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Toro 5400-D Automobile User Manual

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2. SE Page Greasing the Bearing and Bushings 35 Introduccion canarias E eas 3 General Air Cleaner Maintenance 37 o EE te 3 Servicing the Precleaner Bowl a7 Safe Operating Practices 3 Servicing the Air Cleaner 37 Toro Riding Mower Safety ooo oo oo o 5 Engine Oil and ber 38 Sound Pressure Level uu ss sss ie 6 Servicing the Fuel System 38 Sound Power Level ooooooooooommm o gt 6 Bleeding Air from the Injectors 39 Vibration Level s 4 250 065 24044444 robadas 6 Servicing the Engine Cooling System 39 Safety and Instruction Decals 7 Servicing the Engine Belts 40 SIE e EE 12 Adjusting the Throttle 40 General Specifications 12 Changing the Hydraulic Fluid 41 Measurements ee A deeg swt eben aa 13 Replacing the Hydraulic Filter 41 Optional Equipment oooocooooooccooom gt 15 Checking the Hydraulic Lines and Hoses 42 A E 14 Hydraulic System Test Ports 42 A AA e eg 14 Adjusting the Traction Drive for Neutral 42 Connecting the Battery ooooommmoo o 14 Adjusting the Cutting Unit Lift Rate 43 Mounting the Hood Latch 15 Checking and Adjusting the Traction Linkage 44 Replacing the Panel Fasteners 16 Adjustin
3. Switch Switch Relay Toro Part No 75 1010 Toro Part No 70 1480 Honeywell Part No 1TL1 2 Bosch Part No 0 332 204 Black red and orange wires are located in control con sole Add 10 Amp fuse to fuse block at location shown Punch out in control panel provided for switch installa tion Note Make sure a good ground is achieved to prevent damage to traction unit Backlapping the Cutting Units AA Warning AA Contact with the reels or other moving parts can result in personal injury e Keep fingers hands and clothing away from the reels or other moving parts e Never attempt to turn the reels by hand or foot while the engine is running Note When backlapping the front units all operate together and the rear units operate together 1 Position the machine on a level surface lower the cutting units stop the engine engage the parking brake and move the Enable Disable switch to disable position 2 Unlock and raise the seat to expose controls 3 Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to be backlapped 4 Start engine and run at idle speed Changing the engine speed while backlapping may cause the reels to stall e Never change the engine speed while backlapping e Only backlap at idle engine speed 5 Set both reel speed controls to position 11 Select either front or rear on backlap switch to determine which units
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5. 5 Coat both battery connections with Grafo 112X skin over grease Toro Part No 505 47 petroleum jelly or light grease to prevent corrosion and slide rubber boot over positive terminal 6 Close hood Mounting the Hood Latch 1 Remove plug from hole in left front corner of hood Fig 2 2 Open hood Figure 2 1 Hood plug 3 Mount locking switch to hood with lock washer and nut Position switch with latch toward front of machine Fig 3 Figure 3 1 Locking switch 2 Latch bracket 4 Loosely mount latch bracket to radiator support with 2 capscrews 1 4 x 3 4 in flat washers and locknuts Fig 3 5 Adjust latch bracket until aligned with switch latch then tighten capscrews 6 Rotate latch to locked and unlocked position with key Remove key and store in memorable place 7 Close hood Replacing the Panel Fasteners 1 Remove fasteners securing left front corner of floor panel and left end of access panel to frame Fig 4 TIR a T GET i i gt GR SS H Figure 4 1 Floor panel 2 Access panel 2 Replace floor panel fastener with flange head capscrew 5 16 x 5 8 in supplied in loose parts Fig 4 3 Replace access panel fastener with flange head capscrew 5 16 x 3 4 in supplied in loose parts Fig 4 Checking the Tire Pressure The tires are over inflated for shipping Therefore release
6. 93 6680 93 6680 Diesel fuel 2 Engine stop 105 7506 105 7506 3 On 4 Engine preheat 5 Engine start Read the Operator s Manual 93 1263 Read operator s manual To engage parking brake connect pedals with locking pin push down on both pedals and pull parking brake latch out To release parking brake press both pedals until parking brake latch retracts Danger reels enabled 10 93 6689 93 6689 Danger no riders Sr BS Battery Symbols Some or all of these symbols are on your battery Explosion hazard No fire open flames or smoking Caustic liquid chemical burn hazard Wear eye protection Read the Operator s Manual Keep bystanders a safe distance from the battery 7 10 Wear eye protection explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns Flush eyes immediately with water and get medical help fast Contains lead do not discard Read the Operator s Manual Do not tow the machine Warning read the Operator s Manual Cutting hazard of hand or foot stay away from moving parts READ THE OPERATORS MANU DO NOT OPERATE THE MACHINE WITHOUT GUARDS SHIELDS AND SAFETY DEVICES IN PLACE AND WORKING DG NOT OPERATE THE MACHINE WHEN CHILDREN AND OTHERS ARE AROUND DO NOT ALLOW OPERATION OF THE MACHINE BY UNTRAINED
7. API GL 4 AGCO Powerfluid 821 XL Ford New Holland FNHA 2 C 201 00 Kubota UDT John Deere J20C Vickers 35VQ25 and Volvo WB 101 BM Note Many hydraulic fluids are almost colorless making it difficult to spot leaks A red dye additive for the hydraulic system oil is available in 2 3 oz 20 ml bottles One bottle is sufficient for 4 6 gal 15 22 1 of hydraulic oil Order part no 44 2500 from your authorized Toro distributor 1 Position machine on a level surface lower the cutting units and stop the engine 2 Clean area around filler neck and cap of hydraulic tank Fig 19 Remove cap from filler neck Figure 19 1 Hydraulic tank cap 3 Remove dipstick from filler neck and wipe it with a clean rag Insert dipstick into filler neck then remove it and check level of fluid Fluid level should be within 1 4 inch of mark on dipstick 4 If level is low add appropriate fluid to raise level to full mark 5 Install dipstick and cap onto filler neck Checking the Rear Axle Lubricant Note This procedure is for Model 03544 only The rear axle has three separate reservoirs which use SAE SOW 90 wt gear lube Although the axle is shipped with lubricant from the factory check the level before operating the machine 1 Position the machine on a level surface 2 Remove the 3 check plugs from axle Fig 20 and 21 and make sure lubricant is up to bottom of each hole Figure 20 i Check plug 2
8. connector from the alternator to prevent damage to the electrical system Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns e Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Fill the battery where clean water is always available for flushing the skin Charging the battery produces gasses that can explode A Warning Never smoke near the battery and keep sparks and flames away from battery Note Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly To clean the battery wash the entire case with solution of baking soda and water Rinse with clear water Coat the battery 46 posts and cable connectors with Grafo 112X skin over grease Toro Part No 505 47 or petroleum jelly to prevent corrosion Fuses There are 4 fuses in the machines electrical system They are located below control panel Fig 71 and 72 Figure 72 Optional Lighting Important If optional lighting is be added to the traction unit use the following schematic and part numbers to prevent damage to the traction units electrical system SCHEMATIC FOR OPTIONAL LIGHTING To Lights w external ground 30 To Lights Red Orange pe O O
9. the injection pump 3 Hold the injection pump lever arm Fig 57 against the high idle stop and tighten the cable connector Note When tightened the cable connector must be free to swivel 4 Torque the locknut used to set the friction device on the throttle lever to 40 55 in lb The maximum force required to operate the throttle lever should be 20 Ib Figure 57 1 Injection pump lever arm Changing the 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 1 Turn engine off and raise hood 2 Remove drain plug from bottom of reservoir Fig 58 and let hydraulic fluid flow into drain pan Reinstall and tighten plug when hydraulic fluid stops draining Figure 58 1 Hydraulic reservoir 3 Fill reservoir with approximately 8 5 gallons of hydraulic fluid refer to Checking the Hydraulic Fluid page 22 BEIEN Use only hydraulic fluids specified Other fluids could cause system damage 4 Install reservoir cap Start engine and use all hydraulic controls to distribute hydraulic fluid throughout the system Also check for leaks Then stop the engine 5 Check level of fluid and add enough to raise level to FULL mark on dipstick Do not over fill Replacing the Hydraulic Filter The hyd
10. to backlap To avoid personal injury be certain that you are clear of the cutting units before proceeding 6 Move Enable Disable switch to Enable position Move Lower Mow Lift control forward to start backlapping operation on designated reels 7 For the cutting units being backlapped move the reel speed control to position 1 8 Apply lapping compound with the long handle brush supplied with machine Never use a short handled brush 9 If reels stall or become erratic while backlapping select a higher speed setting until speed stabilizes then return reel speed to setting 1 or desired speed 10 To make an adjustment to the cutting units while backlapping turn reels OFF by moving the Lower Mow Raise lever rearward move the Enable Disable switch to Disable and turn the engine OFF After adjustments have been completed repeat steps 5 9 11 Repeat procedure for all cutting units to be backlapped 12 When backlap operation has been completed return the backlap switch to OFF lower seat and tighten both locking bolts securely and wash all lapping compound off cutting units Adjust cutting unit reel to bedknife as needed Important If the backlap switch is not returned to OFF position after backlapping the cutting units will not raise or function properly 48 Electrical Schematic
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12. Not functioning correctly Check electrical connections input fuses and diagnostic light bulb to determine malfunction Make sure loopback connector is secured to wire harness connector Diagnostic ACE Display The RM 5200 D 5400 D is equipped with an electronic controller which controls most machine functions The controller determines what function is required for various input switches i e seat switch 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 desired each of the input switches output solenoids and relays must be connected and functioning properly The Diagnostic ACE display is a tool to help the user verify correct electrical functions of the machine Checking the Interlock Switches The purpose of the interlock switches are to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL the Enable Disable switch is in DISABLE and the Lower Mow Raise control is in the neutral position In addition the engine will stop when the traction pedal is depressed with operator off the seat If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury Caution e Do not tamper with the interlock switches e Check the operation of the interlock switches daily and replace any damaged switches before operating the mac
