Service Manual

ManualsBrandsToro ManualsRiding ProductsReelmaster 5400-D 4-Wheel Drive

PART NO. 99046SL (Rev. E)

Service Manual

Reelmaster



5200-D/5400-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 5200-D/5400-D.

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR’S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC-

TIONS. Space is provided in Chapter 2 of this book to

insert the Operator’s Manuals and Parts Catalogs for

your machine. Replacement Operator’s Manuals are

available by sending complete Model and Serial Num-

ber to:

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

The Toro Company reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing, or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

 The Toro Company - 1999, 2001, 2002, 2003, 2004, 2007

Summary of content (298 pages)

PAGE 1
PART NO. 99046SL (Rev. E) Service Manual Reelmaster 5200-D/5400-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 5200-D/5400-D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Reelmaster 5200-D/5400-D
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Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Electrical System Quick Check . . . . . . . . . . . . . . 5 - 14 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 - 33 Chapter 2 - Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . .
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Reelmaster 5200-D/5400-D
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Table Of Contents Chapter 9 - 4WD Rear Axle Chapter 8 - Cutting Units Unit Serial No. 80001 Thru 99999 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-3 9-4 9-5 Chapter 9.1 - 4WD Rear Axle Unit Serial No. 200000001 & Up Cutting Units Specifications . .
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Reelmaster 5200-D/5400-D
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Chapter 1 Safety Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4 General Safety Instructions The REELMASTER 5200-D/5400-D was tested and certified by TORO for compliance with the B71.
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While Operating 9. Sit on the seat when starting and operating the machine. 10.Before starting the engine: A. Engage the parking brake. 16.Operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause loss of control and vehicle to tip or roll possibly resulting in personal injury or death. On 4-wheel drive models, always use the seat belt and ROPS together. B. Make sure traction pedal is in NEUTRAL and the ENABLE / DISABLE switch is in DISABLE.
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22.Before servicing or making adjustments, stop engine and remove key from the switch. parts of the body away from cutting units and other moving parts. Keep everyone away. 23.Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 30.Do not overspeed the engine by changing governor setting. To assure safety and accuracy, have an Authorized Toro Distributor check maximum engine speed. 24.
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Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or solid wood blocks to support the raised machine.
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Chapter 2 Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) . . . . . . . . . . Other Torque Specifications . . . . . . . . . . . . . . . . . . Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .
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Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - 2 Rev.
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Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N-cm 10 2 13 2 147 23 # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC 13 2 25 5 282 30 # 8 - 36 UNF # 10 - 24 UNC 18 2 30 5 339 56 # 10 - 32 UNF SAE Grade 5 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE
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Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 5 in-lb 640 60 N-cm 78 7 in-lb 885 80 N-cm M6 X 1.0 96 9 in-lb 1018 100 N-cm 133 13 in-lb 1500 150 N-cm M8 X 1.25 19 2 ft-lb 26 3 N-m 27 2 ft-lb 36 3 N-m M10 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 140 20 in-lb 73 12 in-lb 5/16 - 18 UNC 215 35 in-lb 145 20 in-lb 3/8 - 16 UNC 35 10 ft-lb 1/2 - 13 UNC 75 15 ft-lb 1/4 - 20 UNC 7/16 - 20 UNF Grade 5 65 10 ft-lb 88 14 N-m 1/2 - 20 UNF Grade 5 80 10 ft-lb 108 14 N-m 18 3 ft-lb M12 X 1.25 Class 8.
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Chapter 3 Kubota Diesel Engines INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fill Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Cooling System . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . . . .
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Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 5200-D/5400-D. test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, 05 Series.
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Specifications Item Description Make / Designation Kubota, 4-Cycle, 3 Cylinder, Water Cooled, Diesel Engine Horse Power RM 5200-D RM 5400-D 25.0 HP @ 3000 RPM 31.5 HP @ 3000 RPM Bore mm (in.) 78.0 (3.07) Stroke mm (in.) 78.4 (3.09) Total Displacement cc (cu. in.) 1123 (68.53) Torque N-m (ft-lb) 68.2 (50.3) @ 2000 RPM 1-2-3 Combustion Chamber Spherical Type Fuel No. 2 Diesel Fuel (ASTM D975) Fuel Capacity liters (gallons) 37.9 (10.
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General Information Check Engine Oil 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 1 2. Remove, wipe clean, and reinstall dipstick. Remove dipstick, and check oil level on dipstick. Oil level should be up to FULL mark (Reelmaster 5200 - Fig. 1), (Reelmaster 5400 - Fig. 2). 3.
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Check Cooling System The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check level of coolant at the beginning of each day before starting the engine. System capacity is about 9.6 quarts (9.1 l). 2 1 IMPORTANT: Clean debris off the screen, oil cooler, and front of the radiator daily, and more often if conditions are extremely dusty or dirty (see Engine Cooling System). 1.
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Adjustments Adjust Throttle Cable 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Position throttle lever forward so it stops against the seat base slot. 2 1 3. At the fuel injection pump, loosen throttle cable connector on the control lever arm. Note: Do not over tighten the cable connector. The connector must be free to swivel. 4.
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Adjust Alternator/Fan Belt The condition and tension of all belts should be checked periodically as recommended in the maintenance schedules in Chapter 2 - Product Records and Manuals. 1 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Open hood. 4 2 Alternator Belt (Fig. 7) 5 2. Check tension by depressing belt midway between alternator and crankshaft pulleys with 22 lb. (98 N) of force. Belt should deflect 7/16 in.
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Service and Repairs Bleed Fuel System 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Make sure fuel tank is at least half full. Gain access to the engine. 1 2 DANGER Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area.
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Bleed Air from Fuel Injectors IMPORTANT: This procedure should be used only if the fuel system has been purged of air through normal priming procedures (see Bleed Fuel System) and engine will not start. 2 1 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 3 DANGER 2. Loosen pipe connection to the No. 1 injector nozzle and holder assembly. Figure 12 1. No. 1 injector nozzle 2. No. 2 injector 3. No. 3 injector nozzle 3. Move throttle to FAST position. 4.
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Clean Radiator and Oil Coolers The radiator and oil cooler should be checked for dirt and debris daily, and hourly if conditions are extremely dusty or dirty. 2 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2 CAUTION If engine has been running, the radiator may be hot and cause burns. Work on radiator only when the engine and radiator are cool. Figure 15 1. Screen 2. Latch 2. Open engine hood. 3 3.
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Muffler 5 1 7 3 4 15 17 16 8 20 17 9 2 4 11 6 12 15 10 12 13 14 Kubota Diesel Engines 20 12 19 15 12 18 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Muffler Muffler bracket Cap screw Flat washer Muffler clamp Lock nut Exhaust tube 15. 16. 17. 18. 19. 20.
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Fuel System 5 11 33 32 29 3 30 3 11 12 34 13 15 2 4 16 17 35 10 11 14 18 9 17 19 35 20 8 21 7 31 6 22 28 1 26 36 27 23 24 25 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Fuel filter Barbed fitting Fuel fitting Hose clamp Fuel hose Gasket Sending unit Lock washer Round head screw Fuel hose Hose clamp Fuel hose 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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Fuel Tank Removal Fuel Tank Installation (Fig. 19) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install fuel tank to the frame using Figure 19 as a guide. A. Apply antiseize lubricant to the threads of all three cap screws. 2. Remove left fender and tool box from the frame to gain access to the top of the fuel tank. B. Torque all three cap screws from 30 to 60 in-lb (3.4 to 6.8 N-m). 3.
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Air Filtering System General Maintenance 2 1 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Check air cleaner body for damage which could cause an air leak. Replace damaged air cleaner body. 3. Service air cleaner filters whenever air cleaner indicator (Fig.
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Water/Fuel Separator DANGER Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety-approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. 1 2 Figure 22 1. Filter element 2.
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Radiator 1 3 2 7 8 9 11 12 13 37 14 15 16 17 18 19 20 21 22 23 61 32 62 25 15 net 6 10 24 5 52 4 39 57 58 60 26 59 25 38 51 50 55 49 54 31 28 56 29 23 53 30 8 42 48 47 46 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 6. Remove four cap screws, flat washers and lock washers securing the radiator support to the frame. Pull radiator and support from the frame. 7. Plug any openings to prevent contamination. Installation 2. Open engine hood on the machine. 1. Remove any plugs used during the removal procedure.
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Engine 38 37 7 10 9 7 58 65 12 11 17 14 52 19 6 5 4 66 3 2 20 18 1 21 15 16 22 8 16 42 25,26 34 19 60 49 53 58 23 15 43 51 34 57 56 46 28 47 53 37 30 48 23 53 60 61 62 24 19 36 32 13 54 52 34 45 12 44 40 27 RH 33 LH 39 63 43 38 36 64 19 41 29 50 31 67 30 19 53 34 61 19 37 59 55 29 19 27 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Open engine hood. 1 3. Disconnect both battery cables at the battery (see Battery Service in Chapter 5 - Electrical system). 2 4. Disconnect yoke flange from the lower fan belt pulley (Fig. 26). Figure 26 1. Lower fan belt pulley 2. Yoke flange Do not open radiator cap or drain coolant if the radiator or engine is hot.
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13.Remove flange head nuts, flat washers, cap screws, snubbing washers, and engine mount washers securing the engine mounts to the engine brackets. 2 CAUTION 1 3 One person should operate lift or hoist while the other person guides the engine out of the machine. IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness, or other parts while removing the engine. Figure 29 1. Battery & frame ground 2. ETR solenoid 3. Wire harness ground 14.
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9. Connect wires and/or electrical connections to the following electrical components: 3 6 A. Glow plug bus (Fig. 31). High temperature shutdown switch (Fig. 30). B. Battery, frame, and wire harness ground to the engine block and the ETR solenoid (Fig. 29). 5 C. The temperature sender (Fig. 28). The oil low pressure switch, starter, and alternator (Fig 27). 1 4 2 10.Connect air filter hose to the engine. Figure 32 11. Connect coolant hoses to the water pump, radiator cap, and engine block.
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Fan Drive Hub Disassembly (Fig. 34) 1. Secure pulley and fan to prevent them from turning. Remove shaft screw and flat washer. 12 80 to 100 ft−lb (108 to 136 N−m) Loctite #242 7 2. Press pulley and fan assembly from fan drive hub. 10 9 7 11 6 5 4 3. Remove bearings and bearing spacer from fan drive hub. 2 3 1 Note: The fan clutch and fan shaft have left hand threads. 8 Loctite #242 4. If necessary, disassemble pulley and fan assembly using Figure 34 as a guide. 13 14 Assembly (Fig. 34) 1.
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Chapter 4 Hydraulic System Table of Contents For hydraulic steering cylinder and valve information, see Chapter 7 “Steering and Brakes” in this manual. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Hydraulic Transmission System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Cooler By-pass Pressure Filter By-pass Pressure Oil Filter In-line Strainer Sauer-Sundstrand M25, U-type 3625 PSI (249.9 bar) 2755 PSI (190.0 bar) 150 PSI (10.3 bar) 70 PSI (4.8 bar) 70 PSI (4.8 bar) Screw-on type 260 micron, 8 GPM (30.
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General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
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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. O-Ring 3. Lubricate the O-ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 3 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
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Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the hydrostatic transmission may occur. 1 If it becomes necessary to tow the machine, tow it forward only and at a speed below 3 mph. IMPORTANT: If drive shaft is not removed before towing, the transmission input shaft will not be able to rotate, thus not allowing the transmission to maintain its internal lubrication. Severe damage to the hydrostatic transmission may occur. 1.
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Check Transmission Fluid The front axle housing acts as the reservoir for the transmission. The transmission and axle housing hold about 5 quarts (4.7 L) of Mobil 424 hydraulic fluid. Check level of transmission oil daily. 1. Position machine on a level surface, lower cutting units, and stop the engine. 1 2. Remove floor panel. 3. Unscrew dipstick cap from the transmission filler neck; wipe it with a clean rag. Screw dipstick into filler neck. Remove dipstick and check level of oil.
