Toro 03540 Reelmaster 5200-D Bedienungsanleitung

PART NO. 99046SL Rev. A

Service Manual

ReelmasterR5200-D/5400-D

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing,

and repair of major systems and components on the

Reelmaster 5200-D/5400-D.

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR’S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC-

TIONS. Space is provided in Chapter 2 of this book to

insert the Operator’s Manuals and Parts Catalogs for

your machine. Replacement Operator’s Manuals are

available by sending complete Model and Serial Num-

ber to:

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

The Toro Company reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing, or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

EThe Toro Company - 1999, 2001

Reelmaster 5200-D/5400-D

Safety

Product Records

and Mantenance

Kubota

Diesel Engine

Hydraulic

System

Electrical

System

Differential

Axle

Steering

and Brakes

Rev. A

Reelmaster 5200-D/5400-D

Table Of Contents

Chapter 1 - Safety

General Safety Instructions 1 - 1. . . . . . . . . . . . . . . . . .

Jacking Instructions 1 - 4. . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2 - Product Records and Maintenance

Product Records 2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Equivalents and Conversions 2 - 2. . . . . . . . . . . . . . . .

Torque Specifications 2 - 3. . . . . . . . . . . . . . . . . . . . . . .

Lubrication 2 - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation and Service History Reports 2 - 9. . . . . . . .

Chapter 3 - Kubota Diesel Engines

Introduction 3 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 3 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 3 - 4. . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 3 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 3 - 8. . . . . . . . . . . . . . . . . . . . . . . .

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

05 SERIES

Chapter 4 - Hydraulic System

Specifications 4 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 4 - 3. . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Schematics 4 - 8. . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Flow Diagrams 4 - 10. . . . . . . . . . . . . . . . . . .

Special Tools 4 - 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 4 - 23. . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing 4 - 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 4 - 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 4 - 37. . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 - Electrical System

Special Tools 5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 5 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Quick Check 5 - 15. . . . . . . . . . . . . .

Component Testing 5 - 16. . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 5 - 33. . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 - Differential Axle

Introduction 6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 6 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 6 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 6 - 3. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 - Steering and Brakes

Introduction 7 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Steering Schematics 7 -3. . . . . . . . . . . . . . . . . . .

Specifications 7 -4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 7 -4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 7 -6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing 7 - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 7 - 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 7 - 10. . . . . . . . . . . . . . . . . . . . . . .

ROSS HYDRAGUIDE TM HYDROSTATIC STEERING

SYSTEM HGF SERIES SERVICE PROCEDURE

Reelmaster 5200-D/5400-D

Cutting nits

Model 03506 & 03509

Cutting nits

4WD Rear Axle

nit S/N 200000001 & p

Electrical

Diagrams Model 03527 & 03528

4WD Rear Axle

nit S/N 80001 Ć 99999

Rev. A

Reelmaster 5200-D/5400-D

Table Of Contents

Chapter 8 -Cutting Units

Model03506, S/N 80001 thru 209999999

Model 03509, S/N 80001 thru 209999999

Specifications 8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 8 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 8 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 8 - 14. . . . . . . . . . . . . . . . . . . . . . .

Chapter 8.1 - Cutting Units

Model03527, S/N 210000001 & Up

Model 03528, S/N 210000001 & Up

Specifications 8.1 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 8.1 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8.1 - 5. . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Set-up and Adjustments 8.1 - 7. . . . . . . . . . . . . .

Service and Repairs 8.1 - 16. . . . . . . . . . . . . . . . . . . . .

Chapter 9 - 4WD Rear Axle

Unit Serial No. 80001 Thru 99999

Introduction 9 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 9 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 9 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 9 - 5. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 9.1 - 4WD Rear Axle

Unit Serial No. 200000001 & Up

Introduction 9.1 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 9.1 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 9.1 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 9.1 - 5. . . . . . . . . . . . . . . . . . . . . .

Chapter 10 - Electrical Diagrams

Reelmaster 5200-D/5400-D

Reelmaster 5200-D/5400-D Page 1 - 1 Safety

Chapter 1

Safety

Table of Contents

GENERAL SAFETY INSTRUCTIONS 1. . . . . . . . . . . .

Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .

JACKING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . .

General Safety Instructions

The REELMASTER 5200-D/5400-D was tested and

certified by TORO for compliance with the B71.4-1990

specifications of the American National Standards Insti-

tute. Although hazard control and accident prevention

partially are dependent upon the design and configura-

tion of the machine, these factors are also dependent

upon the awareness, concern, and proper training of the

personnel involved in the operation, transport, mainte-

nance, and storage of the machine. Improper use or

maintenance of the machine can result in injury or

death. To reduce the potential for injury or death, comply

with the following safety instructions.

