Form No.
Checking Reel to Bedknife Contact . . . . . . . . . . . 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 . . . . . . . .
Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Introduction Read this manual carefully to learn how to operate and maintain your product properly.
• Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly. • Clean grass and debris from cutting units, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. Operation • Let engine cool before storing and do not store near flame. • Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors. • Never run an engine in an enclosed area.
• Whenever the machine is left unattended, make sure the cutting units are lowered to the ground, the key is removed from the ignition switch, and the parking brake is set. • Handle fuel carefully. Wipe up any spills. Operation • Know how to stop the machine and engine quickly. • Do not park on slopes unless the wheels are chocked or blocked. • Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine.
Sound Power Level Vibration Level This unit has a guaranteed sound power level of: 105 dBA/1 pW, based on measurements of identical machines per Directive 2000/14/EC and amendments. This unit does not exceed a vibration level of 2.5 m/s2 at the hands based on measurements of identical machines per ISO 5349 procedures. This unit does not exceed a vibration level of 0.5 m/s2 at the posterior based on measurements of identical machines per ISO 2631 procedures.
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.
93-6699 1. Slow 2. Fast 3. Traction speed 93-8060 1. 2. 3. 4. 5. 6. 7. Danger Read operator’s manual Height–of–cut Move throttle to slow Hazard to feet Hazard to hands Stop reels before touching 93-6691 1. Read operator’s manual–eccentric bolt 93-6697 (Model 03541 & 03544 only) 93-8050 (Model 03541 & 03544 only) 1. Read operator’s manual 2. Lubrication point 3. Time interval 1. 2. 3. 4. Danger Read operator’s manual Tipping hazard Wear seat belts 98-9335 1.
3-6686 1. Hydraulic oil level 2. Read operator’s manual 105-7506 1. Read the Operator’s Manual 2. Engine—stop 3. On 4. Engine—preheat 5. Engine—start 76-8730 1. See operator’s manual 2. Wheel torque specifications 93-1263 104-9294 1. Read operator’s manual 2. To engage parking brake–connect pedals with locking pin, push down on both pedals and pull parking brake latch out. 3. To release parking brake–press both pedals until parking brake latch retracts. 4. Danger –reels enabled 1. 2. 3. 4. 5. 6. 7.
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 Width of Cut 95 in. Overall Width Rear Roller Brush Kit* Model No. 03526 Solid Front Roller* Part No. 82-6680 Front Wiehle Roller Scraper* Part No. 83-5400 5 Blade Cutting Unit Model No. 03527 Model No. 03528 Transport 87 in. 8 Blade Cutting Unit Outside of front tires 87 in. Comb Kit Outside of rear tires 52-1/2 in. Part No. 104-3385 Model No. 03533 Rear Roller Brush Kit Part No. 104-8205 Front H.O.C.
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.
3. Slide the red, positive battery cable onto the positive battery post and tighten nut securely. Warning 2 Incorrect battery cable routing could damage the tractor and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 1 • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always reconnect the positive (red) battery cable before reconnecting the negative (black) cable. Figure 1 1.
2. Replace floor panel fastener with flange head capscrew (5/16 x 5/8 in.) supplied in loose parts (Fig. 4). 1 3. Replace access panel fastener with flange head capscrew (5/16 x 3/4 in.) supplied in loose parts (Fig. 4). 2 Checking the Tire Pressure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in the front and rear tires is 10–15 psi. Important Maintain even pressure in all tires to ensure uniform contact with turf.
1 2 1 2 Figure 6 1. Carrier frame 2. Basket guide Figure 8 5. Install a roll pin (Fig. 7) into hole in appropriate side of each cutting unit carrier frame (Fig. 5). 3 4 1. Basket bracket 2. Torsion spring 7. Align the mounting shaft of the cutting unit with the pivot tube on the carrier frame. Insert the shaft into the tube (Fig. 9). 1 2 2 3 4 Figure 7 1. Carrier frame 2. Roll pin 5 6 3. Basket bracket 4. Basket collar 1 6.
10. Coat the spline shaft of the 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. Ensure that the washers are against the nuts. 1 2 Figure 12 1. Lock-up rollers 2 1 13. Mount a basket to each cutting unit carrier frame by inserting basket mounting pin into basket bracket and depressing opposite mounting pin into pivoting bracket.
“B” “C” Lifted Height of Outer Front Cutting Units (Enable Position) 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 in adjusting the ECU settings. “A” Figure 13 Installing the Rear Weight The Reelmaster 5200-D & 5400-D Traction Units comply with ANSI B71.4-1999 Standards when equipped with rear weight and 90 lb. of calcium chloride ballast is added to rear wheels.
3. If oil is below FULL mark, remove fill cap and add SAE 10W-30 CD, CE, CF, CF-4, or CG-4 classification oil until level reaches FULL mark on dipstick. Do not overfill. Crankcase capacity is 4.0 qt. with filter. Before Operating Caution 4. Install oil fill cap and close hood. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.
Filling the Fuel Tank 3. Unscrew dipstick cap from the transmission filler neck (Fig. 18) and wipe it with a clean rag. Screw dipstick into filler neck. Remove the dipstick and check level of oil. If level is not within 1/2 inch from the groove in the dipstick, add enough oil to raise level to groove mark. Do not overfill by more than 1/4 inch above groove. 1. Remove fuel tank cap (Fig. 17). 2. Fill tank to about one inch below top tank, not filler neck with No. 2 diesel fuel. Then install cap.
