Toro 03540 Reelmaster 5200-D, 03543 Reelmaster 5400-D Operator's Manual

Form No. 3355-138 Rev B

Reelmaster® 5200-D/5400-D Two-Wheel and Four-Wheel Drive Traction Units

Model No. 03540 —Serial No. 260000201 and Up Model No. 03543 —Serial No. 260000201 and Up Model No. 03544 —Serial No. 260000201 and Up

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Diesel engine exhaust and some of its constituents ar e kno wn to the State of Calif or nia to cause cancer , bir th defects, and other r epr oducti v e har m.

Important: T his engine is not equipped with a spar k ar r ester muf ﬂer . It is a violation of Calif or nia Public R esource Code Section 4442 to use or operate the engine on an y f or est-co v er ed, br ush-co v er ed, or g rass-co v er ed land. Other states or federal ar eas may ha v e similar la ws.

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . T he model and serial n umbers are on a plate mounted on the left side of the foot rest. W rite the n umbers in the space pro vided.

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 1 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 1

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Riding Mo w er Safety . . . . . . . . . . . . . . . . . . . 6

Sound Pressure Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sound P o w er Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Vibration Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Connecting the Batter y . . . . . . . . . . . . . . . . . . . . 13

2 Mounting the Hood Latc h (CE

Units Only) . . . . . . . . . . . . . . . . . . . . . . . 14

3 R e placing the P anel F asteners

(CE Units Only) . . . . . . . . . . . . . . . . 15

4 Adjusting the Tire Pressure . . . . . . . . . . . . . . 16

5 Installing the Cutting Units . . . . . . . . . . . . . . 16

6 Adjusting the T urf Compensation

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7 Adjusting the Lifted Height

of the Outer F ront

Cutting Units (Enable

P osition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8 Installing R ear W eights . . . . . . . . . . . . . . . . . . . . 20

9 Installing CE Decals . . . . . . . . . . . . . . . . . . . . . . . . 21

10 R eading the Man ual and Viewing

the Safety Video . . . . . . . . . . . . . . . . . 21

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chec king the Engine Oil Lev el . . . . . . . . . . . 26

Chec king the Cooling System . . . . . . . . . . . . . 27

Filling the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chec king the T ransmission

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chec king the Hy draulic Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chec king the R ear Axle

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chec king the R eel to Bedknife

Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chec k the T or que of the W heel

Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . 30

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Setting the R eel Speed . . . . . . . . . . . . . . . . . . . . . . . . 31

Adjusting the Lift Ar m Do wn

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

T o wing the T raction Unit . . . . . . . . . . . . . . . . . . . 33

Understanding the Diagnostic

Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Diagnostic Ace Displa y . . . . . . . . . . . . . . . . . . . . . . 34

Chec king the Interloc k

Switc hes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Hy draulic V alv e Solenoid

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Daily Maintenance Chec klist . . . . . . . . . . . . . . 41

Ser vice Inter v al Char t . . . . . . . . . . . . . . . . . . . . . . . . 42

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Greasing the Bearings and

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 44

Ser vicing the Engine Oil and

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjusting the T hrottle . . . . . . . . . . . . . . . . . . . . . . . 45

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Draining the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 46

Chec king the Fuel Lines and

Connections . . . . . . . . . . . . . . . . . . . . . . 46

Draining the Fuel Filter/W ater

Se perator . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

R e placing the Fuel Filter

Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

R e placing the Fuel Preﬁlter . . . . . . . . . . . . . . . . 47

Bleeding Air from the Fuel

Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 47

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Optional Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 49

Adjusting the T raction Dri v e for

Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Chec king and Adjusting the

T raction Linkag e . . . . . . . . . . . . . . . 49

Changing the T ransmission

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

R e placing the T ransmission Oil

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Changing the R ear Axle

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Adjusting the R ear W heel

T oe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 52

R emo ving Debris from the Cooling

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Adjusting the Ser vice Brak es . . . . . . . . . . . . . . 52

