Page 1 Bloomington, MN 55420-1196 vent damage to systems or components on the machine. The Toro Company reserves the right to change product specifications or this publication without notice. E The Toro Company - 1999, 2001...
Page 2 Reelmaster 5200-D/5400-D...
Page 3 ......4 - 33 Service and Repairs ..... . . 4 - 37 Reelmaster 5200-D/5400-D Rev. A...
Page 4 Reelmaster 5200-D/5400-D...
Page 5: Table Of Contents
....8.1 - 7 Service and Repairs ..... 8.1 - 16 Reelmaster 5200-D/5400-D Rev. A...
Page 6 Reelmaster 5200-D/5400-D...
Page 7: Table Of Contents
General Safety Instructions The REELMASTER 5200-D/5400-D was tested and death. To reduce the potential for injury or death, comply certified by TORO for compliance with the B71.4-1990 with the following safety instructions. specifications of the American National Standards Insti- tute. Although hazard control and accident prevention...
Page 8 D. Stop engine and remove key from switch. C. Watch for holes or other hidden hazards. E. Toro recommends that anytime the machine is D. Look behind machine before backing up. parked (short or long term) the cutting units should be lowered to the ground.
Page 9 Toro replacement parts and sult. accessories. Replacement parts and accessories made 26.Before disconnecting or performing any work on the...
Page 10 C. Chock both front tires. Jack rear of machine off E. On 2WD models, use jack stands or blocks under the ground. the axle as close to the wheels as possible to secure the machine. Safety Reelmaster 5200-D/5400-D Page 1 - 4...
Page 11 Record maintenance and repair information about your Insert Operator’s Manuals and Parts Catalogs for your Reelmaster 5200-D/5400-D on the OPERATION AND Reelmaster 5200-D/5400-D at the end of this section. SERVICE HISTORY REPORT form. Use this informa- tion when referring to your machine.
Page 12 Equivalents and Conversions Product Records and Maintenance Reelmaster 5200-D/5400-D Page 2 - 2...
Page 13 For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 14 SAE J429. The tolerance is approximately 10% of the nominal torque value. Thin installing fasteners into threaded aluminum or brass. The specific torque value should be determined based height nuts include jam nuts. Product Records and Maintenance Reelmaster 5200-D/5400-D Page 2 - 4...
Page 15 Note: Torque values may have to be reduced when SAE J1199. The tolerance is approximately 10% of installing fasteners into threaded aluminum or brass. the nominal torque value. The specific torque value should be determined based Reelmaster 5200-D/5400-D Page 2 - 5 Product Records and Maintenance...
Page 16: Other Torque Specifications
3/8 - 16 UNC 200 100 in-lb Conversion Factors in-lb X 11.2985 = N-cm N-cm X 0.08851 = in-lb ft-lb X 1.3558 = N-m N-m X 0.7376 = ft-lb Product Records and Maintenance Reelmaster 5200-D/5400-D Page 2 - 6...
Page 17: Lubrication
H. One on the fan shaft (Fig. 10) 3. Wipe each grease fitting with a clean rag. 4. Apply grease until it begins to show. 5. Wipe excess grease away. Figure 6 Figure 3 Figure 7 Reelmaster 5200-D/5400-D Page 2 - 7 Product Records and Maintenance...
Page 18: Chapter 8 -Cutting Units
Apply grease to rear rollers un- til it begins to show around the end washers. 5. Wipe excess grease away. Figure 12 1. Weep Hole Product Records and Maintenance Reelmaster 5200-D/5400-D Page 2 - 8 Rev. A...
Page 19 Warranty Expires___________ Purchased From: _________________________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service _________________________ Phone___________________ Sales _________________________ Phone___________________ See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company. Reelmaster 5200-D/5400-D Page 2 - 9 Product Records and Maintenance...
Page 20 Flush/Replace Cooling System Fluid or 2 years, whichever comes first. Drain/Flush Fuel Tank Drain/Flush Hydraulic Tank (See proper section of Operator’s and Service Manuals for procedures and fluid specifications.) Product Records and Maintenance Reelmaster 5200-D/5400-D Page 2 - 10 Rev. A...
Page 21 2 = Check with engine running and hydraulic oil at operating temperature. 3 = Immediately after every washing, regardless of the interval listed. Notation for areas of concern: Inspection performed by:__________________ Item Date Information Reelmaster 5200-D/5400-D Page 2 - 11 Product Records and Maintenance Rev. A...
Page 22 Product Records and Maintenance Reelmaster 5200-D/5400-D Page 2 - 12 Rev. A...
Page 23 ....... KUBOTA WORKSHOP MANUAL 05 SERIES DIESEL ENGINE Reelmaster 5200-D/5400-D Page 3 - 1 Kubota Diesel Engines...
Page 24: Introduction
Reelmaster 5200-D/5400-D. pair facility. Most repairs and adjustments require tools which are Service and repair parts for Kubota engines are sup- commonly available in many service shops.
Page 25: Specifications
12 VDC, 1.4 KW Alternator/Regulator 12 VDC 40 AMP Coolant Capacity liters (U.S. qt.) 7.1 (7.5) with 0.9 (1.0) Reservoir Dry Weight kilograms (U.S. lbs) RM 5200-D 93.0 (205.0) RM 5400-D 98.0 (215.0) Reelmaster 5200-D/5400-D Page 3 - 3 Kubota Diesel Engines...
Page 26: General Information
(not the filler neck). Do not overfill. Install cap to stop engine, engage parking brake, and remove key the neck from the ignition switch. 2. Clean area around the fuel tank cap. Remove cap from the tank. Kubota Diesel Engines Page 3 - 4 Reelmaster 5200-D/5400-D...
Page 27: Check Cooling System
3. If coolant level is low, remove expansion tank cap and cause burns. Open radiator cap only when and replenish the system. Do not overfill. the radiator and engine are cold. 4. Install expansion tank cap. Reelmaster 5200-D/5400-D Page 3 - 5 Kubota Diesel Engines...
Page 28: Adjustments
20 lb (89 N). Figure 6 1. Throttle cable connector 3. High idle stop screw 2. Control lever arm 4. Fuel injection pump Kubota Diesel Engines Page 3 - 6 Reelmaster 5200-D/5400-D...
Page 29: Adjust Alternator/Fan Belt
Figure 8 8. Tighten both lock nuts to secure the adjustment. 1. Upper lock nut 3. Cooling fan belt 2. Belt tensioner lever Reelmaster 5200-D/5400-D Page 3 - 7 Kubota Diesel Engines...
Page 30: Service And Repairs
However, if the engine does not start, air may be trapped between injection pump and injectors (see Bleed Air from Fuel Injectors). Figure 11 1. Bleed screw 2. Fuel injection pump Kubota Diesel Engines Page 3 - 8 Reelmaster 5200-D/5400-D...
Page 31: Bleed Air From Fuel Injectors
Do not over- Figure 13 tighten filter. 1. Drain plug 2. Drain pan 4. Add oil to the crankcase (see Check Engine Oil). Figure 14 1. Oil filter 2. Radiator hose Reelmaster 5200-D/5400-D Page 3 - 9 Kubota Diesel Engines...
Page 32: Clean Radiator And Oil Coolers
5. Install filter bowl by hand until O-ring contacts mount- Figure 17 ing surface. 1. Fuel filter assembly 4. Filter element 2. Filter bowl 5. Filter head 3. O-ring Kubota Diesel Engines Page 3 - 10 Reelmaster 5200-D/5400-D...
Page 33 2. Remove muffler and/or muffler bracket from the en- gine as necessary using Figure 18 as a guide. Reelmaster 5200-D/5400-D Page 3 - 11 Kubota Diesel Engines...
Page 34: Fuel System
2. Check lines for deterioration, damage, leaking, or proved container and keep cap in place. Use die- loose connections. Replace hoses, clamps, and con- sel fuel for the engine only; not for any other nections as necessary. purpose. Kubota Diesel Engines Page 3 - 12 Reelmaster 5200-D/5400-D...
Page 35: Fuel Tank Removal
Removal). 2. Flush fuel tank out with clean diesel fuel. Make sure tank is free of contaminates and debris. 3. Install fuel tank to the machine (see Fuel Tank Instal- lation). Reelmaster 5200-D/5400-D Page 3 - 13 Kubota Diesel Engines...
Page 36: Air Filtering System
Note: When operating in extremely dusty conditions, C. Dry filter element using warm, flowing air (160_ F an optional extension tube (Toro Part No. 43-3810) max.), or allow element to air-dry. Do not use a light raises the precleaner bowl above the hood; service in- bulb to dry the filter element;...
Page 37: Water/Fuel Separator
6. Screw filter element onto base by hand until the gas- 3. O-ring 8. Plug ket contacts the mounting surface. Rotate element an 4. Base 9. Pipe plug 5. Plug 10. Drain valve additional 1/2 turn. Reelmaster 5200-D/5400-D Page 3 - 15 Kubota Diesel Engines...
Page 38: Radiator
19. Fan shroud 41. Not used 63. Flat washer 20. Pop rivet 42. Starter relay 64. Lock washer 21. Caution plate 43. Not used 22. Flat washer 44. Backlap switch 65. Cap screw Kubota Diesel Engines Page 3 - 16 Reelmaster 5200-D/5400-D...
Page 39 Disconnect hose from the vent tube. fluid (see Check Cooling System). 5. Detach both oil coolers and fan shroud from the ra- 7. Close engine hood to the machine. diator. Reelmaster 5200-D/5400-D Page 3 - 17 Kubota Diesel Engines...
Page 40: Engine
42. Fan idler bracket 20. Flat washer 65. Air cleaner hose 43. Lock washer 21. Lock washer 66. Retaining clamp 44. V-belt 22. Hex nut 45. Cap screw 67. Flange nut Kubota Diesel Engines Page 3 - 18 Reelmaster 5200-D/5400-D...
Page 41: Removal
The cap screw is threaded into the engine pumps. Disconnect fuel hose from the fuel tank at the bracket. fuel pump (Fig. 32). Reelmaster 5200-D/5400-D Page 3 - 19 Kubota Diesel Engines...