13. air Figure 53 1 Screen 3 Slightly raise oil coolers and pivot forward Fig 54 Clean both sides of oil coolers and radiator area thoroughly with compressed air Pivot oil coolers back into position Figure 54 1 Reel oil cooler 3 Transmission oil cooler 2 Radiator 4 Install screen and close hood Servicing the Engine Belts Check condition and tension of all belts after first day of operation and every 100 operating hours thereafter Alternator Belt To Check Tension 1 Open hood 2 Check tension by depressing belt Fig 55 midway between alternator and crankshaft pulleys with 22 Ib of force Belt should deflect 7 16 in If deflection is incorrect proceed to step 3 If correct continue operation 1 Alternator belt 3 Loosen bolt securing brace to engine Fig 55 and bolt securing alternator to brace 4 Insert pry bar between alternator and engine and pry out on alternator 5 When proper tension is achieved tighten alternator and brace bolts to secure adjustment Cooling Fan Belt 1 Loosen locknut on belt tensioner lever Fig 56 2 Apply 5 10 lb of force at end of lever to set the proper tension on the fan belt 3 Tighten locknut to secure adjustment Figure 56 1 Cooling fan belt 2 Tensioner lever Adjusting the Throttle 1 Position throttle lever forward so it stops against seat base slot 2 Loosen the throttle cable connector on the lever arm at
14. by stopping the engine and lowering the cutting units and attachments to the ground e Check all fuel lines for tightness and wear on a regular basis Tighten or repair them as needed e If the engine must be running to perform a maintenance adjustment keep hands feet clothing and any parts of the body away from the cutting units attachments and any moving parts especially the screen at the side of the engine Keep everyone away e To ensure safety and accuracy have an Authorized Toro Distributor check the maximum engine speed with a tachometer Maximum governed engine speed should be 2900 RPM e If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor Use only Toro approved attachments and replacement parts The warranty may be voided if used with unapproved attachments Sound Pressure Level This unit has an equivalent continuous A weighted sound pressure at the operator ear of 88 dB A based on measurements of identical machines per procedures outlined in Directive 98 37 EC and amendments Sound Power Level This unit has a guaranteed sound power level of 105 dBA 1 pW based on measurements of identical machines per Directive 2000 14 EC and amendments Vibration Level This unit does not exceed a vibration level of 2 5 m s at the hands based on measurements of identical machines per ISO 5349 procedures This unit does not exceed a vibration level of 0 5 m s at th
15. information worthy of special attention Safety This machine meets or exceeds CEN standard EN 836 1997 ISO standard 5395 1990 and ANSI B71 4 1999 specifications in effect at time of production when ballast is installed according to the chart on page 19 Improper use or maintenance by the operator or owner can result in injury To reduce the potential for injury comply with these safety instructions and always pay attention to the safety alert amp symbol which means Safe Operating Practices The following instructions are from the CEN standard EN 836 1997 ISO standard 5395 1990 and ANSI B71 4 1999 Training Read the operator s manual and other training material carefully Be familiar with the controls safety signs and the proper use of the equipment Never allow children or people unfamiliar with these instructions to use or service the mower Local regulations may restrict the age of the operator Never mow while people especially children or pets are nearby Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property Do not carry passengers All drivers and mechanics should seek and obtain professional and practical instruction The owner is responsible for training the users Such instruction should emphasize the need for care and concentration when working with ride on machines control of a ride on machine sliding on a sl
16. mark on dipstick Do not overfill 4 Install oil fill cap and close hood Important Be sure to keep the engine oil level between the upper and lower limits on the oil gauge Engine failure may occur as a result of over filling or under filling the engine oil Checking the Cooling System Clean debris off screen oil cooler and front of radiator daily more often if conditions are extremely dusty and dirty refer to section on Engine Cooling System The cooling system is filled with a 50 50 solution of water and permanent ethylene glycol anti freeze Check level of coolant in expansion tank at beginning of each day before starting the engine Capacity of cooling system is 9 6 quarts If the engine has been running the pressurized hot coolant can escape and cause burns Caution e Do not open the radiator cap when the engine is running e Use a rag when opening the radiator cap and open the cap slowly to allow steam to escape 1 Check level of coolant in expansion tank Fig 16 Coolant level should be between the marks on side of tank 20 Figure 16 1 Expansion tank 2 If coolant level is low remove expansion tank cap and replenish the system Do not overfill 3 Install expansion tank cap Filling the Fuel Tank 1 Remove fuel tank cap Fig 17 2 Fill tank to about one inch below top tank not filler neck with No 2 diesel fuel Then install cap Under certain conditions diesel fuel a
17. off before emptying the baskets e Raise the cutting units when driving from one work area to another e Do not touch the engine silencer muffler or exhaust pipe while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns e Stay clear of the rotating screen at the side of the engine to prevent direct contact with your body or clothing e If the engine stalls or loses headway and cannot make it to the top of a slope do not turn the machine around Always back slowly straight down the slope e 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 the area is cleared Maintenance and Storage e Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system e Keep your body and hands away from pin hole leaks or nozzles that eyect hydraulic fluid under high pressure Use paper or cardboard not your hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury Seek immediate medical attention if fluid is injected into skin e Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved
18. some of the air to reduce the pressure Correct air pressure in the front and rear tires is 10 15 psi Important Maintain even pressure in all tires to ensure uniform contact with turf Installing the Cutting Units 1 Remove cutting units from cartons Assemble and adjust per the Operators Manual for the cutting unit 2 If baskets will be installed use chart below Fig 5 to determine locations at which basket guides or basket brackets must be mounted to cutting unit carrier frames If baskets are not to be installed proceed to step 5 BASKET BASKET BASKET BASKET BASKET GUIDE ba GUIDE BRACKET GUIDE FRONT FRONT BASKET BASKET BASKET BRACKET UIDE BRACKET REAR REAR Figure 5 3 Mount a basket guide Fig 6 to the appropriate side of each cutting unit carrier frame see Figure 7 with a capscrew 5 16 x 1 3 4 in flat washer and lock washer or fasteners previously removed as shown in Figure 6 Figure 6 2 Basket guide 1 Carrier frame 4 Install a roll pin Fig 7 into hole in appropriate side of each cutting unit carrier frame Fig 5 G d Figure 7 3 Basket bracket 4 Basket collar 1 Carrier frame 2 Roll pin 16 5 Align the mounting shaft of the cutting unit with the 9 Detach chain from lift arm and secure it to cross tube on pivot tube on the carrier frame Insert the shaft into the each rear cutting unit with a capscrew flat washer and tube Fig 8 locknut Fi
19. start machine 3 Connect the Diagnostic ACE connector to the harness connector Make sure correct overlay decal is positioned on Diagnostic ACE 4 Turn the key switch to the ON position but do not start machine Note The red text on the overlay decal refers to input switches and the green text refers to outputs 5 The outputs displayed LED on lower right column of Diagnostic ACE should be illuminated If inputs displayed LED is illuminated press the toggle button on Diagnostic ACE to change LED to outputs displayed Note It may be necessary to toggle between inputs displayed and outputs displayed several times to do the following step To toggle back and forth press toggle Figure 37 button once This may be done as often as required Do not 1 Diagnostic ACE hold the button 6 Sit on the seat and attempt to operate the desired Note The red text on the overlay decal refers to input function of the machine If you need help verifying the switches and the green text refers to outputs correct input settings for each function refer to the Logic Chart on page 32 The appropriate output LED s 5 The inputs displayed LED on lower right column of should illuminate to indicate that the ECU is turning on the Diagnostic ACE should be illuminated If outputs that function Refer to the list on page 31 or the logic displayed LED is illuminated press the toggle button chart to be
20. 82 6680 Outside of front tires 87 in 5 Blade EH u Model No 03527 Outside of rear tires 52 1 2 in pee Cuan Model No 03528 Rear Roller Brush Kit Model No 03533 Overall Length Without basket 103 1 2 i Front H OC Adjusting Kit Part No 104 8205 tnOut grass DaSKetS In 9 Wiehle Scraper Kit Part No 104 3380 03 With grass baskets Height Without ROPS installed With ROPS installed Recommended Height of Cut 5 Blade Cutting Unit 8 Blade Cutting Unit Weight Models 03540 amp 03543 Model 03544 With 8 Blade Cutting Units baskets 116 in 56 1 2 in 85 In 1 2 3 4 in 1 4 5 8 in 2320 lb 2675 lb and full fluid levels Shoulder Roller Scraper Kit 3 Collar Kit Shoulder Roller High Height of Cut Kit Grass Basket Kit Armrest Kit Thatching Reel 4 Wheel Drive Kit for use with models 03540 and 03543 only TurfDefender Electronic Leak Detector Kit Rear Weight Kit Rear Weight Kit 25 Ib Wheel Weight Kit Precleaner Bowl Extension Tube clamp Part No 20 4840 required to install extension tube Diagnostic ACE Specifications and design subject to change without notice 13 Part No 104 8208 03 Part No 104 8215 Part No 104 3369 Part No 83 5300 Model No 03532 Model No 30707 Model No 03516 Model No 03539 Model No 03521 Part No 75 6690 Part No 98 9780 Part No 104 1478 Part No 43 3810 Part No 85 4750 Setup Note Determine the left and right si
21. Fill plug Figure 21 1 Left check plug rear of axle 3 If level is low remove center fill plug and add enough lubricant to bring the level up to the bottom of the center check plug hole 22 4 Remove each end check plug and add enough lubricant to bring the level up to the bottom of each check plug hole 5 Install all plugs Checking Reel to Bedknife Contact Each day before operating check reel to bedknife contact regardless 1f quality of cut had previously been acceptable There must be light contact across the full length of the reel and bedknife refer to Adjusting Reel to Bedknife in Cutting Unit Operator s Manual Checking the Torque of the Wheel Nuts AA Warning AA Failure to maintain proper torque of the wheel nuts could result in personal injury Torque the wheel nuts to 75 80 ft lb after 1 4 hours of operation and again after 10 hours of operation Torque every 250 hours thereafter 23 Operation Note Determine the left and right sides of the machine from the normal operating position If you leave the key in the ignition switch someone could accidently start the engine and seriously injure you or other bystanders Caution Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine Controls Seat The seat adjusting lever Fig 22 allows 4 inch fore and aft adjustment Sea
22. 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 Operator s Manual C English EN GB I Checking the Torque of the Wheel Nuts 23 Warning AA Operaio easter toads 24 COMUOIS eros EE EEN 24 CALIFORNIA Starting and Stopping 26 Proposition 65 Warning Bleeding the Fuel System cias ee 26 Diesel engine exhaust and some of its constituents setting the Reel Speed een Al are known to the State of California to cause Adjusting the Lift Arm Down Pressure 28 cancer birth defects and other reproductive harm Towing the Traction Unit 28 Diapnostic Light eses keene gta aes 29 Important The engine in this product is not equipped Diagnostic ACE Display 29 with a spark arrester muffler It is a violation of California Checking the Interlock Switches 29 Public Resource Code Section 4442 to use or operate this Hydraulic Valve Solenoid Functions 31 engine on any forest covered brush covered or Operating Characteristics ooo o o o o 31 grass covered land as defined in CPRC 4126 Other states Eat eg nies ach AE 32 or federal areas may have similar laws ENEE 9 44 54 Eer A 33 Recommended Maintenance Schedule ES C O nte nts Daily Maintenance Checklist 34 Service Interval Chart
