Part No. 94819SL, Rev. C Service Manual Reelmaster 5300-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 5300-D REFER TO THE REELMASTER 5300-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 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 5300-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.
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. 25. Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
Safety Instructions Page 1 - 4 Reelmaster® 5300-D
Chapter 2 Product Records and Manuals 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 Reelmaster® 5300-D
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 Engine Table of Contents 2 3 4 6 6 6 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cooling Fan Belt and Alternator Belt Replacement . . . . . . . . . . . . . . . . 7 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . 8 Bleeding Air From the Injectors . . . . . . . . . . . . . . 9 Removing and Installing the Fuel Tank . . . . . . . 10 Replacing and/or Adjusting Engine Stop (ETR) Solenoid . . . . . . . . . . . . . . . 11 Removing the Engine . . . . . . . . .
Introduction This chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the diesel engine used in the Reelmaster® 5300-D mower. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section.
Specifications Item Specification ___________________________________________________________________________________________ Make/Designation Mitsubishi S3L2, 4 cycle, liquid cooled, vertical overhead valve diesel ________________________________________________________________________________________________________________________ ________________________________ Combustion Chamber Swirl chamber type ___________________________________________________________________________________________________
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. 1). Mix with water and use solution to wash the Donaldson air cleaner element. Figure 1 Diesel Engine Compression Test Kit Diesel engine compression test kit (Fig. 2). 0-1000 PSI Gauge allows testing of diesel engines to check general operating condition of engine.
Nozzle Tester Nozzle tester (Fig. 4). Tests condition and opening pressure of fuel injector nozzles. Figure 4 Nozzle Tester Adapter Engine Nozzle tester adapter (Fig.5) is required to test the fuel injection nozzles.
Adjustments Engine Speed Adjustments Adjustments to the engine speed settings are not nor mally necessary unless the throttle linkage, injection pump, or governor mechanism have been repaired, rebuilt, replaced or are not operating correctly. The high speed set bolt has been set properly and sealed at the factory. Never tamper with the seal unless necessary.
Repairs 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. 8). If replacing alternator belt, loosen bolt securing alternator brace to engine and bolt securing alternator to brace (Fig. 9). 2 3. Remove three capscrews securing transmission drive shaft coupler to engine crankshaft pulley (Fig. 10). Do not disconnect drive shaft from transmission. 4.
Bleeding the Fuel System 1. Stop the engine and engage the parking brake. Open the hood. 2. Loosen the air bleed screw on the fuel filter / water separator (Fig. 11). 3. Turn the ignition key switch to the ON position. The electric fuel pump will begin to operate and force fuel out around the screw loosened in step 2. Fuel will fill the filter bowl and then flow out around the screw. When a solid stream of fuel flows out around the screw, tighten the screw and turn the key switch OFF. 4.
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. 13). 1 2. Move the throttle control to the FAST position. 3. Turn the ignition key to the START position to crank the engine and pump fuel to the nozzles.
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 switch. 2. Open drain fitting on bottom of fuel tank and drain fuel into a suitable container (Fig. 14). 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.
Replacing and/or Adjusting Engine Stop (ETR) Solenoid See Chapter 5 - Electrical System for information about testing the engine stop solenoid. An improperly adjusted stop solenoid can result in failure of the engine to stop when the key switch is turned off or could cause injection pump damage or malfunction. 1 Removing the Stop Solenoid 1. Stop the engine.
Removing and Installing the Engine Removing the Engine Figure 18 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 radiator to cool. CAUTION DO NOT open radiator cap or drain coolant if engine or radiator is hot. Pressurized, hot coolant can escape and cause burns. 2. Open hood. Disconnect hood stop cable from frame. Lower hood. Remove left and right hinge plates. Lift hood off chassis.
10. Loosen hose clamp and remove fuel hose from injector pump. Plug end of fuel line to prevent fuel leakage. Loosen hose clamp and remove fuel return hose from rear fuel injector on engine. 11. Disconnect and tag wires that attach to engine or engine components: Alternator Starter motor and solenoid Ground cables Oil pressure switch Temperature gauge sender Thermoswitch Engine stop solenoid Glow indicator 12.
Removing and Installing the Engine Page 3 - 14 Reelmaster® 5300-D
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Chapter 4 Hydraulic System Table of Contents Reelmaster® 5300-D Test No. 2:Traction Circuit System Pressure . . . Test No. 3: Front Mow/Lift Circuit Pressure . . . . Test No. 4: Rear Mow Circuit Pressure . . . . . . . Test No. 5: Reel Drive Pump Efficiency . . . . . . . Test No. 6: Reel Drive Circuit Flow . . . . . . . . . . Test No. 7: Reel Drive Motor Efficiency and Mow Circuit Relief Pressure . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 3600 ± 150 psi at 3250 RPM 3600 ± 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 When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; one to hold the hose straight and one to tighten the hose swivel nut onto the fitting. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by lowering the cut ting units to the ground and stopping the engine.
SAE Straight Thread O-Ring Port (Non-adjustable) 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fitting shows signs of leakage. 3. Lubricate the O-ring with a light 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 Figure 8 Hydraulic Schematic Page 4 - 6 Reelmaster® 5300-D
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) 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 solenoid valve “S8” and out to the front reel motors. Return oil from the motors is directed to tank through valve “S8”. During “backlap”, the circuits operate the same as in the “mow” mode except for the operation of solenoid valves “S8” and “S9”.
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). Some tools may be listed in the Reelmaster 5300-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 5300-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 ___________________________________________________________________________________________ Engine RPM too low. Adjust, use tachometer. ________________________________________________________________________________________________________________________ ________________________________ 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. Replace 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. Replace VS1 if faulty.
Front Reels Stop Under Load Cause Correction ___________________________________________________________________________________________ R1 bypassing. Check relief pressure at port G1 of valve block and adjust valve if necessary. Do cartridge valve service procedure for valve R1. Replace R1 with a new valve.
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 Schematics 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 Electrical 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 temperature by operating the machine for approximate ly 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 temperature by operating the machine for approximate ly 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 temperature by operating the machine for approximate ly 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 temperature by operating the machine for approximate ly 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 Valve 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 complete disassembly and reassembly of 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 cylinder 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 as semblies. Figure 47 9. Use an o-ring pick or wire to remove thrust plates from swashplate and housing (Fig.
11. Use an 8-32 machine screw to remove motor shaft bearing retaining pin from housing (Fig. 50). Figure 50 Figure 51 13. Press motor shaft out of bearings and spacer (Fig. 52). Figure 52 14. Remove spiral retaining ring and remove PTO seal guide (with o-ring) from the housing (Fig. 53). Figure 53 Reelmaster® 5300-D Page 4 - 47 Transmission Repairs Hydraulic System 12. Remove motor shaft from housing (Fig. 51).
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 assemb ly 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 tolerance 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 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. Install assembled guide and pis tons into cylinder block by inserting pistons into cylinder block bores (Fig. 69).
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). 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. Install the six (6) screws that retain the center section to the housing and torque evenly to 33 to 41 ft-lb (Fig. 76). 22.
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. 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 1 Figure 84 Figure 85 Relief valves Flow control solenoid valves 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). 3. Drain the hydraulic reservoir. 1 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 Install with sharp edge facing out IMPORTANT: Keep housings, gears and bear ings for each pump section together; do not mix parts between sections. Tighten in a crossing pattern to 40 - 45 ft-lb Figure 93 1. Retaining ring 2. Shaft seal 3. Flange 4. Dowel pin 5. Housing 6. O-ring 7. Idler gear 8. Drive gear 9. Coupling 10. Bearing 11. E-seal 12. Backup ring 13. Distance plate 14. Housing 4. Clean and air dry all parts.
4. Remove and dispose of the seal. 3. Secure the flange end of the pump (Fig. 93, Item 3) in a vise with the drive shaft pointing down. NOTE: Seal can be removed by punching two holes in face of seal 180o apart, installing metal screws and pulling seal out by grasping the screws. IMPORTANT: Do not try to pry the seal out of the pump. This usually damages the shaft seal bore and mounting hub area so oil will leak past the seal. 5. Clean seal bore and shaft on pump so it is free of any foreign material. 6.
Reel Motor Removal and Installation 1. Disconnect hydraulic lines. Put caps or plugs on fittings and hoses to prevent contamination. Tag hydraulic 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 2. Motor mount nuts Hydraulic System 1.
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.
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 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. Draw a line across the seam areas on the motor case with a scribe or marker to ensure proper reassembly. 10. Body 11. Spacer 12.
become displaced. Insert the capscrews and washers and hand tighten. 14. Tighten the capscrews evenly in a crossing pattern to a torque of 17 ft-lb. 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. 15. Carefully install a new spacer, shaft seal and snap ring.
Figure 98 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 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 failure was severe or system is contaminated (oil appears 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 Tighten mounting capscrews to a torque of 30 to 60 in-lb. 10 Figure 103 1. Filler screen 2. Suction strainer 3. Reservoir 4. Drain plug 5. Breather Mowing Circuit Repairs Page 4 - 68 6. Cap 7. Dipstick 8. Grommet (3) 9.
Chapter 5 Electrical System Table of Contents Backlap Switch . . . . . . . . . . . . . . . . . . . . . . . . . Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Stop (ETR) Solenoid . . . . . . . . . . . . . . . . . Indicator Lights and Gauges . . . . . . . . . . . . . . . Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Page 5 - 2 Reelmaster® 5300-D
(Model 03530, S/N Below 51001 / Model 03531, S/N Below 50301) Electrical System Wiring Schematic Reelmaster® 5300-D Page 5 - 3 Rev.
Reelmaster 5300–D Page 5 – 3.1 Rev.
Wiring Schematic ELECTRIC SOLENOID VALVE BLK RED BLK/Y RED/Y Page 5 – 3.2 Rev. B LEAK DETECTOR ALARM C C B E E B A A TURF DEFENDER LOOPBACK I.D.
Wiring Schematic Page 5 - 4 Reelmaster® 5300-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 5300-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 as sociated with each of the inputs when that input switch is closed. Check each switch (input) by opening and closing 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.
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 simplified by use of the ACE TM Diagnostic Display, Data Log system and ToroPC software. Before testing or replacing any electrical components, it is recommended that you verify electrical performance of the part(s) in question by using the above mentioned tools (see Troubleshooting 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® 5300-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 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.
Fuel Gauge Sender 1. Disconnect wire and remove the fuel gauge sender from the fuel tank. 2. Install an ohm meter between the terminal and base. 1 3. With arm completely down (empty position), resis tance should be 240-260 ohms. 4. With arm completely up (full position), resistance should be 29-34 ohms. NOTE: Bend float arm, if necessary, to get proper gauge reading for a 1/2 full tank. CAUTION Figure 23 Make sure the sending unit is completely dry (no fuel on it) before testing.
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.
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. 28, 29). 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.
Traction (Neutral) Switch Replacement 1. Remove the two wires that are connected to the traction switch (Fig. 30). 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. 31). Figure 31 4. Remove ECU. 1.
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, Make sure O-ring is installed at each end of coil. Apply “Locktite 242" or equivalent to threads on end of stem tube before installing nut. Tighten nut to a torque of 15 in-lb.
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 capscrew and lockwasher through cover into plate. 5. Install machine screw throught plate and cover, then install locknut to machine screw. Figure 34 6. Tighten capscrew and locknut to secure plate to cover. 8.
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 36 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.
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 Differential Axle 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. 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 Differential Axle 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 Differential Axle 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 Differential Axle 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® 5300-D
Chapter 7 Steering And Brakes Table of Contents REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel Removal and Installation . . . . . Rear Axle Bushing Service . . . . . . . . . . . . . . . . Steering Pivot Bushing Service . . . . . . . . . . . . . Rear Wheel Spindle Bushing Service . . . . . . . . Front Wheel Bearing Service . . . . . . . . . . . . . . . Rear Wheel Bearing Service . . . . . . . . . . . . . . . Steering Cylinder Removal and Installation . . . .
Introduction Power Steering The Reelmaster® 5300-D is equipped with power steer ing. 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.
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 approximate ly 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 (counterclockwise) so the steering cylinder rod is ex tended 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. Remove 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 4 5 1 2 13 12 7 11 9 10 8 Figure 16 6. Axle bushings 7. Steering pivot 8. Tie rod 9.
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 replaced. 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. Rear axle 2. Steering cylinder 3. Capscrew 4. Rear axle pin 5. Tie rod 6. Wheel spindle 7. Snap ring 8. Shim washer 9. Thrust washer 10. Bushing 11. Thrust washer Front Wheel Bearing Service Steering and Brakes See Axle Shaft Disassembly and Wheel Bearing Ser vice 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 1. Loosen wheel lug nuts. Jack up machine until front wheel is off of floor. Use jackstands to prevent machine from falling accidentally. Remove wheel lug nuts and slide wheel and tire assembly off of studs. 2. Remove brake drum. If drum will not come off easily, brake shoes may have to be retracted with star nut (see Brake Adjustment). 3. Remove brake shoe return spring (Fig. 22) by prying the end of the spring up and over its retaining boss.
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.
Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5 Factors That Can Affect Quality of Cut . . . . . . . . 5 SET UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . 7 Adjustment Summary and Check List . . . . . . . . . 7 Reel Bearing Service and Adjustment . . . . . . . . . 8 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 Cutting Units NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reel master 5300-D 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.
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.
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 necessary. 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.
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).
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. Cutting Units Bedknife To Reel Adjustment 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.
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. Cutting Units Height Of Cut Adjustment 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.
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. 1 NOTE: Bar should be parallel to reel for optimum per formance and should be adjusted whenever shield height is adjusted or whenever reel is sharpened on a reel grinder. Figure 15 1.
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 decreases down pressure on cutting unit by 8 lbs. 2 1.
Repairs Cutting Units 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 at tempt 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.
Cutting Units 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 Cutting Units 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 2. Remove floor plate in front of seat to get access to front springs or open hood to get access to rear springs. Cutting Units 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. 3 CAUTION Springs are under tension. Use caution when removing or adjusting. 4 2 1 3. Put an open end wrench on hex shaft of spring bracket.
Repairs Page 8 - 22 Reelmaster® 5300-D
Chapter 9 4WD Rear Axle SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . Four-Matic 4WD Over-Running Clutch Operation . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Toe-in . . . . . . . . . . . . . . . . . . . . . . . . TM Reelmaster® 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 49 RPM Locked Unlocked CLUTCH THAT TRANSMITS POWER ONLY IN THE FORWARD DIRECTION (Fig. 4, 5). 50 RPM 49 RPM Front and rear axle gear ratios and tire sizes were carefully selected so that during normal operation, the Rear axle pinion shaft 4WD Rear Axle A drive shaft connected to the front axle provides power for the rear 4WD drive axle.
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 Detail A 4WD Rear Axle 13 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 B 20 Apply Never-seeze 110 - 120 ft-lb (L.H. thread) B 23 Apply Loctite 22 10 17 18 Apply Never-seeze Figure 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.
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. Do steps 6 - 9 only if traction shaft (Item 31) was removed: 6.
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 4WD Rear Axle 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.
4WD Rear Axle 6 - 8 ft-lb 12 - 20 ft-lb Apply Loctite 12 - 20 ft-lb Figure 13 Assembly E. Tighten bolts (Item 1, 35) to a torque of 16 - 20 ft-lb (220-280 Kg-Cm). 1. Use new gaskets and seals when reassembling axle. 3. Assemble knuckle assembly (Fig. 13): 2. Assemble differential case (Fig. 12): A. Assemble differential. Use medium strength Loctite 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).
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). Note that top two (2) capscrews (Item 39), securing cover (Item 30) are a shorter length.
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