Toro 03540 Reelmaster 5200-D Manuals

Manuals and User Guides for Toro 03540 Reelmaster 5200-D. We have 6 Toro 03540 Reelmaster 5200-D manuals available for free PDF download: Service Manual, Operator's Manual

Toro 03540 Reelmaster 5200-D Service Manual (296 pages)

Brand: Toro | Category: Lawn Mower | Size: 6.48 MB

Chapter 1 Safety

7
- Table of Contents
  5
- Table of Contents
  7
Chapter 2 Product Records and Maintenance

11
- Conversion Factors
  16
- Other Torque Specifications
  16
- Lubrication
  17
- Tractor Unit
  17
- Chapter 8 -Cutting Units
  18
Chapter 3 Kubota Diesel Engines

23
- Introduction
  24
  - Specifications
    25
- General Information
  26
  - Check Engine Oil
    26
  - Fill Fuel Tank
    26
  - Check Cooling System
    27
- Adjustments
  28
  - Adjust Throttle Cable
    28
  - Adjust Alternator/Fan Belt
    29
  - Service and Repairs
    30
  - Bleed Fuel System
    30
  - Bleed Air from Fuel Injectors
    31
  - Change Engine Oil and Filter
    31
  - Clean Radiator and Oil Coolers
    32
  - Replace Fuel Filter
    32
- Check Fuel Lines and Connections
  34
- Drain and Clean Fuel Tank
  35
- Fuel Tank Installation
  35
- Fuel Tank Removal
  35
- Air Filtering System
  36
  - General Maintenance
    36
  - Service Precleaner Bowl
    36
  - Service Air Cleaner
    36
- Water/Fuel Separator
  37
  - Draining
    37
  - Filter Element Replacement
    37
- Radiator
  38
- Engine
  40
  - Removal
    41
  - Installation
    42
Chapter 4 Hydraulic System

45
- Specifications
  46
- General Information
  47
  - Hydraulic Hoses
    47
  - Hydraulic Fitting Installation
    47
  - Towing Traction Unit
    49
  - Check Transmission Fluid
    50
  - Check Hydraulic Fluid
    51
- Hydraulic Schematics
  52
- Hydraulic Flow Diagrams
  54
  - Traction Circuit
    55
  - Lower Cutting Units
    57
  - Raise Cutting Units
    59
  - Mow and Backlap
    61
  - Steering
    63
- Special Tools
  64
- Troubleshooting
  67
- Testing
  69
- Adjustments
  77
- General Precautions for Removing and Installing Hydraulic System Components
  81
- Check Hydraulic Lines and Hoses
  82
- Flush Hydraulic System
  82
- Charge Hydraulic System
  83
- Change Hydraulic Fluid
  84
- Replace Hydraulic Oil Filter
  85
- Replace Transmission Filter
  86
- Replace Transmission Fluid
  86
- Transmission Control Linkage
  87
- Transmission
  88
  - Chapter 8.1 - Cutting Units
    89
- Transmission Service
  91
  - Disassembly
    92
  - Inspection
    96
  - Assembly
    96
  - Shaft Seal Replacement
    102
  - Trunnion Seal Replacement
    103
  - Check/High Pressure Relief Valve Replacement
    104
  - Charge Pressure Relief Valve Replacement
    105
  - Heat Exchanger By-Pass Valve Replacement
    106
  - Filter By-Pass Valve Replacement
    107
  - In-Line Filter Check Valve Replacement
    107
  - Charge Pump Replacement
    108
- Gear Pump
  109
- Reel Motor
  112
- Hydraulic Control Manifold
  115
- Lift Cylinders
  120
- Hydraulic Reservoir
  124
  - Heat Exchanger
    126
Chapter 5 Electrical System

127
- Special Tools
  128
- Troubleshooting
  130
  - Quick Reference Troubleshooting Guide
    130
    