23. PERSONNEL STOP ENGINE REMOVE KEY BEFGRE LEAVING OPERATION POSITION GO SLOW AND AVOID SHARP TURNS ON SLOPES TO AVOID ROLLOVER REELS MUST BE LOWERED WHEN OPERATING GN SLOPES AVOID STEEP SLOPES 104 9294 5 Warning keep bystanders 7 a safe distance from the machine 6 Warning lock the parking brake stop the engine and remove the ignition key before leaving the machine the seat belt Warning use a roll over protection system and wear 8 Tipping hazard lower the cutting unit when driving down slopes 104 9295 Cover 104 9296 for CE Read the Operator s Manual Do not tow the machine Warning read the Operator s Manual Cutting hazard of hand or foot stay away from moving parts Warning use a roll over 5 Warning keep bystanders T a safe distance from the protection system and wear machine the seat belt 6 Warning lock the parking brake stop the engine and remove the ignition key before leaving the machine 8 Tipping hazard lower the cutting unit when driving down slopes and do not drive across or down slopes greater than 15 degrees 11 Specifications General Specifications Kubota three cylinder 4 cycle liquid cooled diesel engine 25 hp 3000 rpm for Reelmaster 5200 and 31 5 hp 3000 rpm for Reelmaster 5400 Both governed to 3200 rpm 68 5 Cu in 1123 cc displacement Heavy duty 3 stage remote mounted air cleaner H
24. TIYVLNSAWNOW N A2 NO LNdLNO d N3dO 0 d3S0190 X 32 Maintenance Note Determine the left and right sides of the machine from the normal operating position Important Refer to your engine operator s manual for additional maintenance procedures Recommended Maintenance Schedule Maintenance Service Maintenance Procedure Interval e Check the fan and alternator belt tension e Torque the wheel lug nuts After first 10 hours e Change the transmission fluid e Replace the transmission filter e Replace the engine oil and filter After first 50 hours e Check the engine RPM idle and tull throttle e Check the battery fluid level e Check the battery cable connections e Lubricate all grease fittings e Inspect the air filter dust cup and baffle e Check the fan and alternator belt tension Every 100 hours e Inspect the cooling system hoses Every 150 hours e Replace the engine oil and filter e Torque the wheel lug nuts Drain moisture from the hydraulic tank Every 200 hours Drain moisture from the fuel tank Check the reel bearing preload Lubricate the front axle bearings Every 50 hours Service the air cleaner when the indicator shows red Replace the fuel water separator filter Every 400 hours Replace the fuel filter Inspect the traction linkage movement Check the engine RPM idle and full throttle Change the hydraulic filter Change the transmission fluid Replace the transmis
25. able for indirect incidental or consequential damages in connection with the use of the Toro Products covered by this warranty including any cost or expense of providing substi tute equipment or service during reasonable periods of malfunction or non use pending completion of repairs under this warranty Except for the Emissions warranty referenced below if applicable there is no other express warranty All implied warranties of merchantability and fitness for use are limited to the duration of this express warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Note regarding engine warranty The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U S Environmental Protection Agency EPA and or the California Air Resources Board CARB The hour limitations set forth above do not apply to the Emissions Control System Warranty Refer to the Engine Emission Control Warranty Statement printed in your operator s manual or con tained in the engine manufacturer s documentation for details Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or C
26. ain traction For example in some slope conditions the uphill wheel slips and loses traction If this situation occurs depress uphill turn pedal gradually and intermittently until the uphill wheel stops slipping thus increasing traction on the downhill wheel When operating the machine always use the seat belt and ROPS together Warning Warning System If a warning light comes on during operation stop the machine Immedlately and correct the problem before continuing operation Serious damage could occur if the machine is operated with a malfunction Mowing Start engine and move throttle to FAST so engine is running at maximum speed Move the ENABLE DISABLE switch to ENABLE and use the LOWER MOW RAISE lever to control the cutting units front cutting units are timed to lower before the rear cutting units To move forward and cut grass press traction pedal forward Transport Move the ENABLE DISABLE switch to joy stick DISABLE and raise the cutting units to the transport position Be careful when driving between objects so you do not accidentally damage the machine or cutting units Use extra care when operating machine on slopes Drive slowly and avoid sharp turns on slopes to prevent roll overs The cutting units should be lowered when going downhill for steering control Important Allow engine to idle for 5 minutes before shutting 1t off after a full load operation Failure to do so may lead to turbo charger
27. al retail purchaser Product equipped with hour meter Instructions for Obtaining Warranty Service You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists If you need help locating a Commercial Products Distributor or Authorized Dealer or if you have questions regarding your warranty rights or responsibilities you may contact us at Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 952 888 8801 or 800 982 2740 E mail commercial service toro com Owner Responsibilities As the Product owner you are responsible for required mainte nance and adjustments stated in your operator s manual Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim Items and Conditions Not Covered Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship This express warranty does not cover the following e Product failures which result from the use of non Toro replacement parts or from installation and use of add on modified or unapproved accessories e Product failures which result from failure to perform required maintenance and or adjustments e Product failures which result from operating the Product in an abusiv
28. anada should contact their Toro Distributor Dealer to obtain guarantee policies for your country province or state If for any reason you are dissatisfied with your Distributor s service or have difficulty obtaining guarantee information contact the Toro importer If all other remedies fail you may contact us at Toro Warranty Company Part No 374 0031 Rev C
29. certain of the specified output LED s on Diagnostic ACE to change LED to inputs displayed Note If any output LED is blinking this indicates an electrical problem with that OUTPUT Repair replace 6 The Diagnostic ACE will illuminate the LED associated defective electrical parts immediately To reset a blinking with each of the inputs when that input switch 1s closed LED turn the key switch OFF then back ON Individually change each of the switches from open to If no output LED s are blinking but the correct output closed i e sit on seat engage traction pedal etc and LED s do not illuminate verify that the required input note that the appropriate LED on Diagnostic ACE will switches are in the necessary positions to allow that function to occur Verify correct switch function 30 If the output LED s are on as specified but the machine does not function properly this indicates a non electrical problem Repair as necessary Note Due to electrical system constraints the output LED s for START PREHEAT and ETR ALT may not blink even though an electrical problem may exist for those functions If the machine problem appears to be with one of these functions be certain to check the electrical circuit with a volt ohm meter to verify that no electrical problem exists to these functions If each output switch is in the correct position and functioning correctly but the output LED
30. chine is operated under normal conditions lubricate all bearings and bushings after every 50 hours of operation Lubricate bearings and bushings immediately after every washing regardless of the interval listed The grease fitting locations and quantities are Engine Drive shaft 3 Fig 38 Cutting unit carrier frame and pivot 2 ea Fig 39 Lift arm pivots 5 Drive shaft clutch 1 Fig 40 Rear axle tie rod 2 Steering cylinder ball joints 2 Axle steering pivots 2 Rear axle pivot 1 Fig 41 Traction control linkage at transmission 1 Drive shaft support bearing 1 Rear axle drive shaft 3 Fig 42 Brake pedal 1 Fig 43 Lift cylinders 5 Fig 44 and Fan shaft Fig 45 Figure 39 35 a Figure 42 Figure 45 36 General Air Cleaner Maintenance e Check the air cleaner body for damage which could cause an air leak Replace 1f damaged Check the whole intake system for leaks damage or loose hose clamps e Service the air cleaner filter only when the service indicator requires it Changing the air filter before it 1s necessary only increases the chance of dirt entering the engine when the filter is removed e Be sure the cover is seated correctly and seals with the air cleaner body Servicing the Precleaner Bowl Normally inspect precleaner bowl daily When conditions are extremely dusty and dirty inspect more frequently Do not let dust or debris build
31. chine on a level surface lower the cutting units and stop the machine e Loosen the carriage bolt nut securing the lift arm switch bracket to the No 4 lift arm left front Fig 13 e Move the lift switch bracket inward in the slot until the desired position is attained e Set the distance between the lift arm switch and the flag on the lift arm to approximately 062 inches e Tighten the carriage bolt nut Figure 13 1 Lift arm switch 2 Carriage bolt nut 3 Lift arm flag Installing the Rear Weight The Reelmaster 5200 D amp 5400 D Traction Units comply with CEN standard EN 836 1997 ISO standard 5395 1990 and ANSI B71 4 1999 Standards when equipped with rear weight and 90 Ib of calcium chloride ballast 1s added to rear wheels Use chart below to determine combinations of weight required Order parts from your local Authorized Toro Distributor Rear Weight Weight Part SC eve MES 291 Ib 75 6690 Rear Weight Kit 3 w o baskets E ee 358 Ib 75 6690 Rear Weight Kit 4 with baskets EES 157 Ib 75 6690 Rear Weight Kit 1 w o baskets a UDIN O ROPS 224 Ib 75 6690 Rear w Kit 2 with baskets 4wd Traction Unit with ROPS 157 lb 75 6690 Rear Rear Weight Kit Kit w o baskets 4wd Traction Unit with ROPS SAS 79 6690 Rear Weight Kit with baskets 98 9780 Rear Weight Kit 25 lb Important If a puncture occurs in a tire with calcium chloride remove unit from turf area as quickly as possible To prevent possible damage to
