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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 5300-D
REFER TO THE REELMASTER 5300-D TRACTION
UNIT AND CUTTING UNIT OPERATOR'S MANUALS
FOR OPERATING, MAINTENANCE AND ADJUST-
MENT INSTRUCTIONS. Space is provided in Chap
ter 2 of this book to insert the Operator's Manuals and
Parts Catalogs for your machine. Replacement Opera-
tor's Manuals are available by sending complete Model
and Serial Number of traction unit and cutting unit to:
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.
© The Toro Company - 1995 - 1997, 2004
Service Manual
Reelmaster
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY IN-
STRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
Part No. 94819SL, Rev. C
5300-D
®
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Summary of Contents for Toro Reelmaster 5300-D
- Page 1 IMPORTANT: The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine. © The Toro Company - 1995 - 1997, 2004...
- Page 2 Table Of Contents Chapter 1 - Safety Chapter 5 - Electrical System Safety Instructions ......1 - 1 Wiring Schematics and Diagrams.
- Page 3 While Operating ......2 Safety Instructions The Reelmaster 5300-D was tested and certified by TORO for compliance with the B71.4-1990 specifica...
- Page 4 8. Since diesel fuel is highly flammable, handle it C. Do not smoke while handling fuel. carefully: D. Fill fuel tank outdoors and only to within an inch A. Use an approved fuel container. of the top of the tank, not the filler neck. Do not overfill.
- Page 5 Have it done by your Toro the machine. If major repairs are ever needed, or assis...
- Page 6 Product Records Record information about your Reelmaster 5300-D on Insert Operator’s Manuals and Parts Manuals for your the OPERATION AND SERVICE HISTORY REPORT Reelmaster 5300-D at the end of this section. form. Use this information when referring to your machine. ®...
- Page 7 Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals Fractions Decimals ___________________________________________________________________________________________________ 1/64 0.015625 — 0.397 33/64 0.515625 — 13.097 1/32 ––––– 0.03125 — 0.794 17/32 –––– 0.53125 — 13.494 3/64 0.046875 — 1.191 35/64 0.546875 — 13.891 1/16 –––––––––––– 0.0625 —...
- Page 8 Torque Specifications Use these torque values when specific torque values specified values. Torque values listed are for lubricated are not given. DO NOT use these values in place of threads. Plated threads are considered to be lubricated. Capscrew Markings and Torque Values - U.S. Customary SAE Grade Number ________________________________________________________________________________________________________________________ ________________________________ Capscrew Head Markings...
- Page 9 Maintenance Interval Chart ® Maintenance Interval Chart Page 2 - 4 Reelmaster 5300-D...
- Page 10 REELMASTER® 223-D, 5100-D, and 5300-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Every 800hrs Check Battery Fluid Level Every 400hrs 200hrs 100hrs 50hrs Check Battery Cable Connections Lubricate All Grease Fittings Change Engine Oil A Level Service Inspect Air Filter, Dust Cup, and Baffle...
- Page 11 REELMASTER® 223-D, 5100-D and 5300-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance: TORO ID#:_______-_______ (duplicate this page for routine use) Daily Maintenance Check For Week Of _____________ TUES THURS _____ _____ _____ _____ _____ _____ _____ Maintenance Check Item...
- Page 13 Chapter 3 Engine Table of Contents INTRODUCTION ......2 REPAIRS ....... . . 7 SPECIFICATIONS .
- Page 14 TORO Distributors. Repair parts may Most repairs and adjustments require tools which are be ordered by TORO Part Number. If no parts list is commonly available in many service shops. Special available be sure to provide your dealer or distributor tools are described in the Special Tools section.
- Page 15 Specifications Item Specification ___________________________________________________________________________________________ Make/Designation Mitsubishi S3L2, 4 cycle, liquid cooled, vertical overhead valve diesel ________________________________________________________________________________________________________________________ ________________________________ Combustion Chamber Swirl chamber type ________________________________________________________________________________________________________________________ ________________________________ Number of Cylinders ________________________________________________________________________________________________________________________ ________________________________ Bore x Stroke 78 x 92 mm ________________________________________________________________________________________________________________________ ________________________________ Total Displacement 1.318 Liter ________________________________________________________________________________________________________________________ ________________________________ Compression Ratio...
- Page 16 Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products) . Some tools may be available from a local supplier. Filter Cleaner Filter cleaner (Fig. 1). Mix with water and use solution to wash the Donaldson air cleaner element.
- Page 17 Nozzle Tester Nozzle tester (Fig. 4). Tests condition and opening pressure of fuel injector nozzles. Figure 4 Nozzle Tester Adapter Nozzle tester adapter (Fig.5) is required to test the fuel injection nozzles. Figure 5 ® Reelmaster 5300-D Page 3 - 5 Special Tools...
- Page 18 Adjustments Engine Speed Adjustments Adjustments to the engine speed settings are not nor mally necessary unless the throttle linkage, injection pump, or governor mechanism have been repaired, rebuilt, replaced or are not operating correctly. The high speed set bolt has been set properly and sealed at the factory.
- Page 19 Repairs Fan Belt and Alternator Belt Replacement 1. Put machine on a level surface, engage parking brake, stop engine and remove key from ignition switch. Open hood. 2. Loosen locknut on belt tensioner lever (Fig. 8). If replacing alternator belt, loosen bolt securing alternator brace to engine and bolt securing alternator to brace (Fig.
- Page 20 Bleeding the Fuel System 1. Stop the engine and engage the parking brake. Open the hood. 2. Loosen the air bleed screw on the fuel filter / water separator (Fig. 11). 3. Turn the ignition key switch to the ON position. The electric fuel pump will begin to operate and force fuel out around the screw loosened in step 2.
- Page 21 Bleeding Air From the Injectors This procedure should only be used if the fuel system has been purged of air. (See Bleeding the Fuel System in this section of the book.) 1. Loosen the pipe connection at the number one nozzle and holder assembly on the cylinder head (Fig.
- Page 22 Removing and Installing the Fuel Tank 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove the key from the ignition switch. 2. Open drain fitting on bottom of fuel tank and drain fuel into a suitable container (Fig.
- Page 23 Replacing and/or Adjusting Engine Stop (ETR) Solenoid See Chapter 5 - Electrical System for information about testing the engine stop solenoid. An improperly adjusted stop solenoid can result in failure of the engine to stop when the key switch is turned off or could cause injection pump damage or malfunction.
- Page 24 Removing and Installing the Engine Removing the Engine Figure 18 1. Put machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes and remove key from ignition switch. Allow engine and CAUTION radiator to cool. DO NOT open radiator cap or drain coolant if 2.
- Page 25 9. Remove muffler. Keep muffler bracket on engine. 13. Remove four (4) capscrews, washers and locknuts to remove fan shroud from radiator. 10. Loosen hose clamp and remove fuel hose from injector pump. Plug end of fuel line to prevent fuel 14.
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