2. Clean area around filler neck and cap of hydraulic tank (Fig. 19). Remove cap from filler neck. 1 1 Figure 19 Figure 21 1. Hydraulic tank cap 1. Left check plug (rear of axle) 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. 3.
To stop, reduce foot pressure on traction pedal and allow it to return to center position. Operation 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 2 Lower Mow/Raise Control Lever 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 Refer to Bleeding the Fuel System, page 23. 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.
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.
Logic Chart X=CLOSED, O=OPEN, P=OUTPUT ON, KEY: M=MOMENTARILY CLOSED, 0) Controller OK 1) Preheat 2) Start 29 3) Run (No operator) Run (with operator) 4) Lower (To turn around) Lower (All units when disabled) Lower (All units when enabled) Lower / Mow-Front Lower / Mow-Front & Rear 5) Mow 6) Raise (transport) Raise (To turn around front) Raise (To turn around front & rear) Raise (To turn around front & rear) 7) Backlap Front 8) Backlap Rear X X X X X X O O OO OO O X O X O X O X X O MX X X X X O X 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 After first 10 hours • • • • After first 50 hours • Replace the engine oil filter. • Check the engine RPM (idle and full throttle). Check the fan and alternator belt tension. Torque the wheel lug nuts.
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 Drive shaft support bearing (1), Rear axle drive shaft (3) (Fig. 42); Brake pedal (1) (Fig. 43); Lift cylinders (5) (Fig. 44) and Fan shaft (Fig. 45). 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 42 Figure 39 Figure 43 Figure 40 Figure 44 Figure 41 33
2 1 3 Figure 46 Figure 45 1. Air cleaner indicator 2. Precleaner bowl Servicing the Air Cleaner 3. Dust cup Servicing the Filter Element General Air Cleaner Maintenance 1. Release latches securing air cleaner cover to air cleaner body. Separate cover from body. Clean inside of air cleaner cover. 1. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 2. Gently slide filter element out of air cleaner body (Fig.
4. Washing Method A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes. Refer to directions on filter cleaner carton 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. Rinse filter from clean side to dirty to side. 1 C. Dry filter element using warm, flowing air (160 F max), or allow element to air-dry.
Fuel Filter/Water Separator 3. Loosen the hose clamps at both ends of the filter and pull fuel lines off filter. Drain water or other contaminants from fuel filter / water separator (Fig. 50) daily. 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. 1. Locate fuel filter, under hydraulic tank, and place a clean container under it. 2.
1. Loosen the pipe connection to the No. 1 nozzle and holder assembly (Fig. 52). 1 1 Figure 53 1. Screen 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. Figure 52 1. Fuel injectors (3) 4. Install screen and close hood. 2. Move throttle to FAST position. 3. Turn key in key switch to START position and watch fuel flow around connector.
Servicing the Engine Belts Check condition and tension of all belts after first day of operation and every 100 operating hours thereafter. Alternator Belt 2 To Check Tension: 1. Open hood. 1 2. Check tension by depressing belt (Fig. 55) midway between alternator and crankshaft pulleys with 22 lb. of force. Belt should deflect 7/16 in. If deflection is incorrect, proceed to step 3. If correct, continue operation. 1 2 Figure 56 1. Cooling fan belt 2. Tensioner lever Adjusting the Throttle 1.
Changing the Hydraulic Fluid Replacing the Hydraulic Filter Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 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.
Checking the Hydraulic Lines and Hoses 2 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. 1 Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Figure 60 1.
Outside Front Cutting Units Warning 1. Locate valve on flow divider (under foot rest) (Fig. 63). The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal injury. 2. Loosen setscrew on valve. Rotate valve 1/2 turn clockwise. 3. Verify lift rate adjustment by raising and lowering cutting units several times. Readjust as required.
Adjusting the Service Brakes 4. After desired lift rate is attained, tighten setscrew to lock adjustment. 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. Checking and Adjusting the Traction Linkage 1. Disengage locking pin from brake pedals so both pedals work independently of each other.
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 models 03541 and 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.
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.
Fuses Optional Lighting There are 4 fuses in the machines electrical system. They are located below control panel (Fig. 71 and 72). 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. SCHEMATIC FOR OPTIONAL LIGHTING To Lights w/external ground Black 1 30 Red To Lights 30 Orange 2 3 Switch 85 86 Figure 71 Relay 1. Fuses Switch* Toro Part No. 75-1010 Honeywell Part No.
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 ORANGE FUEL GAGE G S I 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 ORANGE/RED STARTER START RELAY GREEN/BLUE 3 1 WARNING LIGHTS SPEEDOMETER G S I BLACK BLACK GRAY BLACK ALTERNATOR ORANGE BLACK BLACK RED DIAGNOSTIC INDICATOR HOUR METER B A GLOW PLUGS RED RED #2A #2B 7.
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 M4 S5A S3A OUT IN TRW HGF 16 STEERING CONTROL VALVE 6.
Preparation for Seasonal Storage Traction Unit 1. Thoroughly clean the traction unit, cutting units and the engine. 2. Check the tire pressure. Inflate all traction unit tires to 15–20 psi. 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6.
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 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