32. des of the machine from the normal operating position Loose Parts Note Use this chart as a checklist to ensure that all parts necessary for assembly have been received Without these parts total setup cannot be completed eson i oe Locking hood switch Lock washer Nut Key Hood latch bracket Capscrew 1 4 x 3 4 in Mounting locking hood latch for CE Flat washer 1 4 in Locknut 1 4 in Flange head capscrew 5 16 x 5 8 in Replacing floor panel fastener for CE Flange head capscrew 5 16 x 3 4 in nu Securing access panel for CE Hydraulic filter transmission A Se Change filter after first 10 hours of operation CE decal Affix to machine CO certificate Service decal blank decal blank Affix to machine International Affix to machine International on Diagnostic ACE display overlay SE H machine store in service shop until Vo View before operating the machine Operator s Manual Traction Unit 2 Read before operating the machine Engine Manual 1 Connecting the Battery Warning A A Warning A Connecting cables to the wrong post could result in personal injury and or damage to the electrical CALIFORNIA system Proposition 65 Warning i 1 Open hood Battery posts terminals and related accessories contain lead and lead compounds chemicals 2 Ensure battery Is securely fastened in place and check known to the State of California to cause cancer battery charge with a hydrometer If batt
33. dual pedals operated by the left foot Hydrostatic braking through traction drive Automotive type electrical system 12 volt maintenance free battery with 530 cold cranking Amps 0 degrees E and 85 minute reserve capacity 85 degrees F 40 Electrical System amp alternator with I C regulator rectifier Seat switch reel and traction interlock switches An electronic controller monitors and controls safety and operational functions Parking brake switch in steering column Foot operated traction and brake pedals Hand operated throttle traction speed Controls control lever parking brake lock ignition switch with automatic preheat cycle single joy stick control for cutting unit on off and lift lower Cutting unit backlap switch and reel speed controls located under control console Gauqes Hour meter speedometer fuel gauge temperature gauge 4 warning lamps oil 9 pressure water temperature amps and glow plug The Automatic Control Electronics ACE system allows precise timing and control of machine functions for maximum reliability Optional hand held diagnostic display Diagnostics connects to an electronic control unit to pin point any electrical problems quickly and easily Available DATA LOG system allows mechanic to find intermittent problems 12 Measurements Optional Equipment Width of Cut Rear Roller Scraper Part No 104 3395 Overall Width Comb Kit Part No 104 3385 Transpor ST Solid Front Roller Part No
34. e negligent or reckless manner e Parts subject to consumption through use unless found to be defective Examples of parts which are consumed or used up during normal Product operation include but are not limited to blades reels bedknives tines spark plugs castor wheels tires filters belts and certain sprayer components such as diaphragms nozzles and check valves etc The Toro General Commercial Products Warranty A Two Year Limited Warranty e Failures caused by outside influence Items considered to be outside influence include but are not limited to weather storage practices contamination use of unapproved coolants lubricants additives or chemicals etc e Normal wear and tear items Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part Parts replaced under this warranty become the property of Toro Toro will make the final decision whether to repair any existing part or assembly or replace it Toro may use factory remanufactured parts rather than new parts for some warranty repairs General Conditions Repair by an Authorized Toro Distributor or Dealer is your sole remedy under this warranty Neither The Toro Company nor Toro Warranty Company is li
35. e posterior based on measurements of identical machines per ISO 2631 procedures Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost REELMASTER 5200 D QUICK REFERENCE AID CHECK SERVICE daily 1 OIL LEVEL ENGINE 7 RADIATOR SCREEN 2 OIL LEVEL TRANSMISSION 8 BRAKE FUNCTION 3 OIL LEVEL HYDRAULIC TANK 9 TIRE PRESSURE 4 COOLANT LEVEL RADIATOR 10 BATTERY 5 FUEL WATER SEPARATOR 11 BELTS FAN ALT 6 PRECLEANER AIR CLEANER GREASING SEE OPERATOR S MANUAL FLUID SPECIFICATIONS CHANGE INTERVALS SEE OPERATOR S MANUAL FLUID CAPACITY CHANGE INTERVAL FILTER FOR INITIAL CHANGES FLUID FILTER PART NO A ENGINE OIL SAE e Zeg 4 0 QTS sp ups 100HRS 104 5167 B TRANSMISSION OIL MOBIL 424 5QTS 800 ups 1 800 HRS 75 1330 C HYD CIRCUIT OIL 8 5 GALS 800 HRS E D AIR CLEANER Ee EECH 400 HRS 98 9763 E FILTER IN LINE FUEL 400HRS 98 7612 F WATER SEPARATOR Gw 400HRS 98 9764 G FUEL TANK NO 2 Diesel 10 GALS Drain and flush 2 yrs H COOLANT 50 50 Ethylene 9 6 QTS Drain and flush 2 yrs glycol water INCLUDING FILTER 107 8841 IMPORTANT THIS UNIT COMPLIES WITH ANSI B7 1 4 1999 WHEN EQUIPPED WITH REAR BALLAST PER OPERATOR S MANUAL 104 2052 93 6693 104 2052 2 Stop reels before touching 104 9296 104 9296 1 T
36. efore applying pressure to the hydraulic system Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system Get immediate medical help if fluid is injected into skin Hydraulic System Test Ports The test ports are used to test pressure in the hydraulic circuits Contact your local Toro distributor for assistance Test Port 1 Fig 60 is used to assist in trouble shooting the hydraulic circuit for the front cutting units and lift cylinders Test Port 2 Fig 60 is used to assist in trouble shooting the hydraulic circuit for the rear cutting units Test Port 3 not shown is located on the rear of the hydrostatic transmission and is used to measure the charge pressure of the transmission Figure 60 2 Test port 2 1 Test port 1 Adjusting the Traction Drive for Neutral The machine must not creep when traction pedal is released If it does creep an adjustment is required 1 Park machine on a level surface shut engine off and lower cutting units to the floor Depress only the right brake pedal and engage the parking brake 2 Jack up left side of machine until front tire is off the shop floor Support machine with jack stands to prevent it from falling accidentally Note On 4 wheel drive models left rea
37. eparator serviced etc Refer to Bleeding the Fuel System page 26 1 Sit on the seat keep foot off traction pedal Ensure that the parking brake is engaged traction pedal is in NEUTRAL throttle is in FAST position and the ENABLE DISABL E switch is in the DISABLE position 2 Turn ignition switch to ON Preheat position An automatic timer will control preheat for 6 seconds After preheat turn key to START position Crank the engine for no longer than 15 seconds Release key when engine starts If additional preheat is required turn key to OFF position then to ON preheat position Repeat process as required 3 Run engine at idle speed or partial throttle until engine warms up Note Move throttle to FAST position when restarting a warm engine 4 To stop move all controls to NEUTRAL and set parking brake Return throttle to the idle position turn key to OFF and remove it from switch Allow engine to idle for 5 minutes before shutting it off after a full load operation Failure to do so may lead to turbo charger trouble Bleeding the Fuel System 1 Park the machine on a level surface Make sure fuel tank is at least half full 2 Raise hood over engine 3 Open the air bleed screw on the fuel injection pump Fig 29 with a 12 mm wrench Figure 29 1 Fuel injection pump bleed screw 4 Turn key in ignition switch to the ON position Electric fuel pump will begin operation thereby forcing air out aro
38. ery needs and reproductive harm Wash hands after charging be sure at least one battery cable preferable the positive cable is disconnected from the battery before connecting the charger Fig 1 handling 14 Figure 1 1 Positive battery cable 2 Negative battery cable Charging the battery produces gasses that can explode Warning Never smoke near the battery and keep sparks and flames away from the battery Battery terminals or metal tools could short against metal tractor components causing sparks Sparks can cause the battery gasses to explode resulting in personal injury Warning e When removing or installing the battery do not allow the battery terminals to touch any metal parts of the tractor e Do not allow metal tools to short between the battery terminals and metal parts of the tractor 3 Slide the red positive battery cable onto the positive battery post and tighten nut securely Incorrect battery cable routing could damage the tractor and cables causing sparks Sparks can cause the battery gasses to explode resulting in personal injury Warning e Always disconnect the negative black battery cable before disconnecting the positive red cable e Always reconnect the positive red battery cable before reconnecting the negative black cable 15 4 Slide the black negative battery cable onto the negative battery post and tighten nut securely
39. es are designed to allow assembly only when the two halves of the shaft are properly oriented Diagnostic Light The RM 5200 D 5400 D is equipped with a diagnostic light which indicates if the electronic controller is functioning correctly The green diagnostic light is located under the control panel next to the fuse block Fig 35 When the electronic controller is functioning correctly and the key switch is moved to the ON position the controller diagnostic light will be illuminated The light will blink if the controller detects a malfunction in the electrical system The light will stop blinking and automatically reset when the key switch is turned to the OFF position ol e i a ky Ss e A L mn Y k bh k A S lt E l e 8 fe a Figure 35 1 Electronic controller light When the controller diagnostic light blinks one of the following problems has been detected by the controller e One of the outputs has been shorted e One of the outputs is open circuited Using the diagnostic display determine which output is malfunctioning refer to Checking the Interlock Switches page 29 If the diagnostic light is not illuminated when the key switch is in the ON position this indicates that the electronic controller is not operating Possible causes are e Loopback is not connected e The light is burned out e Fuses are blown e
40. et hex shaft 2 Retaining bracket 5 Move spring bracket to desired location and install capscrew and locknut while rotating hex shaft to relieve spring tension Towing the Traction Unit If it becomes necessary to tow the machine tow it forward only for a short distance and at a speed no greater than 3 mph Important If these towing limits are exceeded severe damage to the hydrostatic transmission may occur To tow a disabled machine 1 Loosen and remove capscrews securing the drive shaft to the engine drive coupler Loosen capscrews clamping drive shaft to transmission Fig 33 Remove drive shaft Figure 33 1 Drive shaft Important If drive shaft is not removed before towing the transmission input shaft will not be able to rotate thus not allowing the transmission to maintain its internal lubrication Severe damage to the hydrostatic transmission may occur 2 Attach a suitable chain strap or cable to the center of the front frame member Fig 34 Figure 34 1 Center of front frame member Note Lock both brake pedals together before towing 3 Attach the other end of the towing device to a vehicle that is capable of towing the machine safely and at speeds below 3 mph 4 An operator must be on the machine to steer it and keep the traction pedal fully depressed in the forward position while towing 5 When towing is completed reinstall driveshaft as shown in Figure 33 The splin
