Form No. 3354–501 Rev A Reelmaster 5200-D/5400-D Two-Wheel and Four-Wheel Drive Traction Units Model No. 03540—260000001 and Up Model No. 03543—260000001 and Up Model No.
Checking the Torque of the Wheel Nuts . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . Setting the Reel Speed . . . . . . . . . . . . . . . . . . . . . . Adjusting the Lift Arm Down Pressure . . . . . . . . . Towing the Traction Unit . . . . . . . . . . . .
Introduction CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
Preparation – stay alert for humps and hollows and other hidden hazards; • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. – never mow across the face of the slope, unless the mower is designed for this purpose. • Stay alert for holes in the terrain and other hidden hazards.
• Carefully release pressure from components with stored energy. • Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. • Disconnect battery and remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Keep hands and feet away from the cutting units.
• To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. Maximum governed engine speed should be 2900 RPM. – Do not drive close to sand traps, ditches, creeks, or other hazards. – Reduce speed when making sharp turns. Avoid sudden stops and starts. • If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor. – When near or crossing roads, always yield the right-of-way.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 107-8841 93-6693 104-2052 1. Hazard to hands–pinch points 2. Stop reels before touching 1.
104-9296 1. Throttle—slow 2. Throttle—fast 3. Reels raised & off 4. Reels lowered and on when enabled—forward and backlap 5. Reels—enabled 6. Reels disabled—lift only 7. Reels disabled—lift and lower 8. Headlights (optional) 9. Headlights—on 10. Headlights—off 11. Read operator’s manual 104-9298 1. Read operator’s manual 94-6767 98-9342 1. Read operator’s manual 2. Engine start 3. Headlights (Optional) 1. 2. 3. 4. 5. 6.
3-6699 1. Slow 2. Fast 3. Traction speed 106-9224 1. Warning—read the Operator’s Manual. 2. Cutting hazard of hand and foot—stop the reels before touching. 93-6691 1. Read operator’s manual–eccentric bolt 93-6697 (Model 03544 only) 1. Read operator’s manual 2. Lubrication point 3. Time interval 93-6692 1. Read operator’s manual 2. Do not prime engine 3. Do not use starting fluid 98-9335 1. Cutting dismemberment hazard–stay away from moving parts 93-6686 1. Hydraulic oil level 2.
93-6689 93-6680 1. Danger—no riders 1. Diesel fuel Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 105-7506 1. Read the Operator’s Manual 2. Engine—stop 3. On 4. Engine—preheat 5. Engine—start 93-1263 1. Read operator’s manual 2.
104-9294 1. Read the Operator’s Manual. 2. Do not tow the machine. 3. Warning—read the Operator’s Manual. 4. Cutting hazard of hand or foot—stay away from moving parts. 7. Warning—use a roll over protection system and wear the seat belt. 5. Warning—keep bystanders a safe distance from the machine. 6. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 8. Tipping hazard—lower the cutting unit when driving down slopes.
Specifications General Specifications Engine Kubota three cylinder, 4 cycle liquid cooled diesel engine. 25 hp @ 3000 rpm for Reelmaster 5200 and 31.5 hp @ 3000 rpm for Reelmaster 5400. Both governed to 3200 rpm. 68.5 cu. in. (1123 cc) displacement. Heavy duty, 3-stage, remote mounted air cleaner. High water temperature shutdown switch. Cooling System Radiator capacity is approximately 7-1/2 qt. of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted 1 qt. expansion tank.
Measurements Optional Equipment Width of Cut 95 in. Overall Width Transport 87 in. Outside of front tires 87 in. Outside of rear tires 52-1/2 in. Overall Length Without grass baskets 116 in. Height Without ROPS installed 56-1/2 in. With ROPS installed Part No. 104–3395 Comb Kit Part No. 104–3385 Solid Front Roller Part No. 82-6680 5 Blade Cutting Unit Model No. 03527 8 Blade Cutting Unit Model No. 03528 Rear Roller Brush Kit Model No. 03533 Front H.O.C. Adjusting Kit 103-1/2 in.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts, total setup cannot be completed. Description Qty. Use Locking hood switch 1 Lock washer 1 Nut 1 Key 2 Hood latch bracket 1 Capscrew, 1/4 x 3/4 in. 2 Flat washer, 1/4 in. 2 Locknut, 1/4 in. 2 Flange head capscrew, 5/16 x 5/8 in.
