Form No.
Checking the Rear Axle Lubricant . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . .
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. 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.
• 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. • Carefully release pressure from components with stored energy. • 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 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.
93-6686 1. Hydraulic oil level 2. Read operator’s manual 76-8730 93-1263 1. See operator’s manual 2. Wheel torque specifications 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 93-6680 1. Diesel fuel 93-6689 1. Danger—no riders Battery Symbols 105-7506 1. Read the 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. 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. 7. Warning—use a roll over protection system and wear the seat belt. 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 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.
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.
Installing the Cutting Units 5. Adjust latch bracket, until aligned with switch latch, then tighten capscrews. 1. Remove cutting units from cartons. Assemble and adjust per the Operator’s Manual for the cutting unit. 6. Rotate latch to locked and unlocked position with key. Remove key and store in memorable place. 2. If baskets will be installed, use chart below (Fig. 5) to determine locations at which basket guides or basket brackets must be mounted to cutting unit carrier frames.
5. Install a roll pin (Fig. 7) into hole in appropriate side of each cutting unit carrier frame (Fig. 5). 3 1 2 3 4 5 6 1 4 2 Figure 9 Figure 7 1. Carrier frame 2. Roll pin 1. Cutting unit mounting shaft 2. Carrier frame pivot tube 3. Thrust washer 3. Basket bracket 4. Basket collar 6. On the same side of carrier frame as roll pin is installed, mount a basket bracket with a capscrew (5/16 x 1-3/4 in.
Adjusting the Turf Compensation Spring 11. Detach chain from lift arm and secure it to cross tube on each rear cutting unit with a capscrew, flat washer, and locknut (Fig. 11). Note: This adjustment is needed for Cutting Unit Models 03527 and 03528 only. The turf compensation spring (Fig. 13), connecting carrier frame to cutting unit, controls the amount of fore-aft rotation available. The Turf Compensation Spring also transfers weight from the front to rear roller.
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. Note: The RM CONFIG time delay should not be changed from the original setting of 0 when using this method to adjust turn around height.
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. 19) 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. 18). 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. 20). Remove cap from filler neck. 1 1 Figure 20 Figure 22 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 24 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. 26) shows amount of fuel in tank. 1 4 Lower Mow/Raise Control Lever 2 The lever (Fig. 26) raises and lowers the cutting units and also starts and stops the reels. 5 Glow Plug Indicator Light 7 6 When lit (Fig. 26), indicates a control system problem. Light blinks when glow plugs are preheating. Figure 25 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. 28) 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.
Logic Chart X=CLOSED, O=OPEN, P=OUTPUT ON, KEY: M=MOMENTARILY CLOSED, 13 Preheat 12 Start 11 S7 10 S1 7 ETR Hold / Alt 6 S6 5 S5 4 S4 3 S3 2 S2 1 S8,S9 0 Diagnostic Light OUTPUTS T Timer Involved A1 AO Start Key 17 16 15 14 13 12 Lower / Mow 11 Backlap Rear 10 Backlap Front 9 Front Units Down 8 Enable Reels 7 Raise 6 4 Seat Switch 3 Traction Neutral TIMERS T1= .5 sec T2= 5.0 sec T3= .9 sec T4= .1 sec T5= .
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 The grease fitting locations and quantities are: Engine Drive shaft (3), (Fig. 39); Cutting unit carrier frame and pivot (2 ea.), (Fig. 40); Lift arm pivots (5), Drive shaft clutch (1) (Fig. 41); Rear axle tie rod (2), Steering cylinder ball joints (2), Axle steering pivots (2) Rear axle pivot (1) (Fig. 42); Traction control linkage at transmission (1), Drive shaft support bearing (1), Rear axle drive shaft (3) (Fig. 43); Brake pedal (1) (Fig. 44); Lift cylinders (5) (Fig.
Figure 43 Figure 40 Figure 44 Figure 41 Figure 45 Figure 42 35
2 1 3 Figure 47 Figure 46 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 2. Remove oil filter (Fig. 50). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not over-tighten. 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.
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. 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. 1 • 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.
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. 5. Repeat steps on remaining nozzles. 1 Servicing the Engine Cooling System 3 Removing Debris Figure 55 Remove debris from screen, oil coolers and radiator daily, clean more frequently in dirty conditions. 1. Reel oil cooler 2. Radiator 3. Transmission oil cooler 1. Turn engine off and raise hood.
4. Insert pry bar between alternator and engine and pry out on alternator. 1 5. When proper tension is achieved, tighten alternator and brace bolts to secure adjustment. Cooling Fan Belt 1. Loosen locknut on belt tensioner lever (Fig. 57). Figure 58 2. Apply 5–10 lb. of force at end of lever to set the proper tension on the fan belt. 1. Injection pump lever arm 3. Tighten locknut to secure adjustment.
Replacing the Hydraulic Filter Checking the Hydraulic Lines and Hoses 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. 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.
Adjusting the Traction Drive for Neutral 6. Stop the engine and release the right brake. Remove jack stands and lower the machine to the shop floor. Test drive the machine to make sure it does not creep. The machine must not creep when traction pedal is released. If it does creep, an adjustment is required. Adjusting the Cutting Unit Lift Rate 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.
Checking and Adjusting the Traction Linkage 4. After desired lift rate is attained, tighten set screw to lock adjustment. 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. Park machine on a level surface, lower cutting units to the floor and shut engine off. 1 2.
Adjusting the Service Brakes 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. 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.
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. 69). 3. Remove plug allowing oil to drain into drain pans. 4. After oil is drained, apply thread locking compound on drain plug threads and reinstall in axle. 1 5. Fill axle with lubricant; refer to Checking the Rear Axle Lubricant, page 22. Figure 70 1.
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. posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. Fuses 8. Repeat steps 3 through 7 if necessary. There are 4 fuses in the machines electrical system. They are located below control panel (Fig. 72 and 73). 9.
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.
RELAY 5 4 1 2 LIGHT SWITCH G BLACK OIL PRESS SWITCH S B 6 4 2 RED – BLACK BATTERY 12 VOLTS + RED WATER TEMP SENSOR FUSIBLE LINK HARNESS 5 3 1 ORANGE/RED STARTER START RELAY GREEN/BLUE WARNING LIGHTS SPEEDOMETER G S I BLACK BLACK GRAY BLACK ALTERNATOR ORANGE BLACK FUEL GAGE BLUE/GREEN ORANGE BLUE/WHITE ORANGE TEMP GAGE FUSIBLE LINK OPTIONAL LIGHT ORANGE ORANGE RED GREEN/BLACK ORANGE BLACK ORANGE L BLACK BLACK RED DIAGNOSTIC INDICATOR HOUR METER B A
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.
Engine Preparation for Seasonal Storage 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 SAE 10W-30 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.