41. g 10 Figure 10 1 Lock up chain Figure 8 1 Cutting unit mounting 4 Flat washer Important Diane See gei e ee shaft See routed away from cutting unit so when cutting unit pivots 2 Carrier frame pivot tube 6 Capscrew excessive rubbing does not occur eee 10 Check adjustment of lock up rollers Fig 11 When properly adjusted they will contact the lock up levers on rear lift arms and support the cutting units when 6 Secure shaft in pivot tube with a thrust washer flat fully raised washer lock washer and capscrew Fig 8 7 Assemble the mounting nuts for the reel drive motor to each cutting unit Fig 9 Leave approximately 1 2 in of threads exposed on each mounting stud 8 Coat the spline shaft of the motor with clean grease and install the motor by rotating the motor clockwise so the motor flanges clear the studs Rotate the motor counterclockwise until the flanges encircle the studs and tighten the mounting nuts Ensure that the washers are against the nuts Figure 11 1 Lock up rollers 2 Lock up levers 11 Mount a basket to each cutting unit carrier frame by inserting basket mounting pin into basket bracket and depressing opposite mounting pin into pivoting bracket Figure 9 1 Reel drive motor 2 Mounting nuts 17 Adjusting the Turf Compensation Spring Note This adjustment is needed for Cutting Unit Models 03527 and 03528 only The turf compensation spr
42. g the Service Brakes 44 Checking the Tire Pressure 16 Changing the Transmission Fluid 44 Installing the Cutting Units 16 Replacing the Transmission Filter 45 Adjusting the Turf Compensation Spring 18 Changing the Rear Axle Lubricant 45 Lifted Height of Outer Front Cutting Units 18 Adjusting Rear Wheel Toe In 45 Installing the Rear Weight 19 Servicing the Batter 46 Before Operating 20 PUSE ronca oe are eens 47 Checking the Engine Oil 6 20 Optional Lighting 47 Checking the Cooling System 20 Backlapping the Cutting Units 47 Filling the Fuel Tank 21 Electrical Schematic 49 Checking the Transmission Fluid 2l Hydraulic Schematic 50 Checking the Hydraulic Fluid 22 Preparation for Seasonal Storage 51 Checking the Rear Axle Lubricant 22 The Toro General Commercial Products Warranty 52 Checking Reel to Bedknife Contact 23 2005 by The Toro Company All Rights Reserved 8111 Lyndale Avenue South Bloomington MN 55420 1196 2 Printed in the USA Introduction CAUTION WARNING or DANGER personal safety instruction Failure to comply with the instruction may result in personal injury or death Read thi
43. gine and let run for about two minutes to purge air from the system Stop the engine and check for leaks Check fluid level and replenish if necessary Changing the Rear Axle Lubricant Note This procedure is for model 03544 only After every 800 hours of operation the oil in the rear axle must be changed 1 Position machine on a level surface 2 Clean area around the drain plugs Fig 68 3 Remove plug allowing oil to drain into drain pans 4 After oil is drained apply thread locking compound on drain plug threads and reinstall in axle 5 Fill axle with lubricant refer to Checking the Rear Axle Lubricant page 22 Figure 68 1 Drain plugs Adjusting Rear Wheel Toe In The rear wheels should have 0 to 1 8 in toe in when they are pointed straight ahead To check toe in measure the center to center distance at axle height in front and rear of steering tires If toe in is not within specifications an adjustment is required After every 800 operating hours or annually check rear wheel toe in Models 03540 and 03543 1 Rotate the steering wheel so the rear wheels are straight ahead 2 Loosen the jam nuts on both tie rods Fig 69 Adjust both tie rods equally until center to center distance at front of rear wheels is 0 1 8 in 0 3 mm less than at the rear of the wheels Figure 69 1 Tie rods 3 When toe in is correct tighten jam nuts against tie rods Models 03544 only 1 Rotate
44. hine e Replace switches every two years regardless of whether they are operating properly or not Verifying Interlock Switch Function 1 Park machine on a level surface lower the cutting units stop the engine and engage the parking brake 2 Open control panel cover Locate wire harness and connectors near controller Fig 36 Carefully unplug loop back connector from harness connector 29 blink on and off when corresponding switch is closed Repeat on each switch that is it possible to be changed by hand 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 defective switches and repair any defective wiring The Diagnostic ACE also has the ability to detect which output solenoids or relays are turned on This is a quick way to determine if a machine malfunction is electrical or hydraulic Fi igure 36 Verifying Output Function 1 Wire harness and connectors 1 Park machine on a level surface lower the cutting units stop the engine and engage the parking brake 3 Connect the Diagnostic ACE display connector to the harness connector Fig 37 Make sure correct overlay 2 Open control panel cover Locate wire harness and decal is positioned on Diagnostic ACE display connectors near controller Carefully unplug loopback connector from harness connector 4 Turn the key switch to the ON position but do not
45. hrottle slow 4 Reels lowered and on when 6 Reels disabled lift only 9 Headlights on 2 Throttle fast enabled forward and 7 Reels disabled ift and 10 Headlights off 3 Reels raised amp off 11 Read operator s manual 5 Reels enabled 8 Headlights optional CONTROLLER DIAGNOSTIC LAMP LJ 104 9298 1 Read operator s manual a gt ane 94 6767 1 Read operator s manual 2 Engine start 3 Headlights Optional Height of cut Mow and backlap Read operator s manual Traction unit speed Rear reels circuit controls Front reels circuit controls oe D ee Po a 106 9224 1 Warning read the Operator s Manual 2 Cutting hazard of hand and foot stop the reels before touching 93 6699 1 Slow 2 Fast 3 Traction speed bso SAE 80w 90 API GL 5 93 6697 93 6697 Model 03544 only 1 Read operator s manual 2 Lubrication point 3 Time interval 93 6691 1 Read operator s manual eccentric bolt 98 9335 1 Cutting dismemberment hazard stay away from moving parts 93 6696 1 Danger spring loaded device 2 Read operator s manual 1 Read operator s manual 2 Do not prime engine 3 Do not use starting fluid 1 Hydraulic oil level 2 Read operator s manual 102 108 Hu Lie 75 80 FT LBS 106 9206 1 Wheel torque 2 Read the Operator s specifications Manual
46. igh water temperature shutdown switch Engine Radiator capacity is approximately 7 1 2 gt of 50 50 mixture of ethylene glycol Cooling System anti freeze Remote mounted 1 at expansion tank A two speed fan drive controls air flow from fan Fuel tank capacity is 9 5 gal of 2 diesel fuel Equipped with a fuel filter water Fuel System separator to capture water in the fuel Foot pedal controls forward reverse ground speed Ground speed 0 10 mph forward and 0 4 reverse Hydrostatic transmission mounted directly on a 20 9 1 Traction System ratio front axle Axle reservoir capacity is 5 qt Replaceable filter mounted directly on transmission housing Model 03544 only mechanical rear axle is coupled to front axle by a driveshaft and overrunning clutch Hydraulic reel motors feature quick disconnects to ease removal installation on Cutting Unit Drive System cutting units Hydraulic fluid reservoir capacity is 8 gal System protected by a filter assembly with service indicator S Deluxe high back seat with adjustable fore and aft travel weight and height Tool eat box at left side of seat Steering System Power steering with dedicated power source Two rear tires 20 x 10 00 10 tubeless 6 ply rating Two front tires 26 5 x 14 00 12 Tires tubeless 4 ply rating Recommended tire pressure for front and rear tires is 10 15 psi Individual drum type wheel brakes on front traction wheels Brakes controlled by Brakes indivi
47. ine engage the parking brakes and remove key from ignition switch 2 Clean area around suction line on bottom of transmission Fig 67 Place drain pan under line 3 Remove line from transmission allowing fluid to drain into drain pan 4 Install suction line to transmission 5 Fill with oil refer to Checking the Transmission Fluid page 21 44 6 Before starting the engine after changing transmission fluid disconnect the run ETR solenoid on the engine and crank the engine several times for 15 seconds This allows the charge pump to fill the transmission with fluid before the engine is started Figure 67 1 Transmission suction line 2 Transmission oil filter Replacing the Transmission Filter Change the transmission filter after the first 10 hours of operation and every 800 hours thereafter Only the Toro replacement filter Part No 75 1330 can be used in the hydraulic system Important Use of any other filter may void the warranty on some components 1 Position machine on a level surface lower the cutting units stop the engine engage the parking brakes and remove key from ignition switch 2 Clean area around filter mounting area Fig 67 Place drain pan under filter and remove filter 3 Lubricate new filter gasket with hydraulic oil 4 Ensure that the filter mounting area is clean Screw filter on until gasket contacts mounting plate Then tighten filter 1 2 turn 5 Start en
48. ing Fig 12 connecting carrier frame to cutting unit controls the amount of fore aft rotation available The Turf Compensation Spring also transfers weight from the front to rear roller This helps to reduce a wave pattern in the turf also known as bobbing Important Make spring adjustments with cutting unit mounted to traction unit and lowered to shop floor 1 Tighten locknut on rear of spring rod until the gap C between rear of spring bracket and front of washer is 1 25 in 32 mm Fig 12 2 Tighten hex nuts on front end of spring rod until the compressed length A of spring is 6 25 in 328 mm Fig 12 Note As compressed spring length A decreases weight transfer from front roller to rear roller increases and carrier frame cutting unit rotation angle B decreases Note As gap C between spring bracket and washer increases carrier frame cutting unit rotation angle B increases C Figure 12 Lifted Height of Outer Front Cutting Units Enable Position The turnaround height of the front outer cutting units 4 amp 5 may be increased to provide additional ground clearance on contoured fairways Contact your distributor for assistance Note The RM CONFIG time delay should not be changed from the original setting of 0 when using this method to adjust turn around height To increase the turn around height of the front cutting units proceed as follows e Position ma
49. n reversing Use counterweight s or wheel weights when suggested in the operator s manual Watch out for traffic when crossing or near roadways Stop the blades rotating before crossing surfaces other than grass When using any attachments never direct discharge of material toward bystanders nor allow anyone near the machine while in operation Never operate the machine with damaged guards shields or without safety protective devices in place Be sure all interlocks are attached adjusted properly and functioning properly Do not change the engine governor settings or overspeed the engine Operating the engine at excessive speed may increase the hazard of personal injury Before leaving the operator s position stop on level ground disengage the power take off and lower the attachments change into neutral and set the parking brake stop the engine and remove the key Disengage drive to attachments when transporting or not in use Stop the engine and disengage drive to attachment before refuelling before removing the grass catcher catchers before making height adjustment unless adjustment can be made from the operator s position before clearing blockages before checking cleaning or working on the mower after striking a foreign object or if an abnormal vibration occurs Inspect the mower for damage and make repairs before restarting and operating the equi
