Installation Instructions

ManualsBrandsToro ManualsRiding ProductsFour Wheel Drive Kit, Reelmaster 5200-D, 5400-D and 5500-D

Printed in the USA

W 2005 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Four Wheel Drive Kit

Reelmaster

)

5200, 5400 & 5500

Model No. 03539

Form No. 3352–348

Installation Instructions

Note: Determine the left, right, front, and rear sides of the machine while seated in the normal operating position.

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Capscrew, 1/2 x 1–1/4 in.

Locknut, 1/2

Mount rear axle stops

Flatwasher, 2.50 O.D. x 1.406 I.D. x .018 thk.

Washer, 2.50 O.D. x 1.406 I.D. x .032 thk.

Cylinder support

Shims

Capscrew, M10 x 35mm

Steering cylinder

Shims

Cylinder pin

Self tapping screw

Capscrew, 3/4 x 2–1/8 in.

Thrust washers

Wheel nut

Cable tie

Decal

Traction shaft

Bearing assembly

Bearing bracket

Carriage bolt, 5/16 x 1–1/4 in.

Locknut, 5/16

Socket head screw, 3/8 x 3/4 in.

Capscrew, M8 x 25mm

Lockwasher, M8

Flatwasher, M8

Shims

Locking collar

Seat belts

Capscrew, 7/16 x 1 in.

Lockwasher, 7/16

Roll bar assembly

Capscrew, 1/2 x 1–1/4 in.

Flatwasher, 1/2 in.

Lockwasher, 1/2 in.

Hose clamp, R.H.

Hose clamp, L.H

Summary of content (8 pages)

PAGE 1
Form No. 3352–348 Four Wheel Drive Kit Reelmaster) 5200, 5400 & 5500 Model No. 03539 Installation Instructions Note: Determine the left, right, front, and rear sides of the machine while seated in the normal operating position. Loose Parts Note: Use the chart below to identify parts for assembly. DESCRIPTION QTY. Capscrew, 1/2 x 1–1/4 in. Locknut, 1/2 6 6 Flatwasher, 2.50 O.D. x 1.406 I.D. x .018 thk. Washer, 2.50 O.D. x 1.406 I.D. x .032 thk.
PAGE 2
DESCRIPTION QTY. Decals 2 Installation instructions Parts catalog 1 1 USE Read before installing the kit. Installation 1 Remove Old Axle 1. Block front tires and jack up rear of machine until there is approximately one inch clearance between rear tires and ground. Securely Block Frame and remove rear wheels. 2 2. Thoroughly clean around hydraulic hose connections to steering cylinder and disconnect hoses from cylinder. Make sure to mark or identify hose from rod end of cylinder. Figure 2 1.
PAGE 3
2 1 1 Figure 4 1 1. Rear of axle support 3. Secure rod end of steering cylinder to steering arm with a ball joint and slotted nut as shown in figure 5. Apply medium strength blue Loctite to nut before assembly. Tighten nut to 130–150 ft–lb. Secure with cotter pin. Figure 6 1. Axle hub 3 1 2. Wheel Install Drive Shaft 2 1 1. Apply medium strength Loctite to coupler output shaft on rear of hydrostat (Fig. 7). 1 Figure 5 1. Steering cylinder 2. Ball joint 3.
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6 5 2 1 2 4 3 3 Figure 8 1. Traction shaft 2. Bearing bracket 3. Capscrew, M8 x 25mm 5 4 4. Socket head screw 5. Carriage bolt 6. Bearing assembly 1 Figure 9 1. Bearing bracket 2. Hydrostat 3. Traction shaft 3. Mount side of bracket to hydrostat with a M8 x 25 mm capscrew, m8 lockwasher, M8 flat washer and 1 or 2 shims (Fig. 8). 4. Locking collar 5. Yoke end of drive shaft Note: Top carriage bolt (Fig. 8) must be installed. 9.
PAGE 5
Install Seat Belts To Seat 2. Lower roll bar onto frame, aligning mounting holes in sides and front of machine. 1. Install seat belt to holes in back of seat with (2) 7/16 x 1” lg. capscrews and 7/16 lockwashers. Tighten securely. Latch side of belt to be mounted to left side of seat (Fig. 11). Note: On Reelmaster 5500 models, hose clamps must be removed from each side of machine and replaced with the new left and right hose clamps when installing the roll bar. 3.
PAGE 6
Before Operating Install Decals 1. Using dimensions shown in figure 15, locate and mount a decal on side of tool box and side of control box. Check Rear Axle Lubricant The rear axle has three separate reservoirs which use SAE 80W-90 wt. gear lube. Although the axle is shipped with lubricant from the factory, check the level before operating the machine. 1 1. Position the machine on a level surface. 2. Remove check plugs (3) from axle and make sure lubricant is up to bottom of each hole (Fig. 16 & 17).
PAGE 7
Lubrication Greasing Bearings And Bushings The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation. Lubricate bearings and bushings immediately after every washing, regardless of the interval listed. Figure 20 The grease fitting locations and quantities are: Engine Drive shaft (3), (Fig. 18); Drive shaft clutch (1) (Fig.
PAGE 8
Maintenance Changing Rear Axle Lubricant After every 800 hours of operation the oil in the rear axle must be changed. 1. Position machine on a level surface. 1 2. Clean area around the drain plugs (Fig. 22). 3. Remove plugs allowing oil to drain into drain pans. Figure 24 1. Tie rod 4. After oil is drained, apply thread locking compound on drain plug threads and reinstall in axle. 2. To adjust, loosen clamps at both ends of tie rod. 3. Rotate tie rod to move front of tire inward or outward. 4.