Page 42: Installation
8. Connect fuel hose to the rear injector nozzle (Fig. flat washers, and flange head nuts. 31). 6. Secure fan shroud to the radiator with four cap screws, flat washers, and locknuts (Fig. 33). Kubota Diesel Engines Page 3 - 20 Reelmaster 5200-D/5400-D...
Page 43 Service in Chapter 5 - Electrical system). Figure 33 1. Cap screws 2. Fan shroud 14.Close engine hood. 15.Adjust throttle cable (see Adjust Throttle Cable). 16.Bleed fuel system (see Bleed Fuel System). Reelmaster 5200-D/5400-D Page 3 - 21 Kubota Diesel Engines...
Page 44 Kubota Diesel Engines Page 3 - 22 Reelmaster 5200-D/5400-D...
Page 45 ......Adjust Traction Control Linkage ....Reelmaster 5200-D/5400-D Page 4 - 1 Hydraulic System...
Page 46: Specifications
Hydraulic Reservoir (Reels, Lift, and Steering Circuits) 8.5 gal. U.S. (32.2 L) Hydraulic Oil See Check Hydraulic System Fluid in General Information section Hydraulic Reservoir in Differential Housing (Transmission) 5.0 qts. U.S. (4.7 L) Hydraulic System Page 4 - 2 Reelmaster 5200-D/5400-D...
Page 47: General Information
0.75 + 0.25 8 (1/2 in.) 0.75 + 0.25 Finger Tight After Proper Tightening 10 (5/8 in.) 1.00 + 0.25 12 (3/4 in.) 0.75 + 0.25 16 (1 in.) 0.75 + 0.25 Figure 2 Reelmaster 5200-D/5400-D Page 4 - 3 Hydraulic System...
Page 48 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Figure 5 Hydraulic System Page 4 - 4 Reelmaster 5200-D/5400-D...
Page 49: Towing Traction Unit
5. When towing is completed, reinstall driveshaft. The Figure 7 splines are designed to allow assembly only when the 1. Front frame member two halves of the shaft are properly oriented (Fig. 6). Reelmaster 5200-D/5400-D Page 4 - 5 Hydraulic System...
Page 50: Check Transmission Fluid
Do not overfill by more than 1/4 inch (0.6 cm) 1. Transmission dipstick cap above the groove. 4. Screw dipstick filler cap finger-tight onto filler neck. It is not necessary to tighten cap with a wrench. Hydraulic System Page 4 - 6 Reelmaster 5200-D/5400-D...
Page 51: Check Hydraulic Fluid
Citgo Citgo A/W68 cient for 4 to 6 gal. (15 to 23 L) of hydraulic fluid. Order Conoco Super Hydraulic Oil 31 Part No. 44-2500 from your Authorized Toro Distributor Exxon Nuto H68 Gulf 68AW 1. Position machine on a level surface, lower the cut-...
Page 52: Hydraulic Schematics
Hydraulic Schematics Hydraulic System Page 4 - 8 Reelmaster 5200-D/5400-D...
Page 53 Reelmaster 5200-D/5400-D Page 4 - 9 Hydraulic System Rev. A...
Page 54: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 4 - 10 Reelmaster 5200-D/5400-D...
Page 55: Traction Circuit
150 PSI by a relief valve. Charge pressure can be moni- can be measured at test ports on the transmission. If tored at the charge pump test port. pressure exceeds the relief setting, oil flows through the Reelmaster 5200-D/5400-D Page 4 - 11 Hydraulic System...
Page 56 Hydraulic System Page 4 - 12 Reelmaster 5200-D/5400-D Rev. A...
Page 57: Lower Cutting Units
250 PSI relief position. valve, and to the hydraulic reservoir. The 250 PSI relief valve maintains a back pressure on the lift cylinders as they dump oil to the hydraulic reser- voir. Reelmaster 5200-D/5400-D Page 4 - 13 Hydraulic System...
Page 58 Hydraulic System Page 4 - 14 Reelmaster 5200-D/5400-D Rev. A...
Page 59: Raise Cutting Units
(S3), (S4), and (S5). Solenoid valve (S6) a normally closed poppet-type valve, and the other three valves are The 250 PSI relief valve maintains a back pressure on the lift cylinders. Excess flow is routed to the hydraulic reservoir. Reelmaster 5200-D/5400-D Page 4 - 15 Hydraulic System...
Page 60 Hydraulic System Page 4 - 16 Reelmaster 5200-D/5400-D Rev. A...
Page 61: Mow And Backlap
The electrical system is designed using the backlap switch so that only one cir- cuit (front cutting units or rear cutting units) can be oper- ated when in the backlap mode. Reelmaster 5200-D/5400-D Page 4 - 17 Hydraulic System...
Page 62 Hydraulic System Page 4 - 18 Reelmaster 5200-D/5400-D Rev. A...
Page 63: Steering
The rotary meter ensures that the oil when turning is complete. flow to the cylinder is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinder Reelmaster 5200-D/5400-D Page 4 - 19 Hydraulic System...
Page 64: Special Tools
Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Hydraulic Pressure Test Kit - TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 65 Slide protector over the reel motor shaft before installing the shaft sea. Use this tool with the seal installer - TOR491450. Figure 13 Reelmaster 5200-D/5400-D Page 4 - 21 Hydraulic System...
Page 66 Seal Installer - TOR491450 Use installer and a small hammer to drive the reel motor shaft seal into position in the bore of the reel motor body. Use with seal protector - TOR491430. Figure 14 Hydraulic System Page 4 - 22 Reelmaster 5200-D/5400-D...
Page 67: Troubleshooting
Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Reelmaster 5200-D/5400-D Page 4 - 23...
Page 68 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic System Page 4 - 24 Reelmaster 5200-D/5400-D...
Page 69: Testing
Stop engine; 9. Check control linkages for improper adjustment, lower or support attachments. binding,or broken parts. 10.All hydraulic tests should be made with the hydraulic oil at normal operating temperature. Reelmaster 5200-D/5400-D Page 4 - 25 Hydraulic System...
Page 70: Test No. 1: Traction Circuit Charge Pressure
When the pump and/or motor is worn or damaged the charge pump is not able to keep up with the internal leak- age. Hydraulic System Page 4 - 26 Reelmaster 5200-D/5400-D...
Page 71: Test No. 2: Traction Circuit System Relief Pressure
One valve cartridge has a ma- chined groove on seating surface and must be installed in the ”reverse” port (see Check and High Pressure Re- lief Valves in Transmission Repairs section). Reelmaster 5200-D/5400-D Page 4 - 27 Hydraulic System...
Page 72: Test No. 3: Relief Valve (R1) Pressure
GAUGE READING TO BE 2950 to 3050 PSI. approximately 500 to 600 PSI per cutting unit. Normal operating pressure of front circuit (three cutting units) when mowing is approximately 1500 to 1800 PSI. Hydraulic System Page 4 - 28 Reelmaster 5200-D/5400-D...
Page 73: Test No. 4: Relief Valve (R2) Pressure
7. While sitting on seat, move ”Enable/Disable” switch to ENABLE. Move ”Lower- Mow/Raise” lever forward to engage cutting units, then look at the gauge. GAUGE READING TO BE 1950 to 2050 PSI. Reelmaster 5200-D/5400-D Page 4 - 29 Hydraulic System...
Page 74 6. Stop the engine. If flow was lower than 5 GPM or a pressure of 2000 PSI cannot be obtained, check for re- striction in pump intake line. If not restricted, remove pump and repair or replace as necessary. Hydraulic System Page 4 - 30 Reelmaster 5200-D/5400-D...
Page 75: Test No. 6: Reel Motor Case Drain Leakage
Enable/Disable switch in ENABLE position. Keep away from cutting units during test to pre- vent personal injury from rotating reel blades. Do not stand in front of the machine. Reelmaster 5200-D/5400-D Page 4 - 31 Hydraulic System...
Page 76: Test No. 7: Gear Pump Section (P3) Flow And Relief Valve Pressure
7. While watching pressure gauges, slowly close flow control valve further until 1250 PSI is maintained as the relief valve lifts. TESTER READING: Relief valve setting of 1250 PSI. Hydraulic System Page 4 - 32 Reelmaster 5200-D/5400-D...
Page 77: Adjustments
2. To increase pressure setting, turn the adjustment ting (see Testing). socket inside the valve 1/8 of a turn clockwise. 3. To decrease pressure setting, turn the adjustment socket inside the valve 1/8 of a turn counterclockwise. Reelmaster 5200-D/5400-D Page 4 - 33 Hydraulic System...
Page 78: Adjust Traction Drive For Neutral
Hydraulic System Page 4 - 34 Reelmaster 5200-D/5400-D...
Page 79: Adjust Cutting Unit Lift Rates
3. Verify lift rate adjustment by raising and lowering cut- ting units several times. Readjust as required. 4. After desired lift rate is attained, tighten setscrew to lock adjustment. Figure 31 1. Rear cutting units flow control valve Reelmaster 5200-D/5400-D Page 4 - 35 Hydraulic System...
Page 80: Adjust Traction Control Linkage
(70 mm) (Fig. 32). Tighten outer locknut. 2.75” (70 mm) 4. Operate the machine and check for safe stopping distance. Figure 32 1. Spring anchor plate 3. Inner lock nut 2. Eye bolt 4. Outer locknut Hydraulic System Page 4 - 36 Reelmaster 5200-D/5400-D Rev. A...
Page 81: Service And Repairs
5. Note the position of hydraulic fittings (especially el- bow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes. Reelmaster 5200-D/5400-D Page 4 - 37 Hydraulic System...
Page 82: Check Hydraulic Lines And Hoses
1 through 15 again at Oil Filter). least once and until the oil is clean. 5. Inspect and clean hydraulic reservoir (see Hydraulic 16.Assume normal operation and follow recommended Reservoir Inspection). maintenance intervals. Hydraulic System Page 4 - 38 Reelmaster 5200-D/5400-D...
