2. Lower cutting units, engage parking brake and stop the engine. 3. Set HOC Selector Knob, located under the instrument panel, to position A (full speed). Make sure backlap switch is OFF. 4. Install tester in series between pressure hose and motor fitting on suspected bad circuit (Fig. 22).
TEST NO. 7: Reel Drive Motor Efficiency Reel drive motor efficiency can be tested by blocking outlet flow from the motor, then measuring flow from the motor case drain line. Use a graduated container, such as special tool TOR4077 to measure flow from the motor case drain line over a 15 second time period (Fig. 23b). Use the chart to determine the flow (Fig. 23c). 2 1. Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes. 1 Front 2.
Adjustments Traction Control Neutral Adjustment The machine must not “creep” when traction pedal is released. If it does creep, an adjustment is required. 1. Park machine on a level surface, lower cutting units and shut engine off. Depress only the right brake pedal and engage the parking brake. 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally. 7.
Lift Circuit Variable Orifice Adjustment Adjustable orifices are adjusted at the factory and should not require adjustment unless tampered with or in special situations. Opening valve increases lift speed. Closing valve slows lift speed. NOTE: Adjustment for special operating conditions should not require more than 1/2 turn of valve in either direction from initial adjustment. Front Center Initial Adjustment (Fig. 25) 1 This adjustment affects the front center (No. 1) cutting unit only. Loosen set screw.
Transmission Repairs Shaft Seal Replacement 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Disconnect the drive shaft from the transmission (Fig 27). 2 1 3. Remove retaining ring, then carefully remove seal from bore in charge pump cover (Fig. 28). The face of the seal my be punctured with a sharp instrument (such as a screwdriver) to aid in prying the seal out, or a slide hammer type puller may be used to remove the seal.
Transmission Control Linkage Removal 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 3 2. Disconnect wiring harness from traction neutral switch (Fig. 29, 30). 1 3. Remove eybolt and extension spring. 4 4. Remove cotter pin and washer to disconnect traction control rod from pump control. 5 5. Loosen cap screw and lock nut securing pump control to swashplate control shaft. It is not necessary to disas semble transmission control assembly. 2 6.
Trunnion Seal Replacement 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove control linkage from swashplate control shaft on transmission (see Transmission Control Removal). 4 3 1 3. Remove hex tapping screws retaining trunnion seal cover to transmission housing (Fig. 31). 2 4. Remove trunnion seal cover with lip seal and o-ring. 5. Put seal cover in an arbor press and press out old seal. Once removed, the seal is not reusable. 6.
Check and High Pressure Relief Valves 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 1 2. Remove the check/high pressure relief valve hex plug (Fig 32). 3. Remove the valve cartridge assembly. Inspect the valve and mating seat in the housing for damage or foreign material. It will be necessary to replace the center section if the seat is damaged.
Charge Pressure Relief Valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the charge relief valve hex plug (Fig. 33). 3. Remove the spring and poppet from the housing. 4. Do not interchange parts with another valve. NOTE: The shim(s) which may be installed between the spring and plug may remain inside the plug, being held by an oil film.
Heat Exchanger Bypass Valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the heat exchanger bypass valve hex plug (Fig. 34). 1 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 valve is identified by a yellow dye mark, and requires a force of approximately 5.5 lb. to compress it to a length of 1.28 in. 5.
Filter Bypass Reverse Flow Check Valve 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the heat exchanger bypass valve hex plug (Fig. 36). 3. Remove the spring and poppet from the housing. 4. Do not interchange parts with another valve. The spring used in the heat exchanger bypass valve is identified by a blue dye mark, and requires a force of approximately 0.3 lb. to compress it to a length of 1.28 in. 5.
Charge Pump 1. Park the machine on a level surface, lower cutting units, engage parking brake and stop the engine. 10. Tighten the charge pump cover cap screws to a torque of 27 to 37 ft-lb. 2. Remove the two (2) cap screws retaining the charge pump cover. Remove the charge pump (Fig. 37, 38). 11. Install a new shaft seal (see Shaft Seal Replace ment). 3. Remove geroter drive pin from the groove in the shaft. 12.
Transmission Removal and Installation 1. Park machine on a level surface, lower cutting units, engage parking brake and stop the engine. 2. Remove the two (2) rear cutting units (see Chapter 8 - Cutting Units). 2 3. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of transmission and differential. 3 4. Put a drain pan below the transmission. Remove suction line from bottom of transmission to let oil drain out of differential (Fig. 39). 1 5.
Disassembly of Transmission Figure 41 The procedures on the following pages are for the c o mple te disa ss em bly an d re as se mbly o f the transmission. Cleanliness is a primary means of assuring satisfactory transmission life, on either new or repair units. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and chemi cals.
1. Before performing major repairs on the transmission, remove external components as described in previous procedures. These include the following: Charge Check / High Pressure Relief Valves Charge Relief Valve Heat Exchanger Bypass Valve Filter Bypass Valve Filter Bypass Reverse Flow Check Valve Charge Pump 2. Remove six (6) screws which retain center section to housing (Fig. 42). Note position of longer and shorter screws.
7. Lay transmission on its side and remove motor cylin der block assembly from the housing. Remove pump cylinder block assembly from pump shaft (Fig. 46). Figure 46 8. Remove the slipper guide and piston assemblies from cylinder blocks (Fig. 47). NOTE: Pump and motor cylinder block assemblies are identical. To avoid mixing wear patterns, do not mix parts between pump and motor cylinder block assemblies. Figure 47 9. Use an o-ring pick or wire to remove thrust plates from swashplate and housing (Fig. 48).
11. Use an 8-32 machine screw to remove motor shaft bearing retaining pin from housing (Fig. 50). Figure 50 12. Remove motor shaft from housing (Fig. 51). Figure 51 13. Press motor shaft out of bearings and spacer (Fig. 52). Figure 52 14. Remove spiral retaining ring and remove PTO seal guide (with o-ring) from the housing (Fig. 53).
15. Slide pump shaft and bearing assembly from hous ing. Press shaft out of bearing (Fig. 54). 16. Remove hex tapping screws retaining trunnion seal cover and trunnion cover to housing (Fig. 55). Mark position of covers for reassembly. The trunnion seal cover assembly includes an o-ring, lip seal and trunnion bearing on the control side. The trunnion cover assem bly includes an o-ring and trunnion bearing on the side opposite the control. Remove these parts from the housing. 17.
Assembly of Transmission 1. Clean and lightly oil parts before assembly. Tighten all threaded parts to recommended torque value. IMPORTANT: Most parts have critical, high toler ance surfaces. Use caution to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings and ports from damage and foreign material. 2. Install swashplate into housing (Fig. 58). Make sure swashplate control shaft is located on correct side of housing (note marks made during disassembly). Figure 58 3.
7. Press ball bearing onto pump shaft. Install pump shaft and bearing assembly into housing (Fig. 62). Figure 62 8. Install PTO seal guide and o-ring into housing. Install spiral retaining ring (Fig. 63). Figure 63 9. Press inner bearing, spacer and outer bearing onto motor shaft (Fig. 64). Figure 64 10. Install motor shaft assembly into housing (Fig. 65).
11. Install motor shaft bearing retaining pin into housing (Fig. 66). Figure 66 12. Install pipe plug over motor shaft bearing retaining pin and tighten to a torque of 6 to 9 ft-lb (Fig. 67). Figure 67 13. Coat thrust plates with petroleum jelly and install into housing and swashplate (Fig. 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.
15. Lay the transmission on its side and install cylinder block kits into the housing (Fig. 70). 16. Put the transmission housing on a work surface with the center section opening facing up. Figure 70 17. Install valve plate locating pins into center section (Fig. 71). Figure 71 18. Coat back (steel side) of valve plates with petroleum jelly to hold them in position and install valve plates onto center section, with their bronze faces visible (Fig. 72).
19. Install the two (2) alignment pins and install a new center section gasket onto the housing (Fig. 74). Figure 74 20. Install center section with valve plates onto trans mission housing (Fig. 75). IMPORTANT: Make sure all parts are properly aligned. Do not force center section into position on the housing. NOTE: When the center section is properly installed, the cylinder block springs will hold the end center section away from the housing approximately 1/8 in. Figure 75 21.
Mowing Circuit Repairs Valve Block Service Diagrams to identify function of hydraulic lines and cartridges at each port location.) 1. Before removing any parts from the valve block, park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove key from ignition switch. 3. If necessary, valve block can be removed: A. Disconnect solenoid electrical connecters. 2. Raise seat and secure with prop rod to get access to valve block. B.
Cartridge Valve Service 1. Clean valve block to prevent contamination when valve cartridge is removed. Cartridge Installation 1. Lubricate all o-rings with clean hydraulic oil. 2. Remove the cartridge valve from its port: 2. Carefully thread cartridge into the port by hand. Valve cartridge should go in easily without binding. A. Remove nut from solenoid. B. Remove solenoid coil and O-ring at each end of solenoid coil. C. Use a deep socket to remove solenoid cartridge valve.