50. nd fuel vapors are highly flammable and explosive A fire or explosion from fuel can burn you and others and can cause property damage e Use a funnel and fill the fuel tank outdoors in an open area when the engine is off and is cold Wipe up any fuel that spills Do not fill the fuel tank completely full Add fuel to the fuel tank until the level is 1 4 to 1 2 in 6 to 13 mm below the bottom of the filler neck This empty space in the tank allows the fuel to expand Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a spark Store fuel in a clean safety approved container and keep the cap in place 21 Figure 17 1 Fueltank cap Checking the Transmission Fluid The front axle housing acts as the reservoir for the system The transmission and axle housing are shipped from the factory with approximately 5 quarts of Mobil 424 hydraulic fluid However check level of transmission oil before engine is first started and daily thereafter 1 Position machine on a level surface lower the cutting units and stop the engine 2 Remove floor panel 3 Unscrew dipstick cap from the transmission filler neck Fig 18 and wipe it with a clean rag Screw dipstick into filler neck Remove the dipstick and check level of oil If level is not within 1 2 inch from the groove in the dipstick add enough oil to raise level to groove mark Do not overfill by more than 1 4 inch ab
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52. ntrol Fig 25 forward to increase engine speed rearward to decrease speed Backlap Switch The backlap switch Fig 26 is used in conjunction with lower mow raise control lever for backlapping operation Refer to Cutting Unit Maintenance Backlapping Figure 25 1 Lower mow raise control 5 Engine coolant lever temperature warning light 2 Fuel gauge 6 Glow plug indicator light 3 Engine coolant 7 Charge indicator temperature gauge 8 Throttle control 4 Engine oil pressure 9 Enable disable switch warning light Figure 26 1 Backlap switch 25 Reel Speed Controls The reel speed controls Fig 27 control the RPM of front and rear cutting units 1 position is for backlapping Remaining settings are for mowing operations See section in manual for operating instructions Figure 27 1 Reel speed controls Hour Meter The hour meter Fig 28 shows total hours that machine has been operated i _ u mm sre x 1 a L A i u Him E ch el L KA EE Kb J N zc am E g A im We e x 2 3 K CH EN te e KP j s Figure 28 1 Hour meter Starting and Stopping MOTOS The fuel system must be bled if any of the following situations have occurred A Initial start up of a new machine B Engine has ceased running due to lack of fuel C Maintenance has been performed upon fuel system components i e filter replaced s
53. o seat it in the canister Do not apply pressure to the flexible center of the filter 3 Clean the dirt ejection port located in the removable cover Remove the rubber outlet valve from the cover clean the cavity and replace the outlet valve 4 Install the cover orienting the rubber outlet valve in a downward position between approximately 5 00 to 7 00 when viewed from the end 5 Secure the cover latches 6 Reset indicator Fig 46 if showing red 37 Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation thereafter change oil and filter every 150 hours 1 Remove drain plug Fig 48 and let oil flow into drain pan When oil stops install drain plug Figure 48 1 Engine oil drain plug 2 Remove oil filter Fig 49 Apply a light coat of clean oil to the new filter seal before screwing it on Do not over tighten Figure 49 1 Engine oil filter 3 Add oil to crankcase refer to Checking the Engine Oil page 20 Servicing the Fuel System Fuel Tank Drain and clean fuel tank every 2 years Also drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period Use clean fuel to flush out the tank 38 Fuel Lines and Connections Check lines and connections every 400 hours or yearly whichever comes first Inspect for deterioration damage or loose connections Fuel Filter Water Separator D
54. ollow all safety instructions to avoid serious injury or death Use of this product for purposes other than its intended use could prove dangerous to user and bystanders AA Warning AA Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do not run engine indoors or in an enclosed area e Know how to stop the engine quickly e Do not operate the machine while wearing tennis shoes or sneakers e Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations e Handle fuel carefully Wipe up any spills e Check the safety interlock switches daily for proper operation If a switch should fail replace the switch before operating the machine After every two years replace all four interlock switches in the safety system whether they are working properly or not e Before starting the engine sit on the seat e Using the machine demands attention To prevent loss of control Do not drive close to sand traps ditches creeks or other hazards Reduce speed when making sharp turns Avoid sudden stops and starts When near or crossing roads always yield the right of way Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine e The grass baskets must be in place during operation of the cylinders reels or thatchers for maximum safety Shut the engine
55. ont Cutting Units 1 2 Locate valve on flow divider under foot rest Fig 63 Loosen setscrew on valve Rotate valve 1 2 turn clockwise Verify lift rate adjustment by raising and lowering cutting units several times Readjust as required After desired lift rate is attained tighten set screw to lock adjustment 43 Figure 63 1 Outside front cutting units adjustment valve Rear Cutting Units 1 Raise hood and locate valve on left rear side of machine Fig 64 Figure 64 1 Rear cutting units adjustment valve 2 Loosen setscrew on valve and rotate valve approximately 1 2 turn clockwise 3 Verify lift rate adjustment by raising and lowering cutting units several times Readjust as required 4 After desired lift rate is attained tighten setscrew to lock adjustment Checking and Adjusting the Traction Linkage Due to normal wear in the control linkage and hydrostatic transmission an increased amount of force may be required to return the transmissions to neutral Periodically check the machine 1 Park machine on a level surface lower cutting units to the floor and shut engine off 2 Connect brake pedals together with locking pin push both pedals down and pull parking brake latch out 3 Loosen outer hex nut securing eye bolt to spring anchor plate Fig 65 MEA 4 Figure 65 5 Shorten distance to decrease time required to stop machine Spring anchor
56. ope will not be regained by the application of the brake The main reasons for loss of control are e insufficient wheel grip e being driven too fast e inadequate braking e the type of machine is unsuitable for its task e lack of awareness of the effect of ground conditions especially slopes e incorrect hitching and load distribution The owner user can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation While mowing always wear substantial footwear long trousers hard hat safety glasses and ear protection Long hair loose clothing or jewelry may get tangled in moving parts Do not operate the equipment when barefoot or wearing open sandals Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine Warning Fuel is highly flammable Take the following precautions Store fuel in containers specifically designed for this purpose Refuel outdoors only and do not smoke while refuelling Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot If fuel is spilled do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated Replace all fuel tanks and container caps sec
57. or Areas of Concern Inspection performed by 34 Service Interval Chart REELMASTER 5200 D 5400 D 5500 D QUICK REFERENCE AID CHECK SERVICE daily 1 OIL LEVEL ENGINE 7 RADIATOR SCREEN 2 OIL LEVEL TRANSMISSION 8 BRAKE FUNCTION 3 OIL LEVEL HYDRAULIC TANK 9 TIRE PRESSURE 4 COOLANT LEVEL RADIATOR 10 BATTERY 5 FUEL WATER SEPARATOR 11 BELTS FAN ALT 6 PRECLEANER AIR CLEANER GREASING SEE OPERATOR S MANUAL FLUID SPECIFICATIONS CHANGE INTERVALS SEE OPERATOR S MANUAL FLUID CAPACITY CHANGE INTERVAL FILTER FOR INITIAL CHANGES FLUID FILTER PART NO A ENGINE OIL SCH 10W Ss 4 0 QTS sg HRS 100HRS 104 5167 B TRANSMISSION OIL MOBIL 424 5QTS 800 HRS 800 HRS 75 1330 C HYD CIRCUIT OIL 8 5 GALS 800 HRS D E FILTER IN LINE FUEL SATA 400 HRS 98 7612 F WATER SEPARATOR 400 HRS G FUEL TANK O A 2 Diesel 10 GALS Drain and flush 2 yrs H COOLANT 50 50 Ethylene 9 6 QTS Drain and flush 2 yrs glycol water INCLUDING FILTER AA Caution If you leave the key in the ignition switch someone could accidently start the engine and seriously injure you or other bystanders Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine Greasing the Bearing and Bushings The machine has grease fittings that must be lubricated regularly with No 2 General Purpose Lithium Base Grease If ma
58. ove groove lt N ep i pE 10 01 KS da co VHSW Isg 000 eh o amp d Figure 18 1 Transmission dipstick cap 4 Screw dipstick filler cap finger tight onto filler neck It is not necessary to tighten cap with a wrench Checking the Hydraulic Fluid The machines reservoir is filled at the factory with approximately 8 gallons of high quality hydraulic fluid Check the level of the hydraulic fluid before the engine is first started and daily thereafter The recommended replacement fluid is Toro Premium Transmission Hydraulic Tractor Fluid Available in 5 gallon pails or 55 gallon drums See parts catalog or Toro distributor for part numbers Alternate fluids If the Toro fluid is not available other petroleum based Universal Tractor Hydraulic Fluids UTHF may be used provided its specifications fall within the listed range for all the following material properties and it meets industry standards We do not recommend the use of synthetic fluid Consult with your lubricant distributor to identify a satisfactory product Note Toro will not assume responsibility for damage caused by improper substitutions so use only products from reputable manufacturers who will stand behind their recommendation Material Properties Viscosity ASTM D445 cSt 40 C 55 to 62 cSt 100 C 9 1 to 9 8 Viscosity Index ASTM D2270 140 152 Pour Point ASTM D97 35 F to 46 F Industry Specifications
59. plate Eye bolt Inner locknut Outer locknut ey 4 Rotate clockwise until distance between inside of eye bolt loop and inside of spring anchor plate is shortened 1 8 in as shown in Figure 65 Tighten hex nut 5 Operate the machine and check stopping distance Repeat procedure if required Note Shortening the distance between inside of eye bolt loop and inside of spring anchor plate increases the pedal force on the traction pedal Therefore do not over adjust Adjusting the Service Brakes Adjust the service brakes when there is more than 1 inch of free travel of the brake pedal or when the brakes do not work effectively Free travel is the distance the brake pedal moves before braking resistance is felt 1 Disengage locking pin from brake pedals so both pedals work independently of each other 2 To reduce free travel of brake pedals tighten the brakes by loosening the front nut on threaded end of brake cable Fig 66 Then tighten rear nut to move cable backward until brake pedals have 1 2 to 1 inch of free travel Tighten front nuts after brakes are adjusted correctly ae ei LW MA ee y A vs P e E A My WW K Tp 4 le Du Y ae Cit Figure 66 1 Brake cables Changing the Transmission Fluid Change the transmission fluid after every 800 hours of operation in normal conditions 1 Position machine on a level surface lower the cutting units stop the eng
60. pment Reduce the throttle setting during engine run out and if the engine is provided with a shut off valve turn the fuel off at the conclusion of mowing Keep hands and feet away from the cutting units Look behind and down before backing up to be sure of a clear path Slow down and use caution when making turns and crossing roads and sidewalks Stop cylinders reels if not mowing Do not operate the mower under the influence of alcohol or drugs Use care when loading or unloading the machine into a trailer or truck Use care when approaching blind corners shrubs trees or other objects that may obscure vision Maintenance and Storage Keep all nuts bolts and screws tight to be sure the equipment is in safe working condition Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark Allow the engine to cool before storing in any enclosure To reduce the fire hazard keep the engine silencer muffler battery compartment and fuel storage area free of grass leaves or excessive grease Check the grass catcher frequently for wear or deterioration Keep all parts in good working condition and all hardware and hydraulic fittings tightened Replace all worn or damaged parts and decals If the fuel tank has to be drained do this outdoors Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of