Page 83: Charge Hydraulic System
The charge pump should pick up oil and fill the hydraulic Check hydraulic components for leaks and tighten any system. If there is no indication of fill in 30 seconds, stop loose connections. the engine and determine the cause. Reelmaster 5200-D/5400-D Page 4 - 39 Hydraulic System...
Page 84: Change Hydraulic Fluid
Change 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 85: Replace Hydraulic Oil Filter
GREEN zone. When the in- dicator is in the RED zone, the filter element should be changed. IMPORTANT: Use the Toro replacement filter (Part No. 75-1310). Use of any other filter may void the warranty on some components.
Page 86: Replace Transmission Fluid
800 hours, thereafter. draulic oil. 4. Assure filter mounting area is clean. Screw filter on IMPORTANT: Only the Toro replacement filter (Part No.75-1330) can be used in the hydraulic system. until gasket contacts mounting plate. Then tighten filter Use of any other filter may void the warranty on one-half turn.
Page 87: Transmission Control Linkage
5. Loosen cap screw and lock nut securing pump con- 5. Adjust traction control neutral (see Adjust Traction trol to swashplate control shaft. Drive for Neutral). Reelmaster 5200-D/5400-D Page 4 - 43 Hydraulic System...
Page 88: Transmission
15. Transmission pilot sleeve 52. Rim 34. Transmission 16. Lock nut 53. Tire 35. Lock nut 17. bolt decal 54. Flat washer 36. O-ring 18. O-ring 19. Hydraulic straight fitting 37. Pinion gear Hydraulic System Page 4 - 44 Reelmaster 5200-D/5400-D...
Page 89: Chapter 8.1 - Cutting Units
6. Connect drive shaft to the transmission (Fig. 39). 4. Uncover hole in support plate if necessary. 7. Remove plugs or caps from disconnected hydraulic hoses and open ports of the transmission. Reelmaster 5200-D/5400-D Page 4 - 45 Hydraulic System...
Page 90 Units). minutes. Operate machine slowly in forward and re- verse. Stop engine and check differential oil level. 11. Install a new filter and fill differential with correct oil. Check transmission for leaks. Hydraulic System Page 4 - 46 Reelmaster 5200-D/5400-D...
Page 91: Transmission Service
Cleanliness is a primary means of assuring satisfactory Protect all sealing surfaces and open cavities from dam- transmission life, on either new or repair units. Cleaning age and foreign material. Reelmaster 5200-D/5400-D Page 4 - 47 Hydraulic System...
Page 92: Disassembly
5. Carefully remove valve plates from center section. It may be necessary to pry valve plates off with a small screwdriver (Fig. 45). Figure 45 6. Remove valve plate pins from the center section (Fig. 46). Figure 46 Hydraulic System Page 4 - 48 Reelmaster 5200-D/5400-D...
Page 93 9. Use O-ring pick or wire to remove thrust plates from swashplate and housing (Fig. 49). Figure 49 10.Use an internal hex wrench to remove pipe plug over motor shaft bearing retaining pin (Fig. 50). Figure 50 Reelmaster 5200-D/5400-D Page 4 - 49 Hydraulic System...
Page 94 Figure 52 13.Press motor shaft out of the bearings and spacer (Fig. 53). Figure 53 14.Remove spiral retaining ring and remove PTO seal guide (with O-ring) from the housing (Fig. 54). Figure 54 Hydraulic System Page 4 - 50 Reelmaster 5200-D/5400-D...
Page 95 O-ring and trunnion bearing on the side oppo- site the control. Remove these parts from the housing (Fig. 56). Figure 56 17.Tilt and lift swashplate from housing (Fig. 57). Figure 57 Reelmaster 5200-D/5400-D Page 4 - 51 Hydraulic System...
Page 96: Inspection
2. Install swashplate into housing. Make sure swash- plate control shaft is located on correct side of housing (note marks made during disassembly) (Fig. 59). Figure 59 Hydraulic System Page 4 - 52 Reelmaster 5200-D/5400-D...
Page 97 6. Install hex tapping screws and tighten to a torque of 6 to 9 ft-lb (8 to 12 N-m) (Fig. 62). Figure 62 7. Press ball bearing onto pump shaft. Install pump shaft and bearing assembly into housing (Fig. 63). Figure 63 Reelmaster 5200-D/5400-D Page 4 - 53 Hydraulic System...
Page 98 9. Press inner bearing, spacer and outer bearing onto motor shaft (Fig. 65). Figure 65 10.Install motor shaft assembly into housing (Fig. 66). Figure 66 11. Install motor shaft bearing retaining pin into housing (Fig. 67). Figure 67 Hydraulic System Page 4 - 54 Reelmaster 5200-D/5400-D...
Page 99 15.Lay the transmission on its side and install cylinder block kits into the housing (Fig. 71). 16.Put the transmission housing on a work surface with the center section opening facing up. Figure 71 Reelmaster 5200-D/5400-D Page 4 - 55 Hydraulic System...
Page 100 The pump plate has grooves on one side of the ports (Fig. 74). Figure 74 19.Install the two (2) alignment pins and install a new center section gasket onto the housing (Fig. 75). Figure 75 Hydraulic System Page 4 - 56 Reelmaster 5200-D/5400-D...
Page 101 In-Line Filter Check Valve Replacement Filter By-Pass Valve Replacement Figure 77 Heat Exchanger By-Pass Valve Replacement Charge Pressure Relief Valve Replacement Check/High Pressure Relief Valve Replacement Trunnion Seal Replacement Shaft Seal Replacement Reelmaster 5200-D/5400-D Page 4 - 57 Hydraulic System...
Page 102: Shaft Seal Replacement
0.056 to 0.096 inch (1.42 to 2.44 mm) below the outer surface of the charge pump cover. Install the retaining ring. Figure 79 1. Shaft seal 4. Transmission 2. Charge pump cover 5. Retaining ring 3. Shaft Hydraulic System Page 4 - 58 Reelmaster 5200-D/5400-D...
Page 103: Trunnion Seal Replacement
6 to 9 ft-lbs (8 to 12 N-m). 11. Install pump control onto transmission swashplate control shaft. Check machine for ”creeping” when en- gine is running with foot pedal in neutral position (see Adjust Traction Drive for Neutral). Reelmaster 5200-D/5400-D Page 4 - 59 Hydraulic System...
Page 104: Check/High Pressure Relief Valve Replacement
Start the engine and let it run for one to two minutes, then turn the engine off and check the oil level again. Check transmission for leaks. Hydraulic System Page 4 - 60 Reelmaster 5200-D/5400-D...
Page 105: Charge Pressure Relief Valve Replacement
Start the engine and let it run for one to two minutes, then turn the engine off and check the oil level again. Check the transmission for leaks. Reelmaster 5200-D/5400-D Page 4 - 61 Hydraulic System...
Page 106: Heat Exchanger By-Pass Valve Replacement
Start the engine and let it run for one to two minutes, then 2. O-ring 4. Relief valve turn the engine off and check the oil level again. Check the transmission for leaks. Hydraulic System Page 4 - 62 Reelmaster 5200-D/5400-D...
Page 107: Filter By-Pass Valve Replacement
Start the engine and let it run for one to two minutes, then 2. O-ring 4. Relief valve turn the engine off and check the oil level again. Check the transmission for leaks. Reelmaster 5200-D/5400-D Page 4 - 63 Hydraulic System...
Page 108: Charge Pump Replacement
Make sure the ger- oter engages the drive pin in the shaft. 10.Tighten the charge pump cover cap screws to a torque of 27 to 37 ft-lb (37 to 50 N-m). Hydraulic System Page 4 - 64 Reelmaster 5200-D/5400-D...
Page 109: Gear Pump
6. Connect fuel stop solenoid electrical connector, start the engine and check for proper operation. 7. Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level. Reelmaster 5200-D/5400-D Page 4 - 65 Hydraulic System...
Page 110 Gear Pump Section (P3) Flow and Relief Valve Pres- can be installed at the same pressure setting. sure). 2. Inspect ball for burrs or roughness. Inspect relief valve bore and seat in valve block. Hydraulic System Page 4 - 66 Reelmaster 5200-D/5400-D...
Page 111 DO to a torque of 50 to 55 ft-lb (68 to 75 N-m). NOT mix parts between different sections. 14.Install shaft seal (see Shaft Seal Replacement above). Reelmaster 5200-D/5400-D Page 4 - 67 Hydraulic System...
Page 112: Reel Motor
1. Place motor into position on mounting studs. Rotate 3. Remove caps or plugs from fittings and hoses. Con- motor counterclockwise so motor flanges lock to studs. nect hydraulic lines lines to the motor. 2. Tighten motor mounting nuts Hydraulic System Page 4 - 68 Reelmaster 5200-D/5400-D...
Page 113 1. Apply grease or petroleum jelly to load plate assem- using a vise to avoid distorting any parts. bly and install in body. Insert gear set into body, main- taining the original timing and locations. Reelmaster 5200-D/5400-D Page 4 - 69 Hydraulic System...
Page 114 5. Tighten the cap screws evenly in a crossing pattern hand tighten. to a torque of 17 ft-lb (23 N-m). 6. Carefully install a new spacer, shaft seal and snap ring (see Shaft Seal Installation). Hydraulic System Page 4 - 70 Reelmaster 5200-D/5400-D...
Page 115: Hydraulic Control Manifold
Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 2. Disconnect electrical connectors from the solenoid valves. 3. Remove hydraulic manifold from the frame (Fig. 93). Reelmaster 5200-D/5400-D Page 4 - 71 Hydraulic System...
Page 116 Note: The ports on the manifold are marked for easy identification of components (see Hydraulic Schematics to identify the function of the hydraulic lines and car- tridge valves at each port location). Hydraulic System Page 4 - 72 Reelmaster 5200-D/5400-D...
Page 117 5. Clean relief valve cartridge using clean mineral spir- its. Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves. Use compressed air for cleaning. Reelmaster 5200-D/5400-D Page 4 - 73 Hydraulic System...
Page 118 ”5”. valves. Use compressed air for cleaning. Simultaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing at the number ”1” on the locating plate. Hydraulic System Page 4 - 74 Reelmaster 5200-D/5400-D...
