Form No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . Setting the Reel Speed . . . . . . . . . . . . . . . . . . . . . . Adjusting the Lift Arm Down Pressure . . . . . . . . . Towing the Traction Unit . . . . . . . . . . . . . . . . . . . . Diagnostic Light . . . . . .
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.
• Handle fuel carefully. Wipe up any spills. • 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. 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 sound power level of: 101 Lwa, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments. This unit has a maximum hand-arm vibration level of 2.5 m/s2 and whole body vibration level of 0.5 m/s2, based on measurements of identical machines per EN 1033 and EN 1032.
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 104-9299 76-8730 1. 2. 3. 4. 1. See operator’s manual 2. Wheel torque specifications Read operator’s manual Engine start Engine preheat/on Stop 104-9294 1. 2. 3. 4. 5. 6. 7. Danger Read operator’s manual Thrown objects–keep bystanders away Cutting hazard to hands and feet Do not tow Cutting hazard to hands–keep away from moving parts Danger–set the parking brake, stop the engine, and remove the key before leaving the operator’s position 8.
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. Rear Roller Brush Kit Front H.O.C. Adjusting Kit Overall Length Without grass baskets Wiehle Scraper Kit 103-1/2 in. Rear Roller Scraper Kit 116 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.
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. “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 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. 1 Danger Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
BP Oil Castrol Chevron Citgo Conoco Exxon Gulf Pennzoil Phillips Standard Texaco Union Note: When changing from one type of hydraulic fluid to the other, be certain to remove all the old fluid from the system, because some brands of one type are not completely compatible with some brands of the other type of hydraulic fluid.
Checking the Torque of the Wheel Nuts 2. Remove the 3 check plugs from axle (Fig. 20 and 21) and make sure lubricant is up to bottom of each hole. 2 Warning Failure to maintain proper torque of the wheel nuts could result in personal injury. Torque the wheel nuts to 45–55 ft.-lb. after 1–4 hours of operation and again after 10 hours of operation. Torque every 250 hours thereafter. 1 1 Operation Figure 20 1. Check plug 2.
Traction Pedal 3 The traction pedal (Fig. 23) controls forward and reverse operation. Depress top of pedal to move forward and bottom to move backward. Ground speed depends on how far pedal is depressed. For no load, maximum ground speed, fully depress pedal while throttle is in FAST. 1 4 2 5 To stop, reduce foot pressure on traction pedal and allow it to return to center position. 7 6 Figure 24 1. 2. 3. 4. 1 Traction speed limiter Reel control light Speedometer Brake pedals 5.
Lower Mow/Raise Control Lever The lever (Fig. 25) raises and lowers the cutting units and also starts and stops the reels. Glow Plug Indicator Light 1 When lit (Fig. 25), indicates glow plugs are on. Engine Oil Pressure Warning Light This light (Fig. 25) indicates dangerously low engine oil pressure. Figure 27 1. Reel speed controls Charge Indicator The charge indicator (Fig. 25) illuminates when system charging circuit malfunctions. Hour Meter Enable/Disable Switch The hour meter (Fig.
2. Turn ignition switch to ON/Preheat position. An automatic timer will control preheat for 6 seconds. After preheat, turn key to START position. Crank the engine for no longer than 15 seconds. Release key when engine starts. If additional preheat is required, turn key to OFF position then to ON/preheat position. Repeat process as required. 1 3. Run engine at idle speed or partial throttle until engine warms up. Note: Move throttle to FAST position when restarting a warm engine. 4.
Setting the Reel Speed To achieve a consistent, high quality-of-cut and a uniform after cut appearance, it is important that the reel speed controls (located under seat) be correctly set. Adjust the reel speed controls as follows: 1. Select the height-of-cut at which the cutting units are set. 1 2. Choose the desired ground speed best suited for conditions. 3. Using the appropriate graph (Fig. 32) for 5 blade or 8 blade cutting units, determine the proper reel speed setting. Figure 33 1.
1 2 1 Figure 35 Figure 34 1. Spring bracket hex shaft 1. Drive shaft 2. Retaining bracket 2. Attach a suitable chain, strap or cable to the center of the front frame member (Fig. 36). 5. Move spring bracket to desired location and install capscrew and locknut, while rotating hex shaft to relieve spring tension. 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.
