FORM NO. 3318-590 GB Rev A MODEL NO. 03530—60001 & UP MODEL NO. 03531—60001 & UP OPERATOR'S MANUAL ® REELMASTER® 5300-D 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. It means CAUTION, WARNING or DANGER—personal safety instruction. Failure to comply with the instruction may result in personal injury.
This operator's manual has instructions on safety, operation, and maintenance. This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, understand the safety message that follows. “IMPORTANT” highlights special mechanical information and “NOTE” emphasizes general product information worthy of special attention.
Safety Training • Store fuel in containers specifically designed for this purpose. 1. Read the instructions carefully. Be familiar with the controls and the proper use of the equipment. • Refuel outdoors only and do not smoke while refueling. 2. Never allow children or people unfamiliar with these instructions to use the lawn mower. Local regulations may restrict the age of the operator. • Add fuel before starting the engine.
Safety • never mow across the face of the slope, unless the lawn mower is designed for this purpose. tor’s position. 6. Use care when pulling loads or using heavy equipment. • Use only approved drawbar hitch points. • Limit loads to those you can safely control. • Do not turn sharply. Use care when reversing. • Use counterweight(s) or wheel weights when suggested in the instruction handbook. 7. Watch out for traffic when crossing or near roadways. 8.
Safety Sound & Vibration Levels Sound Levels This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 89.5 dB(A), based on measurements of identical machines per 84/538/EEC. This unit has a sound power level of 103.5 dB(A)/1pW, based on measurements of identical machines per procedures outlined in Directive 79/113/EEC and amendments. Vibration Levels This unit has a vibration level of 2.
Symbol Glossary Caustic liquids, Poisonous Electrical shock, chemical burns to fumes or toxic electrocution fingers or hand gases, asphyxiation Crushing of whole body, applied from above Explosion Shut off engine & remove key before performing maintenance or repair work 6 High pressure High pressure Crushing of Crushing of spray, erosion of spray, erosion of fingers or hand, toes or foot, force flesh flesh force applied from applied from above above Crushing of Crushing of fingers Crushing of leg, Cr
Safety Eye protection must be worn Head protection Hearing Caution, toxic must be worn protection must risk be worn First aid Fire, open light & smoking prohibited Hydraulic system Brake system Coolant (water) Intake air Exhaust gas Pressure Level indicator Liquid level Filter Temperature Failure/ Malfunction On/start Off/stop Engage Disengage Attachment lower Attachment raise Spacing distance Snow thrower, collector auger Plus/increase/ Minus/decrease/ positive polarity negative polar
Safety Engine coolant pressure Engine coolant f Engine ilter lubricating oil pressure Engine failure/ malfunction Engine rotational Choke speed/frequency Engine intake/ Engine intake/ combustion air combustion air pressure Engine intake/ air filter Engine start Engine stop n/min Primer (start aid) Electrical preheat Transmission oil Transmission oil Transmission oil (low temperature pressure temperature start aid) NH L F RP Transmission Clutch failure/malfunction Neutral High Low Forward Reve
Specifications Engine: Mitsubishi three-cylinder, liquid-cooled diesel. 20.9 kW (28 hp) @ governed maximum rpm of 3200; 1,318 cc (80.4 cu. in.) displacement Heavy-duty, 3-stage, remote-mounted air cleaner. High water temperature shutdown switch. Cooling System: Radiator capacity is 7.1 l (7.5 qt.) of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted .9 l (1 qt.) expansion tank. A twospeed fan drive controls air flow. Fuel System: Fuel tank capacity is 37.9 l (10 gal.) of #2 diesel fuel.
Specifications Grass Basket Kit, Model No. 03513 Rear Weight Kit, Part No. 75-6690 Rear Roller Scraper Kit, Model No. 03512 Front Roller Scraper Kit, Model No. 83-5400 High Height-of-Cut Kit, Model No. 83-5300 Scraper/Comb Kit, Model No. 03518 Armrest Kit, Model No. 30707 Front Scraper, HHOC Kit P/N 82-6920 Thatcher Unit, Model No. 03516 Precleaner Bowl Extension Tube, Part No. 43-3810 (Clamp, Part No. 20-4840 required to install extension tube) 4-Wheel Drive Kit, Model No.
Before Operating CHECK THE ENGINE OIL 1. 2. Park the machine on a level surface. Open the hood. Remove the dipstick, wipe it clean, then reinstall it. Remove it again and check the oil level on the dipstick; The oil level should be up to the FULL mark. of the radiator daily, more often if conditions are extremely dusty and dirty. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze.
Before Operating groove mark. DO NOT OVERFILL by more than .6 cm (1/4 inch) above the groove. DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill the fuel tank while the engine is running, hot, or when the machine is in an enclosed area. Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store the fuel in a clean, safety-approved container and keep the cap in place.
Before Operating Phillips HG Fluid Note: Oils within this group are interchangeable. increased engine laboring while cold, sluggish or non-operating valve spools while cold and increased filter back pressure due to the higher oil viscosity.