Page 119 B. Thread cartridge valve carefully into the port (LC1). The valve should go in easily without binding. Torque the valve 30 to 35 ft-lb (41 to 47 N-m). Reelmaster 5200-D/5400-D Page 4 - 75 Hydraulic System...
Page 120: Lift Cylinders
Secure thrust washer and retaining ring to the 1. Self tapping screw 5. Cylinder rod end pin cylinder rod end pin. 2. Cylinder pin (short) 6. Thrust washer 3. Carrier frame 7. Lift arm 4. Retaining ring Hydraulic System Page 4 - 76 Reelmaster 5200-D/5400-D...
Page 121 7. Lift arm 4. Retaining ring and thrust washer through the lift arm and cylinder clevis. Secure thrust washer and retaining ring to the cylinder rod end pin (Fig. 96 and 95). Reelmaster 5200-D/5400-D Page 4 - 77 Hydraulic System...
Page 122 O-ring, back-up ring, rod seal, and dust seal from 2. Mount lift cylinder into a vice. Remove collar with a the head. spanner wrench. 3. Extract shaft, head, and piston by carefully twisting and pulling on the shaft. Hydraulic System Page 4 - 78 Reelmaster 5200-D/5400-D Rev. A...
Page 123 B. Install dust seal, O-ring, back-up ring, and dust seal to the head. IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mount- ing in a vice. Reelmaster 5200-D/5400-D Page 4 - 79 Hydraulic System...
Page 124: Hydraulic Reservoir
3. Drain reservoir into a suitable container (see Change sealant to the first thread. Hydraulic Fluid). 4. Remove oil tank using Figure 100 as a guide. Hydraulic System Page 4 - 80 Reelmaster 5200-D/5400-D...
Page 125 5. Apply an anti-sieze compound to three cap screws 3. Apply Permabond LH150 or equivalent to the securing the reservoir to the frame. threads of the suction strainer. 6. Fill reservoir with hydraulic fluid (see Change Hy- draulic Fluid). Reelmaster 5200-D/5400-D Page 4 - 81 Hydraulic System...
Page 126: Heat Exchanger
FRONT Figure 102 Oil cooler Heat exchanger Hydraulic hose (IN) Hydraulic hose (IN) 3. Hydraulic hose (OUT) 8. Hydraulic hose (OUT) Hydraulic straight fitting Hydraulic straight fitting O-ring 10. O-ring Hydraulic System Page 4 - 82 Reelmaster 5200-D/5400-D...
Page 127 High Temperature Warning and Shutdown Switch ......Reelmaster 5200-D/5400-D Page 5 - 1 Electrical Systems Rev. A...
Page 128: Special Tools
Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt- Ohm-Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 129 Diagnostic help the user verfiy correct electrical functions of the ma- ACE Display chine (Fig. 3 and 4). ACE Display (Toro Part No. 85-4750) Overlays for RM 5200/5400: Unit Serial No. 80001 -209999999 (Toro Part No. 100-3700) Unit Serial No. 210000001 & Up (Toro Part No.
Page 130: Troubleshooting
(i.e. seat sensor, key switch, etc.) and turns on the outputs to actuate solenoids or relays for the requested machine function. For the electronic controller to control the machine as Electrical Systems Page 5 - 4 Reelmaster 5200-D/5400-D Rev. A...
Page 131: Check Interlock Switches
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 defec- tive switches and repair any defective wiring. Reelmaster 5200-D/5400-D Page 5 - 5 Electrical Systems Rev. A...
Page 132: Retrieving Stored Faults
6. Release RAISE lever and turn Ignition switch to illuminated, this indicates an ECU problem. If this oc- OFF. Move the Backlap switch to OFF and the Enable/ curs, contact your Toro Distributor for assistance. Disable switch to DISABLE. Fault memory is now cleared.
Page 133: Starting Problems
The problem is not electrical (see Chapter 3 - Kubota Engines). Starter cranks, but should not when the traction is The traction neutral switch is out of adjustment. depressed. The traction neutral switch or circuit wiring is faulty. Reelmaster 5200-D/5400-D Page 5 - 7 Electrical Systems Rev. A...
Page 134: General Run & Transport Problems
The front cutting units do not operate in either Solenoid S1 or circuit wiring is faulty. direction. Units are able to raise and lower. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System). Electrical Systems Page 5 - 8 Reelmaster 5200-D/5400-D Rev. A...
Page 135 Chapter 4 - Hydraulic System). The rear cutting units do not backlap, but all cutting The rear backlap switch or circuit wiring is faulty. units run in the forward direction. Reelmaster 5200-D/5400-D Page 5 - 9 Electrical Systems...
Page 136 Any time the machine gives a series of 4 short fender alarm or wires. Replace if necessary. beeps. D Alarm short circuit (LED blinking): Check TurfDe- c. False alarms are observed. fender alarm or wires. Replace if necessary. Electrical Systems Page 5 - 10 Reelmaster 5200-D/5400-D Rev. A...
Page 137 Note: Only large air leaks can be detected by Turf- problems previously discussed. Defender. 5. Your Authorized Toro Distributor has equipment to 2. When toggling “output” a LED should display analyze system problems. (Fig. 10) any of the following problems diagnosed by the...
Page 138 “Valve ON” LED lit steadily b. “Self Diagnostic” LED lit steadily c. “DATA LINE” LED lit steadily d. “Alarm ON” LED lit temporarily Problem Diagnosed: The appropriate LED will blink to identify the problem Figure 10 Electrical Systems Page 5 - 12 Reelmaster 5200-D/5400-D...
Page 139: Turfdefender Tm Leak Detector
TurfDefender Leak Detector 94–6345 BLK/BU OR/BLK Reelmaster 5200-D/5400-D Page 5 - 13 Electrical Systems...
Page 140: Electrical System Quick Check
(-) meter lead the the neg- 11.89 V 0% charged ative battery post. NOTE: This test provides a relative condition of the bat- tery. Load testing of the battery will provide additional and more accurate information. Electrical Systems Page 5 - 14 Reelmaster 5200-D/5400-D...
Page 141: Component Testing
Verify continuity between switch terminals. POSITION CIRCUIT NONE B + I + A, X + Y START B + I + S Figure 11 1. Key 3. Lock washer 2. Hex nut 4. Ignition switch Reelmaster 5200-D/5400-D Page 5 - 15 Electrical Systems...
Page 142: Glow And Start Relays
A. Resistance between terminals 30 and 87 should read as an open circuit. B. On the start relay, resistance between terminals 30 and 87A should be 1 ohm or less. 4. Disconnect voltage and leads from all terminals. Electrical Systems Page 5 - 16 Reelmaster 5200-D/5400-D...
Page 143: Fuses
(optional). B. Has two orange wires. Fuse B3 (When Optional Lighting is Installed) A. Supplies power to light relay terminal 30. B. Has two red wires. Reelmaster 5200-D/5400-D Page 5 - 17 Electrical Systems...
Page 144: Hydraulic Valve Solenoids
Lift/lower front, center cutting unit Black/Red Lift/lower rear cutting units Brown/White Lower any cutting units Lift any cutting units 6. Reconnect electrical connector to the solenoid. Backlap front cutting units Backlap rear cutting units Electrical Systems Page 5 - 18 Reelmaster 5200-D/5400-D...
Page 145: High Temperature Warning And Shutdown Switch
B. Screw sender into the water flange and tighten. C. Connect green/white wire to sender. Apply skin- over grease to sender terminal. 7. Fill engine cooling system (see Check Cooling Sys- tem in Chapter 3 - Kubota Diesel Engine). Reelmaster 5200-D/5400-D Page 5 - 19 Electrical Systems...
Page 146: Warning Light Cluster
ON with the engine not running, or with an improperly operating charging circuit while the engine is running. 1. Turn ignition switch to ON; the light should come on. 2. Turn ignition switch to OFF: the light should go off. Electrical Systems Page 5 - 20 Reelmaster 5200-D/5400-D...
Page 147: Fuel Stop Solenoid
5. Remove positive (+) voltage from the pin of the white wire. The solenoid should stay engaged. 6. Remove positive (+) voltage from the pin of the red wire. The solenoid should release. 7. Reconnect the wires to the solenoid. Reelmaster 5200-D/5400-D Page 5 - 21 Electrical Systems...
Page 148: Fuel Sender
2. Lock washer 5. Fuel tank 5. Replace sender as necessary. Reinstall sender into 3. Fuel sender fuel tank. Connect wires. 7.62 inch 100_ (19.4 cm) Figure 27 1. Full position 2. Empty position Electrical Systems Page 5 - 22 Reelmaster 5200-D/5400-D...
Page 149: Fuel Gauge
(full). 3. Turn off the voltage source. Disconnect voltage source, gauge, and variable resistance. Figure 29 1. Empty position 3. Glass face edge 2. Full position Reelmaster 5200-D/5400-D Page 5 - 23 Electrical Systems...
Page 150: Temperature Sender
B. Screw sender into the water flange and tighten. C. Connect blue/white wire to sender. Apply skin- over grease to sender terminal. 5. Fill engine cooling system (see Check Cooling Sys- tem in Chapter 3 - Kubota Diesel Engine). Electrical Systems Page 5 - 24 Reelmaster 5200-D/5400-D...
Page 151: Temperature Gauge
(105_ C). 3. Turn off the voltage source. Disconnect voltage source, gauge, and variable resistance. Figure 33 1. Middle position 3. Edge of glass cover 2. High temp position Reelmaster 5200-D/5400-D Page 5 - 25 Electrical Systems...
Page 152: Hour Meter
BACK Figure 34 Electronic Control Unit (ECU) The Toro electronic control unit (ECU) senses the condi- tion of various switches, such as the seat sensor, cutting unit down switches, traction neutral switch, etc., and di- rects power output to allow certain machine functions, such as engine run, cutting units engage, etc.
Page 153: Traction Speed Sensor
IMPORTANT: When replacing the sensor, see Trac- tion Speed Sensor Replacement in this section of the manual. Figure 36 1. Traction speed sensor 3. Front right axle 2. Differential gear box 4. Jam nut Reelmaster 5200-D/5400-D Page 5 - 27 Electrical Systems...