WARNING

To reduce the potential for injury or death,

comply with the following safety instructions.

Before Operating

1. Read and understand the contents of this manual

before starting and operating the machine. Become fa-

miliar with the controls and know how to stop the ma-

chine and engine quickly. A free replacement manual is

available by sending the complete model and serial

number to:

The Toro Company

8111 Lyndale Avenue South

Bloomington, Minnesota 55420-1196.

2. Never allow children to operate the machine. Do not

allow adults to operate machine without proper instruc-

tion. Only trained operators who have read this manual

should operate this machine.

3. Never operate the machine when under the influ-

ence of drugs or alcohol.

4. Keep all shields, safety devices and decals in place.

If a shield, safety device or decal is defective, illegible or

damaged, repair or replace it before operating the ma-

chine. Also tighten any loose nuts, bolts or screws to en-

sure machine is in safe operating condition.

5. Always wear substantial shoes. Do not operate ma-

chine while wearing sandals, tennis shoes, sneakers or

when barefoot. Do not wear loose fitting clothing that

could get caught in moving parts and possibly cause

personal injury. Wearing safety glasses, safety shoes,

long pants and a helmet is advisable and required by

some local ordinances and insurance regulations.

6. Assure interlock switches are adjusted correctly so

engine cannot be started unless traction pedal is in

NEUTRAL and cutting units are DISENGAGED.

7. Remove all debris or other objects that might be

picked up and thrown by the reels or fast moving compo-

nents from other attached implements. Keep all by-

standers away from operating area.

8. Since diesel fuel is highly flammable, handle it care-

fully:

A. Use an approved fuel container.

B. Do not remove fuel tank cap while engine is hot or

running.

C. Do not smoke while handling fuel.

D. Fill fuel tank outdoors and only to within an inch of

the top of the tank, not the filler neck. Do not overfill.

E. Wipe up any spilled fuel.

Safety

Reelmaster 5200-D/5400-D

Page 1 - 2

Safety

While Operating

9. Sit on the seat when starting and operating the ma-

chine.

10.Before starting the engine:

A. Engage the parking brake.

B. Make sure traction pedal is in NEUTRAL and the

ENABLE / DISABLE switch is in DISABLE.

C. After engine is started, release parking brake and

keep foot off traction pedal. Machine must not move.

If movement is evident, the neutral return mecha-

nism is adjusted incorrectly; therefore, shut engine

off and adjust until machine does not move when

traction pedal is released.

11.Seating capacity is one person. Therefore, never

carry passengers.

12.Do not run engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and

could possibly be deadly.

13.Check interlock switches daily for proper operation.

If a switch fails, replace it before operating the machine.

The interlock system is for your protection, so do not by-

pass it. Replace all interlock switches every two years.

14.Using the machine demands attention and to pre-

vent loss of control:

A. Operate only in daylight or when there is good ar-

tificial light.

B. Drive slowly

C. Watch for holes or other hidden hazards.

D. Look behind machine before backing up.

E. Do not drive close to a sand trap, ditch, creek or

other hazard.

F. Reduce speed when making sharp turns and

turning on a hillside.

G. Avoid sudden stops and starts.

15.Traverse slopes carefully. Do not start or stop sud-

denly when traveling uphill or downhill.

16.Operator must be skilled and trained in how to drive

on hillsides. Failure to use caution on slopes or hills may

cause loss of control and vehicle to tip or roll possibly re-

sulting in personal injury or death. On 4-wheel drive

models, always use the seat belt and ROPS together.

17.If engine stalls or loses power and cannot make it to

the top of a slope, do not turn machine around. Always

back slowly straight down the slope.

18.DON’T TAKE AN INJURY RISK! When a person or

pet appears unexpectedly in or near the mowing area,

STOP MOWING. Careless operation, combined with

terrain angles, ricochets, or improperly positioned

guards can lead to thrown object injuries. Do not resume

mowing until area is cleared.

19.Do not touch engine, muffler or exhaust pipe while

engine is running or soon after it is stopped. These areas

could be hot enough to cause burns.

20.If cutting unit strikes a solid object or vibrates abnor-

mally, stop immediately, turn engine off, set parking

brake and wait for all motion to stop. Inspect for damage.

If reel or bedknife is damaged, repair or replace it before

operating. Do not attempt to free blocked cutting unit by

reversing reel direction. Damage to reel may result.

21.Before getting off the seat:

A. Move traction pedal to neutral.

B. Set parking brake.

C. Disengage cutting units and wait for reels to stop.

D. Stop engine and remove key from switch.

E. Toro recommends that anytime the machine is

parked (short or long term) the cutting units should

be lowered to the ground. This relieves pressure

from the lift circuit and eliminates the risk of cutting

units accidentally lowering to the ground.

