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Toro Reelmaster 5200-D Operator's Manual

Two-wheel and four-wheel drive traction units
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See also: Operator's Manual
Form No. 3353–130
Reelmaster 5200-D/5400-D
Two-Wheel and Four-Wheel Drive Traction Units
03540—250000001 and Up
03543—250000001 and Up
03544—250000001 and Up
Operator's Manual
English (EN, GB)

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Summary of Contents for Toro Reelmaster 5200-D

  • Page 1 Form No. 3353–130 Reelmaster 5200-D/5400-D Two-Wheel and Four-Wheel Drive Traction Units 03540—250000001 and Up 03543—250000001 and Up 03544—250000001 and Up Operator’s Manual English (EN, GB)

  • Page 2: Table Of Contents

    Checking the Rear Axle Lubricant ... . Checking Reel to Bedknife Contact W 2005 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 Checking the Torque of the Wheel Nuts Operation .

  • Page 3: Introduction

    Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. The model and serial number is on a plate that is mounted on the left side of the footrest.
  • Page 4 Preparation • 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. •...

  • Page 5: Toro Riding Mower Safety

    Toro Riding Mower Safety The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN, ISO, or ANSI standard. This product is capable of amputating hands and feet and throwing objects.

  • Page 6: Sound Pressure Level

    Keep everyone away. • 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.

  • Page 7: Safety And Instruction Decals

    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. 93-6693 1. Hazard to hands–pinch points 2. Stop reels before touching 107-8841 104-2052 1.
  • Page 8 1. Throttle—slow 4. Reels lowered and on when enabled—forward and 2. Throttle—fast backlap 3. Reels raised & off 5. Reels—enabled 104-9298 1. Read operator’s manual 94-6767 1. Read operator’s manual 2. Engine start 3. Headlights (Optional) 104-9296 6. Reels disabled—lift only 9.
  • Page 9 106-9224 1. Warning—read the Operator’s Manual. 2. Cutting hazard of hand and foot—stop the reels before touching. 93-6697 (Model 03544 only) 1. Read operator’s manual 2. Lubrication point 3. Time interval 98-9335 1. Cutting dismemberment hazard–stay away from moving parts 93-6696 1.
  • Page 10 93-6680 1. Diesel fuel 105-7506 1. Read the Operator’s 3. On Manual 4. Engine—preheat 2. Engine—stop 5. Engine—start 93-1263 1. Read operator’s manual To engage parking brake–connect pedals with locking pin, push down on both pedals and pull parking brake latch out. 3.
  • Page 11 1. Read the Operator’s Manual. 5. Warning—keep bystanders a safe distance from the 2. Do not tow the machine. machine. 3. Warning—read the 6. Warning—lock the parking Operator’s Manual. brake, stop the engine, and 4. Cutting hazard of hand or remove the ignition key foot—stay away from before leaving the machine.

  • Page 12: Specifications

    Specifications General Specifications 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 Engine 3200 rpm. 68.5 cu. in. (1123 cc) displacement. Heavy duty, 3-stage, remote mounted air cleaner.

  • Page 13: Measurements

    Measurements Width of Cut Overall Width Transport Outside of front tires Outside of rear tires Overall Length Without grass baskets With grass baskets Height Without ROPS installed With ROPS installed Recommended Height of Cut 5 Blade Cutting Unit 8 Blade Cutting Unit Weight Models 03540 &...

  • Page 14: Setup

    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 Locking hood switch Lock washer...

  • Page 15: Mounting The Hood Latch

    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.

  • Page 16: Replacing The Panel Fasteners

    5. Adjust latch bracket, until aligned with switch latch, then tighten capscrews. 6. Rotate latch to locked and unlocked position with key. Remove key and store in memorable place. 7. Close hood. Replacing the Panel Fasteners 1. Remove fasteners securing left front corner of floor panel and left end of access panel to frame (Fig.
  • Page 17 5. Align the mounting shaft of the cutting unit with the pivot tube on the carrier frame. Insert the shaft into the tube (Fig. 8). Figure 8 1. Cutting unit mounting 4. Flat washer shaft 5. Lock washer 2. Carrier frame pivot tube 6.

  • Page 18: Adjusting The Turf Compensation Spring

    Adjusting the Turf Compensation Spring Note: This adjustment is needed for Cutting Unit Models 03527 and 03528 only. The turf compensation spring (Fig. 12), 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.

  • Page 19: Installing The Rear Weight

    Installing the Rear Weight The Reelmaster 5200-D & 5400-D Traction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 Standards when equipped with rear weight and 90 lb. of calcium chloride ballast is added to rear wheels.

  • Page 20: Before Operating

    Preferred oil: SAE 15W–40 (above 0_ F) Alternate oil: SAE 10W–30 or 5W–30 (all temperatures) Toro Premium Engine oil is available from your distributor in either 15W–40 or 10W–30 viscosity. See the parts catalog for part numbers. 1. Park machine on a level surface, stop engine, and remove key from ignition switch.

  • Page 21: Filling The Fuel Tank

    Figure 16 1. Expansion tank 2. If coolant level is low, remove expansion tank cap and replenish the system. Do not overfill. 3. Install expansion tank cap. Filling the Fuel Tank 1. Remove fuel tank cap (Fig. 17). 2. Fill tank to about one inch below top tank, not filler neck with No.

  • Page 22: Checking The Hydraulic Fluid

    (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) Alternate fluids: If the Toro fluid is not available, other petroleum–based Universal Tractor Hydraulic Fluids (UTHF) may be used provided its specifications fall within the listed range for all the following material properties and it meets industry standards.