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Check Hydraulic Fluid Note: The fluids in this group are interchangeable. Group 1 Hydraulic Fluid (Recommended for ambient temperatures consistently below 100_ F.
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DIFFERENTIAL HOUSING INPUT SHAFT Hydraulic System IN---LINE STRAINER SYSTEM PRESSURE (FORWARD) SYSTEM PRESSURE (REVERSE) COOLER BY---PASS 70 PSI FILTER BY---PASS SYSTEM RELIEF 70 PSI OIL FILTER 2755 PSI SYSTEM RELIEF 3625 PSI 150 PSI CHARGE PRESSURE RELIEF Page 4 - 8 Rev.
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Reelmaster 5200-D/5400-D Page 4 - 9 Rev.
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DIFFERENTIAL HOUSING INPUT SHAFT Hydraulic System IN---LINE STRAINER SYSTEM PRESSURE (FORWARD) SYSTEM PRESSURE (REVERSE) COOLER BY---PASS 70 PSI FILTER BY---PASS SYSTEM RELIEF 70 PSI OIL FILTER 2755 PSI SYSTEM RELIEF Page 4 - 10 Rev.
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Traction Circuit 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 in the forward direction.
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Hydraulic System Page 4 - 12 Rev.
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Lower Cuttings Units A three section, gear pump is driven off the PTO output shaft of the hydrostatic transmission. Pump section (P3) provides oil flow through the steering control valve and hydraulic manifolds to all five cutting unit lift cylinders. Maximum circuit pressure (1250 PSI) is limited by a relief valve in the gear pump. The 250 PSI relief valve maintains a back pressure on the lift cylinders as they dump oil to the hydraulic reservoir.
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Hydraulic System Page 4 - 14 Rev.
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Raise Cutting Units A three section, gear pump is driven off the PTO output shaft of the hydrostatic transmission. Pump section (P1) provides oil flow through the hydraulic manifold to all five cutting unit lift cylinders. Maximum circuit pressure (3000 PSI) is limited by a relief valve in the manifold block. normally closed solenoid valves that control raising the cutting units.
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Hydraulic System Page 4 - 16 Rev.
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Mow and Backlap The hydraulic manifold block establishes of two independent control circuits for the front and rear cutting units. Each circuit is supplied by its own pump section. Pump section (P1) supplies hydraulic power to the front cutting units, while section (P2) supplies the the rear units. Both circuits share manifold port (T), which drains to the hydraulic reservoir. On the circuit supplied by pump section (P1), maximum system pressure is limited by relief valve (R1), which is set at 3000 PSI.
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Hydraulic System Page 4 - 18 Rev.
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Steering With the steering wheel in the neutral position (rear wheels positioned straight ahead), the engine running, and the spool valve is in the center position, flow enters the steering control valve at the IN port and goes through the spool valve by-passing the rotary meter (V1) and steering cylinder. Flow leaves the control valve through the AUX port to the 250 PSI relief valve and hydraulic reservoir.
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Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit - TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
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Hydraulic Test Fitting Kit - TOR4079 This kit includes a variety of O-ring Face seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 11 Measuring Container - TOR4077 Hydraulic Systems Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
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Seal Installer - TOR491450 Use installer and a small hammer to drive the reel motor shaft seal into position in the bore of the reel motor body. Use with seal protector - TOR491430.
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Troubleshooting The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific test procedures. Problem Possible Cause Transmission operates in one direction only. Traction control linkage is faulty. Faulty relief valve for inoperative direction. Transmission charge check valve and/or system relief valve is defective.
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Problem Possible Causes No cutting units will operate. Lower-mow/raise lever was improperly used. Electrical problem exists (see Chapter 5 - Electrical System). Gear pump or its coupler is damaged (Steering and lift circuits are also affected). Front (Rear) reels will not turn in either direction. Solenoid valve S1 (S2) is not shifting. Relief valve R1 (R2) is by-passing. Solenoid valve S7 is partially shifted. Solenoid valve S7 energized (see Chapter 5 - Electrical System).
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Testing Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. Precautions for Hydraulic Testing CAUTION Failure to use gauges with recommended pressure (psi) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.
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TEST NO. 1: Traction Circuit Charge Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section. Figure 15 1. Charge pressure test port 2. Oil filter 3.
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TEST NO. 2: Traction Circuit System Relief Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Before doing traction pressure test: 1 A. Drive machine to an open area, lower cutting units, turn the engine off and engage the parking brake. 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.
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TEST NO. 3: Relief Valve (R1) Pressure Note: The front mowing circuit and cutting unit lift circuit share the same relief valve (R1). See Hydraulic Flow Diagrams at the beginning of this chapter. 2 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 1 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. CAUTION Figure 18 Prevent personal injury and/or damage to equipment.
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TEST NO. 4: Relief Valve (R2) Pressure 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION 11. If pressure is too high, remove cap on relief valve R2 and adjust screw to get correct pressure (see Adjust Manifold Relief Valves).
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TEST NO. 5: Gear Pump Section (P1 & P2) Flow (Using Tester with Pressure and Flow Capabilities) 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section. Figure 21 1.
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TEST NO. 6: Reel Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) Note: Over a period of time, a reel motor can wear internally. A worn motor may by-pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the reel motor to stall under heavy cutting conditions. continued operation with a worn, inefficient motor can generate a lot of heat, cause damage to seals and other components in the hydraulic system, and affect quality of cut.
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TEST NO. 7: Gear Pump Section (P3) Flow and Relief Valve Pressure (Using Tester with Pressure Gauges and Flow Meter) 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off. 2 1 CAUTION Prevent personal injury and/or damage to equipment.
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Adjustments Adjust Manifold Relief Valve (R1 and R2) The hydraulic reel circuit is equipped with a relief valve. Valve (R1) is preset at the factory to 3000 PSI and valve (R2) to 2000 PSI. However, an adjustment may be required if the setting proves to be off after testing (see TESTING). If an adjustment is required proceed as follows: 2 WARNING Never adjust the relief valve with the hydraulic system pressurized. Hydraulic oil may spray out of the valve with the cap off. Personal injury may result.
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Adjust Traction Drive for Neutral 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, shut engine off and lower cutting units to the floor. Depress only the right brake pedal and engage the parking brake. 1 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.
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Adjust Cutting Unit Lift Rates The cutting unit lift circuit is equipped with three (3) adjustable flow control valves used to ensure the cutting units do not raise too quickly and bang against lift stops. Adjust cutting units as follows: Center Cutting Unit (Fig. 28) 1 1. Locate valve behind access panel above operator’s platform. 2. Loosen setscrew on valve and rotate valve approximately 1/2 turn clockwise. 3. Verify lift rate adjustment by raising and lowering cutting unit several times.
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Adjust Traction Control Linkage The traction control linkage should not require routine maintenance or adjustment. The following information is provided if the control linkage assembly is disturbed to gain access to other components. Adjust Traction Linkage 2 3 1 1. The machine should be parked on a level surface, cutting units lowered to the floor, and engine off. 2. Connect brake pedals together with locking pin, push both pedals down and pull parking brake latch out. 3.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
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Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.
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Charge Hydraulic System IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 11. After the hydraulic system starts to show signs of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not move after 10 to 15 seconds, or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose filter or suction lines. 1.
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Change Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1 1. Turn engine off and raise hood. 2. Remove drain plug from bottom of reservoir and let hydraulic fluid flow into drain pan. Reinstall and tighten plug when hydraulic fluid stops draining.
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Replace Hydraulic Oil Filter The hydraulic system filter head is equipped with a service interval indicator. With the engine running, view the indicator, it should be in the GREEN zone. When the indicator is in the RED zone, the filter element should be changed. 1 IMPORTANT: Use the Toro replacement filter (Part No. 75-1310). Use of any other filter may void the warranty on some components. 1.
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Replace Transmission Fluid Change the transmission fluid after every 800 hours of operation, in normal conditions. 1 1. Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. 3 2. Clean area around suction line on bottom of transmission. Place drain pan under line. 3. Remove line from transmission allowing fluid to drain into drain pan. 2 4. Reinstall suction line to transmission. 5.
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Transmission Control Linkage 4 1 2 6 7 9 10 8 11 12 11 3 9 13 15 23 29 26 9 25 24 22 19 21 20 28 27 19 22 17 18 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cotter pin Flat washer Cap screw Screw Not used Neutral switch Switch plate Extension spring Lock nut Cap screw 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Figure 36 Ball bearing Spacer Cap screw Not used Traction plate Spring anchor plate Lock washer Cap screw Flanged bushing Grease fitting Removal 1.
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Transmission 17 16 1 2 3 18 19 4 5 6 8 9 25 26 27 28 10 13 15 14 50 4 54 36 39 38 37 27 49 53 21 24 29 7 11 12 51 20 22 23 25 52 35 34 33 32 31 30 28 41 42 40 43 44 48 47 45 46 Figure 37 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
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Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 2. Remove two (2) rear cutting units (see Chapter 8 Cutting Units). 3. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of transmission and differential. 4. Put a drain pan below the transmission. Remove suction line from bottom of in-line filter to let oil drain out of differential (Fig. 38). 1 Figure 38 1. Suction line 5.
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8. Install transmission control linkage to the transmission (see Transmission Control Linkage Installation). 9. Secure suction line to top of in-line filter (Fig. 38). 10.Install two (2) rear cutting units (see Chapter 8 - Cutting Units). 11. Install a new filter and fill differential with correct oil. Hydraulic System 12.Disconnect fuel stop solenoid electrical connector on engine to prevent engine from starting. Prime transmission by turning ignition key switch to crank engine for 10 seconds.
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Transmission Service 1 2 3 7 4 5 8 9 6 10 11 12 51 50 13 49 14 48 6 15 47 20 43 46 21 19 16 22 17 45 36 25 26 21 54 19 29 30 31 32 28 44 21 27 43 18 22 33 34 22 39 20 38 Hydraulic Systems 9 37 19 52 36 35 53 42 41 40 21 20 21 27 26 Figure 41 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Disassembly 1. Remove external components as described in the following sections: Shaft Seal Replacement Trunnion Seal Replacement Check/High Pressure Relief Valve Replacement Charge Pressure Relief Valve Replacement Heat Exchanger By-Pass Valve Replacement Filter By-Pass Valve Replacement In-Line Filter Check Valve Replacement Charge Pump Replacement 2. Remove six (6) screws securing the center section to the housing. Note position of longer and shorter screws.
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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 IMPORTANT: Pump and motor cylinder block assemblies are identical. To avoid mixing wear patterns, do not mix parts between pump and motor cylinder block assemblies. Make sure each piston is returned to the bore it was taken from. 8. Remove slipper guide and piston assemblies from cylinder blocks (Fig. 47). Hydraulic Systems Figure 47 9.
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11. Use an 8-32 machine screw to remove motor shaft bearing retaining pin from housing (Fig. 50). Figure 50 12.Remove motor shaft from housing (Fig. 51). Figure 51 13.Press motor shaft out of the 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).
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15.Slide pump shaft and bearing assembly from housing. Press shaft out of bearing (Fig. 54). Figure 54 16.Remove hex tapping screws retaining the trunnion seal cover and trunnion cover to housing. 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 assembly includes an O-ring and trunnion bearing on the side opposite the control. Remove these parts from the housing (Fig. 55).
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Inspection 1. After disassembly, thoroughly clean all parts in a suitable solvent. Replace all O-rings, gaskets and seals. 2. Inspect all parts for damage, nicks, or unusual wear patterns. Replace all parts having unusual or excessive wear or discoloration. 3. If scratches, which can be felt with a pencil lead, can be found on bronze surface of valve plates or running surface of cylinder blocks, polish or replace the parts. 4. Inspect needle bearings in center section.
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Note: The trunnion bearings are pressed into the cover assemblies so the split in each bearing will be located closest to the center section. 3. Install trunnion cover (with O-ring and trunnion bearing) into housing and over swashplate trunnion (Fig. 59). 4. Use an arbor press to press a new seal into trunnion seal cover. Outer face of seal should be pressed flush with outer surface of seal cover. Be careful not to damage the seal.
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8. Install PTO seal guide and O-ring into housing. Install spiral retaining ring (Fig. 63). Figure 63 9. Press inner bearing, spacer and outer bearing onto motor shaft (Fig. 64). Figure 64 10.Install motor shaft assembly into housing (Fig. 65). Figure 65 11. Install motor shaft bearing retaining pin into housing (Fig. 66).
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12.Install pipe plug over motor shaft bearing retaining pin and tighten to a torque of 6 to 9 ft-lb (8 to 12 N-m) (Fig. 67). Figure 67 13.Coat thrust plates with petroleum jelly and install into housing and swashplate (Fig. 68). The thrust plates are reversible. Hydraulic Systems Figure 68 14.Assemble each cylinder block kit by installing piston assemblies into the slipper guide. Lubricate pistons and cylinder block bores.
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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). The notch on each valve plate must engage its locating pin. Figure 72 Note: Do not interchange pump and motor valve plates when assembling transmission. The motor valve plate has either no grooves, or grooves on both sides of the ports.
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IMPORTANT: Make sure all parts are properly aligned. Do not force center section into position on the housing. 20.Install center section with valve plates onto transmission 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 about 1/8 inch (3.1 mm). Figure 75 21.Install six (6) screws that retain the center section to the housing and torque evenly to 33 to 41 ft-lb (45 to 56 N-m) (Fig. 76). 22.
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Shaft Seal Replacement 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Disconnect drive shaft from the transmission (Fig 77). Note: The face of the seal may 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. Be careful to not damage the charge pump cover or shaft. Once removed the seal is not reusable. 3.
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Trunnion Seal Replacement 4 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 3 1 2. Remove pump control from the swashplate control shaft on transmission (see Hydraulic Transmission Control Linkage Removal). 2 3. Remove hex tapping screws retaining trunnion seal cover to transmission housing. 4. Remove trunnion seal cover with lip seal and O-ring. 5. Put seal cover in an arbor press and press out old seal.
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Check/High Pressure Relief Valve Replacement 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 5 4 2. Remove check/high pressure relief valve hex plug. 1 3 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.
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Charge Pressure Relief Valve Replacement 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove the charge relief valve plug. 3. Remove the spring and poppet from the housing. 4. Do not interchange parts with another valve. 5. Inspect the poppet and mating seat in the end cap for damage or foreign material.
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Heat Exchanger By-Pass Valve Replacement 1 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 3 2. Remove the heat exchanger bypass valve hex plug. 4 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 (24.5 N) to compress it to a length of 1.
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Filter By-Pass Valve Replacement (Fig. 83) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove the filter bypass valve hex plug. 3. Remove the spring and poppet from the housing. 4. Do not interchange parts with another valve. The spring used in the filter bypass valve is identified by a red dye mark, and requires a force of approximately 2.2 lb (9.8 N) to compress it to a length of 1.28 inch (3.25 cm). 5.
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Charge Pump Replacement 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Remove the two (2) cap screws retaining the charge pump cover. Remove the charge pump (Fig. 37, 38). 3. Remove geroter drive pin from the groove in the shaft. 2 4. Remove the geroter assembly from the charge pump cover. Remove the shaft seal from the cover. 5. Each part should be inspected separately if they are to be reused.
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Gear Pump 9 8 1 2 4 3 5 7 6 10 11 19 18 17 16 15 14 12 13 Suction hose Hose clamp Hydraulic fitting Cap screw Lock washer Gasket Transmission coupler 8. 9. 10. 11. 12. 13. Transmission adapter O-ring Hydraulic straight fitting O-ring Hydraulic tube Hydraulic tube 14. 15. 16. 17. 18. 19. Hydraulic hose O-ring Hydraulic straight fitting O-ring Gear pump O-ring Removal Installation 1.
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Install with sharp edge facing out 2 1 3 Install with sping side facing in 4 5 6 7 8 9 10 11 14 12 13 15 22 16 21 20 19 18 50 to 55 ft--lb (68 to 75 N--m) 17 Figure 88 1. 2. 3. 4. 5. 6. 7. 8. Retaining ring Shaft seal Flange Dowel pin Housing O-ring Idler gear Drive gear 9. 10. 11. 12. 13. 14. 15. Coupling Bearing E-seal Backup ring Distance plate Housing Idler gear 16. 17. 18. 19. 20. 21. 22. Idler gear Bolt Valve block Valve kit Idler gear Housing Dowel pin Relief Valve Service 3.
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Shaft Seal Replacement 1. Remove pump (see Pump Removal and Installation). 2. Plug ports and wash exterior of pump with cleaning solvent. Make sure parts and work area are clean. 3. Remove retaining ring (Fig. 93, Item 1). 1. Plug ports and wash exterior of pump with cleaning solvent. 2. Draw a line across seam areas on pump case with a scribe or marker to ensure proper reassembly IMPORTANT: Use caution when clamping in a vise to avoid distorting any parts. 3. Secure the flange end of the pump (Fig.
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Reel Motor (Serial Number Under 230000000) 1 2 3 4 5 6 7 8 9 17 ft--lb (23 N--m) 5 14 10 11 5 12 13 Figure 89 1. 2. 3. 4. 5. Socket head screw Washer Dowel pin Cover Needle bearing 6. 7. 8. 9. 10. Idler gear Drive shaft Ring seal Load plate Body 11. 12. 13. 14. Spacer Shaft seal Retaining ring Dowel pin Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2 2. Disconnect hydraulic lines.
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Shaft Seal Removal 1. Remove reel motor (see Reel Motor Removal and Installation). 1 2. Plug ports and wash exterior of motor with cleaning solvent. Make sure parts and work area are clean. 2 3. Remove retaining ring from motor (Fig. 89). IMPORTANT: Do not try to pry the seal out of the motor. This usually damages the shaft seal bore and mounting hub area so oil will leak past the seal. 4.
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2. Apply grease or petroleum jelly to ring seal and install on body. 3. Apply hydraulic oil to inside of cover and assemble the cover to the body, making sure none of the parts become displaced. Insert the cap screws and washers and hand tighten. 4. Before tightening the cap screws, rotate the drive shaft in the direction of normal rotation (counterclockwise) to check for binding. You may not be able to rotate the drive shaft by hand. Protect the shaft if using a pliers. 5.
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Disassembly (Fig. 92) DIAGONAL MARK 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 2. Use a marker or scribe to make a diagonal mark across the front flange, body, and rear cover for reassembly purposes (Fig. 93). IMPORTANT: Avoid using excessive clamping pressure on the motor flange to prevent distorting the casting. 3. Clamp mounting flange of motor in a vise with the shaft end down. Figure 93 4.
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3. Inspect drive gear, idler gear and bearing blocks (Fig. 96) for the following: A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces, or wear on gear shafts indicates need for replacement. B. Gear teeth should be free of excessive scoring and wear. Any broken or nicked gear teeth must be replaced. C. Inspect gear face edge for sharpness. Sharp edges of gears will mill into bearing blocks and, thus, must be replaced. D.
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Hydraulic Systems Reelmaster 5200-D/5400-D Page 4 - 73 Rev.
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Hydraulic Control Manifold 7 12 13 2 6 9 4 14 13 38 13 39 11 7 20 13 13 9 5 9 10 14 13 37 12 17 18 7 18 17 35 3 33 7 7 7 32 18 40 9 11 7 23 20 21 22 2 13 3 27 26 9 40 31 18 25 1 24 RIGHT FRONT 30 29 28 Figure 97 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. O-ring 90_ hydraulic fitting O-ring Hydraulic hose Straight hydraulic fitting Control manifold O-ring Not used O-ring 45_ hydraulic fitting Test port fitting Test port cap O-ring Hydraulic hose 15. 16. 17. 18. 19.
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24 2 to 5 ft--lb (2.7 to 6.8 N--m) 25 26 31 27 4 Loctite 242 28 4 23 23 30 to 35 ft--lb (41 to 47 N--m) 30 3 7 23 4 29 32 23 4 1 6 2 1 2 10 11 12 13 14 5 2 1 21 20 S1 2 S6 1 S4 S3 S8 S2 1 S5 2 15 S7 1 7 S9 2 RIGHT 23 16 1 18 17 FRONT 19 8 Figure 98 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. O-ring Plug Cartridge valve (N.O.) Solenoid (20 watt) O-ring Plug Cartridge valve (N.C.) Solenoid (28 watt) Not used O-ring 45_ hydraulic fitting 12. 13. 14. 15. 16. 17. 18. 19. 20.
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Solenoid Operated Valve Cartridge 7. Reinstall the cartridge valve: 1. Make sure the manifold is clean before removing the valve. A. Lubricate new O-rings and backup rings of seal kit with clean hydraulic oil and install. The O-ring and backup ring must be arranged properly on the cartridge valve for proper operation and sealing. 2. Remove nut securing solenoid to the cartridge valve. Slide solenoid and both O-rings off the valve. Note: Use care when handling the cartridge valve.
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6. Reinstall relief valve cartridge: 6. Reinstall the cartridge valve: A. Lubricate new O-ring and backup ring of seal kit with clean hydraulic oil and install. The O-ring and backup ring must be arranged properly on the cartridge valve for proper operation and sealing. A. Lubricate new O-ring and backup ring of seal kit with clean hydraulic oil and install. The O-ring and backup ring of seal kit must be arranged properly on the cartridge valve for proper operation and sealing. B.
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Logic Cartridge CAUTION 1. Make sure the manifold is clean before removing logic cartridge valve and seal kit. Remove cartridge valve. 2. Visually inspect the port in the manifold for damage to the sealing surfaces, damaged threads, and contamination. 3. Visually inspect logic cartridge valve for damaged sealing surfaces and contamination. A. Contamination may cause valves to stick or hang up, it can become lodged in small valve orifices or seal areas causing malfunction.
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Flow Divider On machines with serial numbers above 200000001, the lift circuit for the front, outer lift cylinders includes a flow divider to provide for even lifting of those cutting units. Lift speed of the front, outer cutting units should be similar when the flow divider is functioning correctly. The flow divider assembly mounts to the front of the frame (Fig. 99).
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Lift Cylinders Removal 2 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Disconnect hydraulic hoses from lift cylinder. 1 4 3 3. Remove front right or left lift cylinder. A. Remove retaining ring from the cylinder rod end pin. Remove cylinder pin with remaining retaining ring and thrust washers from the lift arm and cylinder clevis (Fig. 102 and 101). B.
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2. Install front center lift cylinder (Fig. 103). A. Insert cylinder pin through the carrier frame and cylinder clevis. Secure self tapping screw to the cylinder pin and carrier frame. 3 1 2 B. Insert cylinder pin with attached retaining ring and thrust washer through the lift arm and cylinder clevis. Secure thrust washer and retaining ring to the cylinder rod end pin. 4 5 6 7 3. Install front right or left lift cylinder. A. Insert cylinder pin through carrier frame and cylinder clevis.
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Lift Cylinder Service SERIAL NUMBER BELOW 250000000 1 2 13 4 5 3 7 8 6 9 10 11 12 FRONT LEFT AND FRONT RIGHT LIFT CYLINDER SHOWN Figure 105 1. 2. 3. 4. Barrel with clevis Nut Uni-ring Piston 5. 6. 7. 8. 9. O-ring Rod seal O-ring Back-up ring Head 10. 11. 12. 13. Dust seal Collar Shaft with clevis Grease fitting SERIAL NUMBER ABOVE 260000000 9 30 to 35 ft--lb (41 to 47 N--m) 10 11 12 8 13 4 14 5 7 3 6 1 2 FRONT LEFT AND FRONT RIGHT LIFT CYLINDER SHOWN Figure 106 1. 2. 3. 4. 5.
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Disassembly Reassembly 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all cylinder parts are clean before reassembly. 2. Mount lift cylinder into a vise. 3. Remove shaft assembly from barrel: A. For serial numbers below 250999999, remove collar with a spanner wrench. B.
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Hydraulic Reservoir 2 25 5 37 14 6 13 7 8 4 1 3 10 9 26 11 12 24 24 22 12 23 20 18 12 42 41 40 44 43 48 28 17 18 18 39 19 24 27 11 38 9 29 10 12 30 31 32 36 10 35 34 12 33 12 16 21 22 23 30 to 60 in--lb (3.4 to 6.8 N--m) Never Seez 15 Thread Sealant 45 21 46 22 47 Figure 107 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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2. Apply Permabond LH150 or equivalent to the threads of the hydraulic straight fitting (suction). Secure fitting to the suction strainer. 3. Apply Permabond LH150 or equivalent to the threads of the suction strainer. 4. Using a wrench, turn strainer into port at least 1-1/2 to 2 full turns beyond finger tight. 5. Apply an anti-seize compound to three cap screws that secure the reservoir to the frame. Install and torque screws 30 to 60 in--lb (3.4 to 6.8 N--m). Hydraulic Systems 6.
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Hydraulic Oil Cooler and Transmission Heat Exchanger Removal 2 CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1 1. Remove oil cooler using Figures 108 and 109 as guides. Inspection Figure 108 1. Oil cooler 2. Heat exchanger CAUTION 1 Use eye protection such as goggles when using compressed air. 1. Back flush oil cooler with cleaning solvent.
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Chapter 5 Electrical System Table of Contents For Electrical Schematics, and Electrical Harness and Connectors Drawings, see Chapter 10 “Electrical Diagrams” in this manual. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Quick Reference Troubleshooting Guide . . . . . . . 4 Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Diagnostic Ace Display . . . . . . . . . . . . . . . . . . . . .
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Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL VoltOhm-Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
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Toro Automated Control Electronics Diagnostic Tool Diagnostic ACE Display The diagnostic display is connected to the wiring harness connector located inside the control console to help the user verfiy correct electrical functions of the machine (Fig. 3 and 4). Overlay Diagnostic ACE Display ACE Display (Toro Part No. 85-4750) Overlays for RM 5200/5400: Unit Serial No. 80001 -209999999 (Toro Part No. 100-3700) Unit Serial No. 210000001 & Up (Toro Part No.
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Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Electrical Schematics and Electrical Harness and Connectors Drawing section of this manual).
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Check Interlock Switches The purpose of the interlock switches 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. The engine will stop when the traction pedal is depressed with operator off the seat. In addition, the engine will stop if the traction pedal is depressed and the parking brake is engaged. 1 2 CAUTION Verify Interlock Switch Function 1.
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Note: If any output LED is blinking, this indicates an electrical problem with that OUTPUT. Repair and/or replace defective electrical parts immediately. To reset a blinking LED, turn the key switch “OFF”, then back “ON” and retest. Memory must be cleared. If no output LED’s are blinking, but the correct output LED’s do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. Verify correct switch function.
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Starting Problems Problem Possible Causes All electrical power is dead, including gauges. The battery charge is low. The ignition switch or circuit wiring is faulty. The fusible link from the battery is faulty. The 20 ampere fuse to the ignition switch is open. Starter solenoid clicks, but starter will not crank. Low battery charge. Note: If the solenoid clicks, the problem is not in the in- Loose or corroded battery cables. terlock circuit wiring or the ECU. Loose or corroded ground.
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General Run and Transport Problems Engine continues to run, but should not, when the ignition switch is turned off. The engine run (ETR) solenoid is stuck open. Engine continues to run, but should not, when the traction pedal is engaged with no operator in the seat. The seat sensor or circuit wiring is faulty. The engine stops during operation, but is able to restart. The parking brake is engaged. Ignition switch or circuit wiring is faulty. Traction neutral switch or circuit wiring is faulty.
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Cutting Unit Operating Problems (Cont.) None of the cutting units operate in either direction. Units are able to raise and lower. The seat sensor actuator is lifting off the seat switch. The seat sensor or circuit wiring is faulty. The enable/disable switch or circuit wiring is faulty. The front reels down sensor or circuit wiring is faulty. Ground circuit wiring to solenoids may be open. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System).
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TurfDefender Leak Detector The TurfDefender 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.
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If 4 beeps are heard: If false alarms are observed: The most common cause for a 4 beep signal is from an improper oil level reading. Make sure machine is on a level surface when checking oil level. Since oil level will vary with temperature, it is best to check when cool. 1. Oil level may be low causing air to be drawn into the system. Check oil level. 2. When toggling “output” a LED should display (Fig.
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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 8 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.
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Reelmaster 5200-D/5400-D ELECTRIC SOLENOID VALVE BLK RED BLK/Y RED/Y − Page 5 - 13 Electrical System LEAK DETECTOR ALARM C C B E E B A A TURF DEFENDER LOOPBACK I.D. DECAL BLK GN/WT BLK/OR YELLOW + (RED) 2D 1B 3B 2C 1E 2E 1C 3C 2A 2F 1F 3F C OR/BLK B 94−6345 TURF DEFENDER BLK/W RED/W D BLK/BU A TO LEAK DETECTOR CONNECTOR OF MAIN HARNESS TURF DEFENDER COMMUNICATION PORT AND LOOPBACK CONNECTOR TurfDefender TM Leak Detector Electrical Systems (Rev.
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Electrical System Quick Check Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100 F (16 to 38 C). The ignition key should be off and all accessories turned off.
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Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: For more component testing information, see the Kubota Workshop Manual, Diesel Engine, 05 Series at the end of Chapter 3 - Kubota Diesel Engines.
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Glow and Start Relays These relays are attached to the radiator shield that is located below the seat. Note: The start relay may be manufactured by one of three different manufacturers. Verify manufacturer name and part number before performing the resistance check on the relay coil. 3 1 2 Note: Prior to taking small resistance readings with a digital multi meter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less).
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Fuses The fuse blocks are located under the control panel and inside the control console. Identification, Function, and Wiring The fuses are held in two fuse blocks. Use Figure 16 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire connected to it. 2 1 Fuse A1 A. Supplies power to Electronic Control Unit (ECU) terminals 1L and 1M. B. Has blue/white wire (1L), green/black wire (1M) and red wire (battery). Figure 15 1. Fuse block A Fuse A2 2.
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Hydraulic Valve Solenoids Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. 8 5 3 2 6 4 1 1. Make sure engine is off. Disconnect solenoid valve electrical connector. 7 2.
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High Temperature Warning and Shutdown Switch The high temperature warning and shut down switch is located on the right side of the water flange that is attached to the front of the engine cylinder head. There is a green/white wire attached to the switch (Fig. 19). 2 1 CAUTION Make sure engine is cool before removing the temperature switch. 1. Lower coolant level in the engine and remove the temperature switch. Figure 19 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig.
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Warning Light Cluster Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 14 VDC to their wiring terminals. 1 2 3 4 Testing Cluster Removed from Connector. 1. Apply 14 VDC to pin D. 5 2. Ground pins F, A, and E. 3. Lamps 1, 2, and 3 should light. 4. Apply 14 VDC to pin B. 2 1 5. Ground pin C. 6. Lamp 4 should light. 6 Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running.
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Fuel Stop Solenoid (Solenoid With 3 Wire Connector) The solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump. 2 In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
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Run (ETR) Solenoid (Solenoid With 2 Wire Connector) The run (ETR) solenoid must be energized for the engine to run. It is mounted on the engine block near the injection pump. 2 1 In Place Testing Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
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Fuel Sender The sender is located on top of the fuel tank under the right, front fender. 1. Remove blue/green wire and black ground wire from the sender. 2 2. Remove round head screws and lock washers from the sender and fuel tank. 3. Remove sender and gasket from the fuel tank. Clean any fuel from the sender. Note: Before taking small resistance readings with a digital multimeter, short test leads together. The meter will display a small resistance value.
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Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect fuel gauge to the variable resistance and DC voltage source (Fig. 29).
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Temperature Sender The sender is located on the left side of the water flange that is attached to the front of the engine cylinder head. There is a blue/white wire attached to the terminal of the switch (Fig. 31). 1 1. Lower coolant level in the engine and remove the high temperature sender. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 32). 2 CAUTION Figure 31 Handle the hot oil with extreme care to prevent personal injury or fire. 1. Temperature sender 2.
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Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. VARIABLE RESISTANCE 14 VDC + 0.01 VDC 1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 29).
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Hour Meter The meter is located under the control panel and inside the control console. Hobbs 1. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. QUARTZ 00001 HOURS 2. Connect the negative (-) terminal of the voltage source to the other terminal of the hour meter. 1 10 + 3. The hour meter should move a 1/10 of an hour in six minutes. 4. Disconnect voltage source from the hour meter.
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Traction Speed Sensor The sensor is located on the right side of differential gear box that is part the front axle. It uses a magnetically biased Hall Effect integrated circuit. As the spur gear turns in the differential, the sensor accurately senses the movement of the gear teeth passing by the sensor. The red connector wire is the positive lead, the black wire is the ground lead, and the gray wire is the signal output. 2 1 The sensor is tested as part of the output checks with the Diagnostic ACE tool.
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Speedometer The speedometer can be tested using a DC pulse generator, or by verifying the gear tooth sensor is operating properly and operating the machine with the wheels off the ground. 2 1 CAUTION 3 Pulse Generator 14 VDC + 0.01 VDC Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. 14 VDC + 0.01 VDC Using Pulse Generator − 1. Connect speedometer to the pulse generator and DC voltage source (Fig. 38).
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3. Start engine. Verify pinion shaft or traction shaft (4WD units) speed (RPM) with phototac. Check corresponding speed on the speedometer (Fig. 40 and 41) 2 4. Turn off engine. Replace meter as necessary. 1 Pinion Speed (RPM) Speedometer (MPH) 291.2 4 582.4 8 873.6 12 Figure 41 1. Traction shaft (4WD) 2. Differential housing Reels Enable/Disable and Backlap Switches The reels enable/disable switch is attached to the instrument panel.
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Traction Neutral Switch The switch is located on the right side of the transmission. It uses its normally open contact that is closed by the switch arm depressing the plunger when the traction pedal is in the neutral position. When the traction pedal is depressed in either the forward or reverse direction, the switch arm releases the plunger on the switch and its normally open contact opens. 1 2 3 2 4 Figure 46 1. Plunger 2. Ground 3. Normally open 4. Normal closed 1 Figure 45 1. Transmission 2.
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Joystick Raise and Lower/Mow Switches Two micro switches for the joy stick are located on the lift control mechanism that is inside the control console. The rear switch on the mechanism is used to lower the reels and the front switch to raise them. A normally open contact closes when the joy stick is positioned to either to lower or raise the reels. Each switch has a electrical connector to make sure the normally closed contact on the switch is not used.
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Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Series at the end of Chapter 3 - Kubota Diesel Engines. Battery Storage 3. Leave cables disconnected if the battery is stored on the machine. If the machine will be stored for more than 30 days 1. Remove the battery and charge it fully (see Battery Service). 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 2.
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Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. 3 1 2 CAUTION When working with batteries, use extreme caution to avoid slashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. Figure 50 1. Ground cable 2.
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2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. A. Measure the specific gravity of each cell with a hydrometer.
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7. Connect a digital multimeter (set to amps) between the negative battery post and the negative (ground) cable connector. The reading should be less than 0.1 amp. If the reading is 0.1 amp or more, the unit’s electrical system should be tested and repaired. 8. Connect negative (ground) cable connector to the negative battery post. Tighten cap screw and lock nut with two wrenches. Battery Reserve Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.
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Traction Speed Sensor Replacement Removal 2 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Jack up the front end of the machine about 1 ft (30 cm) to prevent transmission fluid from leaking from the gear box when the sensor is removed (see Jacking Instructions in Chapter 1 - Safety). 4 5 3 3. Disconnect electrical connector from the harness.
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Electrical Systems (Rev.
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Chapter 6 Differential Axle Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . Axle Assembly Removal and Installation . . . . . . . . Axle Shafts and Wheel Bearings (Serial No. 80001 - 200000200) . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . .
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Specifications Item Specification Front wheel lug nut torque 45 to 55 ft-lbs (61 to 75 Nm) Front to rear housing torque 18 to 28 ft-lbs. (24 to 38 Nm) Transmission to axle torque 25 to 30 ft-lbs. (34 to 41 Nm) Differential bearing cap torque 30 to 45 ft-lbs. (41 to 61 Nm) Pinion coupler nut torque 75 to 90 ft-lbs. (100 to 122 Nm) Ring gear to differential case torque 45 to 65 ft-lbs. (61 to 89 Nm) Fill pipe torque 20 to 30 ft-lbs.
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Service and Repairs Axle Assembly 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 Rear Axle). Remove nut, pinion spacer and pinion coupler. 4. Remove hydrostatic transmission.
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Axle Shafts and Wheel Bearings (Serial No. 80001 - 200000200) Disassembly 6 7 9 10 11 1 8 2 3 4 5 Figure 5 1. Brake drum 2. Bearing retainer/seal plate screw 3. Outer seal plate 4. Washer 5. 6. 7. 8. Locknut Axle shaft Axle shaft inner seal Bearing retainer 9. Bearing 10. Brake backplate 11. Brake assembly 1. Remove axle from traction unit. 2. Slide the brake drum off of the axle flange (Fig. 6).
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3. Align the holes in the axle shaft flange with the backing plate/bearing retainer nuts. Remove and discard the nuts, washers, and bearing retaining bolts (Fig. 7). IMPORTANT: Hold the socket head screws with a hex wrench to prevent the screw head from damaging the axle tube. Figure 7 4. Pull the axle shaft and brake assembly out of the axle housing (Fig 8). NOTE: Remove the bearing race from the axle housing with a bearing puller if necessary. Figure 8 Differential Axle 5.
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6. Center punch and drill a 1/4 inch hole (approximate) into the outside of the bearing retainer to a depth of about 3/4 the thickness of the retainer (Fig. 10). IMPORTANT: Drilling completely through the retainer ring will damage the axle shaft. Figure 10 7. Place a chisel in position across the drilled hole and strike sharply to break the retainer (Fig. 11). Remove and discard the retainer. WARNING Wear protective safety goggles when breaking the retaining ring.
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Assembly 1. Coat a new outer seal plate with a thin film of oil and place the seal plate and brake assembly in position on the axle shaft. 2. Pack the bearing with grease and press it onto the axle shaft (Fig. 13). IMPORTANT: Drive the bearing onto the axle shaft by pressing on the inner race of the bearing only. Figure 13 3. Slide a new bearing retainer on the axle shaft. Support the shaft and retainer in a suitable press and push the bearing retainer firmly against the bearing (Fig. 14).
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5. Apply a 0.0625” (16 mm) bead of gasket material to the axle housing flange. Align the brake backplate and brake assembly with axle housing flange and push the axle shaft assembly all the way into the axle housing. Be careful not to damage the oil seal and bearing (Fig. 16). NOTE: Liquid Gasket Kit (Toro P/N 92-8775) includes Loctite Ultra Gray, gasket eliminator, and instructions. Figure 16 6. Use medium strength Loctite thread locker and install new bearing retaining bolts, washers, and nuts.
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Axle Shafts and Wheel Bearings (Serial No. 200000201 & Up) Lubrication NOTE: It is not necessary to remove the axle assembly to lubricate the axle bearings. 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. Slightly loosen all front wheel lug nuts. Jack both front wheels off the ground and install jackstands or blocks under traction unit frame (not axle tubes) to prevent machine from falling.
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Disassembly 7 6 8 10 11 2 4 9 3 1 5 Figure 20 5. 6. 7. 8. 1. Brake drum 2. Cap screw 3. Bearing cap 4. Bearing cap seal Axle shaft Inner axle shaft seal Bearing retainer Bearing 9. Axle housing 10. Brake assembly 11. Brake backplate 1. Remove axle from traction unit. 2. Slide the brake drum off of the axle flange. 3. Remove cap screws securing bearing cap (Fig. 20). 4. Pull the axle shaft and bearing assembly out of the axle housing. 5. Remove and discard the inner axle shaft seal (Fig. 20). 6.
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Assembly 1. Coat a new bearing cap seal with a thin film of oil and install it in the bearing cap. Place the bearing cap and seal in position on the axle shaft. 2. Pack the bearing with grease and press it onto the axle shaft. IMPORTANT: Drive the bearing onto the axle shaft by pressing on the inner race of the bearing only. 3. Slide a new bearing retainer on the axle shaft. Support the shaft and retainer in a suitable press and push the bearing retainer firmly against the bearing.
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Differential and Housing (All Units) Disassembly 1. Remove the right and left-hand axle assemblies (See Axle Shafts and Wheel Bearings Disassembly in this section of the book). 2. Remove the eight (8) housing cap screws and separate the upper and lower axle housings (Fig. 23). Clean the gasket material from the mating surfaces. Figure 23 3. Remove the four bearing cap screws and remove the caps. Place the caps in a safe place to avoid damaging their machined surfaces (Fig. 24).
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5. Remove the ring gear cap screws. Using a hard wooden block and a hammer, drive the ring gear off of the differential case. Be prepared to protect the ring gear when removing it from the differential case; this will avoid damage of the ring gear teeth (Fig. 26). NOTE: It is recommended that whenever the ring gear screws are removed, they are to be replaced with new screws. Figure 26 6. Do not remove the bearings from the differential case unless bearing failure is evident.
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8. While supporting the differential in a vise, drive the pinion mate shaft from the differential with a long drift punch (Fig. 29). Figure 29 9. 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. 30). Remove the pinion mate gears and the spherical washers behind the gears. Figure 30 10.Remove the eight side cover capscrews. Remove the side cover from the carrier assembly (Fig. 31).
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11. Install differential gear holder to carrier to retain spur gear (see Special Tools). Remove the nut, spacer, pinion coupler, and shim from the pinion shaft (Fig. 32). Remove differential gear holder from carrier. 5 4 6 8 7 2 1 3 Figure 32 1. 2. 3. 4. Nut Spacer Pinion coupler Seal 5. 6. 7. 8. Shim Outer bearing cone Outer bearing cup Bearing spacer 12.Position the housing assembly on a suitable press.
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15.Clamp the inner pinion bearing with a universal bearing remover (Fig. 35). Position the unit in a press and carefully push the drive pinion out of the bearing. IMPORTANT: DO NOT allow the pinion to drop on the floor - damage will result. Figure 35 16.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. 36). Figure 36 17.
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Assembly 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.
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IMPORTANT: Correct engagement between ring gear and pinion gear is critical to axle performance and durability. NOTE: A complete Upper Housing Assembly for Differential repairs is available. Using this assembly eliminates the need for shimming to establish the correct contact pattern between the ring and pinion gears. 4. Determine the correct inner bearing shims for use with ring and pinion gear sets: A.
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5. Install the correct bearing shims and a new inner bearing cup using a press plate of proper diameter. Push the bearing into the housing until it bottoms out against the shims (Fig. 41). Note: Pinion bearing shims are available in 0.003 in. (0.08 mm), 0.005 in. (0.13 mm), 0.010 in. (0.25 mm), and 0.030 in. (0.76 mm) thickness. Figure 41 6. Insert the spur gear into the front housing with the chamfered area of the center spline toward the pinion gear.
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8. Install the outer pinion spacer with the chamfer towards the pinion splines and position the new outer bearing cone on the pinion shaft (Fig. 44). Figure 44 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 felt when the gear is rotated by hand (Fig. 45). If more than 2−13 in-lbs. (.2−1.
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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.
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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-lbs. (61-88 Nm) (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.
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20.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. 21.Check ring to pinion gear engagement (see Ring and Pinion Gear Engagement in this chapter of the manual).
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Ring to Pinion Gear Engagement Final position of pinion is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 55): TOE Toe-the portion of the tooth surface at the end towards the center. LENGTHWISE BEARING ARC HEEL Heel-the portion of the gear tooth at the outer end. Top Land-top surface of tooth. 1. Paint the teeth of the ring gear, both drive and coast side, with a gear marking compound, such as DyKem Steel Blue.
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Example 3: Backlash incorrect. Thinner pinion position shim required. Adjust backlash to match (Fig. 59). DRIVE SIDE COAST SIDE Heel GEAR PATTERN MOVEMENT SUMMARY: Heel Toe Toe A. 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. Figure 59 B. Increasing backlash moves the ring gear away from the pinion.
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Differential Axle Page 6 - 26 Rev.
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Chapter 7 Steering and Brakes Table of Contents 2WD Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Axle Pivot Bushings . . . . . . . . . . . . . . . . . . . . . . . . 12 Steering Pivot Bushings . . . . . . . . . . . . . . . . . . . . . 12 Rear Wheel Spindle Bushings . . . . . . . . . . . . . . . 13 Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Front Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . 14 Rear Wheel Bearings . . . . . . . . . . . .
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Introduction Power Steering The Reelmaster 5200-D/5400-D is equipped with power steering. The power steering valve is enclosed in the steering tower at the front of the traction unit. As the steering wheel is turned, the steering valve meters hydraulic fluid to the double-acting steering cylinder on the rear axle and turns the wheels. Hydraulic fluid flow for power steering is supplied by section P3 of the hydraulic pump. Hydraulic pump section P3 has a built−in relief valve.
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Power Steering Schematics Right Turn With the engine running, and the steering wheel turned to the right, the flow travels through the top of the steering control spool. Flow enters the steering control valve at the IN port and is divided into two paths. Most of the flow through the valve is directed out the AUX port back to the lift manifold, and on to the hydraulic reservoir. The remainder of the flow is sent through the rotary meter (V1) and out the (LH) port to the rod end of the steering cylinder.
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Specifications Item Specification Front wheel lug nut torque 45 to 55 ft-lbs (61 to 75 Nm) Rear wheel lug nut torque 30 to 35 ft-lbs. (41 to 47 Nm) Steering cylinder bolt torque 130 to 150 ft-lbs. (176 to 203 Nm) Rear wheel toe-in 0.000 to 0.125 in. (0.0 to 3.0 mm) Tire pressure (front and rear) 10 to 15 psi. (0.69 to 1.03 Bar) Brake pedal free travel 0.5 to 1.0 in. (6.0 to 25.0 mm) Special Tools Order special tools from your Toro Distributor.
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Hydraulic Tester (Pressure and Flow) - TOR214678 Figure 7 This tester requires O-ring face seal (ORFS) adapter fittings for use on this machine. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 4. HIGH PRESSURE GAUGE: High range gauge which accommodates pressures beyond the capacity of the low pressure gauge, 0 to 5,000 PSI. 5.
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Troubleshooting The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific test procedures. Problem Possible Cause 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.
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Testing Note: For testing the gear pump section that supplies the steering circuit, see Test No. 8 in Chapter 4−Hydraulic System of this manual. 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 extended all the way. 1 3. Turn the engine OFF 4. Disconnect the hydraulic hose from the fitting on the rod end of the cylinder (Fig. 8).
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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. 2WD Traction Units 1. Rotate the steering wheel so the rear wheels are straight ahead. 2. Loosen the jam nuts on both tie rods.
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Brake Adjustment Adjust the service brakes when there is more that 1.0 in. (25.4 mm) of “free travel” of the brake pedals. Free travel is the distance the brake pedal moves before braking resistance is felt (Fig. 11). 0.5 to 1 in. (13 to 25 mm) 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.
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Service and Repairs Steering Wheel Removal 1 1. Remove cover from center of steering wheel. 2 3 2. Remove the lock nut that secures the steering wheel to the shaft. Pull the steering wheel and foam seal off the steering valve shaft (Fig. 14). 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 components. 4 Installation 1.
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2WD Rear Axle Note: For information on 4WD rear axle service and repairs, see Chapter 9−4WD Axle in this manual. 1 6 5 4 7 8 4 9 10 11 12 13 14 5 8 3 2 15 27 18 14 19 20 16 8 17 26 25 27 16 24 23 21 21 22 Figure 15 Rear axle Roll pin Axle pivot pin Thrust washer Axle bushing Thrust washer Jamnut Grease fitting Capscrew 10. 11. 12. 13. 14. 15. 16. 17. 18. Spindle cap Retaining ring Thrust washer Thrust washer Steering pivot bushing Thrust washer Jamnut Spindle Capscrew 19. 20. 21.
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Axle Pivot Bushings Steering Pivot Bushings The rear axle must be held in place snugly by the axle pin. Excessive movement of the axle, which is characterized by erratic steering, usually indicates worn bushings. To correct the problem, replace the bushings. The steering pivot must fit snugly onto the mounting pin. Excessive movement of the steering pivot may indicate worn bushings or tie rod ball joints. 1. Disconnect the hydraulic hoses from the steering cylinder.
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Rear Wheel Spindle Bushings 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.
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Wheel Bearings Front Wheel Bearings See Chapter 6−Differential Axle “Axle Shafts and Wheel Bearings” in this manual. Rear Wheel Bearings Rear wheel bearing buddies should be lubricated every 50 operating hours. Disassemble, clean, repack and adjust the rear wheel bearings after 800 hours of operation or once a year. Use No. 2 general purpose lithium grease containing E.P. additive. If operating conditions are extremely dusty and dirty, it may be necessary to perform this maintenance more often. 1.
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Steering Cylinder Removal 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 2 1 2. 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. 3. Remove the steering cylinder as follows: A.
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Installation B. Install the lock nut, capscrew, and thrust washers securing the rod end of the cylinder to the steering arm. Tighten the cylinder capscrew and nut to 130 to150 ft-lbs. (176 to 203 Nm) 1. Install the steering cylinder as follows: A. (2WD) Hold the steering cylinder in position and install the lock nut and cap screw securing the barrel end of the cylinder to the rear axle (Fig. 17). A. (4WD Unit Serial No.
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Steering Cylinder Service 12 STEERING CYLINDER (2WD UNITS) (4WD UNITS SERIAL NO. 80001 - 200000200) 9 13 12 4 11 2 9 10 6 2 4 5 7 7 10 3 8 1 6 7 5 3 13 1 STEERING CYLINDER (4WD UNITS SERIAL NO. 200000201 & UP) Figure 20 Barrel with clevis Nut Uni-ring Piston 5. 6. 7. 8. 9. 10. 11. 12. 13. O-ring Rod seal O-ring Back-up ring Head IMPORTANT: To prevent damage to rod or barrel, clamp vise on pivot ends only. DO NOT clamp against smooth rod surface. 1.
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Brake Shoe Replacement 5. Pull strut and lever from brake shoes. Remove brake shoes by sliding them both on one motion straight down off cast−iron spider. WARNING Older brake linings may contain asbestos fibers. Breathing dust containing asbestos fibers may be hazardous to your health and may cause serious respiratory or other bodily harm. When servicing wheel brake parts, do not create dust by grinding, sanding or filing brake linings or by cleaning wheel brake parts with a dry brush or compressed air.
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Steering Valve Removal 3 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 2. Remove the front center cutting unit (see Chapter 8−Cutting Units in this manual). 1 2 3. Remove cap screws and cover from steering tower. 4. Clean outside of the steering valve and the area around the hydraulic fittings. Disconnect hydraulic lines from steering valve (Fig. 22).
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Steering Valve Service Note: For repair of the steering valve, see the Ross Hydraguide TM Hydrostatic Steering System HGF Series Service Procedure at the end of this chapter. 1 2 3 1 5 21 6 1 22 7 8 9 10 11 12 4 13 14 15 5 23 1 24 25 5 16 17 18 20 19 26 41 35 40 39 34 38 33 31 30 1 37 36 29 28 27 Figure 23 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
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Chapter 8 Cutting Units Cutting Units Model 03506 & 03509 Model 03506, S/N 80001 - 209999999 Model 03509, S/N 80001 - 209999999 Table of Contents Note: For cutting unit Models 03527 & 03528, see Chapter 8.1 “Cutting Units” in this manual. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . .
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Specifications Figure 1 Bedknife-to-Reel Adjustment Reel Construction Bedknife adjusts against the reel with opposing screw adjustment on each end of the bedbar. 5 or 8 blade welded construction with 5 inch diameter. Height-of-Cut Bedknife Screw Torque 5-blade: 1/2 to 3/4 inch (1.27 to 1.91cm) 180 to 200 in-lb (20.3 to 22.6 N-m) 8-blade: 1/4 to 5/8 inch (0.64 to 1.59 cm) using Standard Rear Roller Kit (2 inch dia.) Model 03525 5/16 to 5/8 inch (0.79 to 1.59 cm) using Premium Rear roller Kit (2.
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Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be available from a local supplier. Cutting Units Model 03506 & 03509 Handle Assembly - TOR299100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel.
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Troubleshooting Turf Condition Turf conditions play a dramatic role in the aftercut appearance. Turf conditions must always be considered before attempting to remedy a problem with adjustments to your turf equipment. Equipment used strictly for mowing cannot remedy turf conditions but can often times be adjusted to adapt to a given turf condition. The goal of a turf equipment service person is to help address concerns by matching the equipment to the current conditions.
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Record information about the machine and turf conditions below to assist with your problem solving. Machine: Model Serial Number Engine @ RPM Serial Number Number of Blades Serial Number Cutting Units Model Model 03506 & 03509 Cutting Units: Use: (describe − i.e. Fairways, Outfields, Greens, etc.) HOC Number of Blades Over-seeded? Type of Grass Last Turf Maintenance Performed Date Current Weather Pattern (i.e. Drought, Hot, Wet, etc.
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Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST. Study this information 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 to a maximum of 40 ft-lb (54 N-m). CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first.
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Reel Bearing Adjustment and Service IMPORTANT: Before removing cutting unit, remove reel motors to prevent damaging hydraulic hoses. Cutting Units Model 03506 & 03509 It is recommended that a check be made periodically of the drag on the reel bearings. Proper adjustment of the reel bearings insures that no end play of reel exists and there is minimum rolling torque of reel assembly. All measurements and adjustments of reel rolling torque must be done with a completely assembled cutting unit.
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Adjust Bedknife to Reel IMPORTANT: The reel and bedknife must be parallel to insure the cutting unit cuts grass across the bedknife, and the reel and bedknife wear evenly. 2 1. Rotate cutting unit backward to gain access to the reel and bedknife. 2. Adjustment of bedknife to reel is accomplished by loosening bottom screw on each side of cutting unit (Fig. 8), and tightening the top adjustment screw (Fig. 9) on each side of cutting unit. This adjustment will position the bedknife closer to the reel blades.
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Level Front Roller to Reel 1. Adjust rear roller assembly to the lowest height-ofcut (see Adjust Height-of-Cut). Do not tighten lock nuts securing rear roller brackets at this time. 3 5 2. Place a 1/4 inch (6.4 mm) or thicker plate under the reel blades and against the cutting edge of the bedknife. Rear roller should not contact surface. 6 1 NOTE: When securing the front roller brackets, tighten fastener on inside of cutting unit frame so position of roller bracket does not change. 3.
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Adjust Height-of-Cut NOTE: Effective height-of-cut (H.O.C.) in the turf can be affected by lift arm down pressure adjustment and turf conditions, such as grass type, grass density, and amount of thatch. 1. Perform Adjust Bedknife to Reel and Level Front Roller to Reel before adjusting the height-of-cut. 2 4 1 2. To adjust height-of-cut, the cutting unit should be turned over. 3. Loosen locknut securing rear roller bracket to the side plate on each end of cutting unit.
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Adjust Front Shield Height Adjust shield to get proper grass clipping discharge into the basket or the desired front discharge when not using baskets. Cutting Units NOTE: Shield can be lowered in dry grass conditions (clippings fly over top of baskets) or raised to allow for heavy wet grass conditions (clippings build up on rear edge of basket. Model 03506 & 03509 1 2 1. Set cutting unit in normal cutting position. 2.
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Adjust Cutoff Bar Adjust top bar to make sure clippings are cleanly discharged from reel area: NOTE: Bar should be parallel to reel for optimum performance and should be adjusted whenever shield height is adjusted or whenever reel is sharpened on a reel grinder. 1 2 1. Loosen screws securing top bar. Insert 0.060 inch (1.52 mm) feeler gauge between the top of the reel and bar; tighten screws. Make sure bar and reel are an equal distance apart across the entire reel. 2.
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2 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 (37 N). 1 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. 2. Remove floor plate in front of seat and open the hood to get access to all five (5) springs.
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Service and Repairs Cutting Unit Removal and Installation Removal 2 Remove cutting unit from traction unit before doing adjustments or repairs. 1 1. Remove basket from cutting unit. 2. Disconnect chain from cross tube on each rear cutting unit (Fig. 18). 3. Loosen reel motor mounting nuts. Rotate motor clockwise so motor flanges clear studs. Pull motor off of cutting unit (Fig. 19). 4. Remove cap screw, lock washer, flat washer and thrust washer from cutting unit mounting shaft (Fig. 20). Figure 18 1.
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Backlapping 2 DANGER Model 03506 & 03509 1 Cutting Units Reels may stall while backlapping. Do not attempt to restart reels by hand or adjust while backlapping. Stop engine and set speed control to position 11 to the start reels; set to position 1 for backlapping. NOTE: Backlap either the front cutting units together or the rear ones together. 1. Park machine on a clean, level surface.
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DANGER Be careful when lapping the reel because contact with the reel or other moving parts can result in personal injury. 8. Apply lapping compound with long handled brush supplied with machine (Fig. 24). 9. To make an adjustment to the cutting units while backlapping, turn reels OFF by moving Lower Mow/ Raise lever REARWARD, Move Enable/Disable switch to DISABLE and turn engine OFF (Fig. 23). Figure 24 10.After adjustments have been completed, repeat steps 3 thru 8. 11.
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Bedbar Removal and Installation The rear roller assembly must be removed so the bedbar can be removed for bedknife sharpening. 3 1 2. Loosen set screws securing the rear roller shaft to rear roller brackets. 2 3. Note position, and unthread and remove height-ofcut (H.O.C.) adjustment bolts from both side plates. 4. Remove bedbar mounting bolts from each end of the cutting unit. Loosen bedknife adjusting screws at each end of cutting unit. Remove bedbar by rotating it away from the reel. 4 Figure 26 1.
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Bedknife Replacement and Grinding Replacement 1. Remove bedbar (see Bedbar Removal and Installation). 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 as follows: A. Make sure bedbar threads are clean. B. Use new bedknife screws (Toro Part No. 57-4910). Apply anti-seize lubricant to the screw threads before installing. IMPORTANT: Do not use an air or manual impact wrench. C.
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Note: Check to make sure reel bearings are in good condition and properly adjusted before grinding reel. IMPORTANT: Some reel grinders may require that the rear roller assembly be mounted to the cutting unit for proper support in the reel grinder. 1. Remove locknuts and cap screws securing the front roller brackets to the sideplates at both ends of the cutting unit (Fig. 11). 2. Remove front roller assembly from the cutting unit by pulling evenly on both sides. 3.
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Reel Removal and Bearing Replacement Removal 1 1. Remove the front roller assembly by removing lock nuts and cap screws securing the brackets to each side plate. Remove counterbalance end cap (Fig. 30) 2 3 2. Remove large bearing adjustment nut from the counterbalance end of the reel shaft and the special spline nut at the opposite end of the reel shaft (Fig. 30). 3. Remove mounting bolts from the bearing housing on both ends of cutting unit.
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Traction Unit Lift Arm Spring Replacement 1. Put machine on a level surface, lower cutting units, stop engine, engage parking brakes, and remove key from the ignition switch. Model 03506 & 03509 3 Cutting Units 2. Remove floor plate in the front of the seat to get access to the front springs, or open hood to get access to the rear springs. CAUTION 4 1 Springs are under tension. Use caution when removing or adjusting. 3. Put an open end wrench on the hex shaft of the spring bracket. 2 Figure 32 1.
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Cutting Units (Model 03506, S/N 80001 - 209999999) (Model 03509, S/N 80001 - 209999999) Page 8 - 22 Rev.
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Chapter 8.1 Model 03527, S/N 210000001 & Up Model 03528, S/N 210000001 & Up Cutting Units Table of Contents For cutting unit Models 03506 & 03509, see Chapter 8 “Cutting Units” in this manual. Reelmaster 5200-D/5400-D SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Cutting Unit Removal and Installation . . . . . . . . . . Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bedknife Replacement and Grinding . . . . . . . . . . Preparing Reel for Grinding . . . . . .
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Specifications Figure 1 REEL CONSTRUCTION: Fairway reels. All welded. 5 or 8 blades. Rear: Screw adjustable with bolt clamp lock used for setting height of cut. HEIGHT OF CUT RANGE: 5 Blade - 5/8” to 1” (13-25 mm) 8 Blade - 1/4” to 5/8” (6-16 mm) Selected Clip Control: The Reelmaster 5200/5400 is equipped with manually adjustable reel speeds (275 rpm to 2000 rpm) which control selected clip. Note: Heavy duty bedknife Part No. 100-3350 available for height-of-cuts over 1/2” (13 mm).
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Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your machine or be available as TORO parts. Some tools may also be available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife attitude. Cutting Units Model 03527 & 03528 Toro P/N 98-1852 Used only with Adjustable Front Height of Cut Kit Figure 2 Angle Indicator Use with Gauge Bar Assembly to verify bedknife attitude.
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Handle Assembly - TOR299100 For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel. Figure 5 Cutting Unit Tool Kit - TOR4070 This tool kit includes special tools required for rebuilding the cutting units on the Reelmaster 5200-D/5400-D.
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Troubleshooting Turf Condition It is important to remember that the same ”fix” will not work for every turf condition and it may not work every time in what seems to be identical conditions. Requirements are different between warm season grasses and cool season grasses and the cutting unit needs to be setup for the grass type and seasonal differences. Cutting Units A cutting unit that is set up incorrectly or improperly maintained can cause many problems.
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Record information about the machine and turf conditions below to assist with your problem solving. Machine: Model Serial Number Engine @ RPM Cutting Units: Model Serial Number Number of Blades Serial Number Use: (describe − i.e. Fairways, Outfields, Greens, etc.) HOC Number of Blades Over-seeded? Type of Grass Last Turf Maintenance Performed Date Current Weather Pattern (i.e. Drought, Hot, Wet, etc.
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Initial Set-up and Adjustments After the cutting unit is unboxed, use the following procedures to assure the cutting units are adjusted properly. 1. Check each end of the reel for grease. Grease should be visibly evident in the reel bearings and internal splines of reel shaft. Note: The cutting unit has been set at the factory at 1/2” (13 mm) height-of-cut and the front roller set in the normal attitude position (middle hole in front brackets).
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Bedknife to Reel Adjustment IMPORTANT: The reel and bedknife must be parallel to insure the cutting unit cuts grass across the bedknife, and the reel and bedknife wear evenly. 1. Rotate cutting unit backward to gain access to the reel and bedknife (Fig. 10). 2. Adjustment of bedknife to reel is accomplished by first, loosening bottom screw on each side of cutting unit (Fig. 9), then tightening the top adjustment screw on each side of cutting unit.
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Setting Cutting Unit Attitude Cutting unit “attitude” has a significant impact on the performance of the cutting unit. Attitude refers to the angle of the bedknife relative to the ground (Fig.11). Adjustable front and rear brackets allow for variable adjustment of cutting unit attitude within the height-of-cut range. All cutting units on a given machine must be set to the same attitude, otherwise after-cut appearance could be negatively affected.
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Adjusting Attitude (New Cutting Units) Table 1—New Cutting Unit Set Up Guide Desired Height of Cut (HOC) Optional Adjustable Front Height of Cut Kit Front Fixed Bracket Position A Position B Position C Attitude Range (min. to max.) Inches (mm) (Degrees) (Degrees) (Degrees) (Degrees) .250 (6) 6 3 Not Recommended 1 to 10 .375 (10) 7 4 1 1 to 11 .500 (13) 9 6 3 1 to 13 .625 (16) 10 7 4 1 to 14 .750 (19) 11 8 5 1 to 15 .875 (22) Not Recommended 10 7 1 to 11 1.
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Decreases Attitude 3 2 2 Increases Attitude 3 Cutting Units Model 03527 & 03528 1 1 Figure 14 1. Height of cut screw 2. Gauge bar angle Figure 15 3. Roller bracket (A, B, C) 1. Attitude screw 2. Gauge bar angle 3. Front height of cut kit Leveling Front Roller 1. Place a 1/2 in. or thicker plate under the reel blades and against the cutting edge of the bedknife (Fig. 16). The rear roller should not contact surface. 1 Note: Be sure the plate covers the full length of reel blades. 2.
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Adjusting Height of Cut 1. Rotate the cutting unit vertical and place the gauge bar across front and rear rollers (Fig. 18). 2. Loosen the locknuts securing the height-of-cut brackets to each end of the cutting unit (Fig. 18). 3. Set the head of the height of cut screw on the gauge bar to the desired height of cut, making this measurement from the bar face to the underside of the screw head. 4.
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Front Grass Shield Adjustment Adjust front grass shield for desired grass clippings dispersion. 1 1. Position cutting unit on a flat level surface. 2. Loosen capscrews and nuts securing shield to each side plate. Move shield to desired angle and tighten fasteners (Fig. 20). Cutting Units Model 03527 & 03528 2 Figure 20 1. Front grass shield 3. Capscrew & nut Rear Shield Adjustment Under most conditions, best dispersion is attained when rear shield is closed (front discharge).
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Adjust Lock-up Roller Adjust lock-up rollers so they contact the lock-up lever on each rear lift arm and support the cutting units when fully raised. The cutting units should have approximately 3/8 to 5/8 inch (9.5 to 15.9 mm) vertical travel when measured at the rear roller. 1 2 Figure 23 1. Lock-up roller 2. Lock-up lever Adjust Lift Arm Down Pressure The down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf conditions.
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Daily Adjustments Prior to each day’s mowing, or as required, each cutting unit must be checked to verify proper bedknife-to-reel contact. This must be performed even though quality of cut is acceptable. 1. Lower cutting units onto a hard surface, shut off engine and remove key from ignition. 2. Slowly rotate reel in reverse direction listening for reel−to−bedknife contact. If no contact is evident, turn bedknife adjusting knob clockwise, one click at a time, until light contact is felt and heard. .
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Service and Repairs Cutting Unit Removal and Installation IMPORTANT: The reel motors must be removed before removing the cutting units to prevent hose damage due to twisting, bending, and kinking. 1 Removal Remove cutting unit from traction unit before doing adjustments or repairs. 2 1. Remove basket from cutting unit. 2. Disconnect chain from each rear cutting unit cross tube (Fig. 27). 3. Loosen reel motor mounting nuts. Rotate motor clockwise so motor flanges clear studs.
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Backlaping 2 DANGER 1 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to disable position. Remove the key from the ignition switch. Figure 30 1. Front reel speed control 2. Unlock and raise the seat to expose the controls. 2. Rear reel speed control 2 3. Make the initial reel to bedknife adjustments appropriate for backlapping on all cutting units. Start the engine and set the engine at idle speed.
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8. Apply lapping compound with the long handled brush supplied with machine (Fig. 33). CAUTION Contact with the reel or other moving parts can result in personal injury. Stay away from the reel and other moving parts while backlapping. 9. To make an adjustment to the cutting units while backlapping, turn the reels Off by moving the lower mow/raise lever rearward, move the enable/disable switch to Disable, and turn the engine off. After adjustments have been completed, repeat steps 3-7. Figure 33 10.
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Bedknife Replacement and Grinding Replacement 1. Remove bedbar. 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 as follows: Cutting Units Model 03527 & 03528 A. Make sure bedbar threads are clean. B. Use new bedknife screws (Toro Part No. 57-4910). Apply anti-seize lubricant to the screw threads before installing. IMPORTANT: Do not use an air or manual impact wrench.
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Preparing Reel for Grinding The front roller may have to be removed so that the reel can be sharpened. Note: Check to make sure reel bearings are in good condition and properly adjusted before grinding reel. IMPORTANT: Some reel grinders may require that the rear roller assembly be mounted to the cutting unit for proper support in the reel grinder. 1. Remove locknuts and cap screws securing the front roller brackets to the sideplates at both ends of the cutting unit. 2.
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Reel and Reel Bearings 6 5 7 Cutting Units Model 03527 & 03528 14 4 13 1 12 11 10 15 8 16 3 9 2 Figure 37 1. 2. 3. 4. 5. 6. Bedbar Bedknife Reel Bedknife adjustment screw Cut-off bar Front grass shield 7. 8. 9. 10. 11. Rear grass shield Counterbalance end weight Spacer Reel adjustment nut Bearing Cone Bearing housing Grease fitting Spline nut Seal Bearing cup assembled cutting unit.
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B. Using a large socket wrench, remove the reel bearing adjustment nut (Fig. 39). Tap on the head of the hex head bolt on the end of the reel shaft, with a small hammer, until end play of the reel can be felt. C. Hold the reel to keep it from turning and slowly tighten the reel bearing adjustment nut until no end play of the reel exists. D. Using an appropriate torque wrench, check the rolling torque of the reel. The rolling torque of the reel should be 5 to 7 in.-lbs.
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Roller Bearing and Seal Replacement 1 2 3 5 6 7 8 9 4 Model 03527 & 03528 Sharp edge out Cutting Units 7 9 8 6 5 3 2 4 1 Lip of seal facing in Figure 40 1. Roller 2. Inner oil seal 3. Bearing 4. Roller shaft 5. Inner seal 6. Outer seal 7. Retaining ring 8. Outer oil seal 9. Washer NOTE: Bearing and seal configurations are the same for both the front and rear rollers. B. Install roller shaft from opposite end of roller. Be careful not to damage the inner oil seals. Removal C.
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Traction Unit Lift Arm Spring Replacement 1. Put machine on a level surface, lower cutting units, stop engine, engage parking brakes, and remove key from the ignition switch. 3 2. Remove floor plate in the front of the seat to get access to the front springs, or open hood to get access to the rear springs. CAUTION 4 1 Springs are under tension. Use caution when removing or adjusting. 3. Put an open end wrench on the hex shaft of the spring bracket. 2 Figure 41 1. Spring bracket hex shaft 2.
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Chapter 9 Unit Serial No. 80001 - 99999 4WD Rear Axle Table of Contents For Unit Serial No. 200000001 & Up, see Chapter 9.1 “4WD Rear Axle” in this manual. Reelmaster 5200-D/5400-D 2 2 3 4 4 5 5 5 6 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4WD Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Introduction Rear Axle and Overrunning Clutch Operation The following explanation is intended to clarify the operation of the 4WD rear axle and overrunning clutch used with this TORO product. 1 A drive shaft connected to the front axle provides power to the rear 4WD axle. The drive shaft incorporates an overrunning clutch that transfers power in the forward direction only (Fig. 1).
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Specifications Item Specification Rear wheel lug bolt torque 30 to 35 ft-lbs. (41 to 47 Nm) Rear wheel toe-in 0.000 to 0.125 in. (0.0 to 3.0 mm) Tire pressure (front and rear) 10 to 15 psi. (0.69 to 1.03 Bar) Axle lubricant SAE GL-5 80W90 gear lube No. 2 general purpose lithium grease 4WD Rear Axle Unit S/N 80001 - 99999 Four-Matic overrunning clutch lubricant Reelmaster 5200-D/5400-D Page 9 - 3 Rev. A 4WD Rear Axle (Unit Serial No.
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Maintenance Changing Rear Axle Lubricant Rear axle lubricant should be changed every 800 hours of operation. There are 3 separate oil reservoirs (axle support, right gear case, and left gear case) that require draining and refilling with SAE GL-5 80W90 gear lube. 1. Position machine on a level surface. 2. Clean area around the drain plugs. 3. Remove plugs allowing oil to drain into drain pans (Fig. 4). 4. After oil is drained, apply thread locking compound to all drain plug threads and reinstall. 5.
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Service and Repairs Drive Shaft 2 14 13 12 6 7 16 11 1 10 9 5 17 4 3 7 4WD Rear Axle 15 Unit S/N 80001 - 99999 18 19 Apply Never-Seez 8 Apply Loctite 110 to 120 ft-lbs. (149 to 163 Nm) Left Hand Threads 6 Apply Never-Seez Figure 7 1. 2. 3. 4. 5. 6. 7. Traction shaft Slip yoke Axle coupling Rear axle input shaft Capscrew Locknut End yoke 8. 9. 10. 11. 12. 13. Drive shaft assembly Set screw Bearing collar Carriage bolt Locknut Bearing support 14. 15. 16. 17. 18. 19.
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Installation 6 1. If front axle or traction shaft was removed: 5 A. Apply medium strength Loctite to coupler output shaft on rear of hydrostatic. 1 B. Slide traction shaft through bearing bracket, aligning the (2) bearing bracket mounting holes with the holes in side and bottom of hydrostatic (Fig. 8). C. Mount side of bracket to hydrostat with a capscrew, lock washer, flat washer and 1 or 2 shims (Fig. 8). D.
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Overrunning Clutch 9 3 Arrow end of roller clutches must face axle coupling mounting flange 1 4 2 9 6 5 8 7 9 Detail A 10 0.34” + 0.03” (8.6 mm +0.7mm) B A 0.04” Max. (1 mm Max.) 5 4WD Rear Axle Unit S/N 80001 - 99999 6 A Detail B Figure 9 1. 2. 3. 4. Capscrew Lock washer Axle coupling Clutch housing 8. Retaining ring 9. Roller clutch 10. Grease fitting 5. Shaft seal 6. Inner thrust washer 7. Outer thrust washer Removal Installation 1.
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4WD Rear Axle Note: For information on 2WD rear axle service and repairs, see Chapter 7−Steering and Brakes in this manual. 9 3 3 5 4 11 2 5 6 11 10 1 7 8 Figure 10 1. 2. 3. 4. Rear axle assembly Steering cylinder Hydraulic hose Tie rod 4WD Rear Axle (Unit Serial No. 80001 - 99999) 5. 6. 7. 8. Steering plate Rear wheel Lug bolt Rear wheel spacers Page 9 - 8 Rev. A 9. Pivot pin screw 10. Pivot pin 11.
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Removal Installation 1. Remove rear axle drive shaft (see Drive Shaft in this section of this manual). 1. Apply a thin coat of grease to the inside of the rear axle pivot bushings and move the rear axle assembly into position under machine frame. 1. Install the tie rod ball joints. Tighten ball joint hex nuts and install new cotter pins. Note: To ease reassembly, tag each of the hoses to show their correct position on the steering cylinder. 2.
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Disassembly 2 1 6 16 14 8 7 1 7 3 15 2 13 9 12 10 5 11 9 4 Figure 11 1. 2. 3. 4. 5. 6. Axle tube Axle Differential housing Pinion gear case Pinion gear Housing cover 7. 8. 9. 10. 11. Differential gear case Ring gear Pinion bearing Pinion nut Lock washer 12. 13. 14. 15. 16. Oil seal Bearing case shim Differential bearing shim Inspection cover Gearbox housing The following procedures assume the rear axle assembly has been removed from the machine. 3. Remove pinion gear case bolts.
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12 5 6 8 7 11 10 3 13 1 4 14 4WD Rear Axle Unit S/N 80001 - 99999 9 2 2 Figure 12 1. 2. 3. 4. 5. Gearbox housing Knuckle cover Knuckle housing Outer axle shaft Outer axle bevel gear 6. 7. 8. 9. 10. 11. 12. 13. 14. Knuckle arm Bearing retainer Knuckle pin Inner bevel gear Needle bearing 7. Remove knuckle cover bolts. Separate knuckle covers from knuckle housing. Remove outer bevel gear (Fig. 12). Washer Spacer Bearing Outer bevel gear 12.Remove the bearing retainer screws.
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Assembly Note: Always use new gaskets and Seals when assembling the rear axle. 1. Assemble differential gear case (Fig. 11). Use medium Loctite thread locker on gear case bolts and tighten evenly to 20 to 24 ft-lbs (27 to 33 Nm). 2. Assemble pinion gear and pinion gear case (Fig. 11). Tighten pinion nut to pre-load bearings. Pinion gear should require 2 to 5.5 in-lbs (0.23 to 0.62 Nm) torque to rotate. Once correct pre-load is set, bend tabs of lock washer and install oil seal. 3.
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Pinion Gear to Ring Gear Engagement Final position of pinion is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 13): TOE Toe−the portion of the tooth surface at the end towards the center. LENGTHWISE BEARING ARC HEEL Heel−the portion of the gear tooth at the outer end. Top Land−top surface of tooth. 1.
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D. Thinner pinion position shim with backlash constant moves the pinion further from the ring gear. Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. When making pinion position changes, shims should be changed in the range of .002 inch to .004 inch until a correct pattern has been obtained. Drive pattern (convex side of gear) moves toward the top of the tooth (face contact) and toward heel.
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Chapter 9.1 Unit Serial No. 200000001 & Up 4WD Rear Axle Table of Contents For Unit Serial No. 80001 - 9999, see Chapter 9 “4WD Rear Axle” in this manual. Reelmaster 5200-D/5400-D Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Introduction Rear Axle and Overrunning Clutch Operation The following explanation is intended to clarify the operation of the 4WD rear axle and overrunning clutch used with this TORO product. 1 A drive shaft connected to the front axle provides power to the rear 4WD axle. The drive shaft incorporates an overrunning clutch that transfers power in the forward direction only (Fig. 1).
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Specifications Item Specification Rear wheel lug nut torque 30 to 35 ft-lbs. (41 to 47 Nm) Rear wheel toe-in 0.000 to 0.125 in. (0.0 to 3.0 mm) Tire pressure (front and rear) 10 to 15 psi. (0.69 to 1.03 Bar) Axle lubricant SAE GL-5 80W90 gear lube No. 2 general purpose lithium grease 4WD Rear Axle Unit S/N 200000001 & Up Four-Matic overrunning clutch lubricant Reelmaster 5200-D/5400-D Page 9.1 - 3 Rev. A 4WD Rear Axle (Unit Serial No.
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Maintenance Changing Rear Axle Lubricant Rear axle lubricant should be changed every 800 hours of operation. There are 3 separate oil reservoirs (axle support, right gear case, and left gear case) that require draining and refilling with SAE GL-5 80W90 gear lube. 1. Position machine on a level surface. 2. Clean area around the drain plugs. 3. Remove plugs allowing oil to drain into drain pans (Fig. 4). 4. After oil is drained, apply thread locking compound to all drain plug threads and reinstall.
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Service and Repairs Drive Shaft 2 14 13 12 6 7 16 11 1 10 9 5 17 4 3 18 7 15 19 Apply Never-Seez 8 Apply Loctite 110 to 120 ft-lbs. (149 to 163 Nm) Left Hand Threads 4WD Rear Axle Apply Never-Seez Figure 7 1. 2. 3. 4. 5. 6. 7. Traction shaft Slip yoke Axle coupling Rear axle input shaft Capscrew Locknut End yoke 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
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Installation 6 1. If front axle or traction shaft was removed: 5 A. Apply medium strength Loctite to coupler output shaft on rear of hydrostatic. 1 B. Slide traction shaft through bearing bracket, aligning the (2) bearing bracket mounting holes with the holes in side and bottom of hydrostatic (Fig. 8). C. Mount side of bracket to hydrostat with a capscrew, lockwasher, flat washer and 1 or 2 shims (Fig. 8). D.
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Overrunning Clutch 9 3 Arrow end of roller clutches must face axle coupling mounting flange 1 4 2 9 6 5 8 7 9 Detail A 10 0.34” + 0.03” (8.6 mm +0.7mm) B A 0.04” Max. (1 mm Max.) 5 6 A Detail B 8. Retaining ring 9. Roller clutch 10. Grease fitting 5. Shaft seal 6. Inner thrust washer 7. Outer thrust washer Removal Installation 1. Remove drive shaft (see Drive Shaft Service in this section of this manual). 1. Install roller clutches in clutch housing. 2.
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4WD Rear Axle Note: For information on 2WD rear axle service and repairs, see Chapter 7−Steering and Brakes in this manual. 16 7 10 11 6 5 1 3 4 14 15 11 12 13 4 3 2 9 8 Figure 10 1. 2. 3. 4. 5. 6. Rear axle assembly Pivot pin Thrust washer Thrust washer Thrust washer Jam nut 4WD Rear Axle (Unit Serial No. 200000001 & Up) 7. 8. 9. 10. 11. Grease fitting Lug nut Rear wheel & tire Tie rod assembly Tie rod ball joints Page 9.1 - 8 Rev. A 12. 13. 14. 15. 16.
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Removal Installation 1. Remove rear axle drive shaft (see Drive Shaft in this section of this manual). 1. Apply a thin coat of grease to the inside of the rear axle pivot bushings and move the rear axle assembly into position under machine frame. 2. Drain rear axle lubricant (see Changing Rear Axle Lubricant in this section of this manual). 3. Thoroughly clean the steering cylinder hydraulic hose connections. Disconnect the hydraulic hoses from the steering cylinder.
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Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 1 Removal 6 5 1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 12). 4 2 2. Mark both right and left bevel gear case/axle case assemblies. 3 IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies. Figure 12 1. 2. 3. 4. 5. Bevel gear case/axle case assembly 6.
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5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 15). 8. Remove the axle case cover screws, cover, and the O-ring from the axle case. 3 4 5 7 9 16 8 10 9. Remove the plug and sealing washer from the center of the axle case cover. While holding the axle case cover, lightly tap the lower end of the bevel gear shaft out of the lower bearing and lower bevel gear. 13 6 10.
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Installation 1. Coat new shaft seals with grease and install in axle case and bevel gear case as shown (Fig. 17). 3 2 1 Figure 17 1. Axle case 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Fig. 18). Tighten cover screws to 17 to 20 ft-lbs. (23 to 27 Nm). 3. Slide the bevel gear case over the bevel gear shaft and install the thrust washer, spacer, bevel gear, and collar.
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5. Determine necessary quantity of support shims. 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin.
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9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 21). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual).
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Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 1 Removal 4 3 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 24). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 25). 3. Remove the shims, spacer, and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. 2 Figure 24 1. Axle case 2. Axle cover assembly 3.
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Input Shaft/Pinion Gear The following procedures assume the rear axle assembly has been removed from the machine. Removal 7 1. Remove input shaft/pinion gear assembly from the axle support. Remove the shims and bearing case Oring. 5 2. Release the stake washer and remove the locknut. Remove and discard the stake washer (Fig. 27). 4 3. Drive the input shaft/pinion gear out from the outer bearing cone and bearing case. Remove and discard the oil seal and O-ring. 8 4.
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9. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Fig. 29). Design Cone Center Distance 1 DESIGN CONE CENTER DISTANCE (distance from mating surface of axle support to end face of pinion gear): 1.870 + 0.002 in. (47.5 + 0.05 mm) 2 Note: Bearing case shims are available in 0.004 in. (0.1 mm) and 0.008 in. (0.
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Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 5 7 6 Removal 2 1 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left differential shafts assemblies. 4 2. Mark and pull the differential shaft assemblies from the axle support. 3 3. Remove input shaft/pinion gear assembly, shims, and O-ring from the axle support (Fig. 31). 4.
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Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 34). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 in. (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 in. (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
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Installation 3 1. If the ring gear was removed, use medium strength Loctite thread locker and tighten the mounting screws to 22 to 25 ft-lbs. (30 to 34 Nm). 2 1 2. Apply molybdenum disulfide to the splines and bearing surfaces of the differential pinion gears, pinion washers, and side gears. 3. Install the side gear shims and side gears in their original location in the differential case. 4. Place the differential pinion gears and pinion washers in their original location in the differential case.
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Pinion Gear to Ring Gear Engagement Final position of pinion is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 38): TOE Toe − the portion of the tooth surface at the end towards the center. LENGTHWISE BEARING ARC HEEL Heel − the portion of the gear tooth at the outer end. Top Land − top surface of tooth. 1.
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Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 2 1. If contact is toward the heel or base of the gear (Fig. 41): 1 A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 41 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. 1. Pinion shaft C.
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Chapter 10 Electrical Diagrams Table of Contents Reelmaster 5200-D/5400-D 3 4 5 6 7 Electrical Diagrams Electrical Schematic (Serial Number Below 210000400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic (Serial Number Above 210000400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Harness Drawing (Serial Number Below 210000400) . . . . . . . . . . . . . . . . . . . . . . . . . .
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Electrical Diagrams Page 10 - 2 Reelmaster 5200-D/5400-D
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2J 3N 3C 2C 3E 2G 2D 3G 2H 3H 3F WHITE BACKLAP REAR SWITCH BACKLAP FRONT SWITCH PINK 2E BLUE BLK LOWER/MOW SWITCH (JOYSTICK) BLACK/WHITE FRONT REELS DOWN SENSOR VIOLET RAISE SWITCH (JOYSTICK) ORANGE REELS DISABLE SWITCH BROWN REELS ENABLE SWITCH TAN SEAT SENSOR GREEN 2B 2F 3L 1A 3K 2K 1K PREHEAT RS232 (TX) RS232 (GND) BLACK GREEN/PINK ORANGE/BLUE BROWN/WHITE 9S BLACK/RED ”M” 8S 5S YELLOW/WHITE 2A 2S YELLOW/BLUE 1F 7S 1E ORANGE/RED 1D 6S ORANGE/BLUE 1C
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(MACHINES WITH SN ABOVE 220000001) Reelmaster 5200-D/5400-D Electrical Schematic (Serial Number Above 210000400) All relays and solenoids are shown as de−energized. All ground wires are black. Page 10 − 4 Rev.
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FUSE BLOCK TOP VIEW TEMP GAUGE COMMUNICATION PORT RED FAIL LIGHT WARNING LIGHT CLUSTER LIFT ARM SENSOR FUSE BLOCK BOTTOM VIEW ”A” ”B” LOOPBACK CONNECTOR ”I” IGNITION SWITCH REELS ENABLE FRAME GROUND HOUR METER FROM SWITCH OPTIONAL LIGHTS TO RELAY LEAK DETECTOR SPEEDOMETER SEAT SENSOR GREEN DIAGNOSTIC LIGHT PARKING BRAKE SWITCH FUEL SENDER TO LIGHTS HYDRAULIC SOLENOID GLOW RELAY HYDRAULIC SOLENOID BACKLAP SWITCH FUEL GAUGE CONTROLLER START RELAY SPEEDOMETER SENSOR NEUTRAL SENSOR FUS
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A3 B3 C3 D3 E3 A2 B2 C2 D2 E2 A1 B1 C1 D1 E1 F3 G3 H3 J3 K3 F2 G2 H2 J2 K2 F1 G1 H1 J1 K1 A3 B3 C3 A2 B2 C2 A1 B1 C1 30 Pin Connector Loop−Back connector Located in the control console Located in the control console 18 Pin Connector Located under the control console Plugged into the ACE control module Cavity Wire A1 Yellow A2 Black/Red A3 Violet/Red B1 Brown/White B2 Green Brown B3 C1 Orange/Blue C2 Green/White C3 Tan Yellow/Black D1 D2 Violet D3 Open E1 Yellow/White E2 Black/White E3 Brown D3 E3
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1 2 2 3 1 1 Hour Meter S1 Solenoid S2 Solenoid S4 Solenoid S5 Solenoid S6 Solenoid S7 Solenoid S8 Solenoid S9 Solenoid Located on RH side of the axle housing Located in the control console Located on lift manifold Located on lift manifold Located on lift manifold Located on lift manifold Located on lift manifold Located on lift manifold Located on lift manifold Located on lift manifold Cavity Wire A Pink/Blue B Red Cavity Wire A Brown/White B Black Cavity Wire A Yellow?Black B Black
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PARKING BRAKE SWITCH (MACHINES WITH SN ABOVE 220000000) Reelmaster 5200-D/5400-D Electrical Harness Drawing (Serial Number Above 210000400) Page 10 − 8 Rev.