61. port Parking Brake Latch A knob on the left side of console Fig 24 actuates parking brake lock To engage parking brake connect pedals with locking pin push down on both pedals and pull parking brake latch out To release parking brake depress both pedals until parking brake latch retracts Key Switch The key switch Fig 24 has three positions OFF ON Preheat and START 24 Fuel Gauge The fuel gauge Fig 25 shows amount of fuel in tank Lower Mow Raise Control Lever The lever Fig 25 raises and lowers the cutting units and also starts and stops the reels Glow Plug Indicator Light When lit Fig 25 indicates a control system problem Figure 24 Light blinks when glow plugs are preheating 1 Traction speed limiter 5 Parking brake latch 2 Reel control light 6 ER pin Engine Oil Pressure Warning Light 3 Speedometer 7 Key switch 4 Brake pedals This light Fig 25 indicates dangerously low engine oil pressure Engine Coolant Temperature Warning Charge Indicator Light The charge indicator Fig 25 illuminates when system The light Fig 25 illuminates and engine shuts down when charging circuit malfunctions coolant reaches a dangerously high temperature Throttle Control Enable Disable Switch The enable disable switch Fig 25 is used in conjunction with lower mow raise control lever Joystick to operate reels Reels can be raised but not lowered when in mid position Move co
62. r tire must also be off the shop floor or 4 wheel drive driveshaft must be removed 3 Under right side of machine loosen locknut on traction adjustment cam Fig 61 H Figure 61 1 Traction adjustment cam Warning The engine must be running so the final adjustment of the traction adjustment cam can be performed This could cause personal injury Keep hands feet face and other body parts away from the muffler other hot parts of the engine and any rotating parts 4 Start engine and rotate cam hex in either direction until wheel ceases rotation 5 Tighten locknut securing adjustment 6 Stop the engine and release the right brake Remove jack stands and lower the machine to the shop floor Test drive the machine to make sure it does not creep 42 Adjusting the Cutting Unit Lift Rate The cutting unit lift circuit is equipped with 3 adjustable valves used to ensure the cutting units do not raise too quickly and bang against lift stops Adjust cutting units as follows Center Cutting Unit 1 1 Locate valve behind access panel above operator s platform Fig 62 Loosen setscrew on valve and rotate valve approximately 1 2 turn clockwise Verify lift rate adjustment by raising and lowering cutting unit several times Readjust as required After desired lift rate is attained tighten setscrew to lock adjustment Figure 62 Center cutting unit adjustment valve Outside Fr
63. rain water or other contaminants from fuel filter water separator Fig 50 daily 1 Locate fuel filter under hydraulic tank and place a clean container under it 2 Loosen drain plug on bottom of filter canister Tighten plug after draining Figure 50 1 Fuel filter water separator 2 Drain plug Replace filter canister after every 400 hours of operation 1 Clean area where filter canister mounts 2 Remove filter canister and clean mounting surface 3 Lubricate gasket on filter canister with clean oil 4 Install filter canister by hand until gasket contacts mounting surface then rotate an additional 1 2 turn Replacing the Fuel Pre Filter Replace the fuel pre filter after every 400 operating hours or yearly whichever occurs first 1 Remove screw securing filter to frame rail 2 Clamp both fuel lines that connect to the fuel filter so fuel cannot drain when lines are removed 3 Loosen the hose clamps at both ends of the filter and pull fuel lines off filter Figure 51 1 Fuel filter 2 Hose clamps 4 Slide hose clamps onto ends of fuel lines Push fuel lines onto fuel filter and secure them with hose clamps Be sure arrow on side of filter points toward the injection pump Under certain conditions diesel fuel and fuel vapors are highly flammable and explosive A fire or explosion from fuel can burn you and others and can cause property damage e Use a funnel and fill the fuel tank ou
64. raulic system filter head is equipped with a service interval indicator With the engine running view the indicator it should be in the GREEN zone When the indicator is in the RED zone the filter element should be changed Use the Toro replacement filter Part No 75 1310 Important Use of any other filter may void the warranty on some components 1 Position machine on a level surface lower the cutting units stop the engine engage the parking brakes and remove key from ignition switch 2 Clean area around filter mounting area Fig 59 Place drain pan under filter and remove filter Figure 59 1 Hydraulic filter 3 Lubricate new filter gasket and fill the filter with hydraulic fluid 4 Ensure that the filter mounting area 1s clean Screw filter on until gasket contacts mounting plate Then tighten filter one half turn 5 Start engine and let run for about two minutes to purge air from the system Stop the engine and check for leaks 41 Checking the Hydraulic Lines and Hoses Daily check hydraulic lines and hoses for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical deterioration Make all necessary repairs before operating Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury e Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight b
65. ropriate graph Fig 30 for 5 blade or 8 blade cutting units determine the proper reel speed setting Figure 30 4 To set reel speed rotate knobs Fig 31 until indicator arrows are in line with the number designating desired setting Figure 31 1 Reel speed control knobs Note Reel speed can be increased or decreased to compensate for turf conditions 27 Adjusting the Lift Arm Down Pressure The down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf conditions Increased down pressure will help keep the cutting units on the ground when mowing at higher speeds and helps maintain a uniform height of cut in rough conditions or in areas of thatch build up Each down pressure spring may be adjusted to one of four settings Each increment increases or decreases down pressure on cutting unit by amp lb 1 Position machine on a level surface lower the cutting units stop the engine engage the parking brakes and remove key from ignition switch 2 Remove floor plate in front of seat and open the hood to gain access to all 5 springs AA Caution AA Springs are under tension Use caution when adjusting 3 Place an open end wrench on the hex shaft of the spring bracket Fig 32 4 Remove the capscrew and locknut securing retaining bracket Fig 32 while rotating hex shaft to relieve Spring tension RH NO SKIVE Figure 32 1 Spring brack
66. s are not correctly illuminated this indicates an ECU problem If this occurs contact your Toro Distributor for assistance Important The Diagnostic ACE display must not be left connected to the machine It is not designed to withstand the environment of the machine s every day use When done using Diagnostic ACE disconnect it from the machine and reconnect loopback connector to harness connector Machine will not operate without loopback connector installed on harness Store Diagnostic ACE in dry secure location in shop not on machine Hydraulic Valve Solenoid Functions Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold Each solenoid must be energized to allow function to occur Front reel circuit Lift lower front wing cutting units Solenoid S1 S2 S3 S5 S6 S7 S8 S9 Lift lower center cutting unit Operating Characteristics Familiarization Before mowing grass practice operating machine in an open area Start and stop the engine Operate in forward and reverse Lower and raise cutting units and engage and disengage reels When you feel familiar with the machine practice operating up and down slopes at different speeds The brakes can be used to assist in turning the machine However use them carefully especially on soft or wet grass conditions because the turf may be torn accidentally Individual turning brakes may also be used to help maint
67. s manual carefully to learn how to operate and maintain your product properly The information in this manual can help you and others avoid injury and product damage Although Toro designs and produces safe products you are responsible for operating the product properly and safely Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready The model and serial number is on a plate that Is mounted on the left side of the footrest Write the product model and serial numbers in the space below Model No Serial No This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death Danger Warning and Caution are signal words used to identify the level of hazard However regardless of the hazard be extremely careful Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions Warning signals a hazard that may cause serious injury or death 1f you do not follow the recommended precautions Caution signals a hazard that may cause minor or moderate injury 1f you do not follow the recommended precautions This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general
68. sion filter Every 800 hours Check rear wheel toe in Pack the bearings to both rear wheels 2WD Change the rear axle lubricant 4WD Adjust the valves Kubota diesel engine Replace all moving hoses Every 1600 hours or 2 Replace the interlock safety switches years whichever occurs Flush replace the cooling system fluid first Drain flush the fuel tank Drain flush the hydraulic tank 33 Daily Maintenance Checklist Duplicate this page for routine use For the week of Formewe Gei netzen II Gerten j j j j j Ge engine ana fuera orante atra eparator II Gei tne air fiter resrioton ee PASO IO O IE eee e O L L S Check unusual engine gees 1 L L L ll Check unusual operating noises YC Checkthe transmission oillevel J To So To Check the hydraulic system geg Check the hydraulio fiter indicator Check hydraulic hoses for damage J L T T Check forfluidleaks YY j Checkthe tire pressure Checkinstrument operations YY To Check the reelto bedknife adjustment Check the height of cut adjustment CY Check the cutting units des Lubricate all grease ftigs 2 L L L o Touchupdamagedpaint J L L L L ll 1Check the glow plugs and injector nozzles if excess smoke or rough running is noted 2Check with the engine running and the oil at operating temperature 3Grease immediately after every washing regardless of the interval listed Notation f
69. t adjusting knob Fig 22 adjusts seat for operators weight To adjust seat fore and aft pull lever on left side of seat assembly outward After moving seat to desired location release lever to lock seat into position To adjust for operators weight turn spring tension knob clockwise to increase tension counterclockwise to decrease spring tension Figure 22 1 Seat adjusting lever 2 Seat adjusting knob Traction Pedal The traction pedal Fig 23 controls forward and reverse operation Depress top of pedal to move forward and bottom to move backward Ground speed depends on how far pedal is depressed For no load maximum ground speed fully depress pedal while throttle is in FAST To stop reduce foot pressure on traction pedal and allow it to return to center position Figure 23 1 Traction pedal Traction Speed Limiter Preset this lever Fig 24 to limit the amount the traction pedal can be depressed in the forward direction to maintain a constant mowing speed Reel Control Light The light Fig 24 illuminates when glow is preheating or blinks when their is a control system problem Speedometer The speedometer Fig 24 indicates ground speed at which machine is traveling Brake Pedals Two foot pedals Fig 24 operate individual wheel brakes for turning assistance parking and to aid in obtaining better sidehill traction Locking pin connects the pedals for parking brake operation and trans
