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Toro Reelmaster 5200-D User Manual

Toro Reelmaster 5200-D
52 pages
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Operators Manual
English (EN, GB)
Form No. 3353–130
Reelmaster 5200-D/5400-D
Two-Wheel and Four-Wheel Drive Traction Units
03540—250000001 and Up
03543—250000001 and Up
03544—250000001 and Up

Table of Contents

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Toro Reelmaster 5200-D Specifications

General IconGeneral
Engine ManufacturerKubota
Engine ModelD1105
Number of Reels5
TransmissionHydrostatic
Fuel TypeDiesel
Transmission TypeHydrostatic
Speed Range0-10 mph
Deck TypeFloating
Reel DriveHydraulic
Engine Power24.8 hp
Fuel Capacity12 gallons

Summary

Introduction and Safety Overview

Safe Operating Practices

Essential safety guidelines from industry standards for operating the mower safely.

General Safety Warnings

Signals potential hazards like Danger, Warning, and Caution for injury prevention.

Operation Guidelines and Slope Safety

Slope Operation Safety

Precautions for safe mowing on slopes, including speed and turning advice.

Transport and Hazard Awareness

Covers safe practices for transporting, avoiding hazards, and machine security.

Mowing Safety and Machine Handling

Toro Riding Mower Specific Safety

Specific safety advice for Toro riding mowers, including engine exhaust dangers.

Maintenance and Storage Safety

Operation on Slopes and Hazard Avoidance

Guidelines for safe operation on slopes and avoiding terrain hazards.

Safety Decals and Quick Reference

Safety and Instruction Decals

Visual guide to safety and instruction decals found on the mower.

Quick Reference Aid

Visual aid and checklist for daily checks and fluid specifications.

Control Panel Overview

Control Functions Overview

Explains the function of various controls like throttle, speed, and reel engagement.

Safety Decal Interpretation and Lubrication

Maintenance and Lubrication Points

Visual guide to lubrication points and maintenance checks.

Fuel and Battery Safety Information

Parking Brake and Control Operation

Instructions for engaging and releasing the parking brake and understanding symbols.

Critical Safety Warnings

Operation Hazard Warnings

Highlights hazards like tipping, cutting hazards, and towing dangers.

General Specifications

Engine and Cooling System Specs

Details on engine type, displacement, cooling system capacity and type.

Fuel, Traction, and Drive System Specs

Information on fuel capacity, traction system, and cutting unit drive.

Measurements and Optional Equipment

Optional Equipment and Accessories

List of optional equipment and their part numbers for customization.

Initial Setup Procedures

Connecting the Battery

Step-by-step guide for safely connecting the battery with warnings.

Loose Parts Checklist

Checklist to ensure all necessary parts for assembly have been received.

Battery Installation and Hood Latch Mounting

Mounting the Hood Latch

Detailed steps for mounting the hood latch bracket and switch.

Panel Fasteners and Tire Pressure

Installing the Cutting Units

Procedures for installing cutting units and attaching basket guides/brackets.

Cutting Unit Installation Details

Lock-up Roller Adjustment

Adjusting lock-up rollers for proper support of raised cutting units.

Adjusting Cutting Unit Performance

Lifted Height Adjustment for Front Units

Adjusting the turn around height of front outer cutting units for clearance.

Installing Rear Weight

Rear Weight Requirements Chart

Chart detailing required rear weight for compliance with standards.

Pre-Operation Checks

Checking Engine Oil Level

Procedure for checking engine oil level, type, and capacity.

Checking Cooling System

Procedure for checking coolant level in the expansion tank.

Fuel and Transmission Fluid Checks

Safely Filling the Fuel Tank

Guidelines for safely filling the diesel fuel tank, including danger warnings.

Checking the Transmission Fluid

Procedure for checking the transmission fluid level.

Hydraulic and Axle Lubricant Checks

Checking Hydraulic Fluid Level

Procedure for checking hydraulic fluid level and recommended types.

Checking the Rear Axle Lubricant

Procedure for checking rear axle lubricant level (Model 03544 only).

Reel Contact and Wheel Nut Torque

Checking Wheel Nut Torque

Torque specifications and schedule for wheel nuts to ensure safety.

Operation and Controls Overview

Seat and Traction Pedal Controls

Adjusting seat position and operating traction pedals for movement.

Traction Speed and Brake Controls

Using speed limiter, brake pedals, parking brake, and key switch.

Control Panel Indicators and Switches

Throttle and Mow/Raise Controls

Operating throttle, mow/raise lever, and understanding indicators.

Backlap and Enable/Disable Switches

Function of backlap and enable/disable switches for reel operation.

Starting, Stopping, and Fuel System

Starting and Stopping Procedures

Step-by-step guide for starting and stopping the engine safely.