Page 154: Speedometer
1. Verify with Ace Diagnostic tool that the traction speed sensor is operating properly. 2. Lift all wheels that will be moving off the ground. Figure 39 1. Pinion shaft (2WD) 2. Differential housing Electrical Systems Page 5 - 28 Reelmaster 5200-D/5400-D...
Page 155: Reels Enable/Disable And Backlap Switches
Positioning the toggle to the left closes the switch between left (blue wire) and center terminals Figure 42 (Fig. 42). 1. Backlap switch 2. Radiator shield FRONT RIGHT Figure 41 Figure 43 1. Reel enable/disable 2. Instrument panel switch Reelmaster 5200-D/5400-D Page 5 - 29 Electrical Systems...
Page 156: Traction Neutral Switch
4. Have the operator sit on the seat, slowly depressing the seat sensor magnet. The continuity tester should show continuity as the seat approaches the bottom of its travel. Electrical Systems Page 5 - 30 Reelmaster 5200-D/5400-D...
Page 157: Joystick Raise And Lower/Mow Switches
The switch has a electrical connector at- tached to the carrier frame. Figure 48 1. Reed switch 3. Carrier frame 2. Switch actuator 4. Lift arm (LH) Reelmaster 5200-D/5400-D Page 5 - 31 Electrical Systems...
Page 158: Service And Repairs
(+) cable first. Coat battery posts and cable are explosive, keep open flames and electrical connectors with Grafo 112X (skin-over) grease (Toro sparks away from the battery; do not smoke. Part No. 505-47) or petroleum jelly to prevent corrosion.
Page 159: Battery Service
Inspection, Maintenance, and Testing 1. Perform following inspections and maintenance: A. Check for cracks. Replace battery if cracked or leaking. B. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts. Reelmaster 5200-D/5400-D Page 5 - 33 Electrical Systems...
Page 160 6. Apply a light coat of skin-over grease on all battery er’s instructions. posts and cable connectors to reduce corrosion after connections are made. C. Make sure battery terminals are free of corrosion. Electrical Systems Page 5 - 34 Reelmaster 5200-D/5400-D...
Page 161 The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for three consecutive readings. Reelmaster 5200-D/5400-D Page 5 - 35 Electrical Systems...
Page 162 5. Lower the machine to the ground. Figure 52 1. O-ring 5. Machine screw 2. Mounting plate 6. Lock nut 3. Cover 7. Jam nut 4. Cap screw & lock washer 8. Sensor Electrical Systems Page 5 - 36 Reelmaster 5200-D/5400-D...
Page 163 The differential axle has a one-piece axle shaft with the flange being part of the axle stem (Fig. 2). Figure 1 Figure 2 Reelmaster 5200-D/5400-D Page 6 - 1 Differential Axle Rev. A...
Page 164: Specifications
Pinion gear end play 0.000 to 0.005 in. (0.000 to 0.127 mm) Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Differential Gear Holder Remove gear cover from right hand side of differential and bolt this tool in place to lock spur gear in position when removing nut that secures pinion coupler for 4WD drive shaft.
Page 165: Service And Repairs
Figure 4 Hydrostatic transmission 5. Differential axle 9. Pinion coupler 2. Transmission support 6. Brake cable 10. Seal 3. Transmission collar 7. Nut 11. Shim 4. Axle shim 8. Spacer Reelmaster 5200-D/5400-D Page 6 - 3 Differential Axle Rev. A...
Page 166: Axle Shafts And Wheel Bearings
Loosen the brake shoes by turning the star wheel inside the brake drum assembly (See Chap- ter 7 - Steering and Brakes). Figure 6 Differential Axle Page 6 - 4 Reelmaster 5200-D/5400-D Rev. A...
Page 167 NOTE: Remove the bearing race from the axle housing with a bearing puller if necessary. Figure 8 5. Remove and discard the inner axle shaft seal (Fig. 9). Figure 9 Reelmaster 5200-D/5400-D Page 6 - 5 Differential Axle Rev. A...
Page 168 10.Inspect all components for wear and damage (Fig. 12). Replace the hub and shaft if the seal has grooved the axle surface more that 1/64 inch (0.4 mm). Figure 12 Differential Axle Page 6 - 6 Reelmaster 5200-D/5400-D Rev. A...
Page 169: Assembly
(surface that con- tacts the axle shaft. Install the new seal to a depth of 1.218 in. (30.9 mm) into the housing (Fig. 15). 1.218” (30.9 mm) Figure 15 Reelmaster 5200-D/5400-D Page 6 - 7 Differential Axle Rev. A...
Page 170 Be careful not to damage the oil seal and bearing (Fig. 16). NOTE: Liquid Gasket Kit (Toro P/N 92-8775) includes Loctiter Ultra Gray, gasket eliminator, and instructions. Figure 16 6.
Page 171: Axle Shafts And Wheel Bearings (Serial No. 200000201 & Up)
Figure 19 and a clean rag if necessary. 1. Grease fitting 5. Install brake drums and wheels. Tighten wheel lug nuts to 45-55 ft-lbs. (61-75 Nm). Reelmaster 5200-D/5400-D Page 6 - 9 Differential Axle Rev. A...
Page 172: Disassembly
1/64 inch (0.4 mm). Wear protective safety goggles when breaking the retaining ring. Personal injury could result from flying metal particles. Keep all personnel away during this procedure. Differential Axle Page 6 - 10 Reelmaster 5200-D/5400-D Rev. A...
Page 173: Assembly
Brakes chapter in this manual). 7. Use medium strength Loctiter thread locker and install the cap screws securing the bearing cap. Tighten the screws to 32 to 35 ft-lbs. (43 to 47 Nm). Reelmaster 5200-D/5400-D Page 6 - 11 Differential Axle Rev. A...
Page 174: Differential And Housing (All Units)
(i.e. hammer handles) under the differential case and pry firmly upward. Mark the bearing cups and cones, they must be reinstalled in matched sets (Fig. 25). Figure 25 Differential Axle Page 6 - 12 Reelmaster 5200-D/5400-D Rev. A...
Page 175 (Fig. 28). Use a small drift punch as shown. WARNING To prevent personal injury, always wear a face shield or safety goggles when striking a drift punch with a hammer. Figure 28 Reelmaster 5200-D/5400-D Page 6 - 13 Differential Axle Rev. A...
Page 176 Figure 30 10.Remove the eight side cover capscrews. Remove the side cover from the carrier assembly (Fig. 31). Clean the gasket material from the mating surfaces before reassembly. Figure 31 Differential Axle Page 6 - 14 Reelmaster 5200-D/5400-D Rev. A...
Page 177 (Fig. 34). If unit was equipped with a pinion coupler for 4WD (no expansion plug), remove oil seal from housing (Fig. 4). Figure 34 Reelmaster 5200-D/5400-D Page 6 - 15 Differential Axle Rev. A...
Page 178 Retain the shims located under the bearing cup (Fig. 37). If the shims are damaged, replace with new shims of the same thickness. Figure 37 Differential Axle Page 6 - 16 Reelmaster 5200-D/5400-D Rev. A...
Page 179 3. Put the front housing on a press. Using a press plate, push the pinion outer bearing cup into the housing until it bottoms in the housing (Fig. 39). Figure 39 Reelmaster 5200-D/5400-D Page 6 - 17 Differential Axle Rev. A...
Page 180 1.207 in. (-0.003 in. from standard). Adding 0.003 in. of bearing shims moves the pinion gear closer to the ring gear, decreasing the pinion to ring gear dis- tance. Differential Axle Page 6 - 18 Reelmaster 5200-D/5400-D Rev. A...
Page 181 Tap the pinion gear with a soft mallet to engage the splines in the spur gear (Fig. 42). Figure 42 7. Support the drive pinion in a suitable press (Fig. 43). Figure 43 Reelmaster 5200-D/5400-D Page 6 - 19 Differential Axle Rev. A...
Page 182 12.Install the spur gear cover. Use Permatex No. 2 or sil- icone sealant when installing the cover. Tighten the capscrews to a torque of 25-40 in.-lb. (3-4.5 Nm) (Fig. 46). Figure 46 Differential Axle Page 6 - 20 Reelmaster 5200-D/5400-D Rev. A...
Page 183 15.Assemble the lock pin. Drive the pin to the approxi- mate center location of the pinion mate shaft. Peen the metal of the case to lock the pin in place (Fig. 49). Figure 49 Reelmaster 5200-D/5400-D Page 6 - 21 Differential Axle Rev. A...
Page 184 Install the bearing caps into their original position as pre- viously marked. Tighten the cap screws to a torque of 30-45 ft-lbs. (41-61 Nm) (Fig. 52). Figure 52 Differential Axle Page 6 - 22 Reelmaster 5200-D/5400-D Rev. A...
Page 185 22.Apply silicone sealant between the front and rear axle housings and install the eight housing cap screws. Tighten the cap screws to a torque of 18-23 ft-lbs. (24-31 Nm) (Fig. 54). Figure 54 Reelmaster 5200-D/5400-D Page 6 - 23 Differential Axle Rev. A...
Page 186 Example 1: Backlash correct. Thicker pinion position shims required (Fig. 57). Figure 58 Example 2: Backlash correct. Thinner pinion position shims required (Fig. 58). Differential Axle Page 6 - 24 Reelmaster 5200-D/5400-D Rev. A...
Page 187 (face contact) and toward the heel. Coast pattern (concave side of gear) moves to- ward the top of the tooth (face contact) and toward the heel. Reelmaster 5200-D/5400-D Page 6 - 25 Differential Axle Rev. A...
Page 188 Differential Axle Page 6 - 26 Reelmaster 5200-D/5400-D Rev. A...
Page 189 ....... . SYSTEM HGF SERIES SERVICE PROCEDURE Reelmaster 5200-D/5400-D Page 7 - 1 Steering and Brakes Rev.
Page 190: Introduction
The brake pedals operate the brakes through a cable system to a strut and lever on the brake shoes. Figure 2 Steering and Brakes Page 7 - 2 Reelmaster 5200-D/5400-D...