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

T ensioning the Alter nator Belt . . . . . . . . . . . 53

T ensioning the Cooling F an

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 54

Changing the Hy draulic Fluid . . . . . . . . . . . . . 54

R e placing the Hy draulic Filter . . . . . . . . . . . . 54

Chec king the Hy draulic Lines and

Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Hy draulic System T est P or ts . . . . . . . . . . . . . . . 55

Cutting Unit System Maintenance . . . . . . . . . . . . . . 56

Adjusting the Cutting Unit Lift

Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Bac klapping the Cutting Units . . . . . . . . . . . . 57

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Pre paring the T raction Unit . . . . . . . . . . . . . . . . 59

Pre paring the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 59

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Safety

T his machine meets or ex ceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 speciﬁcations in ef fect at time of pr oduction, when ballast is installed according to the char t on pa ge 19.

Impr oper use or maintenance by the operator or o wner can r esult in injur y . T o r educe the potential f or injur y , compl y with these safety instr uctions and al w ays pay attention to the safety aler t symbol, which means Caution, W ar ning , or Danger—per sonal safety instr uction. F ailur e to compl y with the instr uction may r esult in per sonal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.

Training

• R ead the operator’ s man ual and other training material carefully . Be familiar with the controls , safety signs , and the proper use of the equipment.

• Nev er allo w c hildren or people unfamiliar with these instr uctions to use or ser vice the mo w er . Local regulations ma y restrict the ag e of the operator .

• Nev er mo w while people , especially c hildren, or pets are nearb y .

• K ee p in mind that the operator or user is responsible for accidents or hazards occur ring to other people or their proper ty .

• Do not car r y passeng ers .

• All dri v ers and mec hanics should seek and

obtain professional and practical instr uction. T he o wner is responsible for training the users . Suc h instr uction should emphasize:

– the need for care and concentration when

w orking with ride-on mac hines;

– control of a ride-on mac hine sliding on a

slope will not be reg ained b y the application of the brak e . T he main reasons for loss of control are:

◊ insufﬁcient wheel g rip;

◊ being dri v en too fast;

◊ inadequate braking;

◊ the type of mac hine is unsuitable for its

task;

◊ lac k of a w areness of the effect of

g round conditions , especially slopes;

◊ incor rect hitc hing and load distribution.

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people , or proper ty .

Preparation

• W hile mo wing, alw a ys w ear substantial footw ear , long trousers , hard hat, safety glasses , and ear protection. Long hair , loose clothing, or jew elr y ma y g et tangled in mo ving par ts . Do not operate the equipment when barefoot or w earing open sandals .

• T horoughly inspect the area where the equipment is to be used and remo v e all objects whic h ma y be thro wn b y the mac hine .

• W ar ning —Fuel is highly ﬂammable . T ak e the follo wing precautions:

– Store fuel in containers speciﬁcally designed

for this pur pose .

– R efuel outdoors only and do not smok e

while refuelling .

– Add fuel before star ting the engine . Nev er

remo v e the cap of the fuel tank or add fuel while the engine is r unning or when the engine is hot.

– If fuel is spilled, do not attempt to star t the

engine but mo v e the mac hine a w a y from the area of spillag e and a v oid creating any source of ignition until fuel v apors ha v e dissipated.

– R e place all fuel tanks and container caps

securely .

• R e place faulty silencers/m ufﬂers .

• Ev aluate the ter rain to deter mine what

accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• Chec k that operator’ s presence controls , safety switc hes and shields are attac hed and

functioning properly . Do not operate unless they are functioning properly .

Operation

• Do not operate the engine in a conﬁned space where dang erous carbon mono xide fumes can collect.

• Mo w only in da ylight or in g ood ar tiﬁcial light.

• Before attempting to star t the engine ,

diseng ag e all blade attac hment clutc hes , shift into neutral, and eng ag e the parking brak e .