Bleeding the Fuel System

Procedure to remove air from the fuel system when the engine won't start.

Setting Reel Speed

Reel Speed Adjustment Guide

Instructions on selecting and setting reel speed based on height-of-cut and ground speed.

Lift Arm and Towing Procedures

Adjusting the Lift Arm Down Pressure

Adjusting down pressure springs on lift arms for turf conditions.

Safely Towing the Traction Unit

Guidelines for towing the machine safely to prevent transmission damage.

Diagnostic Systems and Interlocks

Diagnostic Light and ACE Display Function

Explains the diagnostic light and the ACE display for system checks.

Verifying Interlock Switch Function

Steps to verify interlock switches prevent unintended operation.

Verifying Input and Output Functions

Verifying Input Switch Functions

Checking input switches with the Diagnostic ACE display.

Verifying Output Functions

Checking output solenoids/relays using the Diagnostic ACE display.

Hydraulic Solenoids and Operating Modes

Hydraulic Valve Solenoid Functions

Identifies solenoids and their functions in the hydraulic manifold.

Mowing and Transport Operations

Guidelines for mowing and transport, including slope safety and engine idling.

Logic Chart for Machine Control

Understanding the Logic Grid

Explains the key and symbols used in the logic grid for machine operations.

Maintenance Schedule

Recommended Maintenance Schedule by Hours

Schedule detailing maintenance tasks based on operating hours.

Daily Maintenance Checklist

Areas of Concern Notation

Section for noting inspections performed and relevant information.

Service Intervals and Greasing

Greasing Bearing and Bushing Locations

Identifies locations and quantities of grease fittings for lubrication.

Air Cleaner System Maintenance

Servicing the Precleaner Bowl

Steps for inspecting and cleaning the precleaner bowl.

Servicing the Primary Air Cleaner Filter

Procedure for removing, replacing, and inspecting the primary air filter.

Engine Oil and Fuel System Service

Engine Oil and Filter Replacement

Procedures for changing engine oil and filter.

Fuel Filter and Water Separator Service

Steps for draining the water separator and replacing filters.

Bleeding Injectors and Cooling System Service

Bleeding Air from Fuel Injectors

Procedure to bleed air from fuel injectors after system work.

Servicing the Engine Cooling System

Steps for cleaning debris from the cooling system components.

Engine Belt Service and Throttle Adjustment

Servicing Engine Belts

Checking condition and tension of alternator and fan belts.

Adjusting the Throttle Control

Procedure for adjusting the throttle lever and cable for proper speed control.

Hydraulic System Fluid and Filter Service

Changing Hydraulic Fluid

Procedure for changing the hydraulic fluid and checking level.

Replacing Hydraulic Filter

Steps for replacing the hydraulic filter using the service interval indicator.

Hydraulic System Checks and Traction Adjustment

Checking Hydraulic Lines and Hoses

Daily inspection of hydraulic lines and hoses for leaks and wear.

Adjusting Traction Drive for Neutral

Procedure to adjust the traction drive to prevent creeping.

Adjusting Cutting Unit Lift Rate

Adjusting Center Cutting Unit Lift

Adjusting the valve for the center cutting unit lift rate.

Adjusting Front and Rear Cutting Unit Lift

Adjusting valves for front and rear cutting unit lift rates.

Traction Linkage, Brakes, and Transmission Fluid

Adjusting Service Brakes

Adjusting service brakes to correct excessive pedal free travel.

Changing Transmission Fluid

Procedure for changing transmission fluid and filter.

Rear Axle Lubricant and Wheel Toe-In

Changing Rear Axle Lubricant

Procedure for changing lubricant in the rear axle (Model 03544 only).

Adjusting Rear Wheel Toe-In

Adjusting rear wheel alignment for proper steering and tire wear.

Battery Maintenance and Safety

Servicing the Battery Safely

Detailed safety and maintenance procedures for the battery.

Electrical System and Backlapping

Fuses and Optional Lighting Schematic

Location of fuses and schematic for optional lighting installation.

Backlapping the Cutting Units

Procedure for backlapping cutting units to sharpen reels.

Backlapping Procedure Details

Backlapping Safety and Speed Settings

Safety precautions and reel speed settings for backlapping.

Electrical Schematic

Wiring Harness and Controller Connections

Diagram showing wire harness connections to the controller and other components.

Hydraulic Schematic

Hydraulic System Flow Diagram

Diagram illustrating the flow of hydraulic fluid and component connections.

Preparation for Seasonal Storage

Traction Unit Storage Preparation

Steps for cleaning, checking tires, and servicing the battery for storage.

Engine Storage Preparation

Procedures for draining oil, fuel, and servicing the air cleaner for storage.

Toro Commercial Products Warranty

Obtaining Warranty Service

Instructions on how to obtain warranty service and owner responsibilities.

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