70. tdoors in an open area when the engine is off and is cold Wipe up any fuel that spills Do not fill the fuel tank completely full Add fuel to the fuel tank until the level is 1 4 to 1 2 in 6 to 13 mm below the bottom of the filler neck This empty space in the tank allows the fuel to expand Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a spark Store fuel in a clean safety approved container and keep the cap in place Bleeding Air from the Injectors Note This procedure should be used only if fuel system has been purged of air through normal priming procedures and engine will not start refer to Bleeding the Fuel System page 26 1 Loosen the pipe connection to the No 1 nozzle and holder assembly Fig 52 2 Move throttle to FAST position 3 Turn key in key switch to START position and watch fuel flow around connector Turn key to OFF position when solid flow is observed 39 4 Tighten pipe connector securely 5 Repeat steps on remaining nozzles Figure 52 1 Fuel injectors 3 Servicing the Engine Cooling System Removing Debris Remove debris from screen oil coolers and radiator daily clean more frequently in dirty conditions 1 Turn engine off and raise hood Clean engine area thoroughly of all debris 2 Loosen clamps and pull up on screen to slide 1t out of mounting tracks Fig 53 Clean screen thoroughly with compressed
71. the machine On multi cylinder multi reel machines take care as rotating one cylinder reel can cause other cylinders reels to rotate Disengage drives lower the cutting units set parking brake stop engine and remove key and disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Clean grass and debris from cutting units drives silencers mufflers and engine to help prevent fires Clean up oil or fuel spillage Use jack stands to support components when required e Carefully release pressure from components with stored energy e Disconnect battery and remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last e Use care when checking the cylinders reels Wear gloves and use caution when servicing them e Keep hands and feet away from moving parts If possible do not make adjustments with the engine running e Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools Toro Riding Mower Safety The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN ISO or ANSI standard This product is capable of amputating hands and feet and throwing objects Always f
72. the steering wheel so the rear wheels are straight ahead 2 Remove the cotter pin and slotted hex nut from either tie rod ball joint Use a ball joint fork and remove the tie rod ball joint from the axle case support 3 Loosen clamps on both ends of tie rod Fig 70 Figure 70 1 Tie rod 4 Rotate the detached ball joint inward or outward one 1 complete revolution Tighten the clamp at the loose end of the tie rod 5 Rotate the entire tie rod assembly the same direction inward or outward one 1 complete revolution Tighten the clamp at the connected end of the tie rod 6 Install the ball joint in the axle case support and tighten the slotted hex nut finger tight 7 Measure the distance at the front and the rear of the rear wheels at axle height The distance at the front of the rear wheels should be 0 1 8 in 0 3 mm less than the distance measured at the rear of the wheels 8 Repeat steps 3 through 7 if necessary 9 Tighten ball joint hex nut and install a new cotter pin Servicing the Battery A Warning CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Before welding on the machine disconnect both cables from the battery disconnect both wire harness plugs from the electronic control unit and the terminal
73. trouble 31 Logic Chart D D D 19Y91d CL HEIS cl D aaa ZS LL D A D A O LS OL UV PIOH 43 Z D DO H DO 9S 9 A A a DD D D GS S D D DO D D D DO DO tS t D D D ES d d d d cS 6S 8S L 14617 9 SOUBEeIg O D D n Q A n D DD Q Q QO Q no LO a SLNdLNO Cl Cl GL El Cl LL cO H p3AJOAU JOWIL L LV 9M UEIS OV XOXXO IN X O XX O O X XX O O O OO X XO x xX X gt lt gt O X XIN x 2x2 o 000 OOOO O OO ech O N N O Tl bees z so 2 2 ESEB A o 99S 6 Cc ost i 38 3 gt 9S p1 S gt T gt g O 0 O o 0 v s EL amp 5 6 99S 0 S Z L 99S S LL SUJAL O O duet 1luejooo uBiH S gt lt gt gt Xx gt gt gt YIUMS 18 9S p 211n9N UOUZ2E L x gt O Jeay dey98eg 8 uo14 dejyoeg 2 1891 X 9 wol punoue uin ol asiey Jedd 3 U014 punoJe UN OL eseu 11043 punoJe un OL asiey X X X uuodsuem asiey 9 X MOI S X 19H Y 1U014 MOI N 193M0 X JUOJJ MONN 193MO pa qeua u ym syun IV 19amo palqesip uaym syun IIV 193mo7 punose uain OL 13mo7 r 10 e193do ym uny 10 e1ado ON uny AAA gt gt Hes zZ jesyald L A gt lt HO 13 0140 0 SNOILOV L 0 uny Aey Z da 004pS WH a oo0zsS WH aldo JISOT SLNdNI ONINNNd ATISNOIASdd 343M S 1338 dl NO LAdLNO V 438079 A
74. ttery posts with Grafo 112X skin over grease Toro Part No 505 47 or petroleum jelly to prevent corrosion D Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfation of the battery Engine 1 Drain the engine oil from the oil pan and replace the drain plug 2 Remove and discard the oil filter Install a new oil filter 3 Refill oil pan with 4 quarts of motor oil 4 Start the engine and run at idle speed for approximately two minutes 5 Stop the engine 6 Thoroughly drain all fuel from the fuel tank lines and the fuel filter water separator assembly 7 Flush the fuel tank with fresh clean diesel fuel 8 Re secure all fuel system fittings 9 Thoroughly clean and service the air cleaner assembly 10 Seal the air cleaner inlet and the exhaust outlet with weatherproof tape 11 Check anti freeze protection and add as needed for expected minimum temperature in your area 51 Conditions and Products Covered The Toro Company and its affiliate Toro Warranty Company pursuant to an agreement between them jointly warrant your Toro Commercial Product Product to be free from defects in materials or workmanship for two years or 1500 operational hours whichever occurs first Where a warrantable condition exists we will repair the Product at no cost to you including diagnosis labor parts and transportation This warranty begins on the date the Product is delivered to the origin
75. turf immediately soak affected area with water 19 Before Operating A If you leave the key in the ignition switch someone could accidently start the engine and seriously injure you or other bystanders Caution Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine Checking the Engine Oil The engine is shipped with oil in the crankcase however the oil level must be checked before and after the engine is first started Crankcase capacity is approximately 4 qt 2 8 1 with the filter Use high quality engine oil that meets the following specifications API Classification Level Required CH 4 CI 4 or higher Preferred oil SAE 15W 40 above 0 F Alternate oil SAE 10W 30 or SW 30 all temperatures Toro Premium Engine oil is available from your distributor in either 15W 40 or 10W 30 viscosity See the parts catalog for part numbers 1 Park machine on a level surface stop engine and remove key from ignition switch Open hood 2 Remove dipstick wipe clean and reinstall dipstick Remove dipstick and check oil level on dipstick Oil level should be up to FULL mark Reelmaster 5200 Fig 14 Reelmaster 5400 Fig 15 Figure 14 1 Dipstick 2 Oil fill cap Figure 15 2 Oil fill cap 1 Dipstick 3 If oil is below FULL mark remove fill cap and add oil until level reaches FULL
76. und air bleed screw Leave key in ON position until solid stream of fuel flows out around screw Tighten screw and turn key to OFF 26 Under certain conditions diesel fuel and fuel vapors are highly flammable and explosive A fire or explosion from fuel can burn you and others and can cause property damage e Use a funnel and fill the fuel tank outdoors in an open area when the engine is off and is cold Wipe up any fuel that spills Do not fill the fuel tank completely full Add fuel to the fuel tank until the level is 1 4 to 1 2 in 6 to 13 mm below the bottom of the filler neck This empty space in the tank allows the fuel to expand Never smoke when handling fuel and stay away from an open flame or where fuel fumes may be ignited by a spark Store fuel in a clean safety approved container and keep the cap in place Note Normally engine should start after above bleeding procedures are followed However if engine does not start air may be trapped between injection pump and injectors refer to Bleeding Air from the Injectors page 20 Setting the Reel Speed To achieve a consistent high quality of cut and a uniform after cut appearance it is important that the reel speed controls located under seat be correctly set Adjust the reel speed controls as follows 1 Select the height of cut at which the cutting units are set 2 Choose the desired ground speed best suited for conditions 3 Using the app
77. up above level marks on precleaner bowl 1 Remove thumb screw and separate cover from precleaner bowl Fig 46 Figure 46 1 Air cleaner indicator 2 Precleaner bowl 3 Dust cup 2 Empty precleaner bowl and wipe clean 3 Assemble and install precleaner bowl cover and thumb screw Note When operating machine in extremely dusty conditions an optional extension tube Toro Part No 43 3810 which raises precleaner bowl above hood thus lengthening the time between precleaner bowl servicing is available from your local authorized Toro Distributor Servicing the Air Cleaner 1 Release the latches and remove the cover from the air cleaner body Fig 46 Before removing the filter use low pressure air 40 psi clean and dry to help remove large accumulations of debris packed between outside of primary filter and the canister Avoid using high pressure air which could force dirt through the filter into the intake tract This cleaning process prevents debris from migrating into the intake when the primary filter is removed Figure 47 1 Filter element 2 Remove and replace the primary filter Fig 47 Cleaning of the used element is not recommended due to the possibility of damage to the filter media Inspect the new filter for shipping damage checking the sealing end of the filter and the body Do not use a damaged element Insert the new filter by applying pressure to the outer rim of the element t
78. urely Replace faulty silencers mufflers Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by the manufacturer Check that operator s presence controls safety switches and shields are attached and functioning properly Do not operate unless they are functioning properly Operation Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect Mow only in daylight or in good artificial light Before attempting to start the engine disengage all blade attachment clutches shift into neutral and engage the parking brake Remember there is no such thing as a safe slope Travel on grass slopes requires particular care To guard against overturning do not stop or start suddenly when going up or downhill engage clutch slowly always keep machine in gear especially when travelling downhill machine speeds should be kept low on slopes and during tight turns stay alert for humps and hollows and other hidden hazards never mow across the face of the slope unless the mower is designed for this purpose Stay alert for holes in the terrain and other hidden hazards Use care when pulling loads or using heavy equipment Use only approved drawbar hitch points Limit loads to those you can safely control Do not turn sharply Use care whe

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