• R emember there is no suc h thing as a safe slope . T ra v el on g rass slopes requires par ticular care . T o guard ag ainst o v er tur ning:

– do not stop or star t suddenly when g oing

up or do wnhill;

– eng ag e clutc h slo wly , alw a ys k ee p mac hine

in g ear , especially when tra v elling do wnhill;

– mac hine speeds should be k e pt lo w on

slopes and during tight tur ns;

– sta y aler t for humps and hollo ws and other

hidden hazards;

– nev er mo w across the face of the slope ,

unless the mo w er is designed for this pur pose .

• Sta y aler t for holes in the ter rain and other hidden hazards .

• Use care when pulling loads or using hea vy equipment.

– Use only appro v ed dra wbar hitc h points .

– Limit loads to those y ou can safely control.

– Do not tur n shar ply . Use care when

rev ersing .

– Use counterw eight(s) or wheel w eights

when sug g ested in the operator’ s man ual.

• W atc h out for trafﬁc when crossing or near roadw a ys .

• Stop the blades rotating before crossing surfaces other than g rass .

• W hen using any attac hments , nev er direct disc harg e of material to w ard b ystanders nor allo w any one near the mac hine while in operation.

• Nev er operate the mac hine with damag ed guards , shields , or without safety protecti v e devices in place . Be sure all interloc ks are

attac hed, adjusted properly , and functioning properly .

• Do not c hang e the engine g o v er nor settings or o v er -speed the engine . Operating the engine at ex cessi v e speed ma y increase the hazard of personal injur y .

• Before lea ving the operator’ s position:

– stop on lev el g round; – diseng ag e the po w er tak e-off and lo w er the

attac hments;

– c hang e into neutral and set the parking

brak e;

– stop the engine and remo v e the k ey .

• Diseng ag e dri v e to attac hments when transpor ting or not in use .

• Stop the engine and diseng ag e dri v e to attac hment:

– before refuelling; – before remo ving the g rass catc her/catc hers; – before making height adjustment unless

adjustment can be made from the operator’ s

position. – before clearing bloc kag es; – before c hec king, cleaning or w orking on

the mo w er; – after striking a foreign object or if an

abnor mal vibration occurs . Inspect the

mo w er for damag e and mak e re pairs before

restar ting and operating the equipment.

• R educe the throttle setting during engine r un-out and, if the engine is pro vided with a shut-off v alv e , tur n the fuel off at the conclusion of mo wing .

• K ee p hands and feet a w a y from the cutting units .

• Look behind and do wn before bac king up to be sure of a clear path.

• Slo w do wn and use caution when making tur ns and crossing roads and sidew alks . Stop cylinders/reels if not mo wing .

• Do not operate the mo w er under the inﬂuence of alcohol or dr ugs .

• Use care when loading or unloading the mac hine into a trailer or tr uc k.

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

Maintenance and Storage

• K ee p all n uts , bolts and screws tight to be sure the equipment is in safe w orking condition.

• Nev er store the equipment with fuel in the tank inside a building where fumes ma y reac h an open ﬂame or spark.

• Allo w the engine to cool before storing in any enclosure .

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

• Charg e batteries in an open w ell v entilated area, a w a y from spark and ﬂames . Unplug c harg er before connecting or disconnecting from batter y . W ear protecti v e clothing and use insulated tools .

• T o reduce the ﬁre hazard, k ee p the engine , silencer/m ufﬂer , batter y compar tment and fuel storag e area free of g rass , lea v es , or ex cessi v e g rease .

• Chec k the g rass catc her frequently for w ear or deterioration.

• K ee p all par ts in g ood w orking condition and all hardw are and h y draulic ﬁttings tightened. R e place all w or n or damag ed par ts and decals .

• If the fuel tank has to be drained, do this outdoors .

• Be careful during adjustment of the mac hine to prev ent entrapment of the ﬁng ers betw een mo ving blades and ﬁx ed par ts of the mac hine .

