FORM NO. 3316664 Rev. A MODEL NO. 03502 — 40001 & UP OPERATOR’S B MODEL NO. 03504 — 40001 & UP MANUAL REELMASTER® 5100-D 2 & 4 WHEEL DRIVE TRACTION UNITS J To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. A it means CAUTION, WARNING or DANGER personal safety instruction. Failure to comply with the instruction may result in personal injury.
FOREWORD This operator's manual has instructions on safety, proper set—up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual.
TABLE OF CONTENTS Page SAFETY INSTRUCTIONS Before Operating .. While Operating Maintenance SAFETY INSTRUCTIONS & DECALS SPECIFICATIONS .. LOOSE PARTS CHART SET-UP INSTRUCTIONS .10 Install Front Wheels .10 Install Steering Wheel . .10 Install Seat .10 Install Seat Belt {(Model 03504 only} . ..o 10 install Roll Bar {(Model 03504 only) .. .
A SAFETY INSTRUCTIONS The REEL MASTER 5100-D was tested and certified by TOR for compliance with the specifications of the American National Standards Institute, 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 operation, transport, maintenance, and storage of the machine.
A SAFETY INSTRUCTIONS 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 wheal drive medal, always use the seat belt and TOPS together. 17. f engine stalls or loses power and cannot make it to the top of a slope, do not turn machine around. Always back slowly straight down the slope.
A SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are affixed to the traction unit, if any decal becomes illegible or damaged, install a new decal. Part numbers are sifted below and in your Parts Catalog. ‘ HYDRAULIC OIL ONLY OLDSMOBILE £ ON RIGHT FENDER { Park No. 85-4730) N IMPORTANT ‘fl THIS UNIT COMPLIES WITH ANG) TERR BALLAST P57 GENERATORS ) 67141980 WHEN EQUIPPED Wit H D) ON LEFT FENDER ON TOOL BOX COVER { Part No. 886700 ) { Part No, 52-1320) WARNING {Part No.
SPECIFICATIONS Engine: Mitsubishi three liquidizer cooled diesel engine. 23.0 hp @ governed maximum rpm of 3200. 58.1 cu. in. (952 cc) displacement. Heavy duty, 3-stage, remote mounted air cleaner. High water temperature shutdown switch, Cooling System: Radiator capacity is approximately 6 qts. of50/50 mixture of ethylene glycol anti—freeze. Remote mounted 1 gt. expansion tank, A two speed fan drive controls air flow from fan. Fuel System: Fuel tank capacity is 10 gal. of #2 diesel fuel.
LOOSE PARTS CHART Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total set-up cannot be completed. Some parts may have already been assembled at factory. DESCRIPTION Qry. USE Nuts Mount front wheels.
SET-UP INSTRUCTIONS INSTALL FRONT WHEELS 1. Mount wheels and tongue nuts to 45-55 ft-In. INSTALL STEERING WHEEL (Fig. 1) 1. Remove jam nut from steering shaft. Slide foam seal and steering wheel onto steering shaft. 2. Secure steering wheel to shaft with harm nut and tighten it to 1015 ft-tb. 3. Install cap to steering wheel with screw, 0 0 5 Figure 1 1. Steering Hes! 4. Crow 2. Jam Nut 5. Foam Seal 3. Cap INSTALL SEAT (Fig. 2) 1. Loosely assemble seat suspension to seat base with (4) 5/16 ~ 18 x .75" Ig.
SET-UP INSTRUCTIONS Figure 5 1. Front of Golf bar NOTE: When operating machine, always use the seat belt and TOPS together. CONNECT BATTERY (Fig. 6) A WARNING Connecting cables to the wrong post could result in personal injury and/or damage 1o the electrical system. 1. Open hood. 2. Ensure battery is securely fastened in place and check battery charge with a hydrometer.
SET-UP INSTRUCTIONS Mount a gasket guide {Fig. 8) to the appropriate chicle of each cutting unit carrier frame {see figure 7) with screwball (5/16x lat washer and lock washer as shown in figure Figure 8 1, Carrier Frame 4. Lock washer 2. Basket Guide 5. Caps crow 3. Fiat washer 4. Installs roll pin {Fig, 9) into hole in appropriate side of each cutting unit carrier frame (Fig. 7). ; Figure 10 1. Basket Bracket 2. Torsion Spring 6.