4. Slide the black, negative battery cable onto the negative battery post and tighten nut securely. 5. Coat both battery connections with Grafo 112X (skin over) grease, Toro Part No. 505–47, petroleum jelly or light grease to prevent corrosion and slide rubber boot over positive terminal. 2 6. Close hood. 1 Mounting the Hood Latch 1. Remove plug from hole in left front corner of hood (Fig. 2). 2. Open hood. Figure 1 1. Positive battery cable 1 2.
5. Adjust latch bracket, until aligned with switch latch, then tighten capscrews. BASKET BASKET GUIDE BRACKET 6. Rotate latch to locked and unlocked position with key. Remove key and store in memorable place. BASKET GUIDE L.H. FRONT 7. Close hood. Replacing the Panel Fasteners BASKET GUIDE L.H. REAR 1. Remove fasteners securing left front corner of floor panel and left end of access panel to frame (Fig. 4). R.H. FRONT CENTER BASKET BRACKET BASKET GUIDE BASKET BRACKET BASKET BRACKET R.H.
5. Align the mounting shaft of the cutting unit with the pivot tube on the carrier frame. Insert the shaft into the tube (Fig. 8). 2 3 4 9. Detach chain from lift arm and secure it to cross tube on each rear cutting unit with a capscrew, flat washer, and locknut (Fig. 10). 5 1 6 1 Figure 10 1. Lock-up chain Figure 8 1. Cutting unit mounting shaft 2. Carrier frame pivot tube 3.
Adjusting the Turf Compensation Spring Lifted Height of Outer Front Cutting Units (Enable Position) Note: This adjustment is needed for Cutting Unit Models 03527 and 03528 only. The turnaround height of the front outer cutting units (#4 & #5) may be increased to provide additional ground clearance on contoured fairways. Contact your distributor for assistance. The turf compensation spring (Fig. 12), connecting carrier frame to cutting unit, controls the amount of fore-aft rotation available.
Installing the Rear Weight The Reelmaster 5200-D & 5400-D Traction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 Standards when equipped with rear weight and 90 lb. of calcium chloride ballast is added to rear wheels. Use chart below to determine combinations of weight required. Order parts from your local Authorized Toro Distributor. Rear Weight Required Weight Part Number Weight Description Qty. 2wd Traction Unit with ROPS w/o baskets 291 lb.
Before Operating 2 Caution 1 If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine. Figure 15 1. Dipstick Checking the Engine Oil 2. Oil fill cap 3. If oil is below FULL mark, remove fill cap and add oil until level reaches FULL mark on dipstick. Do not overfill.
1 1 Figure 17 1. Fuel tank cap Checking the Transmission Fluid Figure 16 1. Expansion tank The front axle housing acts as the reservoir for the system. The transmission and axle housing are shipped from the factory with approximately 5 quarts of Mobil 424 hydraulic fluid. However, check level of transmission oil before engine is first started and daily thereafter. 2. If coolant level is low, remove expansion tank cap and replenish the system. Do not overfill. 3. Install expansion tank cap. 1.
Checking the Hydraulic Fluid 3. Remove dipstick from filler neck and wipe it with a clean rag. Insert dipstick into filler neck; then remove it and check level of fluid. Fluid level should be within 1/4 inch of mark on dipstick. The machines reservoir is filled at the factory with approximately 8 gallons of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is: 4.
4. Remove each end check plug and add enough lubricant to bring the level up to the bottom of each check plug hole. 5. Install all plugs. Checking Reel to Bedknife Contact Each day before operating, check reel to bedknife contact, regardless if quality of cut had previously been acceptable. There must be light contact across the full length of the reel and bedknife (refer to Adjusting Reel to Bedknife in Cutting Unit Operator’s Manual).
Operation To stop, reduce foot pressure on traction pedal and allow it to return to center position. Note: Determine the left and right sides of the machine from the normal operating position. Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. 1 Figure 23 Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine. 1.
Fuel Gauge 3 The fuel gauge (Fig. 25) shows amount of fuel in tank. 1 4 Lower Mow/Raise Control Lever 2 The lever (Fig. 25) raises and lowers the cutting units and also starts and stops the reels. 5 Glow Plug Indicator Light 7 6 When lit (Fig. 25), indicates a control system problem. Light blinks when glow plugs are preheating. Figure 24 1. 2. 3. 4. Traction speed limiter Reel control light Speedometer Brake pedals 5. Parking brake latch 6. Locking pin 7.
Reel Speed Controls 1. Sit on the seat, keep foot off traction pedal. Ensure that the parking brake is engaged, traction pedal is in NEUTRAL, throttle is in FAST position and the ENABLE/DISABLE switch is in the DISABLE position. The reel speed controls (Fig. 27) control the RPM of front and rear cutting units. #1 position is for backlapping. Remaining settings are for mowing operations. See section in manual for operating instructions. 2. Turn ignition switch to ON/Preheat position.
Danger Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck.
Adjusting the Lift Arm Down Pressure Towing the Traction Unit If it becomes necessary to tow the machine, tow it forward only, for a short distance and at a speed no greater than 3 mph. The down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf conditions. Increased down pressure will help keep the cutting units on the ground when mowing at higher speeds and helps maintain a uniform height-of-cut in rough conditions or in areas of thatch build up.
3. Attach the other end of the towing device to a vehicle that is capable of towing the machine safely and at speeds below 3 mph. • Fuses are blown. 4. An operator must be on the machine to steer it and keep the traction pedal fully depressed in the forward position while towing. Check electrical connections, input fuses and diagnostic light bulb to determine malfunction. Make sure loopback connector is secured to wire harness connector. • Not functioning correctly. 5.
blink on and off when corresponding switch is closed. Repeat on each switch that is it possible to be changed by hand. 7. If switch is closed and appropriate LED does not turn on, check all wiring and connections to switch and/or check switches with an ohm meter. Replace any defective switches and repair any defective wiring. The Diagnostic ACE also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic.
If the output LED’s are on as specified, but the machine does not function properly, this indicates a non–electrical problem. Repair as necessary. Operating Characteristics Note: Due to electrical system constraints, the output LED’s for “START”, “PREHEAT” and “ETR/ALT” may not blink even though an electrical problem may exist for those functions.
INPUTS 32 8) Backlap Rear Raise (To turn around front & rear) Raise (To turn around front & rear) 7) Backlap Front Raise (To turn around front) 6) Raise (transport) 5) Mow Lower / Mow–Front & Rear Lower / Mow–Front Lower (All units when enabled) Lower (All units when disabled) 4) Lower (To turn around) Run (with operator) 8 Enable Reels 7 Raise OO OO O X O X O X O X X O MX X X X X O X O X O X O X O O 9 Front Units Down X X O X X X X O X O X X X 11 Backlap Rear 10 Backlap Front O O O O
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important Refer to your engine operator’s manual for additional maintenance procedures. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure Check the fan and alternator belt tension. Torque the wheel lug nuts. Change the transmission fluid. Replace the transmission filter. After first 10 hours • • • • After first 50 hours • Replace the engine oil and filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the transmission oil level. Check the hydraulic system oil level. Check the hydraulic filter indicator.
Service Interval Chart Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine. Figure 38 Greasing the Bearing and Bushings The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Figure 40 Figure 43 Figure 41 Figure 44 Figure 42 Figure 45 36
General Air Cleaner Maintenance Servicing the Air Cleaner 1. Release the latches and remove the cover from the air cleaner body (Fig. 46). Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract.
Engine Oil and Filter Fuel Lines and Connections Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections. 1. Remove drain plug (Fig. 48) and let oil flow into drain pan. When oil stops, install drain plug. Fuel Filter/Water Separator Drain water or other contaminants from fuel filter / water separator (Fig.
4. Tighten pipe connector securely. 3. Loosen the hose clamps at both ends of the filter and pull fuel lines off filter. 5. Repeat steps on remaining nozzles. 2 2 1 1 Figure 51 1. Fuel filter 2. Hose clamps 4. Slide hose clamps onto ends of fuel lines. Push fuel lines onto fuel filter and secure them with hose clamps. Be sure arrow on side of filter points toward the injection pump. Figure 52 1.
3. Slightly raise oil coolers and pivot forward (Fig. 54). Clean both sides of oil coolers and radiator area thoroughly with compressed air. Pivot oil coolers back into position. 3. Loosen bolt securing brace to engine (Fig. 55) and bolt securing alternator to brace. 4. Insert pry bar between alternator and engine and pry out on alternator. 5. When proper tension is achieved, tighten alternator and brace bolts to secure adjustment. 2 Cooling Fan Belt 1 1. Loosen locknut on belt tensioner lever (Fig.
Replacing the Hydraulic Filter 1 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. Use the Toro replacement filter (Part No. 75-1310). Figure 57 Important Use of any other filter may void the warranty on some components. 1. Injection pump lever arm 1.
Checking the Hydraulic Lines and Hoses Adjusting the Traction Drive for Neutral Daily, check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating. 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.
Adjusting the Cutting Unit Lift Rate The cutting unit lift circuit is equipped with (3) adjustable valves used to ensure the cutting units do not raise too quickly and bang against lift stops. Adjust cutting units as follows: 1 Center Cutting Unit 1. Locate valve behind access panel above operator’s platform (Fig. 62). 2. Loosen setscrew on valve and rotate valve approximately 1/2 turn clockwise. Figure 63 1. Outside front cutting units adjustment valve 3.
Checking and Adjusting the Traction Linkage Adjusting the Service Brakes Adjust the service brakes when there is more than 1 inch of “free travel” of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. Due to normal wear in the control linkage and hydrostatic transmission, an increased amount of force may be required to return the transmissions to neutral. Periodically check the machine. 1.
Changing the Rear Axle Lubricant 6. Before starting the engine after changing transmission fluid, disconnect the run (ETR) solenoid on the engine, and crank the engine several times for 15 seconds. This allows the charge pump to fill the transmission with fluid before the engine is started. Note: This procedure is for model 03544 only. After every 800 hours of operation the oil in the rear axle must be changed. 1. Position machine on a level surface. 2. Clean area around the drain plugs (Fig. 68). 3.
7. Measure the distance at the front and the rear of the rear wheels at axle height. The distance at the front of the rear wheels should be 0–1/8 in. (0–3 mm) less than the distance measured at the rear of the wheels. 8. Repeat steps 3 through 7 if necessary. 9. Tighten ball joint hex nut and install a new cotter pin. Servicing the Battery Warning 1 CALIFORNIA Figure 69 Proposition 65 Warning 1.
Optional Lighting posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. Important If optional lighting is be added to the traction unit, use the following schematic and part numbers to prevent damage to the traction units electrical system. Fuses There are 4 fuses in the machines electrical system. They are located below control panel (Fig. 71 and 72).
Danger Changing the engine speed while backlapping may cause the reels to stall. • Never change the engine speed while backlapping. • Only backlap at idle engine speed. 5. Set both reel speed controls to position 11. Select either front or rear on backlap switch to determine which units to backlap. Danger To avoid personal injury, be certain that you are clear of the cutting units before proceeding. 6. Move Enable/Disable switch to Enable position.
RELAY 5 4 1 2 LIGHT SWITCH FUEL GAGE G S I BLACK BLACK G BLACK OIL PRESS SWITCH L S B 6 4 2 RED – BLACK BATTERY 12 VOLTS + RED WATER TEMP SENSOR FUSIBLE LINK HARNESS 5 3 1 WARNING LIGHTS SPEEDOMETER G S I ORANGE/RED STARTER START RELAY GREEN/BLUE ALTERNATOR ORANGE BLACK BLACK GRAY BLACK BLUE/GREEN ORANGE BLUE/WHITE ORANGE TEMP GAGE G S I FUSIBLE LINK OPTIONAL LIGHT ORANGE ORANGE RED GREEN/BLACK ORANGE BLACK ORANGE BLACK ORANGE L BLACK BLACK RED
P1 P3 STEERING CYLINDER TANK BREATHER 40 MICRON P2 LH RH 100MESH TEST PORT FOR FRONT UNITS INPUT SHAFT 3200 RPM MAX DIFFERENTIAL HOUSING STRAINER IN TANK 100 MESH INPUT SHAFT TO TRANSMISSION CCW ROTATION R F R F ”A” SYSTEM RELIEF 3625 PSI ”B” CHARGE PRESSURE 150 PSI ”C” COOLER BY–PASS 70 PSI ”D” FILTER BY–PASS 70 PSI ”E” SYSTEM RELIEF 3625 PSI ”C” ”A” FORWARD SIDE OF CLOSED LOOP ”D” ”B” SUNSTRAND M25 1.5 IN3 /REV ”E” M4 S4A S3A OUT IN TRW HGF 16 STEERING CONTROL VALVE 6.
Preparation for Seasonal Storage Engine 1. Drain the engine oil from the oil pan and replace the drain plug. Traction Unit 2. Remove and discard the oil filter. Install a new oil filter. 1. Thoroughly clean the traction unit, cutting units and the engine. 3. Refill oil pan with 4 quarts of motor oil. 2. Check the tire pressure. Inflate all traction unit tires to 15–20 psi. 4. Start the engine and run at idle speed for approximately two minutes. 3.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