• On m ulti-cylinder/m ulti-reel mac hines , tak e care as rotating one cylinder/reel can cause other cylinders/reels to rotate .

• Diseng ag e dri v es , lo w er the cutting units , set parking brak e , stop engine and remo v e k ey and disconnect spark plug wire . W ait for all mo v ement to stop before adjusting, cleaning or re pairing .

• Clean g rass and debris from cutting units , dri v es , silencers/m ufﬂers , and engine to help prev ent ﬁres . Clean up oil or fuel spillag e .

• Use jac k stands to suppor t components when required.

• Carefully release pressure from components with stored energ y .

• Disconnect batter y and remo v e spark plug wire before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect positi v e ﬁrst and neg ati v e last.

• Use care when c hec king the cylinders/reels . W ear glo v es and use caution when ser vicing them.

Toro Riding Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products or other safety infor mation that y ou m ust kno w that is not included in the CEN , ISO , or ANSI standard.

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Use of this product for pur poses other than its intended use could pro v e dang erous to user and b ystanders .

Engine exhaust contains carbon mono xide, which is an odor less, deadl y poison that can kill y ou.

Do not r un engine indoor s or in an enclosed ar ea.

• Kno w ho w to stop the engine quic kly .

• Do not operate the mac hine while w earing

tennis shoes or sneak ers .

• W earing safety shoes and long pants is advisable and required b y some local ordinances and insurance regulations .

• Handle fuel carefully . Wipe up any spills .

• Chec k the safety interloc k switc hes daily

for proper operation. If a switc h should fail, re place the switc h before operating the mac hine . After ev er y tw o years , re place all four interloc k switc hes in the safety system, whether they are w orking properly or not.

• Before star ting the engine , sit on the seat.

• Using the mac hine demands attention. T o

prev ent loss of control:

– Do not dri v e close to sand traps , ditc hes ,

creeks , or other hazards .

– R educe speed when making shar p tur ns .

A v oid sudden stops and star ts .

– W hen near or crossing roads , alw a ys yield

the right-of-w a y .

– Apply the ser vice brak es when g oing

do wnhill to k ee p forw ard speed slo w and to maintain control of the mac hine .

• T he g rass bask ets m ust be in place during operation of the cylinders/reels or thatc hers for maxim um safety . Shut the engine off before emptying the bask ets .

• Raise the cutting units when dri ving from one w ork area to another .

• Do not touc h the engine , silencer/m ufﬂer , or exhaust pipe while the engine is r unning or soon after it has stopped because these areas could be hot enough to cause bur ns .

system m ust be reliev ed b y stopping the engine and lo w ering the cutting units and attac hments to the g round.

• Chec k all fuel lines for tightness and w ear on a regular basis . Tighten or re pair them as needed.

• If the engine m ust be r unning to perfor m a maintenance adjustment, k ee p hands , feet, clothing, and any par ts of the body a w a y from the cutting units , attac hments , and any mo ving par ts , especially the screen at the side of the engine . K ee p ev er y one a w a y .

• T o ensure safety and accuracy , ha v e an A uthorized T oro Distributor c hec k the maxim um engine speed with a tac hometer . Maxim um g o v er ned engine speed should be 2900 RPM.

• If major re pairs are ev er needed or if assistance is desired, contact an A uthorized T oro Distributor .

• Sta y clear of the rotating screen at the side of the engine to prev ent direct contact with y our body or clothing .

• If the engine stalls or loses headw a y and cannot mak e it to the top of a slope , do not tur n the mac hine around. Alw a ys bac k slo wly , straight do wn the slope .

• W hen a person or pet appears unexpectedly in or near the mo wing area, stop mo wing . Careless operation, combined with ter rain angles , ricoc hets , or improperly positioned guards can lead to thro wn object injuries . Do not resume mo wing until the area is cleared.

Maintenance and Storage

• Mak e sure all h y draulic line connectors are tight and all h y draulic hoses and lines are in g ood condition before applying pressure to the system.