Before Operating ➁ ➀ ➀ Figure 7. Figure 6 1. Hydraulic Tank Cap 3. Remove the dipstick from the filler neck and wipe it with a clean cloth. Insert it into the filler neck; then remove it and check the fluid level. It should be within 6 mm (1/4 inch) of the mark on the dipstick. 4. If the level is low, add fluid to raise the level to the full mark. 5. Install the dipstick and cap onto the filler neck. 1. Check Plugs (2) ➀ CHECK REAR AXLE LUBRICANT (Model 03531 only) Figure 8. 1.
Controls Seat (Fig. 9)—The seat adjusting lever allows 10 cm (4 inches) fore and aft adjustment. The seat adjusting knob adjusts the seat for operators’ weight. To adjust the seat fore and aft, pull lever on the left side of the seat assembly outward. After moving the seat to the desired location, release the lever to lock the seat into position. To adjust for the operator’s weight, turn spring tension knob—clockwise to increase tension, counterclockwise to decrease spring tension.
Controls Charge Indicator (Fig. 11)—Illuminates when system charging circuit malfunctions. Key Switch (Fig. 11)—Three positions: OFF, ON/Preheat and START. Throttle Control (Fig. 11)—Move the control forward to increase engine speed, rearward to decrease speed. Enable/Disable Switch (Fig. 11)—Used in conjunction with lower mow / raise the control lever to operate reels. Reel Control Light (Fig.
Operation CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. BLEEDING THE FUEL SYSTEM 1. Raise the hood over the engine. 2. Loosen the air bleed screw on top of the fuel filter/water separator (Fig. 15) 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. The engine has ceased running due to lack of fuel. C.
Operating Instructions 5. Turn the key in the ignition switch to ON. The electric fuel pump will begin operation, forcing air out around the air bleed screw on the fuel injection pump. Leave the key in the ON position until a solid stream of fuel flows out around the screw. Tighten the screw and turn the key to OFF. Note: Normally the engine should start after the above bleeding procedures.
Operating Instructions the height-of-cut selector knob may be set to position "A", which will direct the machine controller to run the reels at full speed at all times. Also, set the height-of-cut selector knob to position "A" when troubleshooting the electrical system. REEL CONTROL LIGHT The reel control light on the front control panel is used to tell the operator that the machine controller is able to achieve the desired clip.
Operating Instructions 3. A foreign object, such as a stick, piece of turf, etc., is stuck in the reel, restricting rotation. If changing the traction speed does not cause the light to go out, and the reel control light remains illuminated regardless of traction speed, then a service issue is required. In this case contact your local authorized Toro Distributor ADJUSTING LIFT ARM DOWN PRESSURE Place an open end wrench on the hex shaft of the spring bracket. 4.
Operating Instructions center of the front frame member (Fig. 20). Figure 21 1. ➀ Figure 20 1. Note: Center of Front Frame Member Lock both brake pedals together before towing. Electron~ Controller Light When the controller diagnostic light blinks, one of the following problems has been detected by the controller: 1. 2. One of the outputs has been shorted. One of the outputs is open circuited.
Operating Instructions properly. The Diagnostic ACE display is a tool to help the user verify correct electrical functions of the machine. CHECKING INTERLOCK SWITCHES Figure 22 CAUTION THE INTERLOCK SWITCHES ARE FOR THE PROTECTION OF THE OPERATOR AND BYSTANDERS, AND TO ENSURE CORRECT OPERATION OF THE MA-CHINE, SO DO NOT BYPASS OR DISCONNECT THEM. CHECK OPERATION OF THE SWITCHES DAILY TO ASSURE INTERLOCK SYSTEM IS OPERATING. IF A SWITCH IS DEFECTIVE, REPLACE IT BEFORE OPERATING.
Operating Instructions ate LED on Diagnostic ACE will blink on and off when corresponding switch is closed. Repeat on each switch that it is possible to be changed by hand. 7. If the switch is closed and the appropriate LED does not turn on, check all wiring and connections to the switch and/or check the 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 on.
Operating Instructions LEAK DETECTOR OPERATION a. No beeps are heard when the ignition switch is turned "ON". 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 that 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.
Operating Instructions 1. Check the alarm wires to make sure they are not disconnected, broken or "+" and "–" are reversed. 2. Toggle "outputs displayed" on Diagnostic ACE display (Fig. 26). • Alarm open circuit (LED blinking): Check / replace the TurfDefender alarm or wires. • Alarm short circuit (LED blinking): Check / replace the TurfDefender alarm or wires. • • Data Line LED Blinking: Problem with communications between the machine and the leak detector; or problem with wires.