Page 191: Power Steering Schematics
Fluid leaving the steering cylinder flows back through Figure 5 the steering control valve, exits through the OUT port, travels to the lift manifold, and returns to the hydraulic reservoir. Reelmaster 5200-D/5400-D Page 7 - 3 Steering and Brakes Rev. A...
Page 192: Specifications
Brake pedal free travel 0.5 to 1.0 in. (6.0 to 25.0 mm) Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Steering Valve Service Fixture To avoid distorting or damaging the steering valve when repairing, do not clamp it directly into a vise.
Page 193 0 to 1000 PSI. A protector valve cuts out when pressure is about to exceed the normal range for the gauge. The cutout pressure is adjustable. Reelmaster 5200-D/5400-D Page 7 - 5 Steering and Brakes Rev. A...
Page 194: Troubleshooting
Excessive heat in hydraulic system Undersized replacement hose or tube line. Kinked or severely bent hose or tube line. Restricted oil cooler. Restricted re-centering of steering valve control valve plate. Steering and Brakes Page 7 - 6 Reelmaster 5200-D/5400-D Rev. A...
Page 195: Testing
Note: DO NOT turn the steering wheel to the right (clockwise) or the steering valve will meter oil out the dis- connected hydraulic hose. Reelmaster 5200-D/5400-D Page 7 - 7 Steering and Brakes Rev. A...
Page 196: Adjustments
8. Repeat steps 3. through 7. if necessary. 9. Tighten ball joint hex nut and install a new cotter pin. Steering and Brakes Page 7 - 8 Reelmaster 5200-D/5400-D Rev. A...
Page 197: Brake Adjustment
9. Remove jack stands or blocking and lower machine to floor. Tighten wheel lug nuts to a torque of 45 to 55 ft-lbs. (61 to 75 Nm). 10.Adjust brake cables (see step 2. of this procedure) Reelmaster 5200-D/5400-D Page 7 - 9 Steering and Brakes Rev. A...
Page 198: Service And Repairs
(Fig. 14). Tighten the nut to 10 to 15 ft- 1. Steering wheel 3. Cover lbs. (13 to 20 Nm). 2. Locknut 4. Foam seal 3. Install steering wheel cover. Steering and Brakes Page 7 - 10 Reelmaster 5200-D/5400-D...
Page 199: 2Wd Rear Axle
15. Thrust washer 24. Thrust washer 7. Jamnut 16. Jamnut 25. Locknut 8. Grease fitting 17. Spindle 26. Steering pivot plate 9. Capscrew 18. Capscrew 27. Steering pivot bushing Reelmaster 5200-D/5400-D Page 7 - 11 Steering and Brakes Rev. A...
Page 200: Axle Pivot Bushings
10.Lubricate the rear axle pivot bushings through the grease fitting on the pivot pin (or axle body). 11. Install the hydraulic hoses to the steering cylinder. 12.Check steering cylinder hydraulic connections for leaks. Steering and Brakes Page 7 - 12 Reelmaster 5200-D/5400-D Rev. A...
Page 201: Rear Wheel Spindle Bushings
Slide the spindle, washer, and wheel assembly out 16.Check steering cylinder hydraulic connections for of the axle tube to expose the bushings. leaks. Reelmaster 5200-D/5400-D Page 7 - 13 Steering and Brakes Rev. A...
Page 202: Wheel Bearings
3. Remove the cotter pin, retainer, slotted nut, and ing buddy and dust cap. washer. Slide the wheel off the spindle shaft. 4. Pull the seal out of the wheel hub. Steering and Brakes Page 7 - 14 Reelmaster 5200-D/5400-D Rev. A...
Page 203: Steering Cylinder
Re- 2. Thrust washer 5. Pivot Pin move the steering cylinder. 3. Steering cylinder 6. Cylinder support Figure 19 1. Steering cylinder 2. Retaining ring Reelmaster 5200-D/5400-D Page 7 - 15 Steering and Brakes Rev. A...
Page 204: Installation
(see Loctiter thread locker and tighten the capscrew to 70 Chapter 4–Hydraulic System “Bleeding the Hydraulic to 80 in-lbs. (8 to 9 Nm). System” in this manual). Steering and Brakes Page 7 - 16 Reelmaster 5200-D/5400-D Rev. A...
Page 205: Steering Cylinder Service
16.Install head into tube and tighten by hand to properly engage threads. Tighten head with a spanner wrench. 7. Remove piston. Slide head off of piston rod. Reelmaster 5200-D/5400-D Page 7 - 17 Steering and Brakes Rev. A...
Page 206: Brake Shoe Replacement
4. Remove brake lever retainers (cotter pins) with a slip joint pliers. Figure 21 Return spring 3. Strut and lever 5. Star wheel assembly 2. Cotter pins 4. Adjusting screw spring Steering and Brakes Page 7 - 18 Reelmaster 5200-D/5400-D Rev. A...
Page 207: Steering Valve
6. Check hydraulic connections for leaks. 7. Install cap screws and cover to steering tower. 8. Install the front center cutting unit (see Chap- ter 8–Cutting Units in this manual). Reelmaster 5200-D/5400-D Page 7 - 19 Steering and Brakes...
Page 208: Steering Valve Service
11. Commutator seal 25. Spring 39. Retaining plate washer 12. Commutator cover 26. Upper cover plate 40. Retaining ring 13. Commutator 27. Nut 41. Input shaft 14. Commutator ring 28. Seal Steering and Brakes Page 7 - 20 Reelmaster 5200-D/5400-D...
Page 209 ..... . . Adjust Lift Arm Down Pressure ....Reelmaster 5200-D/5400-D Page 8 - 1 Cutting Units (Model 03506, S/N 80001 - 209999999) Rev.
Page 210: Model 03506, S/N 80001 - 209999999 Model 03509, S/N 80001 - 209999999
4 to 7 in-lb (0.45 to 0.79 N-m) with no end play Front: Fixed Rear: Screw adjustable with bolt clamp lock Cutting Units Page 8 - 2 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 211: Special Tools
Figure 2 Bedknife Screw Tool - TOR510880 This screwdriver type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar.
Page 212: Troubleshooting
• Check and recheck the cutting units for accurate and proper setup. Cutting Units Page 8 - 4 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 213 Current Weather Pattern (i.e. Drought, Hot, Wet, etc.) Condition Found: Condition Environment (when it happens, what needs to be done to duplicate the condition): Note: For additional information see Toro Commercial Products Aftercut Appearance Troubleshooting Aid. Part No. 00076SL. Reelmaster 5200-D/5400-D...
Page 214: Adjustment Summary And Check List
NOTE: Reel speed settings may require ”fine tuning” from initial adjustment for optimum cutting performance. Cutting Units Page 8 - 6 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 215: Reel Bearing Adjustment And Service
Figure 7 to make sure no end play exists and reel spins freely. Reel bearing adj. nut Reel shaft E. Reinstall counterbalance end cap. Reelmaster 5200-D/5400-D Page 8 - 7 Cutting Units (Model 03506, S/N 80001 - 209999999) Rev. A...
Page 216: Adjust Bedknife To Reel
Note: If reel makes contact on both sides of bedknife but still does not cut paper, cutting unit may need to be backlapped (refer to backlapping) or reel and/or bed- knife may need to be reground (refer to Toro manual for Sharpening Reel and rotary Mowers, Form No. 80–300PT).
Page 217: Level Front Roller To Reel
To prevent moving the front roller bracket when tighten- ing, hold nut and tighten cap screw. NOTE: This adjustment should be made on a flat working surface. Reelmaster 5200-D/5400-D Page 8 - 9 Cutting Units (Model 03506, S/N 80001 - 209999999) Rev.
Page 218: Adjust Height-Of-Cut
6. Tighten height-of-cut adjustment bolt locknut and rear roller bracket locknut at both ends of cutting unit. Check adjustment and readjust if necessary. Cutting Units Page 8 - 10 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 219: Adjust Front Shield Height
2. Open rear shield to desired operating position. 3. Tighten locking bolt on each side of cutting unit. Figure 14 1. Locking bolt 2. Rear shield Reelmaster 5200-D/5400-D Page 8 - 11 Cutting Units (Model 03506, S/N 80001 - 209999999) Rev. A...
Page 220: Adjust Cutoff Bar
3/8 to 5/8 inch (9.5 to 15.9 mm) vertical travel when mea- sured at the rear roller. Figure 16 Lock-up roller Lock-up lever Cutting Units Page 8 - 12 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 221: Adjust Lift Arm Down Pressure
5. Move spring bracket to desired position and install cap screw and locknut, while rotating hex shaft to relieve spring tension. Reelmaster 5200-D/5400-D Page 8 - 13 Cutting Units (Model 03506, S/N 80001 - 209999999) Rev. A...
Page 222: Service And Repairs
5. Install basket to the cutting. Figure 20 Cap screw, lock washer, flat washer, & thrust washer Cutting unit mounting shaft Cutting Units Page 8 - 14 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 223: Backlapping
7. For the cutting units being backlapped, move the reel speed control to position 1. Figure 23 Enable/Disable switch Lower Mow/Raise lever Reelmaster 5200-D/5400-D Page 8 - 15 Cutting Units (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 224 14.Wash all lapping compound off cutting units. Figure 25 NOTE: For additional instructions and procedures on backlapping, see the Toro Sharpening Reel & Rotary Mowers Book, Part No. 80300SL. NOTE: For a better cutting edge, run a file across the front face of the bedknife when the lapping operation is completed.
Page 225: Bedbar Removal And Installation
Remove bedbar by rotating it away 3. H.O.C. adjustment screw from the reel. NOTE: For proper grinding of bedknife follow proce- dures in the Toro Sharpening Reel and Rotary Mowers Book, Part No. 80300SL. Installation IMPORTANT: When installing bedbar, be sure to as- semble rear roller brackets UNDER arms of bedbar.
Page 226: Bedknife Replacement And Grinding
Figure 28 NOTE: For proper grinding of bedknife, follow proce- dures in the Toro Sharpening Reel and Rotary Mowers Book, Part No. 80300SL. Note: When grinding, be careful to not overheat the bedknife. Remove small amounts of material with each pass of the grinder.
