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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. Major sections are: - Safety Instructions - Know Your Controls - Specifications - Operating Instructions - Set-up Instructions - Maintenance - Schematics - Before Operating This manual emphasizes safety, mechanical and general product information.
Connect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . Mount Hood Latch . . . . . . . . . . . . . . . . . . . . . . . . Install Lift Control Kit . . . . . . . . . . . . . . . . . . .
The REELMASTER 5200ĆD/5400-D was tested and certified by TORO for compliance with the B71.4Ć1990 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.
!% ! " ! ! ! " % When a person or pet appears unexpectedly in or near the mowing area, ! $ . Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until area is cleared. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it is stopped. These areas could be hot enough to cause burns.
" 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 listed below and in your Parts Catalog.
! "' !" # " ! " & (.0 - " (.0 - #"" # " (.0 - " % (.0 - " & $ (.0 - " ! (.0 - ! (.0 - & (.0 - -)*+/ -,+1 (.0 - -)*+/ -,+1 (.0 - ! # (.0 - (.0 - " (.
" " 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, 3Ćstage, remote mounted air cleaner. High water temperature shutdown switch. ## " -'( ! Radiator capacity is approximately 7-1/2 qts. of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted 1 qt. expansion tank.
Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total setĆup cannot be completed. Locking Hood Switch Lockwasher Nut Key Hood Latch Bracket Capscrew 1/4-20 x 3/4" lg. Flat Washer .281 x .625 Locknut 1/4-20 Joystick Kit Flange Head Capscrew 5/16-18 x 5/8" Lg. Cutting Unit Stop Capscrew 3/8 - 16 x 1" Locknut Screw Flatwasher Thrust Washer Capscrew 5/16 x1-3/4" lg. Lockwasher 5/16 Flatwasher .344 x .
!=" ! " ! ! !! $ -+ # 322)'7-2+ '%&0)6 73 7,) :532+ 4367 '380( 5)6807 -2 4)5632%0 -2.85< %2( 35 (%1%+) 73 7,) )0)'75-'%0 6<67)1 Open hood. Ensure battery is securely fastened in place and check battery charge with a hydrometer. If battery needs charging, be sure at least one battery cable, preferable the positive (+) cable, is disconnected from the battery before connecting the charger. Coat both battery connections with Grafo 112X (skin over) grease, Toro Part No.
5 (& Unthread knob from lift control shaft (Fig. 4). Remove boot, washer and snap ring from lift control shaft (Fig. 4). (& Remove fastener securing left front corner of floor panel to frame (Fig. 6). (&2/$ (%1 #-,1/-* 0'!%1 (%1 #-,1/-* ),-" --1 Insert new boot and sleeve assembly onto lift control shaft (Fig. 5). (&2/$ *--/ .!,$* Replace with 5/16-18 x 5/8" lg.
2 Remove hardware securing Turf compensation kit to each end of carrier frame (Fig. 8 & 9) and reuse when installing basket guides and basket brackets. and (3) R.H. springs. Longer leg of spring is to be positioned forward as shown in Fig. 10. Mount a basket guide (Fig. 8) to the appropriate side of each cutting unit carrier frame (see figure 7) with a 5/16-18 x 1-3/4" lg. capscrew, flatwasher and lockwasher or fasteners previously removed, as shown in figure 8.
! "=# !" # " ! " " %.) 685) %// ,<(5%8/-' ,26)6 %5) 5287)( %:%< *520 '877-1+ 81-7 62 :,)1 '877-1+ 81-7 3-9276 );')66-9) 58&&-1+ (2)6 127 2''85 Check adjustment of lock-up rollers (Fig. 14). When properly adjusted, they will contact the lock-up levers on rear lift arms and support the cutting units when fully raised. The cutting units should have approximately 3/8"- 5/8" vertical travel measured at the rear roller.
" #" )*35) 6)59-'-2+ 35 1%/-2+ %(.8671)276 73 7,) 1%',-2) 6734 )2+-2) %2( 5)139) /)< *531 7,) 6:-7', -+ Park machine on a level surface, stop engine and remove key from ignition switch. Open hood. Remove dipstick, wipe clean and reinstall dipstick. Remove dipstick and check oil level on dipstick; Oil level should be up to FULL mark (Reelmaster 5200 Fig. 15, Reelmaster 5400 - Fig. 16).
