Toro 5400-D User Manual

Operator’s ManualEnglish (EN, GB)Form No. 3353–130Reelmaster 5200-D/5400-DTwo-Wheel and Four-Wheel Drive Traction Units03540—250000001 and Up03543—250

1093-66801. Diesel fuel105-75061. Read the Operator’sManual2. Engine—stop3. On4. Engine—preheat5. Engine—start93-12631. Read operator’s manual2. To e

11104-92941. Read the Operator’s Manual.2. Do not tow the machine.3. Warning—read theOperator’s Manual.4. Cutting hazard of hand orfoot—stay away from

12SpecificationsGeneral Specifications EngineKubota three cylinder, 4 cycle liquid cooled diesel engine. 25 hp @ 3000 rpm forReelmaster 5200 and 31.5

13MeasurementsWidth of Cut 95 in.Overall WidthTransportOutside of front tiresOutside of rear tires87 in.87 in.52-1/2 in.Overall LengthWithout grass ba

14SetupNote: Determine the left and right sides of the machine from the normal operating position.Loose PartsNote: Use this chart as a checklist to en

152 1Figure 11. Positive battery cable 2. Negative battery cableCharging the battery produces gasses that canexplode.Never smoke near the battery and

165. Adjust latch bracket, until aligned with switch latch,then tighten capscrews.6. Rotate latch to locked and unlocked position with key.Remove key

175. Align the mounting shaft of the cutting unit with thepivot tube on the carrier frame. Insert the shaft into thetube (Fig. 8).12 3 456Figure 81. C

18Adjusting the TurfCompensation SpringNote: This adjustment is needed for Cutting Unit Models03527 and 03528 only.The turf compensation spring (Fig.

19Installing the Rear WeightThe Reelmaster 5200-D & 5400-D Traction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, andANSI B7

2All Rights ReservedPrinted in the USAW 2005 by The Toro Company8111 Lyndale Avenue SouthBloomington, MN 55420-1196CALIFORNIAProposition 65 WarningDi

20Before OperatingIf you leave the key in the ignition switch, someonecould accidently start the engine and seriouslyinjure you or other bystanders.Re

211Figure 161. Expansion tank2. If coolant level is low, remove expansion tank cap andreplenish the system. Do not overfill.3. Install expansion tank

22Checking the Hydraulic FluidThe machines reservoir is filled at the factory withapproximately 8 gallons of high quality hydraulic fluid.Check the le

234. Remove each end check plug and add enough lubricantto bring the level up to the bottom of each check plughole.5. Install all plugs.Checking Reel

24OperationNote: Determine the left and right sides of the machinefrom the normal operating position.If you leave the key in the ignition switch, some

251234576Figure 241. Traction speed limiter2. Reel control light3. Speedometer4. Brake pedals5. Parking brake latch6. Locking pin7. Key switchEngine C

26Reel Speed ControlsThe reel speed controls (Fig. 27) control the RPM of frontand rear cutting units. #1 position is for backlapping.Remaining settin

27DangerUnder certain conditions, diesel fuel and fuelvapors are highly flammable and explosive. A fireor explosion from fuel can burn you and othersa

28Adjusting the Lift Arm DownPressureThe down pressure spring on each cutting unit lift arm canbe adjusted to compensate for different turf conditions

293. Attach the other end of the towing device to a vehiclethat is capable of towing the machine safely and atspeeds below 3 mph.4. An operator must b

3IntroductionRead this manual carefully to learn how to operate andmaintain your product properly. The information in thismanual can help you and othe

301Figure 361. Wire harness and connectors3. Connect the Diagnostic ACE display connector to theharness connector (Fig. 37). Make sure correct overlay

31If the output LED’s are on as specified, but the machinedoes not function properly, this indicates a non–electricalproblem. Repair as necessary.Note

32Logic Chart Raise (To turn around front & Raise (To turn around front &A=OUTPUT ON IF REELS WERE PREVIOUSLY RUNNING2) Start0) Controller

33MaintenanceNote: Determine the left and right sides of the machine from the normal operating position.Important Refer to your engine operator’s man