Page 227: Prepare Reel For Grinding
Blade Relief Angle 3. For proper grinding of reel, grind in accordance with Relief Angle Range 20_ to 40_ procedures in the Toro Sharpening Reel and Rotary Mowers Book, Part No. 80300SL. Blade Land Width 0.040 inch (1.0 mm) Land Width Range 0.030 to 0.060 inch (0.7 to 1.5 mm)
Page 228: Reel Removal And Bearing Replacement
3. Install bearing housing to reel shaft ends and side plate. Secure bearing housing to side plate with mount- ing bolts. Cutting Units Page 8 - 20 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 229: Traction Unit Lift Arm Spring Replacement
7. Use an open end wrench to move spring bracket to the desired position. Install cap screw and locknut while rotating the hex shaft to relieve spring tension. Reelmaster 5200-D/5400-D Page 8 - 21 Cutting Units (Model 03506, S/N 80001 - 209999999) Rev.
Page 230 Cutting Units Page 8 - 22 Reelmaster 5200-D/5400-D (Model 03506, S/N 80001 - 209999999) Rev. A (Model 03509, S/N 80001 - 209999999)
Page 231 Lubrication ....... . . Reelmaster 5200-D/5400-D Page 8.1 - 1 Cutting Units (Model 03527, S/N 210000001 &...
Page 232: Model 03527, S/N 210000001 & Up Model 03528, S/N 210000001 & Up
Both rollers use heavy duty ball bearings REEL DIAMETER: 5 in. (127 mm) with two conventional single lip seals and a Toro laby- rinth seal to provide four sealing surfaces to protect the REEL BEARINGS: Taper roller bearings bearings.
Page 233: Special Tools
Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your machine AND APPLICATIONS GUIDE (COMMERCIAL PROD- or available as TORO parts. Some tools may also be UCTS). available from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife atti- tude.
Page 234 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro Part No. 97931SL)
Page 235: Troubleshooting
• Check and recheck the cutting units for accurate and proper setup. Reelmaster 5200-D/5400-D Page 8.1 - 5 Cutting Units (Model 03527, S/N 210000001 & Up) Rev. A...
Page 236 Current Weather Pattern (i.e. Drought, Hot, Wet, etc.) Condition Found: Condition Environment (when it happens, what needs to be done to duplicate the condition): Note: For additional information see Toro Commercial Products Aftercut Appearance Troubleshooting Aid. Part No. 00076SL. Cutting Units Page 8.1 - 6...
Page 237: Initial Set-Up And Adjustments
Initial Set-up and Adjustments IMPORTANT: Toro strongly recommends the use of a IMPORTANT: Each cutting unit must be set consis- leveling plate when setting-up or adjusting any reel type tently. Minor differences in either height-of-cut, atti- cutting unit. The leveling plate will help to ensure accu- tude, bedknife wear, or reel blade wear, among rate and consistent adjustments.
Page 238: Bedknife To Reel Adjustment
Note: If reel makes contact on both sides of bedknife but still does not cut paper, cutting unit may need to be backlapped (refer to backlapping) or reel and/or bed- knife may need to be reground (refer to Toro manual for Sharpening Reel and rotary Mowers, Form No. 80–300PT).
Page 239: Setting Cutting Unit Attitude
Therefore, minimum recommended attitude is 1 degree. “A” For setting consistent cutting unit attitude, Toro strongly recommends using a two-screw gauge bar, Toro part no. 98-1852 (Fig.12). The Height of Cut Screw is set for Height of Cut Screw *Attitude Screw height-of-cut, and the Attitude Screw is set for cutting unit attitude.
Page 240 1. Rotate the cutting unit backward to gain access to reel and bedknife. 2. Place an angle indicator, Toro Part No. 99-3503, on the bedknife and record the bedknife angle (Fig. 13). 3. Using a two-screw gauge bar, Toro Part No.
Page 241: Leveling Front Roller
Note: If rollers are parallel to reel before changing bedknife attitude, you can change one roller at a time and still maintain parallelism. Figure 17 1. Capscrews Reelmaster 5200-D/5400-D Page 8.1 - 11 Cutting Units (Model 03527, S/N 210000001 & Up) Rev. A...
Page 242: Adjusting Height Of Cut
(B) in- and carrier frame/cutting unit rotation angle (B) de- creases. creases. Cutting Units Page 8.1 - 12 Reelmaster 5200-D/5400-D (Model 03527, S/N 210000001 & Up) Rev. A Rev. A (Model 03528, S/N 210000001 & Up)
Page 243: Front Grass Shield Adjustment
0.060” (2 mm) feeler gauge between top of reel and Cut–Off bar. Figure 22 1. Cut-off bar 3. Screw (4) Reelmaster 5200-D/5400-D Page 8.1 - 13 Cutting Units (Model 03527, S/N 210000001 & Up) Rev. A (Model 03528, S/N 210000001 & Up)
Page 244: Adjust Lock-Up Roller
Cutting Units Page 8.1 - 14 Reelmaster 5200-D/5400-D (Model 03527, S/N 210000001 & Up) Rev. A (Model 03528, S/N 210000001 & Up)
Page 245: Daily Adjustments
1. Weep Hole 3. Apply grease to the (2) front and (2) rear roller bear- ings until clean grease comes out seals. 4. Wipe excess grease away. Reelmaster 5200-D/5400-D Page 8.1 - 15 Cutting Units (Model 03527, S/N 210000001 & Up) Rev.
Page 246: Service And Repairs
(Fig. 27). Figure 29 Cap screw, lock washer, Cutting unit mounting flat washer, & thrust washer shaft Cutting Units Page 8.1 - 16 Reelmaster 5200-D/5400-D (Model 03527, S/N 210000001 & Up) Rev. A (Model 03528, S/N 210000001 & Up)
Page 247 7. For the cutting units being backlapped, move the reel speed control to position 1. Figure 32 Enable/Disable switch Lower Mow/Raise lever Reelmaster 5200-D/5400-D Page 8.1 - 17 Cutting Units (Model 03527, S/N 210000001 & Up) Rev. A (Model 03528, S/N 210000001 & Up)
Page 248 Note: Additional instructions and procedures on backlapping are available in the Toro Sharpening Reel and Rotary Mowers Manual, Form No. 80-300PT. Note: For a better cutting edge, run a file across the front face of the bedknife when the lapping operation is completed.
Page 249: Bedknife Replacement And Grinding
Front Angle surface is true. NOTE: For proper grinding of bedknife, follow proce- Figure 35 dures in the Toro Sharpening Reel and Rotary Mowers Book, Part No. 80300SL. Bedknife Regrinding Specifications Note: When grinding, be careful to not overheat the...
Page 250: Preparing Reel For Grinding
Blade Relief Angle 3. For proper grinding of reel, grind in accordance with Relief Angle Range 20_ to 40_ procedures in the Toro Sharpening Reel and Rotary Mowers Book, Part No. 80300SL. Blade Land Width 0.040 inch (1.0 mm) Land Width Range 0.030 to 0.060 inch (0.7 to 1.5 mm)
Page 251: Reel And Reel Bearings
A. Remove the mounting nuts from the counterbal- the reel assembly. All measurements and adjustments ance end weight (Fig. 38). of the reel rolling torque must be done with a completely Reelmaster 5200-D/5400-D Page 8.1 - 21 Cutting Units (Model 03527, S/N 210000001 & Up) Rev.
Page 252: Reel Removal
C. Install bearing housing to frame. Pack bearing cone with grease and install over reel shaft into bear- ing cup. Cutting Units Page 8.1 - 22 Reelmaster 5200-D/5400-D (Model 03527, S/N 210000001 & Up) Rev. A (Model 03528, S/N 210000001 & Up)
Page 253: Roller Bearing And Seal Replacement
Wipe off excess grease. 2. Install bearings: A. Use tool TOR4066, handle TOR4073 to install bearing into one end of roller. Reelmaster 5200-D/5400-D Page 8.1 - 23 Cutting Units (Model 03527, S/N 210000001 & Up) Rev. A...
Page 254 7. Use an open end wrench to move spring bracket to the desired position. Install cap screw and locknut while rotating the hex shaft to relieve spring tension. Cutting Units Page 8.1 - 24 Reelmaster 5200-D/5400-D (Model 03527, S/N 210000001 & Up) Rev. A (Model 03528, S/N 210000001 & Up)
Page 255: Removal
......Gear Pattern Movement Summary ... Reelmaster 5200-D/5400-D Page 9 - 1 4WD Rear Axle (Unit Serial No.
Page 256: Chapter 9 - 4Wd Rear Axle
The following explanation is intended to clarify the op- eration of the 4WD rear axle and overrunning clutch used with this TORO product. A drive shaft connected to the front axle provides power to the rear 4WD axle. The drive shaft incorporates an overrunning clutch that transfers power in the forward direction only (Fig.
Page 257: Specifications
10 to 15 psi. (0.69 to 1.03 Bar) Axle lubricant SAE GL-5 80W90 gear lube Four-Matict overrunning clutch lubricant No. 2 general purpose lithium grease Reelmaster 5200-D/5400-D Page 9 - 3 4WD Rear Axle (Unit Serial No. 80001 - 99999) Rev. A...
Page 258: Maintenance
(Fig. 6). 7. Install all plugs and bolts. Figure 5 1. Check/fill plug Figure 6 1. Check plug 2. Knuckle arm bolt 4WD Rear Axle Page 9 - 4 Reelmaster 5200-D/5400-D (Unit Serial No. 80001 - 99999) Rev. A...
Page 259: Service And Repairs
5. Loosen capscrews and locknuts securing end yoke sion. to traction shaft, and slide drive shaft assembly off trac- tion shaft (Fig. 7). Reelmaster 5200-D/5400-D Page 9 - 5 4WD Rear Axle (Unit Serial No. 80001 - 99999) Rev. A...
Page 260 Tighten collar set screws (Fig. 7). 4. Slide end yoke of drive shaft assembly onto traction shaft and tighten end yoke capscrews and locknuts (Fig. 7). 4WD Rear Axle Page 9 - 6 Reelmaster 5200-D/5400-D (Unit Serial No. 80001 - 99999) Rev. A...