! ! # .,85* .,85* 8*0 #&2/ &4 ;)5&80.( #&2/ &4 #! " "" $ ., The front axle housing acts as the reservoir for the system. The transmission and axle housing are shipped from the factory with approximately 5 quarts of Mobil 424 hydraulic fluid. However, check level of transmission oil before engine is first started and daily thereafter. Position machine on a level surface, lower the cutting units and stop the engine.
" 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 Mobil DTE 26 type fluids are straight viscosity fluids which remain slightly more viscous at higher temperatures than the multi-viscosity fluids. Position the machine on a level surface. Remove a check plug from each end of axle and make sure lubricant is up to bottom of hole.
%!1 (Fig. 23) - Seat adjusting lever allows 4 inch fore and aft adjustment. Seat adjusting knob adjusts seat for operators weight. To adjust seat fore and aft, pull lever on left side of seat assembly outward. After moving seat to desired location, release lever to lock seat into position. To adjust for operators weight, turn spring tension knob; clockwise to increase tension, counterclockwise to decrease spring tension. !2*1 (&'1 (Fig. 24) - When lit, indicates control system problem.
!" % * ( (Fig. 26) - Used in conjunction with lower mow / raise control lever for backlapping operation. Refer to Cutting Unit Maintenance, Backlapping. )& $)& ( & & ! "' (Fig. 29) - Two foot pedals operate individual wheel brakes for turning assistance, parking and to aid in obtaining better sidehill traction. Locking pin connects the pedals for parking brake operation and transport. )& !" % * ( " % $#(&$"' (Fig.
%&/1% 2%15)#).' /1 -!+).' !$*423-%.32 3/ 3(% -!#().% 23/0 %.').% !.$ 1%-/5% +%7 &1/3(% 26)3#( (% &4%, 2723%- -423 "% ",%$ )& !.7 /& 3(% &/,,/6).' 2)34!3)/.2 (!5% /##411%$ )'41% )1 ",%%$ 2#1%6 .)3)!, 23!13 40 /& ! .%6 -!#().% .').% (!2 #%!2%$ 14..).' $4% 3/ ,!#+ /& &4%, Pump lever on fuel pump (Fig. 31) until a solid stream of fuel flows out around screw. Tighten air bleed screw. !).3%.!.#% (!2 "%%.
! Pump lever on fuel pump (Fig. 31) until a solid stream of fuel flows out around screw on fuel injection pump. Tighten air bleed screw. To set reel speed, rotate knobs (Fig. 34) until indicator arrows are in line with the number designating desired setting. 04' 02.#--8 '/)+/' 3*05-& 34#24 #(4'2 #$06' $-''&+/) 120%'&52'3 #2' (0--07'& 07'6'2 +( '/)+/' &0'3 /04 34#24 #+2 .#8 $' 42#11'& $'47''/ +/,'%4+0/ 15.1 #/& +/,'%4023 2'('2 40 -''&+/) +2 20.
! +)52' '/4'2 0( 20/4 2#.' '.$'2 +)52' 04' Lock both brake pedals together before towing. 12+/) 2#%,'4 '8 *#(4 '4#+/+/) 2#%,'4 Remove the capscrew and locknut securing retaining bracket, while rotating hex shaft to relieve spring tension. Move spring bracket to desired location and install capscrew and locknut, while rotating hex shaft to relieve spring tension.
! Using the diagnostic display, determine which output is malfunctioning, refer to Checking Interlock Switches. If the diagnostic light is not illuminated when the key switch is in the ON position, this indicates that the electronic controller is not operating. Possible causes are: Loopback is not connected. The light is burned out. Fuses are blown. Not functioning correctly. 0 5(1,)7 ,/3(1.
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. . 4%0)&6 .32/32 &3-#2).
- If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if the machine is operated with a malfunction. -Start engine and move throttle to FAST so engine is running at maximum speed. Move the ENABLE / DISABLE switch to ENABLE and use the LOWER MOW / RAISE lever to control the cutting units (front cutting units are timed to lower before the rear cutting units).
3 Traction Neutral INPUTS 8) Backlap Rear Raise (To turn around front & rear) Raise (To turn around front & rear) 7) Backlap Front Raise (To turn around front) 6) Raise (transport) 5) Mow Lower / Mow-Front & Rear Lower / Mow-Front Lower (All units when enabled) Lower (All units when disabled) 4) Lower (To turn around) Run (with operator) 3) Run (No operator) 2) Start 5 High Coolant Temp 4 Seat Switch 0 1 2 Key Run 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 X O X O X O X X 8 En
!"*,! -!,0% %)# *, ( '%)# &/-.(!).- .* .$! ( $%)! -.*+ !)#%)! ) ,!(*0! '!2 ",*( .$! -1%. $ %# 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 50 hours of operation. Lubricate bearings and bushings immediately after every washing, regardless of the interval listed.
Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance C Check Item b MON TUES WED THURS FRI SAT SUN n Safety Interlock Operation n Brake Operation n Engine Oil & Fuel Level n Cooling System Fluid Level Drain Water/Fuel Separator n Air Filter Restriction Indicator n Radiator and Screen for Debris n Unusual Engine Noises1 n
Gently slide filter element out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. &'02& 3&26*$*/( 02 .#,*/( #%+534.&/43 40 4)& .#$)*/& 3401 &/(*/& #/% 2&.06& ,&8 '20. 4)& 37*4$) Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. Service the air cleaner filters when ever air cleaner indicator (Fig.
%&/1% 2%15)#).' /1 -"+).' "$*423-%.32 3/ 3(% -"#().% 23/0 %.').% ".$ 1%-/5% +%7 &1/3(% 26)3#( )' Change oil and filter initially after the first 50 hours of operation, thereafter change oil every 50 hours and filter every 100 hours. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug. 4%, ).%2 ".$ /..%#3)/.2 Check lines and connections every 400 hours or yearly, whichever comes first.
Repeat steps on remaining nozzles. '& $*,1'+& $!-'. - Remove debris from screen, oil coolers and radiator daily, clean more frequently in dirty conditions. A. Turn engine off and raise hood. Clean engine area thoroughly of all debris. B. Loosen clamps and pull up on screen to slide it out of mounting tracks. Clean screen thoroughly with water or compressed air. '&0-$ 0$) %')/$- ..
Check tension by depressing belt 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. Tighten lock nut to secure adjustment. %$ Apply 5 -10 lb. of force at end of lever to set the proper tension on the fan belt. Position throttle lever forward so it stops against seat base slot.
# ! Position machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. ! ()24( 5(48,&,1* 24 0$.,1* $'-7560(165 62 6+( 0$&+,1( 5623 (1*,1( $1' 4(028( .(: )420 6+( 59,6&+ # ! ! ,* Clean area around filter mounting area. Place drain pan under filter and remove filter. Change hydraulic fluid after every 800 operating hours, in normal conditions.
" ! 0)+0' /645 $' 3600+0) 41 (+0#. #&,645/'05 1( 5*' 53#%5+10 #&,645/'05 %#/ %#0 $' 2'3: (13/'& 1 )6#3& #)#+045 2144+$.' 2'3410#. +0,639 -''2 *#0&4 (''5 (#%' #0& 15*'3 2#354 1( 5*' $1&9 #8#9 (31/ 5*' /6((.'3 15*'3 *15 2#354 1( 5*' '0)+0' #0& 15*'3 315#5+0) 2#354 Start engine and rotate cam hex in either direction until wheel ceases rotation. +)63' '45 135 '45 135 '45 135 15 *180 Tighten locknut securing adjustment.
. '$"* 1 "3(.- (-* &$ On a large, flat open area, drive the machine at full throttle and full traction speed. Remove foot from traction pedal and measure the distance required for the machine to come to a stop. If the distance required to stop is greater than 18 feet (5.5 meters) an adjustment to the traction linkage is required. Proceed to next step. . #)423 1 "3(.- (-* &$ Park machine on a level surface, lower cutting units to the floor and shut engine off.
cable. Then tighten rear nut to move cable backward until brake pedals have 1/2 to 1 inch of free travel. Tighten front nuts after brakes are adjusted correctly. %&/1% 2%15)#).' /1 -!+).' !$*423-%.32 3/ 3(% -!#().% 23/0 %.').% !.$ 1%-/5% +%7 &1/3(% 26)3#( )' 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.