• K ee p y our body and hands a w a y from pin hole leaks or nozzles that eject h y draulic ﬂuid under high pressure . Use paper or cardboard, not y our hands , to searc h for leaks . Hy draulic ﬂuid escaping under pressure can ha v e sufﬁcient force to penetrate the skin and cause serious injur y . Seek immediate medical attention if ﬂuid is injected into skin.

• Use only T oro-appro v ed attac hments and re placement par ts . T he w ar ranty ma y be v oided if used with unappro v ed attac hments .

Sound Pressure Level

T his unit has an equi v alent contin uous A-w eighted sound pressure at the operator ear of: 88 dB(A), based on measurements of identical mac hines per EN 11094 and EN 836.

Sound Power Level

T his unit has a guaranteed sound po w er lev el of: 105 dB A/1 pW , based on measurements of identical mac hines per EN 11094.

Vibration Level

T his unit does not ex ceed a vibration lev el of 2.5

m/s

at the hands based on measurements of

identical mac hines per EN 1033.

T his unit does not ex ceed a vibration lev el of 0.5

m/s

at the posterior based on measurements of

identical mac hines per EN 1032.

• Before disconnecting or perfor ming any w ork on the h y draulic system, all pressure in the

Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

1. Read the Operator’s Manual.

93-6693

1. Crushing hazard of hand—wait for moving parts to stop.

104-2052

110-9721

1. Throttle—slow 4. Reels lowered and on when enabled—forward and backlap

2. Throttle—fast 5. Reels enabled

3. Reels raised and off 6. Reels disabled—lift only 9. Headlights—On

104-9298

1. Read the Operator’s Manual .

104-9296

7. Reels disabled—lift and lower 10. Headlights—Off

8. Headlights (optional) 11. Read the Operator’s Manual for further instructions.

1. Read the Operator’s

2. Headlights

94-6767

3. Engine—start

Manual.

93-6697

1. Read the Operator’s Manual .

2. Add SAE 80w-90 (API GL-5) oil every 50 hours.

98-9335

1. Cutting/dismemberment hazard, fan—stay away from moving parts.

93-6696

1. Stored energy hazard—read the Operator’s Manual .

98-9342

1. Reel—height of cut 4. Machine speed

2. Reel—mow and backlap 5. Rear reels circuit controls

3. Read the Operator’s

Manual.

6. Front reels circuit controls

106-9224

1. Warning—read the Operator’s Manual.

2. Cutting hazard of hand and foot—stop the reels before touching.

93-6699

1. Machine speed 3. Continuous variable setting

2. Slow

4. Fast

93-6691

1. Read the Operator’s Manual.

93-6692

1. Read the Operator’s Manual —do not prime or use starting uid.

93-6686

1. Hydraulic oil

2. Read the Operator’s Manual.

93-1263

1. Read the Operator’s Manual.

2. To engage the parking brake, connect the brake pedals with the locking pin, push down on both pedals, and pull the brake latch out.

3. To release the parking brake, press both pedals until the parking brake latch retracts.

4. Danger—reels enabled.

1. Wheel torque specications

2. Read the Operator’s Manual .

106-9206

93-6689

1. Warning—do not carry passengers.

93-6680

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

1. Read the Operator’s

Manual.

2. Engine—stop 5. Engine—start

3. On

105-7506

4. Engine—preheat

1. Read the Operator’s Manual .

2. Do not tow the machine. 4. Cutting hazard of hand

3. Warning—Read the Operator’s Manual .

or foot—stay away from moving parts.

104-9294

5. Warning—keep bystanders a safe distance from the machine.

6. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine.

7. Warning—use a rollover protection system and wear the seat belt.

8. Tipping hazard—lower the cutting unit when driving down slopes.

1. Read the Operator’s Manual .

2. Do not tow the machine. 4. Cutting hazard of hand

3. Warning—Read the Operator’s Manual .

or foot—stay away from moving parts.

