User manual | Toro 5400-D Automobile User Manual

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
English (EN, GB)
Checking the Torque of the Wheel Nuts . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping . . . . . . . . . . . . . . . . . . . . . .
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . .
Setting the Reel Speed . . . . . . . . . . . . . . . . . . . . .
Adjusting the Lift Arm Down Pressure . . . . . . . .
Towing the Traction Unit . . . . . . . . . . . . . . . . . . .
Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic ACE Display . . . . . . . . . . . . . . . . . . .
Checking the Interlock Switches . . . . . . . . . . . . .
Hydraulic Valve Solenoid Functions . . . . . . . . . .
Operating Characteristics . . . . . . . . . . . . . . . . . . .
Logic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule . . . . . . . . .
Daily Maintenance Checklist . . . . . . . . . . . . . . . .
Service Interval Chart . . . . . . . . . . . . . . . . . . . . . .
Greasing the Bearing and Bushings . . . . . . . . . . .
General Air Cleaner Maintenance . . . . . . . . . . . .
Servicing the Precleaner Bowl . . . . . . . . . . . . . . .
Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . .
Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel System . . . . . . . . . . . . . . . . . .
Bleeding Air from the Injectors . . . . . . . . . . . . . .
Servicing the Engine Cooling System . . . . . . . . .
Servicing the Engine Belts . . . . . . . . . . . . . . . . . .
Adjusting the Throttle . . . . . . . . . . . . . . . . . . . . .
Changing the Hydraulic Fluid . . . . . . . . . . . . . . .
Replacing the Hydraulic Filter . . . . . . . . . . . . . . .
Checking the Hydraulic Lines and Hoses . . . . . . .
Hydraulic System Test Ports . . . . . . . . . . . . . . . . .
Adjusting the Traction Drive for Neutral . . . . . . .
Adjusting the Cutting Unit Lift Rate . . . . . . . . . .
Checking and Adjusting the Traction Linkage . . .
Adjusting the Service Brakes . . . . . . . . . . . . . . . .
Changing the Transmission Fluid . . . . . . . . . . . . .
Replacing the Transmission Filter . . . . . . . . . . . .
Changing the Rear Axle Lubricant . . . . . . . . . . . .
Adjusting Rear Wheel Toe-In . . . . . . . . . . . . . . . .
Servicing the Battery . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Lighting . . . . . . . . . . . . . . . . . . . . . . . . .
Backlapping the Cutting Units . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . .
Preparation for Seasonal Storage . . . . . . . . . . . . .
The Toro General Commercial Products Warranty . .
Warning
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices . . . . . . . . . . . . . . . . . . . .
Toro Riding Mower Safety . . . . . . . . . . . . . . . . . .
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . .
Sound Power Level . . . . . . . . . . . . . . . . . . . . . . .
Vibration Level . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications . . . . . . . . . . . . . . . . . . . . .
Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Battery . . . . . . . . . . . . . . . . . . . . .
Mounting the Hood Latch . . . . . . . . . . . . . . . . . .
Replacing the Panel Fasteners . . . . . . . . . . . . . . .
Checking the Tire Pressure . . . . . . . . . . . . . . . . . .
Installing the Cutting Units . . . . . . . . . . . . . . . . .
Adjusting the Turf Compensation Spring . . . . . . .
Lifted Height of Outer Front Cutting Units . . . . .
Installing the Rear Weight . . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil . . . . . . . . . . . . . . . . . . .
Checking the Cooling System . . . . . . . . . . . . . . .
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . .
Checking the Transmission Fluid . . . . . . . . . . . . .
Checking the Hydraulic Fluid . . . . . . . . . . . . . . .
Checking the Rear Axle Lubricant . . . . . . . . . . . .
Checking Reel to Bedknife Contact . . . . . . . . . . .
W 2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
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All Rights Reserved
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 this 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.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.
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.
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.
Write the product model and serial numbers in the space
below:
• Never mow while people, especially children, or pets
are nearby.
Model No.
• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
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.
• 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:
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
– the need for care and concentration when working
with ride-on machines;
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
• insufficient wheel grip;
• being driven too fast;
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
• inadequate braking;
• the type of machine is unsuitable for its task;
• lack of awareness of the effect of ground
conditions, especially slopes;
Safety
• incorrect hitching and load distribution.
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.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.