Diagnostic Light Diagnostic ACE Display The RM 5200-D/5400-D is equipped with a diagnostic light which indicates if the electronic controller is functioning correctly. The green diagnostic light is located under the control panel, next to the fuse block (Fig. 37). 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.
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.
0) Controller OK 1) Preheat 2) Start 30 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 O X O X O X X X X X X X X X X X X X X X X X X X X X X X X X T6 O O 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
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. 44); Brake pedal (1) (Fig. 45); Lift cylinders (5) (Fig. 46) and Fan shaft (Fig. 47). 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 44 Figure 41 Figure 45 Figure 42 Figure 46 Figure 43 34
2 1 3 Figure 48 Figure 47 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 Drain water or other contaminants from fuel filter / water separator (Fig. 52) daily. 1. Locate fuel filter, under hydraulic tank, and place a clean container under it. 2. Loosen drain plug on bottom of filter canister. Tighten plug after draining. 1 3 4 2 Figure 53 1. Fuel filter assembly 2. Filter bowl 1 3. Filter 4. O-ring 2. Remove the filter bowl (Fig. 53) and clean mounting surface. 3. Remove filter from bowl (Fig. 53) and replace with new filter. 2 4.
2. Move throttle to FAST position. 3. Turn key in key switch to START position and watch fuel flow around connector. Turn key to OFF position when solid flow is observed. 2 4. Tighten pipe connector securely. 1 5. Repeat steps on remaining nozzles. Servicing the Engine Cooling System 3 Removing Debris Figure 56 Remove debris from screen, oil coolers and radiator daily, clean more frequently in dirty conditions. 1. Reel oil cooler 2. Radiator 1. Turn engine off and raise hood.
3. Loosen bolt securing brace to engine (Fig. 57) 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. 1 Cooling Fan Belt 1. Loosen locknut on belt tensioner lever (Fig. 58). Figure 59 1. Injection pump lever arm 2 Changing the Hydraulic Fluid 1 Change hydraulic fluid after every 800 operating hours, in normal conditions.
4. Install reservoir cap. Start engine and use all hydraulic controls to distribute hydraulic fluid throughout the system. Also check for leaks. Then stop the engine. Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 5. Check level of fluid and add enough to raise level to FULL mark on dipstick. Do not over-fill.
Center Cutting Unit 1. Park machine on a level surface, shut engine off, and lower cutting units to the floor. Depress only the right brake pedal and engage the parking brake. 1. Locate valve behind access panel above operator’s platform (Fig. 64). 2. Jack up left side of machine until front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally. 2. Loosen setscrew on valve and rotate valve approximately 1/2 turn clockwise. 3.
Rear Cutting Units 2 1. Raise hood and locate valve on left rear side of machine (Fig. 66). 3 1 5 1 4 Figure 67 1. 2. 3. 4. Figure 66 1. Rear cutting units adjustment valve 2. Loosen setscrew on valve and rotate valve approximately 1/2 turn clockwise. Spring anchor plate Eye bolt Inner locknut Outer locknut 5. Shorten distance to decrease time required to stop machine. 4. Rotate clockwise until distance between inside of eye bolt loop and inside of spring anchor plate is shortened 1/8 in.
2 1 1 Figure 68 Figure 69 1. Brake cables 1. Transmission suction line Changing the Transmission Fluid 2. Transmission oil filter Replacing the Transmission Filter Change the transmission fluid after every 800 hours of operation, in normal conditions. Change the transmission filter after the first 10 hours of operation and every 800 hours thereafter. 1. Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove key from ignition switch.
Changing the Rear Axle Lubricant 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. 70). 3. Remove plug allowing oil to drain into drain pans. 1 4. After oil is drained, apply thread locking compound on drain plug threads and reinstall in axle. 5. Fill axle with lubricant; refer to Checking the Rear Axle Lubricant, page 20. Figure 71 1.
Fuses 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. There are 4 fuses in the machines electrical system. They are located below control panel (Fig. 73 and 74). 8. Repeat steps 3 through 7 if necessary. 9. Tighten ball joint hex nut and install a new cotter pin.
Optional Lighting Danger 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. 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. SCHEMATIC FOR OPTIONAL LIGHTING To Lights w/external ground Black 30 Red 5. Set both reel speed controls to position 11.
5 4 1 RELAY TEMP GAGE 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.