Page 261: Overrunning Clutch
6. Lubricate clutch through grease fitting with No.2 gen- eral purpose lithium grease. 7. Install drive shaft (see Drive Shaft Service in this sec- tion of this manual). Reelmaster 5200-D/5400-D Page 9 - 7 4WD Rear Axle (Unit Serial No. 80001 - 99999)
Page 262: 4Wd Rear Axle
2. Steering cylinder 6. Rear wheel 10. Pivot pin 3. Hydraulic hose 7. Lug bolt 11. Washer 4. Tie rod 8. Rear wheel spacers 4WD Rear Axle Page 9 - 8 Reelmaster 5200-D/5400-D (Unit Serial No. 80001 - 99999) Rev. A...
Page 263: Removal
11. Wipe the rear axle pivot pin and pivot bushings with a rag to remove dirt and grease. Inspect the pin and bushings for wear or damage. Replace components as necessary. Reelmaster 5200-D/5400-D Page 9 - 9 4WD Rear Axle (Unit Serial No. 80001 - 99999)
Page 264: Disassembly
Do not interchange right and left 6. Remove differential gear case bolts. Separate gear components or assemblies. case halves and disassemble gear case. 4WD Rear Axle Page 9 - 10 Reelmaster 5200-D/5400-D (Unit Serial No. 80001 - 99999) Rev. A...
Page 265: Inspection
Note: Differential ring and pinion gears are a matched 11. Pull the knuckle housing from the gearbox housing. set, and must be replaced as a set. Reelmaster 5200-D/5400-D Page 9 - 11 4WD Rear Axle (Unit Serial No. 80001 - 99999)
Page 266: Assembly
5. Tighten pinion gear case bolts to 16 to 20 ft-lbs (22 12.Install axle assembly (see 4WD Rear Axle Installa- to 27 Nm). tion in this section of this manual). 4WD Rear Axle Page 9 - 12 Reelmaster 5200-D/5400-D (Unit Serial No. 80001 - 99999) Rev. A...
Page 267: Pinion Gear To Ring Gear Engagement
Example: If you have the backlash set correctly to speci- fications and you change the pinion position shim, you may have to readjust backlash to the correct specifica- tion before checking the pattern. Reelmaster 5200-D/5400-D Page 9 - 13 4WD Rear Axle (Unit Serial No. 80001 - 99999)
Page 268: Gear Pattern Movement Summary
Coast pattern (concave side of gear) moves deep- er on the tooth and toward heel. 4WD Rear Axle Page 9 - 14 Reelmaster 5200-D/5400-D (Unit Serial No. 80001 - 99999) Rev. A...
Page 269: Removal
........Gear Pattern Movement Summary ... Reelmaster 5200-D/5400-D Page 9.1 - 1 4WD Rear Axle (Unit Serial No.
Page 270: Unit Serial No. 200000001 & Up
The following explanation is intended to clarify the op- eration of the 4WD rear axle and overrunning clutch used with this TORO product. A drive shaft connected to the front axle provides power to the rear 4WD axle. The drive shaft incorporates an overrunning clutch that transfers power in the forward direction only (Fig.
Page 271: Specifications
10 to 15 psi. (0.69 to 1.03 Bar) Axle lubricant SAE GL-5 80W90 gear lube Four-Matict overrunning clutch lubricant No. 2 general purpose lithium grease Reelmaster 5200-D/5400-D Page 9.1 - 3 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 272: Maintenance
(Fig. 6). 7. Install all plugs. Figure 5 1. Check plug 2. Fill plug Figure 6 1. Check plug 4WD Rear Axle Page 9.1 - 4 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 273: Service And Repairs
5. Loosen capscrews and locknuts securing end yoke sion. to traction shaft, and slide drive shaft assembly off trac- tion shaft (Fig. 7). Reelmaster 5200-D/5400-D Page 9.1 - 5 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 274 Tighten collar set screws (Fig. 7). 4. Slide end yoke of drive shaft assembly onto traction shaft and tighten end yoke capscrews and locknuts (Fig. 7). 4WD Rear Axle Page 9.1 - 6 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 275: Installation
6. Lubricate clutch through grease fitting with No.2 gen- eral purpose lithium grease. 7. Install drive shaft (see Drive Shaft Service in this sec- tion of this manual). Reelmaster 5200-D/5400-D Page 9.1 - 7 4WD Rear Axle (Unit Serial No. 200000001 & Up)
Page 276 4. Thrust washer 10. Tie rod assembly 15. Steering cylinder 5. Thrust washer 11. Tie rod ball joints 16. Hydraulic hoses 6. Jam nut 4WD Rear Axle Page 9.1 - 8 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 277 11. Wipe the rear axle pivot pin and pivot bushings with a rag to remove dirt and grease. Inspect the pin and bushings for wear or damage. Replace components as necessary. Reelmaster 5200-D/5400-D Page 9.1 - 9 4WD Rear Axle (Unit Serial No. 200000001 & Up)
Page 278 (Fig. 13). Figure 13 1. Axle case 3. Mounting screw 2. Axle case support 4. Support shim 4WD Rear Axle Page 9.1 - 10 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 279 2. Axle case support 2. Inspect all gears, shafts, bearings, cases, and cov- ers for damage and wear. Replace components as nec- essary. Reelmaster 5200-D/5400-D Page 9.1 - 11 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 280 2. Lower bevel gear 7. Upper bevel gear 3. Bevel gear shaft 8. Collar 4. Lower bearing 9. Upper bearing 5. Thrust washer 10. Knuckle pin 4WD Rear Axle Page 9.1 - 12 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 281 (0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm) Figure 20 thickness. 1. Axle cover assembly 4. Dial indicator 2. Lower bevel gear 5. Axle bearing shims 3. Axle gear Reelmaster 5200-D/5400-D Page 9.1 - 13 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 282: Differential Shafts
Bevel Gear Case/Axle Case Assembly in this section of 1. Retaining ring 5. Spacer this manual). 2. Bevel gear 6. Bearing shims 3. Differential shaft 7. O-ring 4. Bearing 4WD Rear Axle Page 9.1 - 14 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 283: Axle Shafts
4. Spacer 2. Bevel gear 5. Retaining ring 3. Shims Figure 25 1. Axle shaft seal 3. Bearing 2. Axle cover 4. Axle shaft Reelmaster 5200-D/5400-D Page 9.1 - 15 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 284: Input Shaft/Pinion Gear
8. Secure the lock nut with the stake washer. Figure 27 1. Oil seal 2. Bearing case 4WD Rear Axle Page 9.1 - 16 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 285 Tighten mounting screws to 35 to 41 ft-lbs. (47 Figure 29 to 56 Nm). 1. Axle case 3. Dial indicator 2. Screwdriver 4. Input shaft/pinion gear Reelmaster 5200-D/5400-D Page 9.1 - 17 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 286: Differential Gear
1. Differential pinion shaft 5. Side gear shims 2. Pinion gear 6. Ring gear 3. Pinion washer 7. Differential case 4. Side gear 4WD Rear Axle Page 9.1 - 18 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 287 3. Inspect all gears, shafts, bearings, cases, and cov- ers for damage and wear. Replace components as nec- essary. Figure 34 1. Pinion shaft 2. Pinion gear Reelmaster 5200-D/5400-D Page 9.1 - 19 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 288: Installation
10.Align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin. 4WD Rear Axle Page 9.1 - 20 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 289: Pinion Gear To Ring Gear Engagement
2. Bearing case shims shims 3. Differential gear case may have to readjust backlash to the correct specifica- tion before checking the pattern. Reelmaster 5200-D/5400-D Page 9.1 - 21 4WD Rear Axle (Unit Serial No. 200000001 & Up) Rev. A...
Page 290: Gear Pattern Movement Summary
Coast pattern (concave side of gear) moves deep- er on the tooth and toward heel. 4WD Rear Axle Page 9.1 - 22 Reelmaster 5200-D/5400-D (Unit Serial No. 200000001 & Up) Rev. A...
Page 291: Chapter 10 - Electrical Diagrams
....Electrical Connectors Drawing (Cont.) ... Reelmaster 5200-D/5400-D Page 10 - 1 Electrical Diagrams...
Page 292 Electrical Diagrams Page 10 - 2 Reelmaster 5200-D/5400-D...
Page 293 ECU COMMUNICATION PORT GLOW PLUGS AND LOOPBACK PULL (B) HOLD (A) CONNECTOR ORANGE/RED RED/WHITE BLACK BLACK/WHITE Reelmaster 5200-D/5400-D FUSIBLE LINK LEAK DETECTOR Electrical Schematic OUTPUT (B) FIELD (R) All relays and solenoids "H" are shown as de–energized. WRNG LIGHTS (L) All ground wires are black.
Page 294 SPEEDOMETER START RELAY SENSOR NEUTRAL SENSOR FUSIBLE LINK HARNESS GROUND ALTERNATOR "R" "L " STARTER HOLD SOLENIOD PULL ALTERNATOR GLOW PLUGS PRESSURE TEMPERATURE SENSOR WATER TEMP . SWITCH GAUGE (SHUT DOWN) STARTER Reelmaster 5200-D/5400-D Harness Drawing Page 10 – 4...
Page 295 Orange Black/White Brown Open Green/White Orange Black Pink Black Blue/White Green/Black Orange Black Black Black Orange Green/White Ye llow Open Blue/Green Open Violet Red/Blue Open Black Violet/Red Orange/ Red Black Green/White Reelmaster 5200-D/5400-D Electrical Connectors Drawing Page 10 – 5...
Page 296 Fault Light Fault Light Engine Oil Pressure Located in Located in Located on LH steering column steering column side of engine Wire Color Wire Color Wire Color Black Violet/Red Green/Blue Reelmaster 5200-D/5400-D Electrical Connectors Drawing (Cont.) Page 10 – 6...

This manual is also suitable for:

Reelmaster 5400-d

Toro Reelmaster 5200-D Service Manual

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

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Toro Reelmaster 5200-D