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
symbol, which means
3
Preparation
– stay alert for humps and hollows and other hidden
hazards;
• 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.
– 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.
• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
• Use care when pulling loads or using heavy equipment.
– Use only approved drawbar hitch points.
• Warning—Fuel is highly flammable. Take the
following precautions:
– Limit loads to those you can safely control.
– Do not turn sharply. Use care when reversing.
– Store fuel in containers specifically designed for this
purpose.
– Use counterweight(s) or wheel weights when
suggested in the operator’s manual.
– Refuel outdoors only and do not smoke while
refuelling.
• Watch out for traffic when crossing or near roadways.
• Stop the blades rotating before crossing surfaces other
than grass.
– 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.
• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
– 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.
• 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.
– Replace all fuel tanks and container caps securely.
• Replace faulty silencers/mufflers.
• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
• 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.
• Before leaving the operator’s position:
– stop on level ground;
• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
Operation
– stop the engine and remove the key.
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
• Disengage drive to attachments when transporting or
not in use.
• Mow only in daylight or in good artificial light.
• Stop the engine and disengage drive to attachment
• Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake.
– before refuelling;
– before removing the grass catcher/catchers;
• Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– before making height adjustment unless adjustment
can be made from the operator’s position.
– do not stop or start suddenly when going up or
downhill;
– before clearing blockages;
– engage clutch slowly, always keep machine in gear,
especially when travelling downhill;
– after striking a foreign object or if an abnormal
vibration occurs. Inspect the mower for damage and
make repairs before restarting and operating the
equipment.
– before checking, cleaning or working on the mower;
– machine speeds should be kept low on slopes and
during tight turns;
4
• Carefully release pressure from components with stored
energy.
• 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.
• 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.
• Keep hands and feet away from the cutting units.
• Look behind and down before backing up to be sure of
a clear path.
• Use care when checking the cylinders/reels. Wear
gloves and use caution when servicing them.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop cylinders/reels if not
mowing.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Do not operate the mower under the influence of
alcohol or drugs
• 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.
• 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.
Toro Riding Mower Safety
Maintenance and Storage
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.
• 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.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
• Allow the engine to cool before storing in any
enclosure.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
• To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment and fuel storage
area free of grass, leaves, or excessive grease.
Warning
• Check the grass catcher frequently for wear or
deterioration.
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
• Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
Do not run engine indoors or in an enclosed area.
• If the fuel tank has to be drained, do this outdoors.
• Know how to stop the engine quickly.
• Be careful during adjustment of the machine to prevent
entrapment of the fingers between moving blades and
fixed parts of the machine.
• Do not operate the machine while wearing tennis shoes
or sneakers.
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
• On multi-cylinder/multi-reel machines, take care as
rotating one cylinder/reel can cause other
cylinders/reels to rotate.
• Handle fuel carefully. Wipe up any spills.
• 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.
• 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.
• Clean grass and debris from cutting units, drives,
silencers/mufflers, and engine to help prevent fires.
Clean up oil or fuel spillage.
• Before starting the engine, sit on the seat.
• Using the machine demands attention. To prevent loss
of control:
• Use jack stands to support components when required.
5
• 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.
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
– When near or crossing roads, always yield the
right-of-way.
• Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
• The grass baskets must be in place during operation of
the cylinders/reels or thatchers for maximum safety.
Shut the engine off before emptying the baskets.
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.
• Raise the cutting units when driving from one work
area to another.
• 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.
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.
• Stay clear of the rotating screen at the side of the engine
to prevent direct contact with your body or clothing.
• 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.
Vibration Level
This unit does not exceed a vibration level of 2.5 m/s2 at
the hands based on measurements of identical machines per
ISO 5349 procedures.
• 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.
This unit does not exceed a vibration level of 0.5 m/s2 at
the posterior based on measurements of identical machines
per ISO 2631 procedures.
Maintenance and Storage
• Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
• Keep your body and hands away from pin hole leaks or
nozzles that eject 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.
• Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units and attachments to the ground.
• Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
• 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.
6
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.
107-8841
93-6693
104-2052
1. Hazard to hands–pinch points
2. Stop reels before touching
1. See operator’s manual
7
104-9296
1. Throttle—slow
2. Throttle—fast
3. Reels raised & off
4. Reels lowered and on when
enabled—forward and
backlap
5. Reels—enabled
6. Reels disabled—lift only
7. Reels disabled—lift and
lower
8. Headlights (optional)
9. Headlights—on
10. Headlights—off
11. Read operator’s manual
104-9298
1. Read operator’s manual
94-6767
98-9342
1. Read operator’s manual
2. Engine start
3. Headlights (Optional)
1.