SET-UP INSTRUCTIONS 9. Assemble the mounting nuts for the reel drive motor to each cutting unit (Fig. 13). Leave approximately 1/2” of threads exposed on each mounting stud. Figure 13 1. Root Drive Motor 2. Mounting Nuts 10. Coat the spline softhearted motor with clean grease and install the motor by rotating the motor clockwise so the motor flanges clear the studs. Rotate the motor counterclockwise until the flanges encircle the studs and tighten the mounting nuts.
SET-UP INSTRUCTIONS 7. Through hole in end of counterweight, carefully position and mount a magnet (supplied in traction unit footie parts) to the end of the reel shalt with cap screw (supplied in traction unit {code parts). Magnet to be installed with counter bore side toward the end of reel shalt and the smooth side outward {Fig. 17). Torque capstone a maximum of ft-lb. IMPORTANT. Over—torquing the cap screw will damage the magnet thus leaving the sensor not operational. Figure 17 1.
BEFORE OPERATING CHECK ENGINE OIL (Fig. 1819} 1. Park machine on a level surface. Open hood. 2. Remove dipstick, wipe clean and reinstall dipstick. Remove dipstick and sack oll level on dipstick; Oil level should be up to FULL mark. Figure 18 1. Dipstick 3. if oil is below FULL mark, remove fill cap and add SAE 10W~30 CD classification oil unfit level reaches FULL mark on dipstick. DO NOT OVERFILL. Crankcase capacity is 3.9 gt. with filter. Figure 19 1. Oil Fill Cap 4. Install ail fill cap and close hood.
BEFORE OPERATING Figure 21 1. Foul Tank Cap CHECK TRANSMISSION FLUID (Fig. 22) The front axis housing acts as the reservoir for the system. The transmission and axle housing are shipped from the factory with approximately § quarts of Mobil 424 hydraulic fluid. However, check level of transmission ail before engine is first started and daily thereafter. 1. Position machine on a level surface, lower the cutting units and stop the engine. 2. Remove access panel behind foot rest. 3.
BEFORE OPERATING Using the Mobil 424 type fluids in the higher ambient temperatures may result in decreased efficiency in some of the hydraulic components compared to using the Mobil DTE 26 type fluids. The Obit DTE 26 type fluids are straight viscosity fluids which remain slightly more viscous at higher temperatures than the multi—viscosity fluids.
BEFORE OPERATING CHECK REEL TO BED KNIFE CONTACT Each day before operating, check reel to knitted contact. regardless if quality of cut had previously been acceptable, There must be light contact across the full length of the real and penknife (refer to Adjusting Reel to Bed knife in Cutting Unit Operator's Manual). CHECK TORQUE OF WHEEL NUTS A WARNING Tighten wheel nuts to 45.55 #~Ib after 1-4 hours of operation and again after 10 hours of operation and every 250 hours thereafter.
KNOW YOUR CONTROLS Reel Control Light (Fig. 28) — When lit, indicates machine is being operated in a way in which the automatic reel speed control cannot obtain the desired clip. Figure 28 1. Lower Mow / Raise Control Lever 2. Speedometer 3. Fuel Gauge 4. Engine Coolant Temperatures Gauge 5. Engine Oif Pressures Warning Light &. Engine Coolant Temperature Warning Light 7. Glow Pius Indicator Light 8, Charge indicator 3. Koy Switch 10.
OPERATING INSTRUCTIONS A CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. STARTING AND STOPPING IMPORTANT: The fuel system must be bled if any of the following situations have occurred. A. initial start up of a new machine. B. Engine has ceased running due to lack of fuel, C. Maintenance has been performed upon fuel system components; i.e., filter replaced, separator serviced, ete. Refer to Bleeding The Fuel System 1.
OPERATING INSTRUCTIONS AUTOMATIC CLIP CONTROL The RM 5100~D is equipped with an electronic controller which is programmed to achieve automatic clip control. The machine will automatically adjust the reel speed to attain the desired clip as the traction speed changes. In order for the controller to know what clip is desired, the operator needs to input the number of biased on the reels and the height of cut at which the machine is set.
OPERATING INSTRUCTIONS CLIP RATE (REEL SPEED) SELECTION CHART 8 Blade C.U. HOC Knob Position FULL SPEED 28 in. (8.4 mm) 30in. (7.6 mm) .35 in. (8.9 mm) .40 in. {10.2 mm) A5 in. (1.4 mm) 50 in. (12.7 mm) 55 in. (14.0 mm) .60 in. (15.2 mm) .65 in. (16.5 mm) 70in. (17.8 mm) 75 in. (18.0 mm) .80 in. {20.3 mm) 85 in. (21.6 mm) 90 in. (22.9 mm) 95 in. (24.1 mm) VTOZErRAE"ZITOMNMOUO® > FULL SPEED — Cutting units always set to full speed in this position. 5 Blade C.U.
OPERATING INSTRUCTIONS ADJUSTING LIFT ARM DOWN PRESSURE (Fig. 35) The down pressure spring on each cutting unit fight arm can be adjusted to compensate for different turf conditions. Increased down pressure wilt hap keep the cutting units on the ground when mowing at higher speeds and helps maintain a uniform weightlifting rough conditions or in areas of thatch build up. Each down pressure spring may be adjusted to one of four settings.
OPERATING INSTRUCTIONS DIAGNOSTIC LIGHT (Fig. 38) The RM 5100-D is equipped with a diagnostic fight which indicates if the electronic controller is functioning correctly. The green diagnostic light is located under the control panel, extinction the fuse block. When the electronic controller is functioning correctly and the key switch is moved to the ON position, the controller diagnostic light will be illuminated. The light will blink if the controller detects a malfunction in the electrical system.
OPERATING INSTRUCTIONS Figure 40 1. Diagnostic ACE 4, Turn the key switch to the ON position, but do not start machine. Note: The red text on the overlay decal refers to input switches and the green text refers to outputs. 5. The “inputs displayed” LED, on lower right column of the Diagnostic ACE, should be illuminated. If "outputs displayed" LED is illuminated, press the toggle button, on Diagnostic ACE, to change LED to “inputs displayed”. 8.
OPERATING INSTRUCTIONS HYDRAULIC VALVE SOLENOID FUNCTIONS Use the list below 1o identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow function to occur.
A CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. GREASING BEARINGS AND BUSHINGS (Fig. 41 ~ 47) 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 25 hours of operation. 1. The grease fitting locations and quantities are: Engine Drive shaft (2}, {Fig.
LUBRICATION SERVICE INTERVAL CHART REEL MASTER 5100-D QUICK REFERENCE AID CHECK/SERVICE (daily) 1. OIL LEVEL, ENGINE 7. RADIATOR SCREEN 2. QI LEVEL, TRANSMISSION 8. BRAKE FUNCTION 3. OIL LEVEL, HYDRAULIC TANK 8. TIRE PRESSURE 4, COOLANT LEVEL, RADIATOR 10. BATTERY 5. FUEL WATER SEPARATOR 11. BELTS (FAN, ALT) 6. CLEANER ~ AIR CLEANER GREASING ~ SEE OPERATOR'S MANUAL FLUID SPECIFICATIONS/CHANGE INTERVALS SEE OPERATOR'S MANUAL. FLUID CAPACITY | CHANGE INTERVAL | FILTER FOR INITIAL CHANGES. TYPE FLOOD [ FILTER.
AIR CLEANER MAINTENANCE A CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch, GENERAL MAINTENANCE PRACTICES Inspect air cleaner and hose periodically to maintain maximum engine protection and to ensure maximum service life. 1. Check air cleaner body for dents and other damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2. Be sure dust cup is sealing around air cleaner body. SERVICING CLEANER BOWL {Fig.
AIR CLEANER MAINTENANCE Washing Method IMPORTANT: Do not remove plastic fin assembly because washing removes dust from beneath fins. A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes.Refer to directions on filter cleaner cation for complete information, B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the filter element. C.
ENGINE MAINTENANCE Fuel Filter / Water Separator Drain water or other contaminants from fuel filter / water separator (Fig. 52) daily. 1. Place a clean container under fuel filter, 2. Loosen drain plug on bottom of filter canister. Tighten plug after draining. o~ Figure 52 1. Fuel Fitter / Water Separator 2. Drain Plug Replace filter canister after every 400 hours of operation. 1. Clean area where filter canister mounts, 2. Remove filter canister and clean mounting surface. 3.
ENGINE MAINTENANCE ENGINE COOLING SYSTEM (Fig. Removing Debris — Remove debris from screen, oil cooler and radiator daily, clean more frequently in dirty conditions. A. Turn engine off and raise hood. Clean engine area thoroughly of all debris. 8. Pull up on screen to slide it out of mounting tracks. Clean screen thoroughly with water or compressed air. Figure 55 1. Screen C. Sightly raise oil cooler and pivot forward. Clean both sides of oil cooler and radiator area thoroughly with water or compressed air.
ENGINE MAINTENANCE ADJUSTING THROTTLE (Fig. 59) 1. Position throttle lever forward so it stops against seat base slot. 2. Loosen the throttle cable connector on the lever arm at the injection pump. 3. Hold the injection pump lever arm against the high die stop and tighten the cable connector. Note: When tightened, the cable connector must be free to swivel. 4.
HYDRAULIC MAINTENANCE Lt i E Figure 61 1. Hydraulic Filter 3. Lubricate new filter gasket and fill the filter with hydraulic oit. 4. Assure filter mounting area is clean. Screw filter on until gasket contacts mounting plate. Then tighten filter one~half turn. 5. Start engine and let run for about two minutes to purge air from the system. Stop the engine and check for leaks.
HYDRAULIC MAINTENANCE A WARNING Engine must ba running so final adjustment of the fraction adjustment cam can be performed. To guard against possible personal injury, keep hands, feet, face and other parts of the body away from the muffler, other hot parts of the engine, and other rotating parts. 4. Start engine and rotate cam hex in dither direction until wheel ceases rotation. 5. Tighten lockout securing adjustment. 6. Stop the engine and release the right brake.
HYDRAULIC MAINTENANCE 4. Rotate, clockwise, until distance between inside of eye balloon and inside of spring anchor plate is shortened 1/8%, as shown in figure 66. Tighten hex nut. ®\ O 5. Operate the machine and check stopping distance. Repeat procedure if required, 1 Note: Shortening the distance between inside of eye g bolt loop and inside of spring anchor plate increases the pedal force on the traction pedal. Therefore, do not over adjust. —® Figure 66 1. spring Anchor Plate 4. Outer lockout 2.
AXLE MAINTENANCE CHANGING TRANSMISSION FLUID (Fig. 68) Change the transmission fluid after every 800 hours of operation, in normal conditions. 1. Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. 2. Clearinghouse suction line on bottom of transmission. Place drain pan under fine. Figure 68 1. Transmission Suction Line 2. Transmission Oil Filter 3. Remove line from transmission allowing fluid to drain into drain pan.
AXLE MAINTENANCE Figure 70 1. Tie Rod{s) ELECTRICAL MAINTENANCE FUSES (Fig. 71) BATTERY CARE IMPORTANT: Before welding on the machine, disconnect both cables from the battery, disconnect both wire harness plugs from the electronic control unit and the termini connector from the alternator to prevent damage to the electrical system. A CAUTION Oar safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated so gases produced while charging can dissipate.
CUTTING UNIT MAINTENANCE BACKSLAPPING A DANGER REELS MAY STALL WHILE BACKSLAPPING. DO NOT ATTEMPT TO RESTART REELS BY HAND OR TO REELS WHILE BACKSLAPPING. STOP ENGINE AND TURN H.0.C. KNOB ONE POSITION TOWARD Note: When backslapping, the front units all operate together, and the rear units operate together. 1. Position the machine on a revel surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to disable position. 2.
PREPARATION FOR SEASONAL STORAGE Traction Unit 1. Thoroughly clean the traction unit, curling units and the engine. 2. Check the tire pressure, Inflate all fraction unit tires {o 1520 psi. 3. Check ail fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant, 8, Lightly sand and use touch—up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body.
he Turn Promise A ONE YEAR LIMITED WARRANTY The Tore Company promises 1o repair pour TOR Product if defective in materials or workmanship. The following time periods from the date of purchase apply: Commercial Products . 1 Year The costs of parts and labor are included, but the customer pays the transportation costs on walk rotary mowers with cutting unit widths of less than 257, {f you feel your TOR product is defective and wish to rely an The Toto Promise, the following procedure is recommended: 1.