& # Remove line from transmission allowing fluid to drain into drain pan. Reinstall suction line to transmission. Fill with oil; refer to Check Transmission Fluid. 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. ! #! " "" # ! ., .,85* 5'.
! ! !! $ ! ! )*24) 9)/(-1+ 21 6,) 0%',-1) (-5'211)'6 &26, '%&/)5 *420 6,) &%66)4; (-5'211)'6 &26, 9-4) ,%41)55 3/7+5 *420 6,) )/)'6421-' '21642/ 71-6 %1( 6,) 6)40-1%/ '211)'624 *420 6,) %/6)41%624 62 34)8)16 (%0%+) 62 6,) )/)'64-'%/ 5;56)0 "! #)%4 5%*)6; +2++/)5 %1( 47&&)4 +/28)5 9,)1 924.-1+ 9-6, )/)'642/;6) ,%4+) 6,) &%66)4; -1 % 9)// 8)16-/%6)( 52 +%5)5 342(7')( 9,-/) ',%4+-1+ '%1 (-55-3%6) -1') 6,) +%5)5 %4) ):3/25-8) .))3 23)1 */%0) %1( )/)'64-'%/ 53%4.
"!! " ! ! Set both reel speed controls to position 11. Select either front or rear on backlap switch to determine which units to backlap.
5 4 1 2 LIGHT SWITCH "J" LINK "G" G S I FUEL GAGE G S B SPEEDOMETER G S I RED 5 3 1 RED RED BLACK - BATTERY 12 VOLTS + FUSIBLE LINK WATER TEMP SENSOR 6 4 2 WARNING LIGHTS ORANGE/RED STARTER START RELAY GREEN/BLUE ALTERNATOR BLACK BLACK BLUE/GREEN BLACK GRAY BLACK OIL PRESS SWITCH FUSIBLE OPTIONAL LIGHT RED GREEN/BLACK BLACK ORANGE ORANGE BLACK ORANGE BLACK ORANGE BLACK ORANGE BLUE/WHITE TEMP GAGE BLACK "P" "K" BLACK DIAGNOSTIC INDICATOR HOUR METER
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.
! Check Battery Fluid Level Check Battery Cable Connections Lubricate All Grease Fittings Change Engine Oil Inspect Air Filter, Dust Cup and Baffle ! ! Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs { Check Fan and Alternator Belt Tension } Replace Engine Oil Filter Inspect Cooling System Hoses Drain Moisture-Hyd.
& '#%$ $#' $"#$! Thoroughly clean the traction unit, cutting units and the engine. Drain the engine oil from the oil pan and replace the drain plug. Check the tire pressure. Inflate all traction unit tires to 15-20 psi. Remove and discard the oil filter. Install a new oil filter. Check all fasteners for looseness; tighten as necessary. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant.
)& /2/ /--&2$*", 2/%5$43 7/ !&"2 *-*4&% "22".49 )& /2/ /-0".9 7"22".43 9/52 /2 .&7&2 /2/ /--&2$*", 2/%5$4 : 2/%5$4 052$)"3&% "'4&2 ".5"29 4/ #& '2&& '2/- %&'&$43 *. -"4&2*",3 /2 7/2+-".3)*0 '/2 4)& 0&2*/% /' 4*-& ,*34&% #&,/7 )&2& " 7"22".4"#,& $/.%*4*/. &8*343 /2/ 7*,, 2&0"*2 4)& 2/%5$4 "4 ./ $/34 4/ 9/5 *.$,5%*.( %*"(./3*3 ,"#/2 0"243 ".% 42".30/24"4*/. )*3 7"22".49 #&(*.3 /. 4)& %"4& 4)& 2/%5$4 *3 %&,*6&2&% 4/ 4)& /2*(*.", 2&4"*, 052$)"3&2 "22".49 52"4*/.