F. Do not park on slopes unless wheels are chocked

or blocked.

Reelmaster 5200-D/5400-D Page 1 - 3 Safety

Maintenance and Service

22.Before servicing or making adjustments, stop engine

and remove key from the switch.

23.Make sure machine is in safe operating condition by

keeping all nuts, bolts and screws tight.

24.Make sure all hydraulic line connectors are tight, and

all hydraulic hoses and lines are in good condition be-

fore applying pressure to the system.

25.Keep body and hands away from pin hole leaks in hy-

draulic lines that eject high pressure hydraulic fluid. Use

cardboard or paper to find hydraulic leaks. Hydraulic

fluid escaping under pressure can penetrate skin and

cause injury. Fluid accidentally injected into the skin

must be surgically removed within a few hours by a doc-

tor familiar with this form of injury or gangrene may re-

sult.

26.Before disconnecting or performing any work on the

hydraulic system, all pressure in system must be re-

lieved by stopping engine and lowering cutting units to

the ground.

27.If major repairs are ever needed or assistance is de-

sired, contact an Authorized Toro Distributor.

28.To reduce potential fire hazard, keep engine area

free of excessive grease, grass, leaves and dirt. Clean

protective screen on front of engine frequently.

29.If engine must be running to perform maintenance or

an adjustment, keep hands, feet, clothing and other

parts of the body away from cutting units and other mov-

ing parts. Keep everyone away.

30.Do not overspeed the engine by changing governor

setting. To assure safety and accuracy, have an Autho-

rized Toro Distributor check maximum engine speed.

31.Shut engine off before checking or adding oil to the

crankcase.

32.Disconnect battery before servicing the machine. If

battery voltage is required for troubleshooting or test

procedures, temporarily connect the battery.

33.At the time of manufacture, the machine conformed

to the safety standards for riding mowers. To assure op-

timum performance and continued safety certification of

the machine, use genuine Toro replacement parts and

accessories. Replacement parts and accessories made

by other manufacturers may result in non-conformance

with the safety standards, and the warranty may be

voided.

34. When changing attachments, tires, or performing

other service, use correct blocks, hoists, and jacks.

Make sure machine is parked on a solid level floor such

as a concrete floor. Prior to raising the machine, remove

any attachments that may interfere with the safe and

proper raising of the machine. Always chock or block

wheels. Used jack stands or solid wood blocks to sup-

port the raised machine. If the machine is not properly

supported by blocks or jack stands, the machine may

move or fall, which may result in personal injury (see

Jacking Instructions).

Safety

Reelmaster 5200-D/5400-D

Page 1 - 4

Safety

Jacking Instructions

CAUTION

When changing attachments, tires, or performing

other service, use correct blocks, hoists, and

jacks. Make sure machine is parked on a solid lev-

el surface such as a concrete floor. Prior to rais-

ing machine, remove any attachments that may

interfere with the safe and proper raising of the

machine. Always chock or block wheels. Use jack

stands or solid wood blocks to support the raised

machine. If the machine is not properly sup-

ported by blocks or jack stands, the machine may

move or fall, which may result in personal injury.

Jacking the Front End (Fig. 1)

1. Set parking brake and chock both rear tires to pre-

vent the machine from moving.

2. Position jack securely under the tie down rod that is

welded to the square tube of the front frame.

3. Position jack stands or hardwood blocks under the

square tube as close to the wheels as possible to sup-

port the machine.

Jacking the Rear End

1. The preferred method of lifting the rear end of the

machine is (Fig. 3):

A. Secure a chain fall or hoist to the tie down rod on

the rear of the frame.

B. Chock both front tires. Lift rear of the machine off

the ground.

C. On 2WD models, use jack stands or blocks under

the axle as close to the wheels as possible to secure

the machine.

D. On 4WD models, use jack stands or blocks under

the axle tube as close to the gear box housings as

possible to secure the machine.

2. If the rear of the machine can not be lifted as above:

A. On 2WD models, place jack securely under the

pivot bracket for the steering cylinder (Fig. 2).

B. On 4WD models, place jack securely under the

differential casing (Fig. 3).

C. Chock both front tires. Jack rear of machine off

the ground.

1. Tie down rod 2. Square tube (front frame)

Figure 1

1. Pivot bracket 2. Steering Cylinder

Figure 2

1. Differential case

2. Axle tube 3. Gearbox housing

4. Tie down rod

Figure 3

D. On 4WD models, use jack stands or blocks under

the axle tube as close to the gear box housings as

possible to secure the machine.

E. On 2WD models, use jack stands or blocks under

the axle as close to the wheels as possible to secure

the machine.

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