  • Page 23: Checking Reel To Bedknife Contact

    4. Remove each end check plug and add enough lubricant to bring the level up to the bottom of each check plug hole. 5. Install all plugs. Checking Reel to Bedknife Contact Each day before operating, check reel to bedknife contact, regardless if quality of cut had previously been acceptable.

  • Page 24: Operation

    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. Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine.

  • Page 25: Fuel Gauge

    Figure 24 1. Traction speed limiter 5. Parking brake latch 2. Reel control light 6. Locking pin 3. Speedometer 7. Key switch 4. Brake pedals Engine Coolant Temperature Warning Light The light (Fig. 25) illuminates and engine shuts down when coolant reaches a dangerously high temperature.

  • Page 26: Starting And Stopping

    Reel Speed Controls 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. Figure 27 1. Reel speed controls Hour Meter The hour meter (Fig.

  • Page 27: Setting The Reel Speed

    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.

  • Page 28: Adjusting The Lift Arm Down Pressure

    Adjusting the Lift Arm Down Pressure 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.

  • Page 29: Diagnostic Light

    Diagnostic Light 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.
  • Page 30 Figure 36 1. Wire harness and connectors 3. Connect the Diagnostic ACE display connector to the harness connector (Fig. 37). Make sure correct overlay decal is positioned on Diagnostic ACE display. 4. Turn the key switch to the ON position, but do not start machine.

  • Page 31: Hydraulic Valve Solenoid Functions

    If each output switch is in the correct position and functioning correctly, but the output LED’s are not correctly illuminated, this indicates an ECU problem. If this occurs, contact your Toro Distributor for assistance. Important The Diagnostic ACE display must not be left connected to the machine.

  • Page 32: Logic Chart

    Logic Chart Preheat Start Hold S8,S9 Light Diagnostic OUTPUTS Involved Timer Start Lower Rear Backlap Front Backlap Down Units Front Reels Enable Raise Temp Coolant High Switch Seat Neutral Traction INPUTS...

  • Page 33: Maintenance

    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 Maintenance Procedure Interval • Check the fan and alternator belt tension. •...

  • Page 34: Daily Maintenance Checklist

    Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item 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.

  • Page 35: Service Interval Chart

    Service Interval Chart 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.
  • Page 36 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45...

  • Page 37: General Air Cleaner Maintenance

    3. Assemble and install precleaner bowl, cover, and thumb screw. Note: When operating machine in extremely dusty conditions, an optional extension tube (Toro Part No. 43-3810), which raises precleaner bowl above hood, thus, lengthening the time between precleaner bowl servicing, is available from your local authorized Toro Distributor.

  • Page 38: Engine Oil And Filter

    Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1. Remove drain plug (Fig. 48) and let oil flow into drain pan. When oil stops, install drain plug. Figure 48 1.

  • Page 39: Bleeding Air From The Injectors

    3. Loosen the hose clamps at both ends of the filter and pull fuel lines off filter. Figure 51 1. Fuel filter 2. Hose clamps 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.

  • Page 40: Servicing The Engine Belts

    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 54 1. Reel oil cooler 3. Transmission oil cooler 2. Radiator 4.

  • Page 41: Changing The Hydraulic Fluid

    Changing the Hydraulic Fluid 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.

  • Page 42: Checking The Hydraulic Lines And Hoses

    Hydraulic System Test Ports The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. Test Port #1 (Fig. 60) is used to assist in trouble shooting the hydraulic circuit for the front cutting units and lift cylinders.

  • Page 43: Adjusting The Cutting Unit Lift Rate

    Adjusting the Cutting Unit Lift Rate The cutting unit lift circuit is equipped with (3) adjustable valves used to ensure the cutting units do not raise too quickly and bang against lift stops. Adjust cutting units as follows: Center Cutting Unit 1.

  • Page 44: Checking And Adjusting The Traction Linkage

    Checking and Adjusting the Traction Linkage 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.

  • Page 45: Replacing The Transmission Filter

    Filter Change the transmission filter after the first 10 hours of operation and every 800 hours thereafter. Only the Toro replacement filter (Part No.75-1330) can be used in the hydraulic system. Important Use of any other filter may void the warranty on some components.

  • Page 46: Servicing The Battery

    Figure 69 1. Tie rods 3. When toe-in is correct, tighten jam nuts against tie rods. Models 03544 only 1. Rotate the steering wheel so the rear wheels are straight ahead. 2. Remove the cotter pin and slotted hex nut from either tie rod ball joint.

  • Page 47: Fuses

    Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. Fuses There are 4 fuses in the machines electrical system. They are located below control panel (Fig. 71 and 72). Figure 71 1.
  • Page 48 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.

  • Page 49: Electrical Schematic

    Electrical Schematic WHITE SWITCH REAR BACKLAP BLACK BLUE SWITCH FRONT BACKLAP PINK (JOYSTICK) SWITCH LOWER/MOW BLACK/WHITE SENSOR DOWN REELS FRONT VIOLET (JOYSTICK) SWITCH RAISE ORANGE SWITCH DISABLE REEL BROWN SWITCH ENABLE REEL GREEN/WHITE SENSOR TEMP WATER ENGINE SENSOR SEAT GREEN SENSOR NEUTRAL GRAY...

  • Page 50: Hydraulic Schematic

    Hydraulic Schematic...

  • Page 51: Preparation For Seasonal Storage

    B. Clean the battery, terminals, and posts with a wire brush and baking soda solution. C. Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. D. Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfation of the battery.

  • Page 52: The Toro General Commercial Products Warranty

    If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

This manual is also suitable for:

Reelmaster 5400-d035400354303544

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