2.
3.
4.
5.
6.
8
Height–of–cut
Mow and backlap
Read operator’s manual
Traction unit speed
Rear reels circuit controls
Front reels circuit controls
93-6699
1. Slow
2. Fast
3. Traction speed
106-9224
1. Warning—read the Operator’s Manual.
2. Cutting hazard of hand and foot—stop the reels before
touching.
93-6691
1. Read operator’s manual–eccentric bolt
93-6697
(Model 03544 only)
1. Read operator’s manual
2. Lubrication point
3. Time interval
93-6692
1. Read operator’s manual
2. Do not prime engine
3. Do not use starting fluid
98-9335
1. Cutting dismemberment hazard–stay away from moving parts
93-6686
1. Hydraulic oil level
2. Read operator’s manual
93-6696
1. Danger–spring loaded device
2. Read operator’s manual
106-9206
1. Wheel torque
specifications
9
2. Read the Operator’s
Manual.
93-6689
93-6680
1. Danger—no riders
1. Diesel fuel
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the Operator’s
Manual.
6. Keep bystanders a safe
distance from the battery.
105-7506
1. Read the Operator’s
Manual
2. Engine—stop
3. On
4. Engine—preheat
5. Engine—start
93-1263
1. Read operator’s manual
2. To engage parking brake–connect pedals with locking pin,
push down on both pedals and pull parking brake latch out.
3. To release parking brake–press both pedals until parking brake
latch retracts.
4. Danger –reels enabled
10
7. Wear eye protection;
explosive gases can
cause blindness and
other injuries
8. Battery acid can cause
blindness or severe
burns.
9. Flush eyes immediately
with water and get
medical help fast.
10. Contains lead; do not
discard.
104-9294
1. Read the Operator’s Manual.
2. Do not tow the machine.
3. Warning—read the
Operator’s Manual.
4. Cutting hazard of hand or
foot—stay away from
moving parts.
5. Warning—keep bystanders
a safe distance from the
machine.
6. Warning—lock the parking
brake, stop the engine, and
remove the ignition key
before leaving the machine.
7. Warning—use a roll over
protection system and wear
the seat belt.
8. Tipping hazard—lower the
cutting unit when driving
down slopes.
104-9295
(Cover 104–9296 for CE)
1. Read the Operator’s Manual.
2. Do not tow the machine.
3. Warning—read the
Operator’s Manual.
4. Cutting hazard of hand or
foot—stay away from
moving parts.
5. Warning—keep bystanders
a safe distance from the
machine.
6. Warning—lock the parking
brake, stop the engine, and
remove the ignition key
before leaving the machine.
7. Warning—use a roll over
protection system and wear
the seat belt.
11
8. Tipping hazard—lower the
cutting unit when driving
down slopes and do not
drive across or down slopes
greater than 15 degrees.
Specifications
General Specifications
Engine
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. High water temperature shutdown switch.
Cooling System
Radiator capacity is approximately 7-1/2 qt. of 50/50 mixture of ethylene glycol
anti-freeze. Remote mounted 1 qt. expansion tank. A two speed fan drive controls
air flow from fan.
Fuel System
Traction System
Fuel tank capacity is 9.5 gal. of #2 diesel fuel. Equipped with a fuel filter/water
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
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.
Seat
Steering System
Tires
Brakes
Deluxe high back seat with adjustable fore and aft travel, weight and height. Tool
box at left side of seat.
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
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
individual pedals operated by the left foot. Hydrostatic braking through traction
drive.
Electrical System
Automotive type electrical system. 12 volt, maintenance free battery with 530 cold
cranking Amps @ 0 degrees F. and 85 minute reserve capacity @ 85 degrees F. 40
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.
Controls
Foot operated traction and brake pedals. Hand operated throttle, traction speed
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.
Gauges
Hour meter, speedometer, fuel gauge, temperature gauge. 4 warning lamps: oil
pressure, water temperature, amps, and glow plug.
Diagnostics
The Automatic Control Electronics, ACET system allows precise timing and control
of machine functions for maximum reliability. Optional hand held diagnostic display
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
95 in.