104-9295

(Cover 104–9296 for CE)

5. Warning—keep bystanders

6. Warning—lock the parking

a safe distance from the machine.

brake, stop the engine, and remove the ignition key before leaving the machine.

7. Warning—use a rollover protection system and wear the seat belt.

8. Tipping hazard—lower the cutting unit when driving down slopes and do not drive across or down slopes greater than 15 degrees.

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

3 4

5 6

No parts required

Locking hood switch Lock washer Nut 1 Key 2 Hood latch bracket Bolt (1/4 x 3/4 inch) Flat washer (1/4 inch) Locknut (1/4 inch) Flange-head bolt (5/16 x 5/8 inch) Flange-head bolt (5/16 x 3/4 inch)

No parts required

Cutting unit (sold separately)

No parts required

Description

Qty.

–

1 1

1 2 2 2 1 1

–

Connect the Battery

Mount the hood latch.

Replace the panel fasteners (CE only).

Adjust the tire pressure.

Install the cutting units

Adjust the turf compensation spring.

Adjust the lifted height of the outer front cutting units (enable position).

Use

Rear weights (size varies with

8 9

conguration). CE decal

Blank service decal Operator’s Manual Engine Operator’s Manual Parts Catalog CE certicate Safety Video Diagnostic ACE display overlay

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Varies

1 1 1 1 1 2 1 1

Install rear weights.

Install the CE Decals

Read the Operator’s Manual and watch the video before operating the machine.

Step

Connecting the Battery

No Parts Required

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om the batter y .

Procedure

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Connecting ca bles to the wr ong post could r esult in per sonal injur y and/or dama ge to the electrical system.

1. Open hood.

2. Ensure that the batter y is securely fastened in place and c hec k the batter y c harg e with a h y drometer . If the batter y needs c harging, ensure that the positi v e (+) cable is disconnected from the batter y before connecting the c harg er ( Figure 2 ).

Batter y ter minals or metal tools could shor t a gainst metal tractor components, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the tractor .

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the tractor .

3. Slide the red, positi v e batter y cable onto the positi v e batter y post and tighten the n ut securely .

Incor r ect batter y ca ble r outing could dama ge the tractor and ca bles, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

Figure 2

1. Positive battery cable 2. Negative battery cable

• Al w ays connect the positi v e (r ed) batter y ca ble bef or e connecting the negati v e (black) ca ble.

4. Slide the blac k, neg ati v e batter y cable onto the neg ati v e batter y post and tighten the n ut securely .

5. Coat both batter y connections with Grafo 112X (skin o v er) g rease (T oro P ar t No . 505-47), petroleum jelly , or light g rease to prev ent cor rosion and slide the r ubber boot o v er the positi v e ter minal.

6. Close the hood.

Step

Mounting the Hood Latch (CE Units Only)

Parts needed for this step:

Locking hood switch

Lock washer 1 Nut 2 Key 1

Hood latch bracket 2

Bolt (1/4 x 3/4 inch) 2

Flat washer (1/4 inch) 2

Locknut (1/4 inch)

Procedure

1. R emo v e the plug from the hole in the left front cor ner of the hood ( Figure 3 ).

Figure 4

1. Locking switch 2. Latch bracket

4. Loosely mount the latc h brac k et to the radiator suppor t with 2 bolts (1/4 x 3/4 inc h), ﬂat w ashers , and loc kn uts ( Figure 4 ).

5. Adjust the latc h brac k et, until it is aligned with the switc h latc h, then tighten the bolts .

Figure 3

1. Hood plug

2. Open the hood.

3. Mount the loc king switc h to the hood with a loc k w asher and n ut. P osition the switc h with the latc h to w ard the front of the mac hine ( Figure 4 ).

6. R otate the latc h to the loc k ed and unloc k ed positions with the k ey . R emo v e the k ey and store it in a memorable place .