Operating Instructions Diagnostic ACE Display Functions 1. 2. 3. 4. Overlay decal (English shown) “Inputs Displayed” LED (Red) “Outputs Displayed” LED (Green) Toggle button Figure 24 Using “Inputs Displayed” (Red Text) 1. 2. 3. 4. 5. 6. 7. LED is lit if the oil level is too high LED is lit if the oil level is too high LED is lit if the oil level is too high LED is lit if the oil level is too high LED is lit if a system air leak has been detected.
Operating Instructions Store the Diagnostic ACE in a dry, secure location in the shop, not on the machine. HYDRAULIC VALVE SOLENOID FUNCTIONS Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized for the function to occur.
Maintenance CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. GREASING BEARINGS AND BUSHINGS The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation.
Maintenance Figure 32 Figure 33 CHECK/SERVICE (DAILY) 1. 2. 3. 4. 5. 6. Oil level, engine Oil level, transmission Oil level, hydraulic tank Coolant level, radiator Fuel/Water separator Precleaner—air cleaner 7. 8. 9. 10. 11. Radiator screen Brake function Tire pressure Battery Belts (Fan, alt) FLUID SPECIFICATIONS/ CHANGE INTERVALS FLUID TYPE CAPACITY CHANGE FLUID CHANGE FILTER FILTER PART NO. SAE 10W-30 3.7 l 50 hours 100 hours 67-4330 TRANSMISSION OIL Mobil 424 4.
Maintenance Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check battery fluid level Every 50 Every 100 Check battery cable connectors hours hours Lubricate all grease fittings Change engine oil ✝Check Instpect air filter, dust cup and baffle fan and alternator belt tension ‡Replace engine oil filter Inspect cooling system hoses Every 200 hours Every 400 hours Every 800 hours Drain moisture—hydraulic tank Drain moisture—Fuel tank Check the reel bearing
Maintenance Daily Maintenance Checklist 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16 17. 18. 18. 19.
Maintenance ➀ ➀ Figure 34 1. Figure 37 Pre Cleaner Bowl 1. Engine Oil Filter 1. 2. Fuel Filter/Water Separator Drain plug ➁ 3 ➀ Figure 38 Figure 35 1. 2. Dust Cup & Baffle Filter Element 3. Air Cleaner Body Figure 36 1. Engine Oil Drain Plug Figure 39 1. 32 Fuel pump 2.
Maintenance ➀ Figure 40 1. Figure 43 Fuel Injectors (3) 1. Alternator Belt ➀ ➀ ➁ Figure 41 Figure 44 1. Pull up screen and slide it out of the mounting tracts. Clean it thoroughly with water or compressed air. 1. Cooling Fan Belt 2. Tensioner Lever ➁ ➂ ➀ ➀ Figure 45 Figure 42 1. 2. Oil Cooler Radiator 3. Transmission Oil Cooler 1. Injection Pump Lever Arm IMPORTANT: Use only hydraulic oils specified. Other fluids could cause system damage.
Maintenance WARNING ➀ Figure 46 1. Hydraulic Reservoir Keep your 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 skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
Maintenance WARNING The engine must be running for the final adjustment of the traction cam. To guard against possible personal injury, keep hands, feet, face and other parts of the body away from the muffler, other hot parts or the engine, and other rotating parts. 4. Start the engine and rotate the cam hex in either direction until the wheel ceases rotation. 5. Tighten the locknut securing adjustment. 6. Stop the engine and release the right brake.
Maintenance may be required to return the transmissions to neutral. Periodically check the machine. To Check Traction Linkage 1. On a large, flat open area, drive the machine at full throttle and full traction speed. 2. Remove your foot from the traction pedal and measure the distance required for the machine to come to a stop. 3. If the distance required to stop is greater than 5.5 meters, (18 feet) an adjustment to the traction linkage is required. Go to the next step.
Maintenance REAR WHEEL TOE-IN After every 800 operating hours or annually, check the rear wheel toe-in. 1. Measure center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 3 mm less than the rear measurement. ➀ Figure 51 1. Drain Plugs (3) CHANGING REAR AXLE LUBRICANT (Model 03531 only) After every 800 hours of operation the oil in the rear axle must be changed. 1. 2. ➀ Position the machine on a level surface. Figure 53 1.
Maintenance FUSES IMPORTANT 4. Make initial reel-to-bedknife adjustments appropriate for backlapping on all cutting units that are to be backlapped. 5. Start the engine and run at idle speed. USE CORRECT FUSES. WRONG FUSES CAN CAUSE DAMAGE TO CONTROLLER AND VOID WARRANTY. CONTROLLER LOGIC CONTROLLER POWER 4A 10A ACCESSORY POWER IGNITION SWITCH 7.
Maintenance 11. Repeat this procedure for all cutting units to be backlapped. with Grafo 112X skin-over grease (Toro Part No. 50547) or petroleum jelly to prevent corrosion. 12. When backlap operation has been completed, return the backlap switch to OFF, lower the seat and tighten both locking bolts securely, and wash all lapping compound off the cutting units. Adjust cutting unit reel-to-bedknife as needed.