34Daily Maintenance ChecklistDuplicate this page for routine use.For the week of:Maintenance Check ItemMon. Tues. Wed. Thurs. Fri. Sat. Sun.Check safe

35Service Interval ChartIf you leave the key in the ignition switch, someonecould accidently start the engine and seriouslyinjure you or other bystand

36Figure 40Figure 41Figure 42Figure 43Figure 44Figure 45

37General Air CleanerMaintenance• Check the air cleaner body for damage which couldcause an air leak. Replace if damaged. Check the wholeintake system

38Engine Oil and FilterChange oil and filter initially after the first 50 hours ofoperation, thereafter change oil and filter every 150 hours.1. Remov

393. Loosen the hose clamps at both ends of the filter andpull fuel lines off filter.122Figure 511. Fuel filter 2. Hose clamps4. Slide hose clamps ont

4Preparation• While mowing, always wear substantial footwear, longtrousers, hard hat, safety glasses, and ear protection.Long hair, loose clothing, or

403. Slightly raise oil coolers and pivot forward (Fig. 54).Clean both sides of oil coolers and radiator areathoroughly with compressed air. Pivot oil

411Figure 571. Injection pump lever armChanging the Hydraulic FluidChange hydraulic fluid after every 800 operating hours, innormal conditions. If flu

42Checking the Hydraulic Linesand HosesDaily, check hydraulic lines and hoses for leaks, kinkedlines, loose mounting supports, wear, loose fittings, w

43Adjusting the Cutting Unit LiftRateThe cutting unit lift circuit is equipped with (3) adjustablevalves used to ensure the cutting units do not raise

44Checking and Adjusting theTraction LinkageDue to normal wear in the control linkage and hydrostatictransmission, an increased amount of force may be

456. Before starting the engine after changing transmissionfluid, disconnect the run (ETR) solenoid on the engine,and crank the engine several times f

461Figure 691. Tie rods3. When toe-in is correct, tighten jam nuts against tie rods.Models 03544 only1. Rotate the steering wheel so the rear wheels a

47posts and cable connectors with Grafo 112X (skin-over)grease (Toro Part No. 505-47) or petroleum jelly to preventcorrosion.FusesThere are 4 fuses in

48DangerChanging the engine speed while backlapping maycause the reels to stall.• Never change the engine speed whilebacklapping.• Only backlap at idl

49Electrical SchematicSTARTRELAY2ARUN (ETR)SOLENOIDOUTPUTS INPUTSBAIYXRUNSTARTS3C2B3MENGINE WATER TEMP SENSORSTART – KEY SWITCHSTARTER1S1B2S3S4S1

5• Reduce the throttle setting during engine run-out and, ifthe engine is provided with a shut-off valve, turn thefuel off at the conclusion of mowing

50Hydraulic SchematicC2FD1C1PP3P1 P2TEST PORTFOR FRONTUNITS(3)STEERINGCYLINDERFORWARD SIDEOF CLOSED LOOPSUNSTRAND M25 1.5 IN3 /REV”A””A” SYSTEM RELIEF

51Preparation for SeasonalStorageTraction Unit1. Thoroughly clean the traction unit, cutting units and theengine.2. Check the tire pressure. Inflate a

The Toro General Commercial Products WarrantyA Two-Year Limited WarrantyConditions and Products CoveredThe Toro Company and its affiliate, Toro Warran

6– Do not drive close to sand traps, ditches, creeks, orother hazards.– Reduce speed when making sharp turns. Avoidsudden stops and starts.– When near

7Safety and Instruction DecalsSafety decals and instructions are easily visible to the operator and are located near any areaof potential danger. Repl

8104-92961. Throttle—slow2. Throttle—fast3. Reels raised & off4. Reels lowered and on whenenabled—forward andbacklap5. Reels—enabled6. Reels disab

9106-92241. Warning—read the Operator’s Manual.2. Cutting hazard of hand and foot—stop the reels beforetouching.93-6697(Model 03544 only)1. Read opera