7. Close the hood.

Step

Replacing the Panel Fasteners (CE Units Only)

Parts needed for this step:

Flange-head bolt (5/16 x 5/8 inch)

Flange-head bolt (5/16 x 3/4 inch)

Procedure

1. R emo v e the fasteners securing the left front cor ner of the ﬂoor panel and the left end of the access panel to the frame ( Figure 5 ).

Figure 5

1. Floor panel 2. Access panel

2. R e place the ﬂoor panel fastener with a ﬂang e-head bolt (5/16 x 5/8 inc h) supplied in loose par ts ( Figure 5 ).

Step

Installing the Cutting Units

Parts needed for this step:

Cutting unit (sold separately)

Procedure

1. R emo v e the cutting units from the car tons . Assemble and adjust the as described in the cutting unit Operator’ s Manual .

2. If y ou will be using bask ets on the cutting units , use the c har t belo w ( Figure 6 ) to deter mine the locations at whic h y ou need to mount bask et guides to the cutting unit car rier frames . If y ou will not be using bask ets , proceed to ste p 4 .

3. R e place the access panel fastener with a ﬂang e-head bolt (5/16 x 3/4 inc h) supplied in loose par ts ( Figure 5 ).

Step

Adjusting the Tire Pressure

No Parts Required

Procedure

T he tires are o v er -inﬂated for shipping . T herefore , release some of the air to reduce the pressure . Cor rect air pressure in the front and rear tires is 10 to 15 psi (69 to 103 kP a).

Important: Maintain ev en pr essur e in all tir es to ensur e unif or m contact with the turf.

Figure 6

3. Mount a bask et guide ( Figure 7 ) to the appropriate side of eac h cutting unit car rier frame ( Figure 8 ) with a bolt (5/16 x 1-3/4 inc hes), ﬂat w asher , and loc k w asher or fasteners previously remo v ed, as sho wn in Figure 7 .

Figure 7

1. Carrier frame 2. Basket guide

4. Install a roll pin ( Figure 8 ) into the hole in the appropriate side of eac h cutting unit car rier frame ( Figure 6 ).

Figure 8

1. Carrier frame 3. Basket bracket

2. Roll pin 4. Basket collar

Figure 9

1. Cutting unit mounting shaft

2. Carrier frame pivot tube 5. Lock washer

3. Thrust washer 6. Bolt

4. Flat washer

6. Secure the shaft in the pi v ot tube with a thr ust w asher , ﬂat w asher , loc k w asher , and bolt ( Figure 9 ).

7. Assemble the mounting n uts for the reel dri v e motor to eac h cutting unit ( Figure 10 ). Lea v e appro ximately 1/2 inc h (1.25 cm) of threads exposed on eac h mounting stud.

5. Align the mounting shaft of the cutting unit with the pi v ot tube on the car rier frame . Inser t the shaft into the tube ( Figure 9 ).

Figure 10

1. Reel drive motor

2. Mounting nuts

8. Coat the spline shaft of the motor with clean g rease and install the motor b y rotating it cloc kwise so that the motor ﬂang es clear the studs . R otate the motor countercloc kwise until the ﬂang es encircle the studs and tighten the

mounting n uts . Ensure that the w ashers are ag ainst the n uts .

9. Detac h the loc k-up c hain from the lift ar m and secure it to the cross tube on eac h rear cutting unit with a bolt, ﬂat w asher , and loc kn ut ( Figure 11 ).

Figure 11

1. Lock-up chain

Important: Mak e sur e that all h y draulic hoses ar e r outed a w ay fr om cutting unit so that when the cutting unit pi v ots ex cessi v e r ub bing does not occur .

10. Chec k the adjustment of the loc k-up rollers ( Figure 12 ). W hen properly adjusted, they will contact the loc k-up lev ers on rear lift ar ms and suppor t the cutting units when fully raised.

the bask et brac k et and pressing the opposite mounting pin into the pi v oting brac k et.