    Diagnostic Light
    130
    
    Diagnostic Ace Display
    130
    
    Check Interlock Switches
    131
    
    Verify Output Functions
    131
    
    Retrieving Stored Faults
    132
    
    Clearing Fault Memory
    132
  - Starting Problems
    133
  - General Run & Transport Problems
    134
  - Cutting Unit Operating Problems
    134
  - Turfdefender TM Leak Detector
    139
- Electrical System Quick Check
  140
- Component Testing
  141
  - Ignition Switch
    141
  - Glow and Start Relays
    142
  - Fuses
    143
  - Hydraulic Valve Solenoids
    144
  - High Temperature Warning and Shutdown Switch
    145
- Warning Light Cluster
  146
- Fuel Stop Solenoid
  147
- Fuel Sender
  148
- Fuel Gauge
  149
- Temperature Sender
  150
- Temperature Gauge
  151
- Electronic Control Unit (ECU)
  152
- Hour Meter
  152
- Parking Brake Switch
  152
- Traction Speed Sensor
  153
- Speedometer
  154
- Reels Enable/Disable and Backlap Switches
  155
- Seat Sensor
  156
- Traction Neutral Switch
  156
- Front Reels down Sensor
  157
- Joystick Raise and Lower/Mow Switches
  157
- Battery Care
  158
- Battery Storage
  158
- Service and Repairs
  158
- Battery Service
  159
Chapter 6 Differential Axle

163
- Special Tools
  164
- Specifications
  164
- SERVICE and REPAIRS
  165
  - Axle Assembly Removal and Installation
    165
  - Axle Shafts and Wheel Bearings
    166
    
    Disassembly
    166
    
    Assembly
    169
  - Lubrication
    171
  - Disassembly
    172
  - Assembly
    173
- Differential and Housing (All Units)
  174
  - Disassembly
    174
Chapter 7 Steering and Brakes

189
- Introduction
  190
  - Power Steering
    190
  - Brakes
    190
- Power Steering Schematics
  191
- Special Tools
  192
- Specifications
  192
- Troubleshooting
  194
- Testing
  195
  - Steering Cylinder Internal Leakage Test
    195
- Adjustments
  196
  - Rear Wheel Toe-In Adjustment
    196
    
    2WD Traction Units
    196
  - Brake Adjustment
    197
- Service and Repairs
  198
  - Steering Wheel
    198
    
    Removal
    198
    
    Installation
    198
  - Axle Pivot Bushings
    200
  - Steering Pivot Bushings
    200
  - Rear Wheel Spindle Bushings
    201
- Wheel Bearings
  202
  - Front Wheel Bearings
    202
  - Rear Wheel Bearings
    202
- Steering Cylinder
  203
  - Removal
    203
  - Installation
    204
- Steering Cylinder Service
  205
- Brake Shoe Replacement
  206
- Steering Valve
  207
  - Removal
    207
  - Installation
    207
- Steering Valve Service
  208
Section 8

209
- Model 03506, S/N 80001 - 209999999 Model 03509, S/N 80001 - 209999999
  210
- Specifications
  210
- Special Tools
  211
- Troubleshooting
  212
  - Adjustment Summary and Check List
    214
  - Reel Bearing Adjustment and Service
    215
  - Adjust Bedknife to Reel
    216
  - Level Front Roller to Reel
    217
  - Adjust Height-Of-Cut
    218
  - Adjust Front Shield Height
    219
  - Adjust Cutoff Bar
    220
  - Adjust Lock-Up Roller
    220
  - Adjust Lift Arm down Pressure
    221
- Cutting Units
  221
- Cutting Unit Removal and Installation
  222
- Service and Repairs
  222
- Backlapping
  223
- Bedbar Removal and Installation
  225
- Bedknife Replacement and Grinding
  226
- Prepare Reel for Grinding
  227
- Reel Removal and Bearing Replacement
  228
- Traction Unit Lift Arm Spring Replacement
  229
Section 9

231
- Model 03527, S/N 210000001 & up Model 03528, S/N 210000001 & up
  232
- Specifications
  232
- Special Tools
  233
- Troubleshooting
  235
- Initial Set-Up and Adjustments
  237
- Bedknife to Reel Adjustment
  238
- Setting Cutting Unit Attitude
  239
- Leveling Front Roller
  241
- Adjusting Height of Cut
  242
- Cut-Off Bar Adjustment
  243
- Front Grass Shield Adjustment
  243
- Rear Shield Adjustment
  243
- Adjust Lift Arm down Pressure
  244
- Adjust Lock-Up Roller
  244
- Daily Adjustments
  245
  - Lubrication
    245
  - Cutting Units
    245
  - Service and Repairs
    246
- Cutting Unit Removal and Installation
  246
- Bedknife Replacement and Grinding
  249
- Preparing Reel for Grinding
  250
- Reel and Reel Bearings
  251
  - Bearing Adjustment
    251
  - Reel Removal
    252
  - Inspection
    252
- Roller Bearing and Seal Replacement
  253
  - Removal
    253
  - Installation
    253
Removal/Installation

255
- Installation
  255
- Removal
  255
- Chapter 9 - 4WD Rear Axle
  256
- Introduction
  256
- Specifications
  257
- Maintenance
  258
- Service and Repairs
  259
- Overrunning Clutch
  261
- Unit Serial No. 80001 - 99999
  261
- 4WD Rear Axle
  262
- Installation
  263
- Removal
  263
- Disassembly
  264
- Inspection
  265
- Assembly
  266
- Pinion Gear to Ring Gear Engagement
  267
- 4WD Rear Axle
  268
- Gear Pattern Movement Summary
  268
Wd Rear Axle

269
- Installation
  269
  - Inspection
    269
    
    Unit Serial No. 200000001 & up
    270
  - Introduction
    270
  - Specifications
    271
  - Maintenance
    272
  - Service and Repairs
    273
  - Installation
    275
- Removal
  269
- Differential Shafts
  282
  - Removal
    282
  - Installation
    282
- Axle Shafts
  283
  - Removal
    283
  - Installation
    283
- Input Shaft/Pinion Gear
  284
  - Removal
    284
  - Installation
    284
- Differential Gear
  286
  - Removal
    286
  - Installation
    288
- Pinion Gear to Ring Gear Engagement
  289
  - Gear Pattern Movement Summary
    290
  - 4WD Rear Axle
    290
- Chapter 10 - Electrical Diagrams
  291

Toro 03540 Reelmaster 5200-D Operator's Manual (64 pages)

Two-Wheel and Four-Wheel Drive Traction Units

Brand: Toro | Category: Lawn Mower | Size: 3.92 MB

Table of Contents
2
Introduction
2
Safety
4
- Safe Operating Practices
  4
- Toro Riding Mower Safety
  6
- Sound Pressure Level
  7
- Sound Power Level
  7
- Vibration Level
  7
- Safety and Instructional Decals
  8
- Setup
  13
1 Connecting the Battery

14
2 Mounting the Hood Latch

15
- Units Only)
  15
3 Replacing the Panel Fasteners

15
- (CE Units Only)
  15
4 Adjusting the Tire Pressure

16
5 Installing the Cutting Units

16
6 Adjusting the Turf Compensation Spring

18
7 Adjusting the Lifted Height

19
- Of the Outer Front Cutting Units (Enable Position)
  19
- Cutting Units (Enable Position)
  19
8 Installing Rear Weights

20
9 Installing CE Decals

21
10 Reading the Manual and Viewing the Safety Video

21
- Product Overview
  22
  - Controls
    22
    
    Brake Pedals
    23
    
    Throttle Control
    23
    
    Fuel Gauge
    23
    
    Key Switch
    23
    
    Hour Meter
    24
    
    Enable/Disable Switch
    24
    
    Reel Speed Controls
    24
  - Speciﬁcations
    26
- Operation
  26
  - Checking the Engine Oil Level
    26
  - Checking the Cooling System
    27
  - Filling the Fuel Tank
    27
  - Checking the Transmission
    28
  - Fluid
    28
  - Checking the Hydraulic Fluid Level
    28
  - Checking the Rear Axle
    29
    
    Lubricant
    29
  - Checking the Reel to Bedknife Contact
    30
  - Check the Torque of the Wheel
    30
  - Nuts
    30
  - Bleeding the Fuel System
    30
  - Starting and Stopping the Engine
    31
  - Setting the Reel Speed
    31
  - Adjusting the Lift Arm down
    32
    
    Pressure
    32
  - Towing the Traction Unit
    33
  - Understanding the Diagnostic Light
    34
  - Diagnostic Ace Display
    34
  - Checking the Interlock
    34
    
    Switches
    34
  - Hydraulic Valve Solenoid
    38
    
    Functions
    38
  - Operating Tips
    38
    
    Maintenance
    39
- Recommended Maintenance
  39
  - Schedule(S)
    39
  - Daily Maintenance Checklist
    41
  - Service Interval Chart
    42
- Lubrication
  42
  - Greasing the Bearings and Bushings
    42
- Engine Maintenance
  44
- Fuel System Maintenance
  46
  - Draining the Fuel Tank
    46
  - Checking the Fuel Lines and Connections
    46
  - Draining the Fuel Filter/Water
    46
    
    Seperator
    46
  - Replacing the Fuel Filter
    47
    
    Canister
    47
  - Replacing the Fuel Preﬁlter
    47
  - Bleeding Air from the Fuel
    47
    
    Injectors
    47
- Electrical System Maintenance
  47
  - Servicing the Battery
    48
  - Fuses
    48
  - Optional Lighting
    48
  - Drive System Maintenance
    49
  - Adjusting the Traction Drive for Neutral
    49
    
    Checking and Adjusting the Traction Linkage
    49
    
    Changing the Transmission
    50
    
    Fluid
    50
    
    Replacing the Transmission Oil Filter
    50
    
    Changing the Rear Axle
    51
    
    Lubricant
    51
    
    Adjusting the Rear Wheel
    51
    
    Toe-In
    51
  - Cooling System Maintenance
    52
    
    Removing Debris from the Cooling System
    52
- Brake Maintenance
  52
  - Adjusting the Service Brakes
    52
  - Belt Maintenance
    53
    
    Tensioning the Alternator Belt
    53
    
    Tensioning the Cooling Fan
    53
    
    Belt
    53
  - Hydraulic System Maintenance
    54
    
    Changing the Hydraulic Fluid
    54
    
    Replacing the Hydraulic Filter
    54
    
    Checking the Hydraulic Lines and Hoses
    55
    
    Hydraulic System Test Ports
    55
  - Cutting Unit System Maintenance
    56
    
    Adjusting the Cutting Unit Lift
    56
    
    Rate
    56
    
    Backlapping the Cutting Units
    57
- Storage
  59
  - Preparing the Traction Unit
    59
  - Preparing the Engine
    59
- Schematics
  60

Toro 03540 Reelmaster 5200-D Operator's Manual (52 pages)

Two-Wheel and Four-Wheel Drive Traction Units

Brand: Toro | Category: Lawn and Garden Equipment | Size: 4.14 MB

Table of Contents
2
Introduction
3
Safety
3
Specifications
12
- General Specifications
  12
- Measurements
  13
- Optional Equipment
  13
Setup
14
Before Operating
20
Operation
24
- Controls
  24
  - Fuel Gauge
    25
  - Engine Oil Pressure Warning Light
    25
  - Charge Indicator
    25
- Starting and Stopping
  26
- Bleeding the Fuel System
  26
- Setting the Reel Speed
  27
- Adjusting the Lift Arm down Pressure
  28
- Towing the Traction Unit
  28
- Diagnostic Light
  29
- Diagnostic ACE Display
  29
- Checking the Interlock Switches
  29
- Hydraulic Valve Solenoid Functions
  31
- Operating Characteristics
  31
- Logic Chart
  32
Maintenance
33
- Recommended Maintenance Schedule
  33
- Daily Maintenance Checklist
  34
- Service Interval Chart
  35
- Greasing the Bearing and Bushings
  35
- General Air Cleaner Maintenance
  37
- Servicing the Precleaner Bowl
  37
- Servicing the Air Cleaner
  37
- Engine Oil and Filter
  38
- Servicing the Fuel System
  38
- Bleeding Air from the Injectors
  39
- Servicing the Engine Cooling System
  39
- Servicing the Engine Belts
  40
- Adjusting the Throttle
  40
- Changing the Hydraulic Fluid
  41
- Replacing the Hydraulic Filter
  41
- Checking the Hydraulic Lines and Hoses
  42
- Hydraulic System Test Ports
  42
- Adjusting the Traction Drive for Neutral
  42
- Adjusting the Cutting Unit Lift Rate
  43
- Checking and Adjusting the Traction Linkage
  44
- Adjusting the Service Brakes
  44
- Changing the Transmission Fluid
  44
- Replacing the Transmission Filter
  45
- Changing the Rear Axle Lubricant
  45
- Adjusting Rear Wheel Toe-In
  45
- Servicing the Battery
  46
- Fuses
  47
- Optional Lighting
  47
- Backlapping the Cutting Units
  47
- Electrical Schematic
  49
- Hydraulic Schematic
  50
- Preparation for Seasonal Storage
  51
The Toro General Commercial Products Warranty
52

Toro 03540 Reelmaster 5200-D Operator's Manual (52 pages)

Two-Wheel and Four-Wheel Drive Traction Units

Brand: Toro | Category: Lawn Mower | Size: 1.16 MB

Table of Contents
2
Contents
2
Introduction
3
Safety
3
- Safe Operating Practices
  3
- Toro Mower Safety
  4
- Sound Pressure Level
  5
- Sound Power Level
  6
- Vibration Level
  6
- Safety and Instruction Decals
  6
Specifications
10
- General Specifications
  10
- Measurements
  11
- Optional Equipment
  11
Setup
12
Before Operating
18
Operation
21
- Controls
  21
  - Fuel Gauge
    22
  - Throttle Control
    22
  - Backlap Switch
    22
- Starting and Stopping
  23
- Bleeding the Fuel System
  23
- Setting the Reel Speed
  24
- Adjusting the Lift Arm down Pressure
  25
- Towing the Traction Unit
  25
- Diagnostic Light
  26
Diagnostic ACE Display
26
- Checking the Interlock Switches
  26
- Hydraulic Valve Solenoid Functions
  28
- Operating Characteristics
  28
- Logic Chart
  29
Maintenance
30
- Recommended Maintenance Schedule
  30
- Daily Maintenance Checklist
  31
- Service Interval Chart
  32
- Greasing the Bearing and Bushings
  32
- Servicing the Air Cleaner
  34
- Engine Oil and Filter
  35
- Servicing the Fuel System
  35
- Bleeding Air from the Injectors
  36
- Servicing the Engine Cooling System
  37
- Servicing the Engine Belts
  38
- Adjusting the Throttle
  38
- Changing the Hydraulic Fluid
  39
- Replacing the Hydraulic Filter
  39
- Checking the Hydraulic Lines and Hoses
  40
- Hydraulic System Test Ports
  40
- Adjusting the Traction Drive for Neutral
  40
- Adjusting the Cutting Unit Lift Rate
  41
- Checking and Adjusting the Traction Linkage
  42
- Adjusting the Service Brakes
  42
- Changing the Transmission Fluid
  42
- Replacing the Transmission Filter
  43
- Changing the Rear Axle Lubricant
  43
- Adjusting Rear Wheel Toe-In
  43
- Servicing the Battery
  44
- Fuses
  45
- Optional Lighting
  45
- Backlapping the Cutting Units
  45
- Electrical Schematic
  47
- Hydraulic Schematic
  48
- Preparation for Seasonal Storage
  49
The Toro General Commercial Products Warranty
52

Toro 03540 Reelmaster 5200-D Operator's Manual (44 pages)

Brand: Toro | Category: Lawn Mower | Size: 3.91 MB

Table of Contents
2
Safety
3
Specifications
9
Before Operating
11
Controls
15
- Starting and Stopping
  17
- Bleeding the Fuel System
  17
Operating
26
Maintenance
28
- Air Cleaner Maintenance
  31
- Servicing the Air Cleaner
  31
- Engine Oil and Filter
  32
- Fuel Tank
  33
- Replacing the Fuel Filter
  33
- Engine Cooling System
  34
- Battery Care
  41

Toro 03540 Reelmaster 5200-D Operator's Manual (44 pages)

2 & 4 Wheel Drive Traction Units

Brand: Toro | Category: Lawn Mower | Size: 1.21 MB

Toro Categories

Lawn Mower Lawn Mower Accessories Snow Blower Lawn and Garden Equipment Utility Vehicle

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Toro 03540 Reelmaster 5200-D Manuals

Toro 03540 Reelmaster 5200-D Service Manual (296 pages)

Table of Contents

Chapter 1 Safety

Chapter 2 Product Records and Maintenance

Chapter 3 Kubota Diesel Engines

Chapter 4 Hydraulic System

Chapter 5 Electrical System

Chapter 6 Differential Axle

Chapter 7 Steering and Brakes

Section 8

Section 9

Removal/Installation

Wd Rear Axle

Toro 03540 Reelmaster 5200-D Operator's Manual (64 pages)

Table of Contents

1 Connecting the Battery

2 Mounting the Hood Latch

3 Replacing the Panel Fasteners

4 Adjusting the Tire Pressure

5 Installing the Cutting Units

6 Adjusting the Turf Compensation Spring

7 Adjusting the Lifted Height

8 Installing Rear Weights

9 Installing CE Decals

10 Reading the Manual and Viewing the Safety Video

Toro 03540 Reelmaster 5200-D Operator's Manual (52 pages)

Table of Contents

Toro 03540 Reelmaster 5200-D Operator's Manual (52 pages)

Table of Contents

Toro 03540 Reelmaster 5200-D Operator's Manual (44 pages)

Table of Contents

Toro 03540 Reelmaster 5200-D Operator's Manual (44 pages)

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