Cartridge Valve Identification NOTE: When troubleshooting hydraulic problems, keep in mind that is possible for some cartridge valves to be installed in the wrong ports, causing the system to malfunction. Solenoid valves in valve block must not be interchanged between ports, with the following exceptions: S1 and S2 are the same design and can be inter changed (Fig. 79). Note poppet valve S3, S4 and S5 are the same design and can be interchanged (Fig. 80).
Relief valves in the valve block cannot be interchanged between ports R1 and R2 because they have different internal parts and pressure settings (Fig. 84). Flow control cartridges are the same and can be inter changed between ports VS1 and VS2 (Fig. 85). 2 Figure 84 Figure 85 Relief valves Flow control solenoid valves R1 – 3000 PSI R2 – 2000 PSI Reelmaster® 5100-D 1 1. VS1 2.
Pump Removal and Installation Removal 1. Park machine on a level surface, lower cutting units, engage parking brake and stop the engine. Remove key from ignition switch. 2. Raise seat and secure with prop rod to get access to pump (Fig. 91, 92). 1 3. Drain the hydraulic reservoir. 4. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump and fittings. 5. Disconnect hydraulic lines from pump and put caps or plugs on open hydraulic lines and fittings.
Pump Repair Figure 93 1. Gear plate (2) 2. Dowel pin (2) 3. Cap screw (4) 4. Washer (4) 5. Cover assembly 6. Seal ring (6) 7. Gear plate 8. Retaining ring (2) 9. Gear 10. Woodruff key 11. Drive shaft 12. Idler shaft assembly 13. Dowel pin (2) 14. Coupling (2) 15. Plate assembly 16. High press. load seal (4) 17. Pre-load high press. load seal (4) 18. Load plate (4) 19. Idler shaft (2) 20. Drive gear Relief Valve Service 1. Remove cap (Fig. 93, Item 30).
3. Secure the flange end of the pump (Fig. 88, Item 23) in a vise with the drive shaft (Item 24) pointing down. cover or plate assemblies as necessary. The bushings are not serviceable. 4. Remove the four (4) capscrews (Item 3) and washers (Item 4). 10. Replace load plates if excessively worn or scored. Replace gears in sets if scored or worn excessively. 5. Put your hand on the pump case and gently tap the pump case with a soft face hammer to loosen the pump sections.
Reel Motor Removal and Installation 1. Disconnect hydraulic lines. Put caps or plugs on fittings and hoses to prevent contamination. Tag hydrau lic lines for proper reassembly. 2. Loosen motor mount nuts (Fig. 94). 3. Rotate motor clockwise so motor flanges clear studs and pull motor out. 2 4. Reverse steps 1 - 3 to reinstall motor. 1 Figure 94 1. Motor Reelmaster® 5100-D Page 4 - 61 2.
Reel Motor Shaft Seal Replacement 1. Remove reel motor (see Reel Motor Removal and Installation). 2. Plug ports and wash exterior of motor with cleaning solvent. Make sure parts and work area are clean. 3. Remove snap ring from motor (Fig. 95). 4. Install threaded metal o-ring seal plugs in the two (2) pressure ports on the motor or put metal threaded caps on the fittings in these ports. 5.
Reel Motor Repair Figure 96 1. Socket head screw (2) 2. Washer (2) 3. Dowel pin (2) 4. Cover 5. Needle bearing 6. Idler gear assembly 7. Drive shaft assembly 8. Ring seal 9. Load plate assembly 10. Body 11. Spacer 12. Shaft seal 13. Retaining ring 1. Plug ports and wash exterior of motor with cleaning solvent. Make sure parts and work area are clean. IMPORTANT: Extreme caution must be used when using a vise to avoid distorting any parts. 2.
12. Apply hydraulic oil to inside of cover and assemble the cover to the body, making sure none of the parts become displaced. Insert the capscrews and washers and hand tighten. 13. Before tightening the capscrews, rotate the drive shaft in the direction of normal rotation (counterclock wise) to check for binding. You may not be able to rotate the drive shaft by hand. Protect the shaft if using a pliers. 14. Tighten the capscrews evenly in a crossing pattern to a torque of 17 ft-lb. 15.
Lift Cylinder Repair Figure 98 1. Barrel 2. Nut 3. Uni-ring seal 4. Piston 5. 6. 7. 8. O-ring seal Rod seal O-ring seal Back-up ring 9. Head 10. Dust seal 11. Retaining ring 12. Rod IMPORTANT: To prevent damage when clamping the cylinder barrel in a vise, clamp only on the pivot end. Do not clamp the vise jaws against the smooth shaft surface. Protect the shaft surface before mounting in the vise. 1.
Figure 100 1. Barrel 2. Nut 3. Uni-ring seal 4. Piston 5. O-ring seal 6. Rod seal 7. O-ring seal 8. Back-up ring 9. Head 10. Dust seal 11. Retaining ring 12. Rod 5. Grasp the clevis end of the shaft and use a twisting and pulling motion to carefully extract the piston, shaft, and head from the barrel. A.Soak the seal rings in hot water. The hot water will soften the rings allowing then to stretch over the piston. 6.
Flushing The Hydraulic System IMPORTANT: Drain and refill reservoir, change oil filter and flush hydraulic system if component fail ure was severe or system is contaminated (oil ap pears milky or black or contains metal particles. 1. Lower cutting units, stop engine, engage parking brake and remove key from ignition switch. 14. Shut off engine and check for hydraulic oil leaks. Check oil level in hydraulic reservoir and add correct oil if necessary. 15.
Inspecting Reservoir Parts 1. Clean filler screen, suction screen and reservoir with clean solvent (Fig. 103). 6 7 2. Inspect reservoir for leaks, cracks or other damage. 1 5 3. Replace hoses or fittings if worn or leaking. 4. Replace breather with new part. 3 4 2 8 9 10 Tighten mounting cap screws to a torque of 30 to 60 in-lb. Figure 103 1. 2. 3. 4. 5. Mowing Circuit Repairs Filler screen Suction strainer Reservoir Drain plug Breather Page 4 - 68 Rev. A 6. Cap 7. Dipstick 8. Grommet (3) 9.
Chapter 5 Electrical System Table of Contents WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . 3 LOGIC CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 7 Quick Reference Troubleshooting Guide . . . . . . 7 Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . 9 General Run and Transport Problems. . . . . . . . .
Logic Chart Page 5 - 2 Reelmaster ® 5100-D
Wiring Schematic Reelmaster® 5100-D (S/N Below 51001) Page 5 - 3 Rev.
Reelmaster 5100–D Page 5 – 3.1 Rev.
Wiring Schematic Page 5 – 3.2 Rev.
Reelmaster 5100–D ELECTRIC SOLENOID VALVE BLK RED BLK/Y RED/Y Page 5 – 4 Rev. B LEAK DETECTOR ALARM C C B E E B A A TURF DEFENDER LOOPBACK I.D.
Special Tools NOTE: Special tools may be ordered from: Owatonna Tool Co. 2013 4th Street, NW Owatonna, MN 55060 Some tools may bebe listed in the Reelmaster 5100-D Parts Catalog or sold under Toro Model Numbers. Some tools may also be available from a local supplier. Digital Multimeter The meter can test electrical components and circuits for current, resistance, or voltage drop. NOTE: Toro recommends the use of a DIGITAL mutli meter when testing electrical circuits.
Diagnostic ACE Display The diagnostic display (Fig. 4) is connected to the wiring harness connector near the electronic control unit (ECU) to help the user verfiy correct electrical functions 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.
Troubleshooting For all electrical problems, the use of the quick refer ence troubleshooting method is recommended. Using the Diagnostic ACE TM Display allows you to quickly find the source of the electrical problem. For intermittent electrical problems, which are not repeatable, use of the Data Log System is recom mended. The data log system records the actual state of machine inputs and outputs at the time of malfunction. Your Toro Distributor can then isolate the cause of the electrical problem.
6. The diagnostic display will illuminate the LED asso ciated with each of the inputs when that input switch is closed. Check each switch (input) by opening and clos ing switch, then verifying that corresponding LED goes on and off as switch position is changed. For example, with traction pedal in neutral, “TR. NEUTRAL” LED should be on, then go off, when traction pedal is moved out of neutral. Check function for each switch that can be changed manually. 7.
Retrieving Stored Faults Clearing Fault Memory NOTE: The machine may require installaton of updated software for this function to operate. This required software was installed on machines starting with S/N 70001. Older machines can have new software installed. Contact your Toro Distributor for assistance. 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.
TurfDefender Leak Detector The TurfDefendert 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 TurfDefender’s internal microprocessor analyzes the float movement and determines if there is a leak in the system.
2. When toggling “output” a LED should display (Fig. 8d) any of the following problems diagnosed by the TurfDefender: D Valve open circuit (LED blinking): Check / replace TurfDefender electric solenoid valve or wires. D Valve short circuit (LED blinking): Check / replace TurfDefender electric solenoid valve or wires. D Self diagnostic LED Blinking: Internal circuit failure in TurfDefender. Consult your Authorized Toro Distributor for assistance.
1 Diagnostic ACE Display Functions 1. 2. 3. 4. 2 3 Overlay decal (English shown) “Inputs Displayed” LED (Red) “Outputs Displayed” LED (Green) Toggle button 4 Figure 8b Using “Inputs Displayed” (Red Text) 1 2 1. 2. 3. 4. 5. LED lit if oil level is too high LED lit if oil level is OK LED lit if oil level is too low LED lit if oil is too hot LED lit if system air leak has been detected 6. One or two LED’s lit displaying relative position of the Turfdefender’s internal float. 7.
Starting Problems Condition Possible Cause Correction _________________________________________________________________________________________ __ All electrical is dead, including gauges. Low battery charge. Charge battery. Replace battery if it will not hold a charge. Thermal circuit breaker No. 1 open. Find cause for open circuit breaker and correct. Circuit breaker will reset automatically after has cooled. 5A key switch fuse open. Check fuse and replace if fuse is open.
Condition Possible Cause Correction __ ________________________________________________________________________________________ Nothing happens when start attempt is made (control panel lights and gauges DO operate with ignition key switch in ON position). Faulty ignition (key) switch or wiring. Test switch and replace if faulty. Correct wiring problem if necessary. Traction neutral switch circuit open. Check traction control linkage and adjust or repair.
General Run and Transport Problems Condition Possible Cause Correction _________________________________________________________________________________________ __ Engine continues to run, but should not, when ignition key is turned off. Engine fuel lever or run solenoid stuck in “on” position. Check operation of run solenoid and adjust or replace if necessary. Make sure fuel stop lever moves without sticking and repair if necessary. Ignition switch faulty. Replace ignition switch.
Condition Possible Cause Correction __ ________________________________________________________________________________________ Engine kills when traction pedal is depressed. Seat lifting off seat switch. Instruct operator to sit back in seat during operation. Check seat plate hinges and seat support pin and repair if faulty. Seat switch circuit open. Test seat switch and replace if faulty. Check seat switch wiring and repair if faulty.
Condition Possible Cause Correction _________________________________________________________________________________________ __ Cutting units run, but should not, when raised and do not shut off with Enable/Disable switch. Both the front reels down sensor and enable switch circuits are closed. Check front reels down sensor and enable switch and replace if necessary. Check wiring to both switches and repair if necessary. Hydraulic problem. See Troubleshooting section of Chapter 4 - Hydraulic System.
Condition Possible Cause Correction __ ________________________________________________________________________________________ Front cutting units do not operate in either direction (raise and lower function OK). Problem with solenoid S1. Test solenoid S1 and replace if faulty. Check wiring to S1 solenoid and repair if faulty. Problem with S7 solenoid. Check wiring to S7 solenoid and repair if faulty. Hydraulic problem. See Troubleshooting section of Chapter 4 - Hydraulic System.
Condition Possible Cause Correction _________________________________________________________________________________________ __ No cutting units lower. Lower - Mow switch circuit is open. Check for faulty Lower-Mow switch (joystick). Check Lower-Mow switch wiring and repair if faulty. Problem with solenoid S6. 5A SOL S3/S6 fuse open. If fuses burn out often, find and correct cause. Faulty S6 solenoid coil. Check S6 solenoid wiring and repair if faulty. Hydraulic problem.
Condition Possible Cause Correction __ ________________________________________________________________________________________ Rear (No. 2 and 3) cutting units will not raise/lower, but other cutting units raise and lower OK. Problem with solenoid S5. Test solenoid S5 and replace if faulty. Check wiring to solenoid S5 and repair if necessary. Hydraulic problem. See Troubleshooting section of Chapter 4 - Hydraulic System.
Verify Interlock System Operation The purpose of the interlock system is to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL the Enable/Disable switch is in DISABLE and the Lower-Mow/Raise control is in the neutral position. Also, the engine will stop when the traction pedal is depressed with the operator off the seat. CAUTION The interlock switches are for the operator’s protection, so do not disconnect them.
Testing Testing of the electrical system has been greatly simpli fied by use of the ACE TM Diagnostic Display, Data Log system and ToroPC software. Before testing or replac ing any electrical components, it is recommended that you verify electrical performance of the part(s) in ques tion by using the above mentioned tools (see Trou bleshooting section of this chapter).
Electronic Control Unit (ECU) The Toro electronic control unit (ECU) senses the con dition of various switches, such as the seat switch, cutting unit down switches, traction neutral switch, etc., and directs power output to allow certain machine func tions, such as engine run, cutting units engage, etc. 1 Because of the solid state circuitry built into the control ler, there is no method to test it directly.
Traction (Neutral) Switch The traction switch is a normally closed and opens when traction pedal is depressed in either direction. The switch is located on the right side of the hydrostatic transmission. 1 IMPORTANT: The traction switch has three (3) ter minals. Make sure the wires are connected to the “COMMON” and “NO” terminals. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two terminals that had wires connected to them.
Lower-Mow/Raise Switches (Joystick) The Lower-Mow/Raise Control has two (2) normally open (NO) switches, one for the Lower-Mow function and one for the Raise function. Each switch is normally open and closes when the joystick is moved (Fig. 15). Test each switch by disconnecting the wiring connector from the switch and connecting a continuity tester across the two terminals of the switch being tested.
Backlap Switch The Backlap switch is a three-way switch (Fig. 17). Test the switch by disconnecting the wires and connecting a continuity tester across terminals of switch. 3 With the switch OFF, the tester should show no continu ity across terminals 4 – 5 or 5 – 6. 2 1 With the switch in the FRONT position (toward keyway), tester should show continuity across terminals 4 and 5. With the switch in the REAR position (away from key way), tester should show continuity across terminals 5 and 6.
RED To test the glow relay (Fig. 17), disconnect the relay wire connector and install a continuity tester between the relay terminals (terminals 30 and 87) (Fig. 19). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is connected and disconnected to terminal 85 with terminal 86 connected to ground. RED/WHITE Glow Relay 85 86 30 ORANGE 87 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.
Fuel Stop (ETR) Solenoid The Reelmaster® 5100-D has an energize-to-run (ETR) fuel stop solenoid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1. Disconnect the wire connector and remove the fuel stop solenoid from the engine (Fig. 21). 1 3 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to terminals A (hold) and B (pull) (Fig. 22). Connect the negative (–) battery terminal to solenoid terminal C (common).
Indicator Lights and Gauges Diagnostic Lamp Amp Light The diagnostic lamp should come on when the ignition key switch is turned to the RUN position. If the lamp is ON, it indicates that the electronic control unit (ECU) is functioning normally. If this lamp is OFF, it indicates a lack of power to the ECU, or a disconnected loop-back connector. If this lamp is flashing ON and OFF, it indi cates an output fault.
High Temperature Shut-Down Switch 1. Lower the coolant leve l in the engine and remove the high temperature shut-down switch (Fig. 23). 2. Put the switch in a container of oi l with a thermometer and heat the oil (Fig. 24). 2 3. The switch is normally open (NO) and should close at 226 - 237o F (108 - 114o C). 1 CAUTION Handle hot oil with special care to prevent personal injury or fire. Figure 23 1. High temperature shut-down switch 2. Temperature gauge sender Figure 24 Temperature Gauge Sender 1.
Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If bulb is not on: 1. Disconnect wire from switch and touch wire to a good ground. 1 2. If lamp comes on, replace switch. 3. If lamp does not come on check wiring between lamp and switch for continuity. Figure 26 1. Engine oil pressure switch If lamp is on with engine running: 1. Shut off engine immediately. 2.
Hydraulic Valve Block Solenoids 1. Disconnect the wire connector. 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to colored solenoid lead. Connect the negative (–) battery terminal to black lead. The valve spool should retract completely as 12 V.D.C is applied between leads. 1 3. If valve spool does not retract check for binding or damage in valve. 4. If valve operates smoothly, but does not retract when 12 V.D.C is applied to solenoid leads, replace solenoid coil. 5.
Checking Starter Pinion Gap 1. Install 12 volt battery between the “S” terminal and the starter body (Fig. 29). The pinion should protrude and stop. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. 2. Lightly push the pinion back and measure the return stroke (called pinion gap). 3. If the pinion gap is not within standard range of 0.5 2.0 mm (0.02 - 0.08 in.), adjust it by increasing or decreasing the number of packings on the magnetic switch.
Magnetic Switch (Solenoid) Attraction Test 1. Disconnect the wire from terminal “M” (Fig. 31). 2. Connect a 12 volt battery to the magnetic switch terminals “S” and “M”. The pinion must protrude. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. Figure 31 Magnetic Switch (Solenoid) Holding Test 1. Disconnect the wire from terminal “M” (Fig. 32). 2. Connect a 12 volt battery to the magnetic switch terminal “S” and the starter body. Pull out the pinion fully.
Alternator Regulated Voltage Test 1. Install an ammeter between the positive (+) terminal of the battery and terminal “B” of the alternator (Fig. 34). 2. Ground alternator terminal “L” through a voltmeter. 3. Note that the voltmeter shows 0 volts when the ignition key switch is in the OFF position. The voltmeter will show voltage lower than battery voltage when the ignition key switch is in the ON position (engine not running). 4. Start the engine. 5.
Repairs IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery, dis connect both wire harness plugs from the electronic control unit and disconnect the terminal connector from the alternator to prevent damage to the electri cal system. Battery Service IMPORTANT: To prevent damage to the electrical components, do not operate the engine with the battery cables disconnected. Electrolyte Specific Gravity Keep the terminals and entire battery case clean.
Fuses The electrical system is protected by fuses located under the control panel to the operator’s right (Fig. 38). NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continutiy tester, not visually. 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.
Traction (Neutral) Switch Replacement 1. Remove the two wires that are connected to the traction switch (Fig. 39). 2. Have a helper push the traction pedal down into either the FORWARD or REVERSE position; this will take the switch arm tension off of the switch. Loosen two (2) screws and remove the switch. 1 3. Install new switch. DO NOT over-tighten screws as the switch case could break. NOTE: Have a helper hold the traction pedal down while installing the switch. 4.
Electronic Control Unit (ECU) Replacement IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery, dis connect both wire harness connectors from the ECU and disconnect the terminal connector from the alternator to prevent damage to the electrical system. 1. Stop the engine. 1 2 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). Figure 40 4. Remove ECU. 5.
Solenoid Valve Coil Replacement 1. Park machine on a level surface, engage parking brake, lower the cutting units and turn engine OFF. 1 2. Disconnect solenoid electrical connector. 3. Remove nut from solenoid. 4. Remove solenoid coil. 5. Install new solenoid coil and secure with nut. Apply “Locktite 242" or equivalent 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. Figure 41 6.
Starter Service Disassembly and Inspection 6. Remove the cover, pry the snap ring out and remove the washer. 1. Remove the starter from the engine (see Starter Removal and Installation in the External Engine Com ponent Repair section of Chapter 4 - Mitsubishi Diesel Engine). 2. Disconnect wire from magnetic switch terminal “M”. 3. Loose two screws securing the magnetic switch (Fig. 44). Remove the magnetic switch. 4. Remove two through bolts and screws securing the brush holder. Remove the rear bracket.
Break and short circuit Wear and chipping One-way mechanism Bear ing: Play, noise, and rough rotation Insulat ion Break and short circuit 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.
11. Put the armature on a growler tester to check for a shorted armature (Fig. 47). A burned commutator bar is an indication of a shorted armature. With the growler turned on, put a thin strip of steel or a hacksaw blade on the armature as it is slowly rotated. If the metal strip vibrates over a winding, that winding is short circuited. Short circuited windings are sometimes caused by met al in the commutator bridging the gap from on commu tator bar to the next.
Assembly and Adjustment of Starter 1. Reverse steps 1 - 10 under Disassembly and Inspec tion and also following the following instructions: Adjusting Washer Gear Washer 2. Set the pinion shaft end play (thrust gap) to 0.5 mm (0.02 in.) or less by inserting an adjusting washer be tween the center bracket and reduction gear (Fig. 50). A. Fit the pinion shaft, reduction gear washer and snap ring to the center bracket. B. Measure end play by moving the pinion shaft in and out. If end play exceeds 0.
Alternator Service 4. Put the rotor in a vise. Remove pulley nut and pull off the pulley and spacer. Disassembly and Inspection 1. Remove the alternator from the engine (see Alterna tor Removal and Installation in the External Engine Component Repair section of Chapter 4 - Mitsubishi Diesel Engine). 5. Pull the rotor assembly from the front bracket. 6. Unsolder the stator core lead wires. Remove the stator assembly. 2. Remove the three through bolts (Fig. 51). 3.
Deformation and damage Break and short circuit Wear and roughness Wear Crack and damage Break and short circuit Wear to limit line Figure 52 9. Check each diode in the rectifier for conduction (Fig. 53). Connect an ohm meter across the lead wire and diode case. 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.
11. Check for continuity between a slip ring and shaft (core) (Fig. 55). Replace the field coil if there is continuity. Figure 55 12. Check for continuity between lead wires of the stator coil (Fig. 56). Replace the stator coil if there is no continuity. Figure 56 13. Check for continuity between each lead wire and stator core (Fig. 57). Replace the stator coil if there is continuity.
Assembly of Alternator 1. Reverse steps 1 - 8 under Disassembly and Inspec tion and also following the following instructions: 2. The rear bearing has an eccentric groove. Install the snap ring so its projection fits in the deepest part of the groove. 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.
Speedometer Sensor Installation To install speedometer sensor: 1. If axle cover plate was not removed, go to step 9. 2. Lubricate and install O-ring into plate. 3. Apply silicone sealant to face of plate where it will contact cover. 1 4. Install plate to inside face of cover, then install cap screw and lockwasher through cover into plate. 5. Install machine screw throught plate and cover, then install locknut to machine screw. Figure 59A 6. Tighten capscrew and locknut to secure plate to cover. 7.
Reel Speed Sensor Installation Reel speed sensors are located on the left front and left rear cutting units. 1. Thread reel speed sensor into sensor holder until dimension shown in Figure 60 is attained. Lock adjust ment with two (2) jam nuts. 2. Align mounting holes and insert sensor and holder into hole in top of counterweight. 3. Secure sensor holder to counterweight with 1/4-20 x 3/4" capscrew. 4. Install magnet on end of reel shaft through opening in end of counterweight with a 3/8-16 x 1" capscrew.
Reel Speed Sensor Installation Reel speed sensors are located on the left front and left rear cutting units. 1. Install magnet on end of reel shaft through opening in end of counterweight. Install magnet so counterbore faces towards end of reel shaft and smooth side faces out. Tighten capscrew securing magnet to a maximum torque of 5 ft-lb. 1 IMPORTANT: Over tightening capscrew securing magnet will damage magnet and cause sensor to malfunction. 2. Install cap plug into end of counterweight. Figure 61 3.
Repairs Page 5 - 48 Rev.
Chapter 6 Differential Axle Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Removal and Installation . . . . . . . . . . . . . . . 1 2 2 3 3 Axle Shaft Disassembly and Wheel Bearing Service . . . . . . . . . . . . . . . . . 4 Differential and Housing Disassembly . .
Specifications Item Specification __________________________________________________________________________________________ Front wheel lug nut torque 45 to 55 ft-lb ________________________________________________________________________________________________________________________ ________________________________ Front to rear housing torque 18 to 28 ft-lb ________________________________________________________________________________________________________________________ _____________________
Repairs Axle Removal and Installation 1. Put machine on a level surface, lower cutting units, stop the engine and remove key from ignition switch. Block rear wheels to prevent machine from moving. 2. Remove the cutting units. (See the Repairs section of Chapter 8 - Cutting Units.) 3. If unit is equipped with 4WD, remove rear axle drive shaft (see Chapter 9 - 4WD Axle). Remove nut, pinion spacer and pinion coupler. 5. Remove hydrostatic transmission. (See Repairs section of Chapter 4 - Hydraulic System.
Axle Shaft Disassembly and Wheel Bearing Service NOTE: When servicing the bearing and seal area of the axle shaft, it is recommended that you replace hex head screws and flange nuts with socket head screws (94 6934), washers (94-6936) and nuts (94-6935). See Figure 18. 1. After the wheel has been removed, slide the brake drum off of the axle flange (Fig. 5). NOTE: It may be necessary to loosen the brake shoes by turning the star wheel inside the brake drum assemb ly. (See Chapter 7 - Steering and Brakes.
4. Remove the inner axle shaft seal (Fig. 8). Discard the seal and replace with a new one at the time of assembly. Figure 8 5. Center punch the outside of the retaining ring (Fig. 9). Figure 9 6. Drill a 1/4 inch hole (approximate) into the outside of the retainer ring to a depth of about 3/4 the thickness of the ring (Fig. 10). IMPORTANT: Drilling completely through the retainer ring could damage the shaft.
7. After drilling, put a chisel in position across the hole and strike sharply to break the ring. Replace with a new ring at time of reassembly (Fig. 11). WARNING Wear protective safety goggles when break ing the retaining ring. Personal injury could result from flying metal particles. Keep all personnel away during this procedure. Figure 11 8. Inspect the shaft for possible damage (Fig. 12). Inspect the sealing surface of the hub and shaft.
11. Slide a new retaining ring on the axle shaft and support the shaft and ring in a suitable press (Fig. 14). Press the retaining ring firmly against the bearing. Figure 14 12. Put a light coating of No. 1 Permatex on the outside diameter of a new grease seal (surface that contacts the axle housing). 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.
13. Assemble the bearing retainer bolts to the axle housing. Apply a .0625 in. (16 mm) bead of gasket material to flange on end of axle housing, then install the axle shaft assembly into the axle housing. Be careful not to damage the, oil seal and bearing. Line up the holes of the brake assembly and oil seal. Push the axle shaft as far as possible into the axle housing (Fig. 17). Wheel end gasket material: Make sure surface is flat. File off any high spots.
2. Remove the four bearing cap screws and remove the caps. Place the caps in a safe place to avoid damaging their machined surfaces (Fig. 20). The bearing caps are marked for identification. The letters or numbers are in horizontal and vertical posi tions. When reassembling, place them back in the same position. Figure 20 3. To remove the differential assembly, place two wooden devices (i.e. hammer handles) under the dif ferential case and pry firmly upward.
5. Do not remove the bearings from the differential case unless bearing failure is evident. It is recommended that whenever bearings are removed (regardless of usage) they must be replaced with new ones. Remove the case side bearing with a puller as shown (Fig. 23). Figure 23 6. Put the case in a vise. Drive the lock pin out of the pinion shaft (Fig. 24). Use a small drift punch as shown.
8. To remove the side gears and pinion mate gears, rotate the side gears. This will allow the pinion mate gears to turn to the opening of the case (Fig. 26). Remove the pinion mate gears and the spherical washers behind the gears. Figure 26 9. Remove 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.
11. Before pressing pinion out of housing: If unit was equipped with an expansion plug (removed in step 10), remove the snap ring and shim from the end of the pinion (Fig. 29). If unit is equipped with a pinion coupler for 4WD (no expansion plug), nut, pinion spacer and pinion coupler (Fig. 3) must be removed before pressing pinion out of housing. Figure 29 12. Position the housing assembly on a suitable press. Place a 1/8 inch (3 mm) piece of steel or a screwdriver blade under the edge of the spur gear.
13. Clamp the inner pinion bearing with a universal bearing remover (Fig. 32). Position the unit in a press and carefully push the drive pinion out of the bearing. DO NOT allow the pinion to drop on the floor - damage will result. Figure 32 14. To remove the outer pinion bearing cup, position the housing in a press. Place a press plate of the proper size against the cup. Press the cup out of the housing (Fig. 33). Figure 33 15.
Differential and Housing Reassembly 1. Inspect the differential parts for damage before assembling. A. If any bearings are damaged they must be replaced with new ones. B. Check the ring, pinion, and spur gear for abnormal wear and damage; replace worn components. C. Inspect the housings for cracks and external damage that could affect the operation of the axle assembly. D. Inspect the differential case for wear in the side gear and pinion mate area.
Ring and Pinion Set Rings gears and pinions are supplied in matched sets only. Matching numbers are etched on both the pinion and ring gear (Fig. 37). The mounting distance from the bottom of the differen tial bearing bores to the button end of the pinion is 1.210 in. On the button end of each pinion there is a plus (+) or minus (–) number, or a (0) number. This number indi cates the best running position for each particular gear set.
4. Install a new inner bearing cup using a press plate of proper diameter. Reuse the original shims or use new shims of the same thickness. Push the bearing cup into the housing until it bottoms against the housing (Fig. 38). Figure 38 5. Insert the pinion into the housing. NOTE: A number marked on the new ring and pinion set is used to establish the proper amount of shims required prior to installing the pinion gear (see page 15).
7. Support the drive pinion in a suitable press (Fig. 41). Figure 41 8. Install the outer pinion spacer with the chamfer towards the pinion splines and install the new outer pinion bearing cone (Fig. 42). Figure 42 9. With a hollow press sleeve of proper diameter, press on the outer bearing cone race until the drive pinion seats in the carrier and a slight drag is noticed when the gear is rotated by hand (2-13 in.-lb. torque to rotate) (Fig. 43).
10. Install the shim and snap ring onto the end of the pinion shaft. Use the thickest shim possible which will permit installation of the snap ring (Fig. 44). Limit the end play to 0.000 - 0.005 inch (0.000 - 0.127 mm). Figure 44 11. Apply a small 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.
13. Place the differential case in a vise as shown (Fig. 47). Apply grease to new side gear thrust washers and hubs of the side gears. Apply grease to new pinion mate spherical washers and pinion mate gears. Place the side gears and thrust washers in the case. Install the pinion gears while holding the side gears in place. Rotate the side gears until the holes of the washers and pinion gears line up with the holes of the case.
16. Put the ring gear onto the differential case and start the new capscrews into the gear with your fingers. Tighten the screws, alternating back and forth across the gear to allow the gear to be pulled evenly into place. Tighten the cap screws to a torque of 45 - 65 ft-lb (6.2 9.0 KgM) (Fig. 50). Figure 50 17. When installing new differential bearings, reuse the original shims or use new shims of the same thickness. Press the bearing onto the differential case.
19. Using a dial indicator, check the ring gear backlash in three equally spaced points. Ring gear backlash should be .003 - .007 inch (.076 - .178 mm) and must not vary more than .002 in. between points checked (Fig. 53). If the backlash is not in this range, move the shims which are located beneath the differential bearings, from one side to the other until the correct backlash is attained.
Drive Side Heel Toe Coast Side Heel Toe Backlash correct. Thicker pinion position shims required. Figure 55 Drive Side Heel Toe Coast Side Heel Toe Backlash correct. Thinner pinion position shims required. Figure 56 Drive Side Heel Toe Coast Side Heel Toe Backlash incorrect. Thinner pinion position shim re quired. Adjust backlash to match. Figure 57 Repairs Page 6 - 22 Rev.
Gear Pattern Movements Summary 1. Decreasing backlash moves the ring gear closer to the pinion. Drive pattern (convex side of gear) moves lower and toward the toe. Coast pattern (concave side of gear) moves slightly higher and toward the heel. 2. Increasing backlash moves the ring gear away from the pinion. Drive pattern moves higher and toward the heel. Coast pattern moves slightely lower and toward the toe. 3.
Repairs Page 6 - 24 Reelmaster® 5100-D
Chapter 7 Steering And Brakes Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Valve and Pump Tests . . . . . . . . . . . .
Introduction Power Steering The power steering valve is enclosed in the steering tower at the front of the traction unit. As the steering wheel is turned, the steering valve meters hydraulic fluid to the double-acting steering cylinder on the rear axle and turns the wheels. Hydraulic fluid flow for power steering is supplied by the front section of auxiliary hydraulic pump. The steering section of the pump has a built-in relief valve. The Model HGF Hydraguide TM steering valve (Fig.
Power Steering Schematics FROM PUMP STEERING VALVE When the steering wheel is turned to the right (Fig. 3), the control valve within the steering valve shifts to close the “AUX” port. This directs oil supplied by the steering pump to the metering section of the steering valve. As the steering wheel is turned, system oil is metered out port “RT” to the steering cylinder.
Specifications Item Specification __ ________________________________________________________________________________________ Front wheel lug nut torque 45 to 55 ft-lb ________________________________________________________________________________________________________________________________________________________ Rear wheel lug nut torque 30 to 35 ft-lb _________________________________________________________________________________________________________________________________________________
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.
Problem Possible Causes __ ________________________________________________________________________________________ Steering Wheel Lash (Free Movement) Steering wheel loose on column. Steering linkage loose or worn. Steering valve loose at mounting. Air in hydraulic system. Internal leakage in hydraulic cylinder.
Testing Steering Valve and Pump Tests 1. Make sure the hydraulic oil is at normal operating temperautre by operating the machine for approxi mately 5 minutes. 2. Engage the parking brakes, lower the cutting units to the floor and turn the engine OFF. 3. Remove the cover from the steering tower. 4. Place a drain pan under the steering valve. Discon nect the hydraulic hose at the AUX port of the steering valve (Fig. 7a). 11. If flow is lower than 3.
Steering Cylinder Internal Leakage Test 1. Engage the parking brake, and lower the cutting units to the floor. 2. Turn the steering wheel all the way to the left (coun terclockwise) so the steering cylinder rod is extended all the way. 1 3. Turn the engine OFF. 4. Disconnect the hydraulic hose from the fitting on the rod end of the cylinder (Fig. 8). Put a plug in the end of the hose to prevent contamination. 5.
Adjustments Rear Wheel Toe-in Adjustment The rear wheels should have 0 to 1/8 of an inch toe-in when they are pointed straight ahead. To check toe-in, measure the center-to-center distance, at axle height, in front and rear of steering tires. If toe-in is not within specifications, an adjustment is required. 1. Rotate the steering wheel so the rear wheels are straight ahead. 2. Loosen the jam nuts on both tie rods.
Brake Adjustment Adjust the service brakes when there is more that one inch of “free travel” of the brake pedals. Free travel is the distance the brake pedal moves before braking resistance is felt (Fig. 11). 1/2 to 1 in. free travel Adjust where brake cables connect to bottom of brake pedals. When cable is no longer adjustable, star nut on inside of the brake drum must be adjusted to move brake shoes outward. Brake pedals must be adjusted again after star nut is adjusted. 1.
Repairs Steering Wheel Removal and Installation Removing the Steering Wheel Remove the cover from the steering wheel hub. Re move the locknut that secures the steering wheel to the shaft (Fig. 15). Pull the steering wheel off the shaft. NOTE: It may be necessary to use a jaw-type puller to remove the steering wheel from the steering shaft. IMPORTANT: DO NOT hit the steering shaft with a hammer. This could damage the steering valve com ponents. Installing the Steering Wheel 1.
Rear Axle Bushing Service The rear axle must be held in place snugly by the axle pin. Excessive movement of the axle, which is charac terized by erratic steering, usually indicates worn bush ings. To correct the problem, replace the bushings. 1. Disconnect the hydraulic hoses from the steering cylinder. Put caps or plugs on all the fittings and hoses to prevent contamination. NOTE: To ease reassembly, tag each of the hoses to show their correct position on the steering cylinder. 2.
7. Connect the tie rod end to the spindle bracket with one (1) nut. Tighten the nut to a torque of 25 - 33 ft-lb. Install the jam nut and tighten against the other nut to secure tie rod end. 8. Install the lock nut and cap screw to secure the steering cylinder rod end to the steering pivot. Tighten the nut to 130 to 150 ft-lb. 9. Lubricate the bushings through the grease fitting on the steering pivot. 3 6 5 4 1 2 13 12 7 11 9 10 8 Figure 16 1. 2. 3. 4. 5.
Rear Wheel Spindle Bushing Service The rear wheel spindles must fit snugly in the rear axle. Excessive movement of the spindle in the axle indicates that the bushings are probably worn and must be re placed. 1. Disconnect the hydraulic hoses from the steering cylinder. Put caps or plugs on the fittings and hoses to prevent contamination. NOTE: To ease reassembly, tag each of the hoses to show their correct position on the steering cylinder. 2.
3 7 8 9 4 10 11 1 2 6 5 Figure 17 1. 2. 3. 4. Rear axle Steering cylinder Capscrew Rear axle pin 5. 6. 7. 8. Tie rod Wheel spindle Snap ring Shim washer 9. Thrust washer 10. Bushing 11. Thrust washer Front Wheel Bearing Service See Axle Shaft Disassembly and Wheel Bearing Serv ice in the Repairs section of Chapter 6 - Differential.
Rear Wheel Bearing Service Disassemble, clean, repack and adjust the rear wheel bearings after each 500 hours of operation or once a year. Use No. 2 general purpose lithium base grease containing E.P. additive. If operating conditions are ex tremely dusty and dirty, it may be necessary to perform this maintenance more often. wear, pitting or other noticeable damage. Replace worn or damaged parts. 1. Jack up the rear of the machine until the tire is off the floor.
Adjusting Rear Wheel Bearings 1. Remove dust cap from end of wheel spindle. Also remove cotter pin retaining slotted nut in place (Fig. 18). 2. Rotate the wheel by hand and tighten the slotted nut (Fig. 19) until the bearing binds SLIGHTLY. Then, loosen the nut until the nearest slot and hole in the spindle line up. Reinstall the cotter pin to retain the slotted nut in place. NOTE: The correct end play of the adjusted assembly is .002 -. 005 inches. 1 3.
Steering Cylinder Removal and Installation 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 2. Disconnect the hydraulic hoses from the steering cylinder. Put caps or plugs on all the fittings and hoses to prevent contamination. 2 2 NOTE: To ease reassembly, tag each of the hoses to show their correct position on the steering cylinder. 3.
Steering Cylinder Service IMPORTANT: To prevent damage to rod or barrel, clamp vise on pivot ends only. DO NOT clamp against smooth rod surface. 1. After removing the cylinder, pump oil out of cylinder into a drain pan by SLOWLY moving piston in and out of cylinder bore. 2. Plug the ports and clean the outside of the cylinder. 3. Mount cylinder in a vise so rod end of cylinder is tilted up slightly. Do not close the vise so firmly that the cylinder barrel could become distorted. 4.
Brake Shoe Replacement CAUTION CAUTION Wear a face shield when removing brake re turn spring (Fig. 22). The spring is under ten sion and could possibly slip during removal. The brake linings contain asbestos fibers. Breathing dust containing asbestos fibers may be hazardous to your health and may cause serious respiratory or other bodily harm.
Steering Valve Removal and Installation 1. Engage the parking brakes, lower the cutting units to the ground, turn the engine OFF and remove the key from the ignition switch. 4 3 2. Remove the front center cutting unit (see Repairs section of Chapter 8 - Cutting Units). 3. Remove cap screws from steering tower cover and remove the cover from steering tower. 4. Clean outside of the steering valve and the area around the hydraulic fittings. Disconnect hydraulic hoses from steering valve (Fig. 23).
Steering Valve Service Before Disassembly When disassembling any of the parts, use a clean work bench. Wash all parts in solvent and dry them with compressed air. DO NOT wipe them dry with a cloth of paper as lint and dirt may remain. Keep each part separate to prevent nicks and burrs. Components of the steering valve are stacked on four bolts and held in alignment with alignment pins. The alignment pins are designed to be a slip fit into the components.
Disassembly of Steering Valve 1. To avoid distorting or damaging the steering valve, do not clamp it directly into a vise. Clamp a service assem bly fixture securely in a vise (Fig. 25). Put the steering valve, input shaft first, into the service assembly fixture. Attache the steering valve to the fixture with four (4) 5/16-24 UNF nuts (Fig. 26).
4. Grasp the port cover assembly (four plates bonded together) and lift it from the unit. Remove and discard the four o-rings and seal ring (Fig. 29). Figure 29 5. Remove the loosened plug and o-ring assembly from the port cover. Be ready to catch the steel check ball as it falls from its cavity (Fig. 30). Discard the o-ring. 6. Inspect the port cover for port fitting sealing surface scratches and thread damage. Replace the port cover if it is damaged.
11. Remove the valve ring (Fig. 32). Remove and dis card the two seal rings (Fig. 33). The valve ring should be free of nicks and scoring. Figure 32 Figure 33 12. Remove the valve plate by lifting it from the isolation manifold (Fig. 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.
14. Remove three springs from the isolation manifold pockets (Fig. 35). NOTE: The unit has two different length spring sets. the set you have just removed from the isolation manifold is 1/2 in. (13 mm) long. Keep this spring set separate from the set removed from the port manifold. Figure 35 15. Inspect the springs for bent or distorted coils. If a spring is broken or deformed, all six springs in the unit must be replaced (Fig. 36). Figure 36 16. Remove the hex drive assembly from the drive link (Fig.
18. Remove the two alignment pins that align the port manifold, valve ring and isolation manifold (Fig. 38). Figure 38 19. Remove the isolation manifold (four plates bonded together) (Fig. 39). 20. Inspect the ground surfaces of the isolation mani fold. You should notice a “normal” polished pattern due 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.
22. Remove the drive link from the unit (Fig. 41). 23. Inspect each end of the drive link. the four crowned contact surfaces should not be worn or scored. Replace if wear or scoring is evident. Figure 41 24. Remove the metering ring and discard the two seal rings (Fig. 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.
26. Remove and discard the commutator seal from the commutator cover (Fig. 44). Figure 44 27. Remove the eleven hex socket head screws, that hold the metering package together (Fig. 45). Use a 3/32 in. allen wrench. Inspect the screws for thread and socket damage and replace as necessary. Figure 45 28. Lift the commutator cover from the metering pack age (Fig. 46). 29. Inspect the ground surfaces of the commutator cover.
30. Remove the commutator ring (Fig. 47). Inspect for cracks, burrs and scoring. IMPORTANT: Handle the commutator ring with care, as it is easily broken. Figure 47 31. Remove the commutator from the rotor (Fig. 48). IMPORTANT: To prevent damage, DO NOT use a screwdriver to remove the commutator. Use a wood dowel if necessary. 32. The commutator is made up of two round plates, pinned and bonded together as a permanent assembly that cannot be disassembled. Inspect the ground sur faces of the commutator.
34. Remove the drive link spacer (Fig. 50). Replace it if it grooved or worn. 35. With the rotor set lying on the drive plate, the rotor should rotate and orbit freely within the stator. The commutator side of the stator face must be free of grooves or scoring. NOTE: the rotor and stator are a matched set. You must replace them as a matched set, if either is worn or damaged. Figure 50 36. Check the rotor lobe “tip” to stator lobe “tip” clear ance, with a feeler gauge (Fig. 51).
39. Inspect the thrust bearing side of the drive plate (Fig. 53) for brinelling (dents) or spalling (flaking). The flat sides of the input shaft engagement hole should not be grooved or worn. If any of these conditions in steps 38 and 39 are present, the drive plate must be replaced. Figure 53 40.Remove the face seal, 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.
43. Remove the upper cover plate (four plates bonded together) (Fig. 56). Inspect the upper cover plate. You should notice some polishing due to the action of the seal. The plate should be free of brinelling (dents) or spalling (flaking). If it is damaged, the upper cover plate must be replaced. 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.
47. Remove the washer and upper cover & jacket (Fig. 59). NOTE: The retaining plate and upper cover & jacket are a matched set. If either part is worn or damaged, both must be replaced. Figure 59 48. Inspect the bushing at the top of the cover & jacket for wear or damage. 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.
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.
Assembly of Steering Valve Replace all seals and o-rings with new ones. Make sure the seals and o-rings remain seated correctly when components are assembled. Before assembling the steering valve, wash all parts in clean solvent. Dry the parts with compressed air. DO NOT wipe them dry with a cloth or paper as lint and dirt may remain. 1. Put the four bolts into the fixture with the shortest threaded end of the bolts through the fixture holes (Fig. 63).
3. Put the upper cover and jacket on the four bolts with the jacket tube pointing down through the hole in fixture (Fig. 66). Make sure the square shoulder of the bolts engage the square holes in the upper cover. 4. Apply a small amount of multi-purpose grease to the recessed face of the retainer plate and washer. Put the retainer plate into the upper cover & jacket with the recessed retainer face out. Put the washer against the recessed face of the retainer plate. Figure 66 5.
8. Apply clean multi-purpose grease to the face of the upper cover plate, input shaft and face seal (Fig. 70). Figure 70 9. Assemble the seal back-up ring and face seal onto the seal spacer (Fig. 71). Figure 71 10. Install the face seal, back-up ring and spacer assem bly over the end of the input shaft and onto the upper cover plate (Fig. 72).
11. Put the drive plate on a clean lint-free surface with the eleven tapped holes facing up. Put the rotor set on top of the drive plate with the five pin holes facing up. Rotate the stator until the eleven hex socket head screw relief slots are aligned with the tapped holes in the drive plate (Fig. 73). Figure 73 12. Apply a small amount of clean multi-purpose grease to the spacer and insert it into the drive slot in the rotor (Fig. 74).
14. Align the five holes and press the five alignment pins in place (Fig. 76). IMPORTANT: Make sure the five alignment pins are pressed below the surface of the commutator. Figure 76 15. Put a few drops of oil into each recess in the commutator (Fig. 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.
17. Put the commutator cover on top of the commutator ring with the flat surface towards the commutator (Fig. 79). Align the screw holes in the cover, with the screw holes in the drive plate. Figure 79 18. Screw the eleven hex socket head cap screws loosely into the metering package (Fig. 80). NOTE: The commutator ring must be concentric with the drive plate within 0.005 in. (0.127 mm) total indicator reading AFTER tightening the eleven hex socket head cap screws.
20. Put another piece of the 0.007 in. (0.18 mm) shim stock between the drive plate and each of the three pieces of shim stock already in place. Lift the metering ring and metering package and remove the wood block. Push the metering package and shims into the metering ring until the drive plate and shims are at least flush with the metering ring (Fig. 82). Figure 82 21. Reverse the metering ring and metering package as a unit on a flat surface.
22. Insert the LARGE tang of the drive link into the slot in the rotor (Fig. 85). IMPORTANT: An incorrect (reversed) assembly of the drive link will prevent the assembly of the hex drive. Figure 85 23. Grasp the drive link and rotate the metering package by hand to make sure the parts do not bind (Fig. 86). The rotor should orbit inside the stator. If they bind, disassemble the metering package, correct the cause and repeat the assembly and concentricity procedures. Figure 86 24.
25. Put the bearing spacer onto the face of the upper cover plate (Fig. 88). Figure 88 26. Lightly grease the roller thrust bearing and put it on the upper cover plate, inside the bearing spacer (Fig. 89). Figure 89 27. 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).
28. Put the metering package, drive plate side first, into the metering ring (Fig. 91). Revolve the input shaft or metering package until the hole in the drive plate en gages the end of the input shaft and the drive plate is seated on the thrust bearing. When properly seated, the metering package 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).
31. Put two alignment pins into the metering ring (Fig. 94). Figure 94 32. Stack the isolation manifold (4 plates bonded to gether) onto the metering ring, aligning the grooves on the side of the manifold with the grooves on the side of the upper cover plate (Fig. 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.
34. Put the three 1/2 in. (13 mm) springs into the spring pockets of the isolation manifold (Fig. 97). NOTE: Two different length springs are used in the unit. Be sure to use the 1/2 in. (13 mm) length springs during this part of the assembly. Figure 97 35. Apply clean grease to a seal ring and put it in the valve ring recess that will face down when installed. Install the valve ring over the bolts and alignment pins with the seal ring facing the isolation manifold (Fig. 98).
37. To install the valve plate correctly, first carefully study Figures 93 and 94 for positioning of the valve plate spring slots and other cavities in relation to the spring and spring recesses on the isolation manifold. Be sure to use the alignment grooves on the side of the isolation manifold for orientation. Put the valve plate with the surface that reads “shaft side” down over the hex drive assembly.
39. Put the port manifold (three plates bonded together), valve side up, in a clean surface. Install three 3/4 in. springs into the spring pockets (Fig. 103). Figure 103 40. Apply a few drops of oil to the valve plate. Align the grooves on the side of the port manifold with the grooves on the side of the isolation manifold and assemble the port manifold with the springs toward the valve plate (Fig. 104). Be careful not to pinch a spring during installation.
42. Apply clean multi-purpose grease to the four o-rings and seal ring. Put the new o-rings and seal ring into their proper location in the port cover (Fig. 106). Figure 106 43. Align a groove on the side of the port cover with the grooves on the side of the port manifold and put the port cover into position (Fig. 107).
44. Install the lock nuts onto the bolts. Tighten each nut gradually until resistance is felt (Fig. 108). Tighten to a torque of 20 - 24 ft-lb (27 - 33 Nm) in the sequence shown (Fig. 109). Figure 108 Figure 109 45. Tighten the plug to a torque of 8 - 12 ft-lb (11 - 16 Nm) (Fig. 110).
46. Apply a small amount of clean multi-purpose grease on the lip of the seal. Install the seal onto the jacket tube and input shaft (Fig. 111). 47. Make a final inspection of the relative groove posi tions on the side of the unit (Fig. 24). Components of the steering valve with alignment grooves, must be assem 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.
Chapter 8 Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . Factors That Can Affect Quality of Cut . . . . . . . SET UP AND ADJUSTMENTS. . . . . . . . . . . . . . . . Adjustment Summary and Check List . . . . . . . . Reel Bearing Service and Adjustment. . . . . . . . Bedknife To Reel Adjustment . . . . . . . . . . . . . .
Specifications Height of Cut: 5 Blade: 1/2 to 3/4 in. 8 Blade: 1/4 to 5/8 in. Bedknife To Reel Adjustment: Bedknife adjusts against reel, with opposed screw adjustment on each end of bedbar. Roller Adjustment: Front: Fixed Rear: Screw adjustable with bolt clamp lock 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.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reelmas ter Parts Catalog. Some tools may also be available from a local supplier. Plastic Plug Insert plug in cutting unit bearing housing in place of reel motor when sharpening or grinding the reel. Figure 2 Handle Assembly For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly.
Bedknife Screw Tool Fits Toro bedknife attaching screws. Use with torque wrench to secure bedknife to bedbar. With clean bedbar threads and new screws, tighten to a torque of 200 in-lb. NOTE: Remove all rust, scale and corrosion from bed bar surface before installing bedknife. DO NOT use an air impact wrench with this tool.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much of the grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are. See the Adjustments and Repairs sections for detailed ad justment and repair information.
Factor Possible Problem/Correction 7. Bedknife to reel contact. Check bedknife to reel contact daily and adjust as nec essary. Bedknife must have light contact all across reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected. Slightly dull cutting edges may be corrected by back lapping. Excessively dull cutting edges must be cor rected by grinding the reel and bedknife. 8. Front roller adjustment.
Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST. Study this infor mation and refer to it often to get maximum life and performance from the cutting units. Weekly Checks 1. Check reel bearing adjustment and bearing condition. 2. Make sure bed bar pivot bolts are securely seated (maximum 40 ft-lb.). Daily Performance Checks NOTE: It is not necessary to remove cutting units from traction unit to perform these daily checks.
Reel Bearing Service and Adjustment 1. Adjust the bedknife so it is not in contact with the reel. 2. Reel bearing drag should be 4 to 7 in-lb. This can be measured with a torque wrench (Fig. 5). If bearing drag does not meet above specification, adjust the reel bear ings. NOTE: If you do not have an inch-pound torque wrench, do steps 1 - 3 under Reel Bearing Adjustment below. Reel Bearing Adjustment 1. Remove mounting nuts from counterbalance end cap and remove end cap from the mounting studs (Fig. 6).
Bedknife To Reel Adjustment IMPORTANT: For adjusting bedknife to reel, use a 3/8 in. open end wrench that is 3 to 6 in. in length. A longer wrench will provide too much leverage and may cause distortion of the adjustment screw mounting plate or bedbar breakage. 1 1. To move bedbar closer to reel blades, loosen bottom screw on each side of cutting unit then tighten top adjustment screw on each side of cutting unit (Fig. 8).
Front Roller Adjustment Loosen four (4) capscrews holding front roller brackets. Push roller towards the rear, then hold in position and tighten capscrews. Make sure roller has not changed position. NOTE: When securing front roller brackets, tighten fastener on inside of cutting unit frame so posi tion of roller bracket does not change. 1 Figure 10 1. Roller bracket Set Up and Adjustments Page 8 - 10 Rev.
Height Of Cut Adjustment NOTE: Effective height of cut in the turf can be affected by lift arm down pressure adjustment and turf condi tions, such as grass type, grass density, and amount of thatch. 1. Do bedknife to reel adjustment and front roller adjust ment before adjusting height of cut. 1 2 3 2. To adjust height of cut, cutting unit should be turned over (Fig. 11). 4 3.
Shield Height Adjustment Adjust shield to get proper grass clipping discharge into basket or for desired front discharge when not using baskets. 1. Set cutting unit in normal cutting position. 2. Loosen capscrews and nuts securing shield to each side-plate, adjust shield to correct height and tighten fasteners (Fig. 13). 1 2 3. Repeat adjustment on remaining cutting units and adjust top bar. (See Top Bar Adjustment in this section of the book.
Top Bar Adjustment Adjust top bar to make sure clippings are cleanly dis charged from reel area: 1. Loosen screws securing top bar (Fig. 15). Insert 0.060 inch feeler gauge between top of reel and bar and tighten screws. Make sure bar and reel are equal dis tance apart across complete reel. 2 2. Do adjustment on remaining cutting units.
Lift Arm Down Pressure Adjustment The down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf condi tions. Increased down pressure will help keep the cut ting units on the ground when mowing at higher speeds and helps maintain a uniform height of cut in rough conditions or in areas of thatch build up. Each down pressure spring may be adjusted to one of four (4) settings. Each increment increases or de creases down pressure on cutting unit by 8 lbs. 2 1.
Repairs Cutting Unit Removal and Installation Remove cutting unit from traction unit before doing adjustments or repairs. 1. Remove basket from cutting unit. 2. Disconnect chain from cross tube on each rear cutting unit (Fig. 17). 1 Figure 17 1. Lock up chain 3. Loosen reel motor mounting nuts (Fig. 18). Rotate the motor clockwise so motor flanges clear studs and pull motor off of cutting unit. 2 1 Figure 18 1. Reel drive motor 2. Mounting nuts 4.
Reel Lapping 2 DANGER Reel may stall while backlapping. Do not attempt to restart reels by hand or adjust while backlapping. Stop engine and turn H.O.C. knob one position toward “A”. 1 1. Put the machine on a clean, level surface, lower cutting units, stop the engine, engage the parking brakes, move the enable/disable switch to DISABLE and remove key from ignition switch (Fig. 20) Figure 20 2. Unlock and raise seat to expose controls. 1. Enable / Disable switch 2. Lower Mow / Raise control lever 3.
8. Apply lapping compound with long-handled brush supplied with machine (Fig. 23). Never use a short handled brush. 9. If reel to be backlapped turns too slowly, or erratically, stop engine and turn H.O.C. knob one position toward “A”. Repeat steps 5 – 8. Position “P” will provide the slowest speed for backlapping. Position “A” will provide the fastest speed for backlapping.
Bedbar Removal and Installation The rear roller assembly must be removed so the bed bar can be removed for bedknife sharpening. 1. Remove locknut securing rear roller height of cut bracket to side plate on both ends of cutting unit (Fig. 25). 3 2. Loosen allen head setscrews securing rear roller shaft to height of cut brackets. 3. Unthread height of cut adjustment bolts and remove them from both side plates. 2 4 5 4. Remove bedbar pivot bolts from each end of cutting unit.
Bedknife Replacement 1. Remove bedbar (see Bedbar Removal and Installa tion). 2. Remove bedknife screws and remove bedknife. 3. Remove all rust, scale and corrosion from bedbar surface before installing the new bedknife. 4. Install new bedknife with the proper bedknife screws (57-4910). Bedknife screws must bottom out on the bedknife, not the bedbar. Tighten the screws to a torque of 200 in-lb, working from the center toward each end of the bedbar (Fig. 26). 5.
Reel Removal and Bearing Replacement 1. Remove front and rear roller assemblies. Remove bedbar. Remove carrier frame. 1 2. Remove counterbalance end cap (Fig. 28). Remove large bearing adjustment nut from left hand end of reel shaft (Fig. 28) and special spline nut from opposite end of reel shaft. 3. Remove machine screws securing bearing housing on each end of cutting unit (Fig. 29). Machine screw heads will have to be cut off before screw can be completely removed: A.
Lift Arm Spring Replacement 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. 2. Remove floor plate in front of seat to get access to front springs or open hood to get access to rear springs. 3 CAUTION Springs are under tension. Use caution when removing or ad justing. 4 2 1 3. Put an open end wrench on hex shaft of spring bracket.
Repairs Page 8 - 22 Reelmaster® 223-D/5100-D/5300-D
Chapter 9 4WD Rear Axle Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . Four-Matic 4WD Over-Running Clutch Operation . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Toe-in. . . . . . . . . . . . . . . . . . . . . . . TM Reelmaster® 223-D/5100-D/5300-D . 2 . 3 . 3 . 4 . 4 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Service . . . .
Specifications Item Specification __ ________________________________________________________________________________________ Lubricant (Fig.
General Information TM Four-Matic 4WD Over-Running Clutch Operation A drive shaft connected to the front axle provides power for the rear 4WD drive axle. The drive shaft tor the rear axl e in c o r porat es an OVER-RUNNING (ROLLER) 49 RPM Locked Unlocked CLUTCH THAT TRANSMITS POWER ONLY IN THE FORWARD DIRECTION (Fig. 4, 5).
Adjustments Rear Wheel Toe-in (Fig. 7) 1. Measure center–to–center distance (at axle height) at front and rear of steering tires. Front measurement must be 1/8 in. less than rear measurement. 2. To adjust, loosen clamps at both ends of tie rod. 3. Rotate tie rod to move front of tire inward or outward. 4. Tighten tie rod clamps when adjustment is correct. 1 Figure 7 1.
Repairs Drive Shaft Service 0.34 ± 0.03″ 22 0.040″ MAX Arrow end of roller clutches must face 6-bolt flange end of clutch housing (toward rear axle) 14 13 Detail A Detail B 14 A 21 15 B 20 Apply Never-seeze 110 - 120 ft-lb (L.H. thread) B 23 Apply Loctite 22 10 17 18 Apply Never-seeze Figure 8 Removing Drive Shaft Clutch Service 1. Put machine on a level surface, lower cutting units, stop the engine and remove the key from the ignition switch.
0.34 ± 0.03″ 22 0.040″ MAX Arrow end of roller clutches must face 6-bolt flange end of clutch housing (toward rear axle) 14 13 Detail A Detail B 14 A 21 15 20 Apply Never-seeze B 110 - 120 ft-lb (L.H. thread) B 23 Apply Loctite 22 10 17 18 Apply Never-seeze Fi gure 9 6. Install clutch assembly onto yoke shaft (Item 12), then install other thrust washer. Install retaining ring (Item 21) to secure clutch assembly to shaft.
If bracket (Item 3) was not removed: 5. Tighten two (2) capscrews (Item 19) and locknuts (Item 6) to secure yoke to shaft. Slide bearing assembly onto traction shaft. Loosely mount bearing support (Item 5) to bracket (Item 3) with three (3) carriage bolts (Item 1) and locknuts (Item 6). 4. Slide locking collar (Item 25) onto traction shaft (Item 31). Do not tighten at this time. Installing Drive Shaft. 1. Apply never-seize to splines of traction shaft and axle input shaft.
Rear Axle Removal and Installation Apply Loctite 0.318″ 0.018″ 0.032″ 0.018″ 45 - 55 ft-lb Figure 10 1. Remove drive shaft (see Drive Shaft Service). 2. Thoroughly clean around hydraulic hoses connections to steering cylinder. Mark hoses so they will be installed correctly during reassembly. Disconnect hoses from fittings on steering cylinder. Put plugs or caps on open hoses and fittings to prevent contamination of hydraulic system. 6. Remove capscrew (Item 4) from pin (Item 44).
Rear Axle Repair Before disassembling axle, remove hydraulic cylinder (Fig. 9, Item 28), cylinder support (Item 17), tie rod tube and clamp assembly (Item 12) and steering arms (Items 46, 31). Disassembly 1. Remove drain plugs (Fig. 11) and let oil drain out into containers. 1 Figure 11 1.
Apply Loctite 20 - 24 ft-lb 16 - 20 ft-lb Shim for backlash adjustment Measure backlash here: 0.003 - 0.01″ Shim for bevel gear to pinion contact adjustment Tighten to pre-load bearings. Pinion shaft should rotate with 2.0 - 5.5 in-lb torque 16 - 20 ft-lb Figure 12 2. Remove bolts (Fig. 12, Item 43) securing axle tubes (Item 16, 44) to differential case (Item 24). Separate axle tubes and axles from differental case. 5. Disassemble differential case (Fig. 12): A.
6 - 8 ft-lb 12 - 20 ft-lb Apply Loctite 12 - 20 ft-lb Figure 13 E. Tighten bolts (Item 1, 35) to a torque of 16 - 20 ft-lb (220-280 Kg-Cm). Assembly 1. Use new gaskets and seals when reassembling axle. 3. Assemble knuckle assembly (Fig. 13): 2. Assemble differential case (Fig. 12): A. Assemble differential. Use medium strength Loc tite on bolts (Item 7) and tighten evenly to a torque of 20 - 24 ft-lb (270-330 Kg-Cm). B. Assemble pinion gear (Item 30) and bearing case (Item 33).
medium strenght Loctite on capscrews (Item 28) securing cover (Item 26). B. Assemble knuckle pin (Item 20) and knuckle case (Item 38) to match knuckle arm (Item 8) with knuckle pin. Fasten capscrew (Item 10) temporarily (will be removed to fill with lubricant). C. Assemble wheel shaft (Item 35) to cover (Item 30). D. Assemble gear (Item 5) to wheel shaft and install cover and wheel shaft assembly to knuckle case (Item 38).
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