Step

Adjusting the Turf Compensation Spring

No Parts Required

Procedure Important: T his adjustment is needed f or

Cutting Unit Models 03527 and 03528 onl y . T he turf compensation spring ( Figur e 13 ),

connecting car rier frame to cutting unit, contr ols the amount of f or e-aft r otation a v aila ble.

T he turf compensation spring also transfers w eight from the front to the rear roller . (T his helps to reduce a w a v e patter n in the turf , also kno wn as bobbing .)

Figure 12

1. Lock-up rollers 2. Lock-up levers

11. Mount a bask et to eac h cutting unit car rier frame b y inser ting the bask et mounting pin into

Figure 13

Important: Mak e spring adjustments with

the cutting unit mounted to the traction unit and lo w er ed to the shop ﬂoor .

1. Tighten the loc kn ut on the rear of the spring rod until the g ap (C) betw een the rear of the

spring brac k et and front of the w asher is 1.25 inc hes (3.2 cm) ( Figure 13 ).

2. Tighten the hex n uts on the front end of the spring rod until the compressed length (A) of spring is 6.25 inc hes (32.8 cm) ( Figure 13 ).

As the compressed spring length (A) decr eases , w eight transfer from the front roller to the rear roller incr eases and the car rier frame/cutting unit rotation angle (B) decr eases .

As the g ap (C) betw een the spring brac k et and w asher incr eases , the car rier frame/cutting unit rotation angle (B) incr eases .

Step

Adjusting the Lifted Height of the Outer Front Cutting Units (Enable Position)

No Parts Required

Procedure

T he tur naround height of the front outer cutting units (#4 & #5) ma y be increased to pro vide additional g round clearance on contoured fairw a ys .

Note: T he RM CONFIG time dela y should not be c hang ed from the original setting of 0 when using this method to adjust tur n around height.

Figure 14

1. Lift arm switch 3. Lift arm ag

2. Carriage bolt nut

3. Mo v e the lift switc h brac k et inw ard in the slot until the desired position is attained.

4. Set the distance betw een the lift ar m switc h and the ﬂag on the lift ar m to appro ximately

0.062 inc hes (1.6 mm).

5. Tighten the car riag e bolt n ut.

T o increase the tur n around height of the front cutting units proceed as follo ws:

1. P osition the mac hine on a lev el surface , lo w er the cutting units , and stop the mac hine .

2. Loosen the car riag e bolt n ut securing the lift ar m switc h brac k et to the No . 4 lift ar m (left front) ( Figure 14 ).

Step

Installing Rear Weights

Parts needed for this step:

Varies

Rear weights (size varies with conguration).

Procedure

T he R eelmaster 5200-D & 5400-D T raction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 Standards when equipped with rear w eights and 90 lb of calcium c hloride ballast is added to rear wheels . Use the c har t belo w to deter mine the combinations of w eights required for y our conﬁguration. Order par ts from y our local A uthorized T oro Distributor .

Traction Unit

Conguration

2wd Traction Unit

with ROPS w/o

baskets

2wd Traction Unit

with ROPS with

baskets

2wd Traction Unit

w/o ROPS w/o

baskets

2wd Traction Unit

w/o ROPS with

baskets

4wd Traction Unit

with ROPS w/o

baskets

4wd Traction Unit

with ROPS with

baskets

Rear Weight

Required

291 lb (132 kg)

358 lb (162 kg)

157 lb (71 kg)

224 lb (102 kg)

157 lb (71 kg)

249 lb (113)

75-6690 and 98-9780

Weight Part

Number

75-6690

Weight

Description

Rear Weight Kit

Rear Weight Kit and

Rear Weight Kit—25 lb

Qty

2 and 1

Important: If a punctur e occur s in a tir e with calcium chloride, r emo v e the machine fr om the turf ar ea as quickl y as possible. T o pr ev ent possible dama ge to the turf, immediatel y soak the af fected ar ea with w ater .

+ 44 hidden pages

Toro 03540 Reelmaster 5200-D, 03543 Reelmaster 5400-D Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual