Toro Reelmaster 5100-d User manual

Part No. 92796SL, Rev. C

Service Manual

Reelmaster® 5100-D

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing,

and repair of major systems and components on the

Reelmaster 5100-D

REFER TO THE REELMASTER 5100-D TRACTION

UNIT AND CUTTING UNIT OPERATOR’S MANUALS

FOR OPERATING, MAINTENANCE AND ADJUST-

MENT INSTRUCTIONS. Space is provided in Chap-

ter 2 of this book to insert the Operator’s Manuals and

Parts Catalogs for your machine. Replacement Opera-

tor’s Manuals are available by sending complete Model

and Serial Number of traction unit and cutting unit to:

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420

TheToroCompanyreservestherighttochangeproduct

specifications or this publication without notice.

This safety symbol means DANGER, WARN-

ING, or CAUTION, PERSONAL SAFETY IN-

STRUCTION. 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 - 1992 - 1997, 2004

This page is blank.

Table Of Contents

Chapter 1 - Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

Chapter 2 - Product Records and Manuals

Product Records. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

Equivalents and Conversions. . . . . . . . . . . . . . . . 2 - 2

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Maintenance Interval Charts. . . . . . . . . . . . . . . . . 2 - 4

Equipment Operation

and Service History Report. . . . . . . . . . . . . . . . 2 - 5

Chapter 3 - Mitsubishi Diesel Engine

Introductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18

Preparation for Engine Repair . . . . . . . . . . . . . . 3 - 25

External Engine Component Repair. . . . . . . . . . 3 - 26

Governor System Repairs . . . . . . . . . . . . . . . . . 3 - 31

Fuel System Repairs . . . . . . . . . . . . . . . . . . . . . 3 - 36

Removing and Installing theEngine. . . . . . . . . . 3 - 44

Cylinder Head Overhaul. . . . . . . . . . . . . . . . . . . 3 - 46

Cylinder Block Overhaul. . . . . . . . . . . . . . . . . . . 3 - 53

Chapter 4 - Hydraulic System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

General Information . . . . . . . . . . . . . . . . . . . . . . . 4 - 3

Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . 4 - 6

Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 - 7

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 33

Transmission Repairs. . . . . . . . . . . . . . . . . . . . . 4 - 35

Mowing Circuit Repairs. . . . . . . . . . . . . . . . . . . . 4 - 54

Hydraulic Reservoir and Filter . . . . . . . . . . . . . . 4 - 67

Chapter 5 - Electrical System

Wiring Schematics and Diagrams. . . . . . . . . . . . . 5 - 2

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32

Chapter 6 - Differential Axle

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 6 - 2

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3

Chapter 7 - Steering and Brakes

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11

Chapter 8 - Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5

Set-up and Adjustments . . . . . . . . . . . . . . . . . . . . 8 - 7

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15

Chapter 9 - 4WD Rear Axle

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2

General Information . . . . . . . . . . . . . . . . . . . . . . . 9- 3

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4

Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5

Reelmaster® 5100-D Rev. A

This page is blank.

Chapter 1

Safety

Table of Contents

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1

Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . 1

While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Instructions

The Reelmaster 5100-D was tested and certified by

TORO for compliance with the B71.4-1990 specifica-

tions of the American National Standards Institute’s

safety standards for riding mowers when 65 lbs. of

ballastis addedtorearwheelsandarearweightkit,part

no. 75-6690 is installed. Although hazard control and

accident prevention partially are dependent upon the

design and configuration of the machine, these factors

are also dependent upon the awareness, concern, and

proper training of the personnel involved in the opera-

tion, transport, maintenance, and storage of the ma-

chine.

Before Operating

1. Read and understand the Operator’s Manual before

starting, operating, maintaining or repairing the ma-

chine. Become familiar with the controls and know how

to stop the machine and engine quickly. Replacement

Operator’s Manuals are available by sending complete

Model and Serial Number of traction unit and cutting

units to:

The Toro Company

8111 Lyndale Avenue South

Minneapolis, MN 55420

UsetheModelandSerialNumberwhenreferringtoyour

machine.If youhave questionsaboutthis ServiceInfor-

mation, please contact:

The Toro Company

Commercial Service Department

8111 Lyndale Avenue South

Minneapolis, MN 55420

2. Never allow children to operate the machine. Do not

allow adults to operate the machine without proper

instruction. Only trained operators who have read the

Operator’s Manual should operate the machine.

While Doing Maintenance, Troubleshooting,

Testing, Adjustments or Repairs . . . . . . . . . . . . . 3

j

Improper operation, maintenance, trou-

bleshooting, testing, adjustments or repairs

ofthemachinecan resultinin uryor death.To

reduce the potential for injury or death, com-

ply with the following safety instructions.

CAUTION

3.Neveroperatethemachine when underthe influence

of drugs or alcohol.

4. Keep all shields, safety devices and decals in place.

If a shield, safety device or decal is defective or dam-

aged,repair or replace it before operating the machine.

Also tighten any loose nuts. bolts or screws to ensure

machine is in safe operating condition.

5. Always wear substantial shoes. Do not operate ma-

chinewhilewearing sandals,tennis shoes,sneakers.or

when barefoot. Do not wear lose fitting clothing that

could get caught in moving parts and possibly cause

personal injury. Wearing safety glasses, safety shoes,

long pants and a helmet is advisable and required by

some local ordinances and insurance regulations.

6. Assure interlock switches are adjusted correctly so

engine cannot be started unless traction pedal is in

NEUTRAL and cutting units are DISENGAGED.

7. Remove all debris or other objects that might be

picked up and thrown by the reels or fast moving com-

ponents from other attached implements. Keep all by-

standers away from operating area.

Reelmaster® 5100-D Page 1 - 1 Safety Instructions

8. Since diesel fuel is highly flammable, handle it C. Do not smoke while handling fuel.

carefully: D. Fill fuel tank outdoors and only to within an inch

A. Use an approved fuel container. of the top of the tank, not the filler neck. Do not

overfill.

B. Do not remove fuel tank cap while engine is hot

or running. E. Wipe up any spilled fuel.

While Operating

9. Sit on the seat when starting and operating the

machine.

10. Before starting the engine:

A. Engage theparking brake.

B. Make sure traction pedal is in NEUTRAL and the

ENABLE / DISABLE switch is in DISABLE.

C. After engine isstarted,release parking brakeand

keep footoff tractionpedal.Machinemustnotmove.

If movement is evident, the neutral return mecha-

nism is adjustedincorrectly;therefor, shutengineoff

and adjust until machine does not move when trac-

tion pedal is released.

11. Seating capacity is one person. Therefore, never

carry passengers.

12. Do not run engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and

could possibly be deadly.

13. Check interlock switches daily for proper operation.

Ifa switchfails,replaceitbeforeoperationthemachine.

The interlock system is for your protection, so do not

bypass it. Replace all interlock switches every two

years.

14. Using the machine demands attention. To prevent

loss of control:

A. Operate only in daylight or when there is good

artificial light.

B. Drive slowly.

C. Watch for holes or other hidden hazards.

D. Look behind machine before backing up.

E. Do not drive close to a sand trap, ditch, creek or

other hazard.

F. Reduce speed when making sharp turns and

turning on a hillside.

G. Avoid sudden stops and starts.

15. Traverse slopes carefully. Do not start or stop sud-

denly when traveling uphill.

16. Operatormustbe skilled and trained in how to drive

onhillsides.Failuretousecautiononslopesorhills 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.

17.Ifenginestalls or loosesheadwayandcannotmake

it to the top of a slope, do not turn machine around.

Always back slowly straight down the slope.

18. DON’T TAKE AN INJURY RISK! When a person or pet

appearsunexpectedlyinornearthemowingarea,STOP

MOWING. Careless operation, combined with terrain

angles, ricochets, or improperly positioned guards can

lead to thrown object injuries. Do not resume mowing

until area is cleared.

19. Do not touch engine, muffler or exhaust pipe while

engine is running or soon afteris stopped. These areas

could be hot enough to cause burns.

20.If cutting unitstrikesasolid objector vibrates abnor-

mally, stop immediately, turn engine off, set parking

brakeandwaitforallmotiontostop.Inspectfordamage.

Ifreel orbedknifeisdamaged,repairorreplace itbefore

operating.Do not attempt to free blocked cutting unit by

reversing its reel direction. Damage to the reel may

result.

21. Before getting off the seat:

A. Move traction pedal to neutral.

B. Set parking brake.

C. Disengagecutting unitsand waitfor reels to stop.

D. Stop engine and remove key from switch.

E.Donotparkon slopes unlesswheels are chocked

or blocked.

Safety Instructions Page 1 - 2 Reelmaster® 5100-D

While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs

22. Before servicing or making adjustments, stop the

engine and remove thekey from the ignition switch.

23.Makesuremachine is insafeoperating condition by

keeping all nuts, bolts and screws tight.

24. Frequently inspect all hydraulic line connectorsand

fittings. Make sure all hydraulic hoses and lines are in

good condition before applying pressure to the system.

25. Keep body and hands away from pin hole leaks or

nozzles that eject high pressure hydraulic fluid. Use

cardboard or paper to find hydraulic leaks. Hydraulic

fluid escaping under pressure can penetrate the skin

andcauseinjury.Fluidaccidentallyinjectedintotheskin

must be surgically removed within a few hours by a

doctor or gangrene may occur.

26.Beforedisconnecting,orperforminganyworkonthe

hydraulic system, lower the cutting units to the ground

and stop the engine so all pressure is relieved.

27.Be sure you understanda service procedurebefore

working on the machine. Unauthorized modifications to

the machine may impair the function, safety and life of

themachine. If major repairsare everneeded,or assis-

tance is desired, contact your TORO Distributor.

28. To reduce potential fire hazard, keep engine area

free of excessive grease, grass, leaves and dirt. Clean

protective screen on front of engine frequently. Do not

use flammable solvents for cleaning parts. Do not use

diesel fuel, kerosene or gasoline.

29. THE ASBESTOS BRAKE LININGS CONTAIN ASBES-

TOSFIBERS.BREATHING ASBESTOSDUSTMAYBEHAZ-

ARDOUS TO YOUR HEALTH AND MAY CAUSE SERIOUS

RESPIRATORY OR OTHER BODILY HARM. For your pro-

tection:

A. AVOID CREATING DUST.

B.DONOT removebrakedrumwithoutproperequip-

ment.

C. DO NOT work on brake linings without proper

protective equipment.

D. DO NOT replace brake linings without proper

protective equipment.

E. DO NOT attempt to sand, grind, chisel, file, ham-

mer, or alter brake linings in any manner without

proper protective equipment.

F. Follow O.S.H.A. standards for proper protective

devices to be used when working with asbestos

materials.

30. If the engine must be running to perform an inspec-

tionorprocedure,use extreme caution.Always usetwo

people, with the operator atthe controls able to see the

person doing the inspection or procedure. Keep hands,

feet, clothing, and body away from cutting units and

other moving parts.

31.Do notoverspeed the engine by changing governor

setting.

32. Shut engine off before checking or adding oil to the

engine crankcase.

33.Disconnect the cables fromthe battery before serv-

icing the machine. If battery voltage is required for

troubleshootingor testprocedures,temporarily connect

the battery.

34. Do not charge a frozen battery because it can

explode and cause injury. Letthe batterywarmto 60oF

(15.5o C) before connecting to a charger. Charge the

batteryinawell-ventilatedplacesothatgasesproduced

while charging can dissipate. Since the gases are ex-

plosive,keepopenflameandelectricalsparkawayfrom

the battery; do not smoke. Nausea may result if the

gases are inhaled. Unplug the charger from the electri-

cal outlet before connecting or disconnecting the

charger leads from the battery posts.

35. Wear safety glasses, goggles or a face shield to

prevent possible eye injury when using compressed air

for cleaning or drying components.

36. Failure to follow proper procedures when mounting

atire ona wheel or rim can producean explosionwhich

may result in serious injury. Do not attempt to mount a

tire unless you have the proper equipment and experi-

ence to perform the job. Have it done by your Toro

Distributor or a qualified tire service.

37. When changing attachments or performing other

service, use the correct blocks and hoists. Always use

jackstands to safely support the machine when it is

raised by a jack orhoist.

38. Do not use your hand to prevent cutting unit reel

from turning while servicing; this can result in personal

injury.Usea 1-1/2 in. thickx 4 in.wide x 8 in. longpiece

of hardwood inserted into front of cutting unit between

reel blades.

39. For optimum performance and safety, use genuine

Toro replacement parts and accessories. Replacement

parts and accessories made by other manufacturers

may result in non-conformance with the safety stand-

ards, and the warranty may be voided.

Reelmaster® 5100-D Page 1 - 3 Safety Instructions

Safety Instructions Page 1 - 4 Reelmaster® 5100-D

Chapter 2

Product Records and Manuals

Table of Contents

PRODUCT RECORDS. . . . . . . . . . . . . . . . . . . . . . . 1

EQUIVALENTS AND CONVERSIONS . . . . . . . . . . 2

Decimal and Millimeter Equivalents . . . . . . . . . . 2

U.S. to Metric Conversions . . . . . . . . . . . . . . . . . 2

Product Records

Record information about your Reelmaster 5100-D on

the OPERATION AND SERVICE HISTORY REPORT

form. Use this information when referring to your ma-

chine.

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3

Capscrew Markings and Torque Values - U.S. . . 3

Capscrew Markings and Torque Values - Metric . 3

MAINTENANCE INTERVAL CHART . . . . . . . . . . . . 4

OPERATON AND SERVICE HISTORYREPORT

Insert Operator’s Manuals and Parts Manuals for your

Reelmaster 5100-D at the end of this section.

Reelmaster® 5100-D Page 2 - 1 Rev. A Product Records

___ ________________ ______ ________________ __________________________________________________

__ __ __ __

Equivalents and Conversions

Decimal and Millimeter Equivalents

Fractions Decimals mm Fractions Decimals mm

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097

1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494

3/64 0.046875 — 1.191 35/64 0.546875 — 13.891

1/16–––––––––––– 0.0625 — 1.588 9/16–––––––––––– 0.5625 — 14.288

5/64 0.078125 — 1.984 37/64 0.578125 — 14.684

3/32 ––––– 0.9375 — 2.381 19/32 –––– 0.59375 — 15.081

7/64 0.109275 — 2.778 39/64 0.609375 — 15.478

1/8––––––––––––– 0.1250 — 3.175 5/8––––––––––––– 0.6250 — 15.875

9/64 0.140625 — 3.572 41/64 0.640625 — 16.272

5/32 ––––– 0.15625 — 3.969 21/32 –––– 0.65625 — 16.669

11/64 0.171875 — 4.366 43/64 0.671875 — 17.066

3/16–––––––––––– 0.1875 — 4.762 11/16 ––––––––––– 0.6875 — 17.462

13/64 0.203125 — 5.159 45/64 0.703125 — 17.859

7/32 ––––– 0.21875 — 5.556 23/32 –––– 0.71875 — 18.256

15/64 0.234375 — 5.953 47/64 0.734375 — 18.653

1/4––––––––––––– 0.2500 — 6.350 3/4––––––––––––– 0.7500 — 19.050

17/64 0.265625 — 6.747 49/64 0.765625 — 19.447

9/32 ––––– 0.28125 — 7.144 25/32 –––– 0.78125 — 19.844

19/64 0.296875 — 7.541 51/64 0.796875 — 20.241

5/16–––––––––––– 0.3125 — 7.938 13/16––––––––––– 0.8125 — 20.638

21/64 0.328125 — 8.334 53/64 0.828125 — 21.034

11/32 –––– 0.34375 — 8.731 27/32 –––– 0.84375 — 21.431

23/64 0.359375 — 9.128 55/64 0.859375 — 21.828

3/8––––––––––––– 0.3750 — 9.525 7/8––––––––––––– 0.8750 — 22.225

25/64 0.390625 — 9.922 57/64 0.890625 — 22.622

13/32 –––– 0.40625 — 10.319 29/32 –––– 0.90625 — 23.019

27/64 0.421875 — 10.716 59/64 0.921875 — 23.416

7/16–––––––––––– 0.4375 — 11.112 15/16––––––––––– 0.9375 — 23.812

29/64 0.453125 — 11.509 61/64 0.953125 — 24.209

15/32 –––– 0.46875 — 11.906 31/32 –––– 0.96875 — 24.606

31/64 0.484375 — 12.303 63/64 0.984375 — 25.003

1/2––––––––––––– 0.5000 — 12.700 1 –––––––––––––– 1.000 — 25.400

1 mm = 0.03937 in. 0.001 in. = 0.0254 mm

U.S to Metric Conversions

To Convert Into Multiply By

Linear Miles Kilometers 1.609

Measurement Yards Meters 0.9144

Feet Meters 0.3048

Feet Centimeters 30.48

Inches Meters 0.0254

Inches Centimeters 2.54

Inches Millimeters 25.4

Area Square Miles

Square Feet

Square Inches

Acre

Square Kilometers 2.59

Square Meters 0.0929

Square Centimeters 6.452

Hectare 0.4047

Vol ume Cubic Yards

Cubic Feet

Cubic Inches

Cubic Meters 0.7646

Cubic Meters 0.02832

Cubic Centimeters 16.39

Weight Tons (Short)

Pounds

Ounces (Avdp.)

Metric Tons 0.9078

Kilograms 0.4536

Grams 28.3495

Pressure Pounds/Sq. In. Kilopascal 6.895

Pounds/Sq. In. Bar 0.069

Work Foot-pounds

Foot-pounds

Inch-pounds

Newton-Meters 1.356

Kilogram-Meters 0.1383

Kilogram-Centimeters 1.152144

Liquid Volume Quarts Liters 0.9463

Gallons Liters 3.785

Liquid Flow Gallons/Minute Liters/Minute 3.785

Temperature Fahrenheit Celsius 1. Subract 32o

2. Multiply by 5/9

Equivalents and Conversions Page 2 - 2 Reelmaster® 5100-D

_____________ ________________ ______ ________________ ______ ________________ __________________________________ ______________________________

__ __ __ __ __ __ ___

Torque Specifications

Use these torque values when specific torque values specified values. Torque values listed are for lubricated

are not given. DO NOT use these values in place of threads.Plated threadsareconsidered tobe lubricated.

Capscrew Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8

Capscrew Head Markings

Capscrew Body Size Capscrew Torque - Grade 5

Cast Iron Alumi Capscrew Torque - Grade 8

num Cast Iron Aluminum

ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm

1/4-20 7 9 6 8 11 15 9 12

-28 912 7 913181014

5/16-18 15 20 12 16 22 30 18 24

-24 17 23 14 19 24 33 19 25

3/8-16 30 40 20 25 40 55 30 40

-24 30 40 25 35 45 60 35 45

7/16-14 45 60 35 45 65 90 50 65

-20 50 65 40 55 70 95 55 75

1/2-13 70 95 55 75 95 130 75 100

-20 75 100 60 80 110 150 90 120

9/16-12 100 135 80 110 140 190 110 150

-18 110 150 85 115 155 210 125 170

5/8-11 135 180 110 150 190 255 150 205

-18 155 210 120 160 215 290 170 230

3/4-10 240 325 190 255 340 460 270 365

-16 270 365 210 285 380 515 300 410

7/8-9 360 490 280 380 550 745 440 600

-14 390 530 310 420 610 825 490 660

1-8 530 720 420 570 820 1100 660 890

-14 590 800 480 650 890 1200 710 960

Capscrew Markings and Torque Values – Metric

Commercial Steel Class 8.8 10.9 12.9

Capscrew Head Markings

Thread Capscrew Torque - Class 8.8 Capscrew Torque - Class 10.9 Capscrew Torque - Class 12.9

Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum

mm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm

65947914711914711

7 914 7111418111418231418

8182514182332182527362128

10 30 40 25 30 45 60 35 45 50 70 40 55

12 55 70 40 55 75 105 60 80 95 125 75 100

14 85 115 65 90 120 160 95 125 145 195 110 150

16 130 180 100 140 175 240 135 190 210 290 165 220

18 170 230 135 180 240 320 185 250 290 400 230 310

Reelmaster® 5100-D Page 2 - 3 Torque Specifications

Maintenance Interval Chart

Maintenance Interval Chart Page 2 - 4 Rev.A Reelmaster® 5100-D

____________________

____________________ __________________

EQUIPMENT OPERATION AND SERVICE HISTORY REPORT

for

REELMASTER®223-D, 5100-D, AND 5300-D

TORO Model and Serial Number:__________-__________

Engine Numbers: ____________________

Transmission Numbers: ____________________

Drive Axle(s)Numbers: ____________________

Date Purchased: ____________________ Warranty Expires__________

Purchased From: ____________________

Contacts: Parts Phone

Service Phone

Sales Phone

See your TORODistributor/Dealer for other Publications, Manuals, and Videos from The TORO Company.

REELMASTER® 223-D, 5100-D, and 5300-D Maintenance Schedule

Minimum Recommended Maintenance Intervals:

Maintenance Procedure Maintenance Interval & Service

Every

Every 800hrs

Check Battery Fluid Level Every 400hrs

200hrs

100hrs

Check Battery Cable Connections 50hrs

Lubricate All Grease Fittings

Change Engine Oil A Level

Inspect Air Filter, Dust Cup, and Baffle Service

† Check Fan and Altenator Belt Tension

‡ Replace Engine Oil Filter B Level

Inspect Cooling System Hoses Service

Drain Moisture-Hyd. Tank

Drain Moisture-Fuel Tank

Check Reel Bearing Preload Adjustment C

† Torque Wheel Lug Nuts Level

Service Air Filter

Replace Electric Fuel Pump Filter

Replace Fuel/WaterSeparator Filter

Inspect Traction Linkage Movement

‡ Torque Head and Adjust Valves D

‡ Check Engine RPM (idle and full throttle) Level

Change Hydraulic Fluid

Change Transmission Fluid

† Replace Transmission Filter

Check Rear Wheel Toe-in

Rear Axle Service

- pack Rear Wheel Bearings (2WD) E Level

- change Rear Axle Lubricant (4WD) Service

† Initial break in at 10 hours

‡ Initial break in at 50 hours

Replace Moving Hoses

Replace Safety Switches Annual Recommendations:

Items listed are recommended every 1600

Coolant System - Flush/Replace Fluid hours or 2 years whichever occurs first.

Fuel Tank - Drain/Flush

Hydraulic Tank - Drain/Flush

(See Operator's and Service Manual for specifications and procedures)

_____________

_____ _____ _____ _____ _____ _____ _____

REELMASTER® 223-D, 5100-D and 5300-D Daily Maintenance Check List

Unit Designation:__________

Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______

Maintenance Check Item

Daily Maintenance Check For Week Of

MON

HRS TUES

HRS WED

HRS THURS

HRS FRI

HRS SAT

HRS SUN

HRS

Safety Interlock Operation

Brake Operation

Engine Oil & Fuel Level

Cooling System Fluid Level

Drain Water/Fuel Separator

Air Filter/Pre-Cleaner Condition

Radiator & Screen for Debris

Unusual Engine Noises1

Unusual Operating Noises

Transmission Oil Level

Hydraulic System Oil Level

Hydraulic Filter Indicator2

Hydraulic Hoses for Damage

Fluid Leaks

Tire Pressure

Instrument Operation

Reel-to-Bedknife Adjustment

Height-of-Cut Adjustment

Cutting Units Shear Pin

Lubricate All Grease Fittings

3

Touch-up damaged paint

1 = Check glow plugs and injector nozzles, if hard starting, excess smoke, or rough running is noted.

2 = Check with engine running and oil at operating temperature.

3 = Immediatelyafter every washing, regardless of the interval listed.

Notation for areas of concern: Inspection performed by:________________

Item Date Information

1

2

3

4

5

6

7

(See Operator's and Service Manual for specifications and procedures)

_________________________________

_________________________________ _________________________________ ______________________________

______________________________

_________________________________ ______________________________

_________________________________ _________________________________ ______________________________

REELMASTER® 223-D, 5100-D, and 5300-D Supervisor Maintenance Work Order Date:______________

(duplicate this page for routine use)

Unit Designation: TORO I.D. #: Remarks:

____________-____________

Service to perform (circle):

A B C D E Other

Technician:

A -Service (every 50 hours) B -Service (every 100 hours) C -Service (every 200 hours)

Check Battery Fluid Level Check Fan and Altenator Belt Tension Drain Moisture-Hyd. Tank

Check Battery Cable Connections Replace Engine Oil Filter Drain Moisture-Fuel Tank

Lubricate All Grease Fittings Inspect Cooling System Hoses Check Reel Bearing Preload

Change Engine Oil A-Service required Torque Wheel Lug Nuts

Inspect Air Filter, Dust Cup, and Baffle A and B Service required

D -Service (every 400 hours) E -Service (every 800 hours) Other

Service Air Filter Change Hydraulic Fluid Replace Moving Hoses

Replace Electric Fuel Pump Filter Change Transmission Fluid Replace Safety Switches

Replace Transmission Filter Coolant System - Flush/Replace Fluid

Inspect Traction Linkage Movement Check Rear Wheel Toe-in Fuel Tank - Drain/Flush

Torque Head and Adjust Valves Pack Rear Wheel Brgs/Change 4WD Oil Hydraulic Tank - Drain/Flush

Check Engine RPM (idle and full throttle) A, B, C, and D Service required

A, B, and C Service required

Hours:

- Annual Service and Specials

Replace Fuel/WaterSeparator Filter

(See Operator's and Service Manual for specifications and procedures) Form No. 95-839-SL

Chapter 3

Mitsubishi Diesel Engine

Table of Contents

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Thermostat Removal and Installation . . . . . . . . 29

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Water Pump Service . . . . . . . . . . . . . . . . . . . . . 30

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GOVERNOR SYSTEM REPAIRS . . . . . . . . . . . . . 31

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Governor Operation. . . . . . . . . . . . . . . . . . . . . . 31

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 7 Governor Inspection . . . . . . . . . . . . . . . . . . . . . 32

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Governor Service. . . . . . . . . . . . . . . . . . . . . . . . 33

Governor System . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation of Torque Spring Set . . . . . . . . . . . . 34

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly of Torque Spring Set . . . . . . . . . . . . . 35

Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . 9 FUEL SYSTEM REPAIRS . . . . . . . . . . . . . . . . . . . 36

Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . 10 Bleeding the Fuel System . . . . . . . . . . . . . . . . . 36

SPECIALTOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Bleeding Air From the Injectors . . . . . . . . . . . . . 37

ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fuel Pump Service . . . . . . . . . . . . . . . . . . . . . . 37

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . 13 Injection Pump Service . . . . . . . . . . . . . . . . . . . 38

Engine Speed Adjustments. . . . . . . . . . . . . . . . 14 Nozzle Service. . . . . . . . . . . . . . . . . . . . . . . . . . 41

Throttle Linkage Adjustment . . . . . . . . . . . . . . . 15 Removing and Installing the Fuel Tank . . . . . . . 43

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . 15 REMOVINGAND INSTALLING THE ENGINE. . . . 44

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removing the Engine . . . . . . . . . . . . . . . . . . . . 44

Glow PlugTest . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installing the Engine . . . . . . . . . . . . . . . . . . . . . 45

Compression Test . . . . . . . . . . . . . . . . . . . . . . . 19 CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . . 46

Nozzle Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Cylinder Head Removal. . . . . . . . . . . . . . . . . . . 46

Injection Pump Test. . . . . . . . . . . . . . . . . . . . . . 22 Cylinder Head Service. . . . . . . . . . . . . . . . . . . . 47

Injection Timing Test . . . . . . . . . . . . . . . . . . . . . 23 Valve Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . 24 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Thermostat Test. . . . . . . . . . . . . . . . . . . . . . . . . 24 Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

PREPARATION FOR ENGINEREPAIR. . . . . . . . . 25 Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Cylinder and Cylinder Block Overhaul . . . . . . . 25 Rocker Arm and Rocker Shaft . . . . . . . . . . . . . 50

EXTERNAL ENGINE COMPONENT REPAIR. . . . 26 Cylinder Head Reassembly and Installation . . . 51

Cooling Fan Belt and CYLINDER BLOCK OVERHAUL . . . . . . . . . . . . . . 53

Alternator Belt Replacement. . . . . . . . . . . . . . . 26 GearCase and Oil Pump . . . . . . . . . . . . . . . . . 53

AlternatorRemoval and Installation . . . . . . . . . 27 Timing Gears and Camshafts . . . . . . . . . . . . . . 56

Starter Removal and Installation. . . . . . . . . . . . 27 Piston and Connecting Rod. . . . . . . . . . . . . . . . 59

Replacing and/or Adjusting Stop Solenoid . . . . 28 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Glow Plug Replacement . . . . . . . . . . . . . . . . . . 29 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Oil Pressure Switch Replacement. . . . . . . . . . . 29

Reelmaster® 223-D/5100-D Page 3 - 1 Table of Contents

Introduction

Most repairs and adjustments require tools which are

commonly available in many service shops. Special

toolsaredescribedintheSpecialTools section.Theuse

of some specialized test equipment is explained, how-

ever, the cost ofthe test equipment and the specialized

nature of some repairs may dictate that the work be

done at a qualified diesel engine repair facility.

The engineismanufacturedbyMitsubishiHeavyIndus-

tries Limited. Service and repair parts for Mitsubishi

engines are supplied through TORO Distributors. Re-

pair parts may be ordered by TORO Part Number. If no

parts list is available be sure to provide your dealer or

distributor with the TORO Model Number and Serial

Number. Figure 1a

The engine model number is cast onto the injection

pump side of the cylinder block (Fig. 1a). The serial

number is stamped on the injection pump mounting

surfaceofthecrankcase(Fig.1b).Thereisalsoamodel

and serial number decal on the valve cover.

Figure 1b

Introduction Page 3 - 2 Reelmaster® 223-D/5100-D

Specifications

The illustrations (Figs. 2a and 2b) will give information Refer to the specifications listed in this section when

about the general construction of the engine. performing tests on the engine or examining parts for

wear. Some specifications are included in the service

procedures later in this chapter.

Figure 2a Figure 2b

Reelmaster® 223-D/5100-D Page 3 - 3 Specifications

________________________________________________________________________________________

______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ ___ ______ _

__

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

General

Item Specification

Make/Designation Mitsubishi L3E-61TG, overhead valve,

vertical in-line, 4 cycle diesel

Combustion Chamber Swirl chamber type

Number of Cylinders 3

Bore x Stroke 76 x 70 mm (2.99 x 2.76 in.)

Total Displacement 952 cc (58 in.3)

Compression Ratio 23:1

Firing Order 1 - 3 - 2

Dry Weight (approximate) 75 kg (165 lb.)

Fuel Diesel

Fuel Injection Pump Bosch type NC

Governor Centrifugal weight type

Fuel Injector Nozzle Throttle type

Fuel Injection Pressure (140 kg/cm2) 1990 psi

Lubrication System Forced lubrication

Oil Pump Gear type

Oil Filter Paper element filter (full flow type)

Crankcase Oil Capacity:

including filter of 0.5 liter (0.6 qt.) capacity - FULL / LOW 3.6 / 1.8 liter (3.8 / 1.9 qt.)

Cooling System Forced circulation, water cooling

Water Pump Centrifugal type

Cooling System Capacity

Engine Only 1.8 liter (1.9 qt.)

Total System (approximate) 6.1 liter (6.4 qt.) with expansion tank

Starter Solenoid shift type

1.6 kW (12 volt)

Alternator AC type 12 volt 40A

Glow Plug Sheathed type

Specifications Page 3 - 4 Reelmaster® 223-D/5100-D

Toro Reelmaster 5100-D User manual

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