Overall Width
Transport
87 in.
Outside of front tires
87 in.
Outside of rear tires
52-1/2 in.
Overall Length
Without grass baskets
116 in.
Height
56-1/2 in.
Without ROPS installed
With ROPS installed
Part No. 104–3395
Comb Kit
Part No. 104–3385
Solid Front Roller
Part No. 82-6680
5 Blade Cutting Unit
Model No. 03527
8 Blade Cutting Unit
Model No. 03528
Rear Roller Brush Kit
Model No. 03533
Front H.O.C. Adjusting Kit
103-1/2 in.
With grass baskets
Rear Roller Scraper
85 in.
Recommended Height of Cut
Part No. 104-8205
Wiehle Scraper Kit
Part No. 104-3380-03
Shoulder Roller Scraper Kit
Part No. 104-8208-03
3” Collar Kit
Part No. 104-8215
Shoulder Roller
Part No. 104-3369
High Height of Cut Kit
Part No. 83-5300
Grass Basket Kit
Model No. 03532
Model No. 30707
5 Blade Cutting Unit
1/2–3/4 in.
Armrest Kit
8 Blade Cutting Unit
1/4–5/8 in.
Thatching Reel
Model No. 03516
4 Wheel Drive Kit (for use with
models 03540 and 03543 only)
TurfDefender® Electronic Leak
Detector Kit
Rear Weight Kit
Model No. 03539
Rear Weight Kit—25 lb.
Part No. 98-9780
Weight
Models 03540 & 03543
2320 lb.*
Model 03544
2675 lb.*
* With 8 Blade Cutting Units, baskets, and full fluid levels
Wheel Weight Kit
Part No. 75-6690
Part No. 104-1478
Precleaner Bowl Extension
Tube (clamp, Part No. 20-4840
required to install extension
tube)
Part No. 43-3810
Diagnostic ACE
Part No. 85-4750
Specifications and design subject to change without notice.
13
Model No. 03521
Setup
Note: Determine the left and right sides 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.
Description
Qty.
Use
Locking hood switch
1
Lock washer
1
Nut
1
Key
2
Hood latch bracket
1
Capscrew, 1/4 x 3/4 in.
2
Flat washer, 1/4 in.
2
Locknut, 1/4 in.
2
Flange head capscrew, 5/16 x 5/8 in.
1
Replacing floor panel fastener for CE
Flange head capscrew, 5/16 x 3/4 in.
1
Securing access panel for CE
Hydraulic filter (transmission)
1
Change filter after first 10 hours of operation.
CE decal
1
CE certificate
2
Service decal, blank
1
Affix to machine (International only).
Diagnostic ACE display overlay
1
Diagnosing machine (store in service shop until
needed)
Video
1
View before operating the machine.
Parts catalog
1
Operator’s Manual (Traction Unit)
2
Engine Manual
1
Mounting locking hood latch for CE
Affix to machine.
Read before operating the machine.
Connecting the Battery
Warning
Warning
Connecting cables to the wrong post could result in
personal injury and/or damage to the electrical
system.
CALIFORNIA
Proposition 65 Warning
1. Open hood.
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.
2. Ensure battery is securely fastened in place and check
battery charge with a hydrometer. If battery needs
charging, be sure at least one battery cable, preferable
the positive (+) cable, is disconnected from the battery
before connecting the charger (Fig. 1).
14
4. Slide the black, negative battery cable onto the negative
battery post and tighten nut securely.
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.
2
6. Close hood.
1
Mounting the Hood Latch
1. Remove plug from hole in left front corner of hood
(Fig. 2).
2. Open hood.
Figure 1
1. Positive battery cable
1
2. Negative battery cable
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from the battery.
Figure 2
1. Hood plug
Warning
3. Mount locking switch to hood with lock washer and
nut. Position switch with latch toward front of machine
(Fig. 3).
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.
1
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the tractor.
• Do not allow metal tools to short between the
battery terminals and metal parts of the tractor.
2
3. Slide the red, positive battery cable onto the positive
battery post and tighten nut securely.
Warning
Incorrect battery cable routing could damage the
tractor and cables, causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
1. Locking switch
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always reconnect the positive (red) battery cable
before reconnecting the negative (black) cable.
4. Loosely mount latch bracket to radiator support with 2
capscrews (1/4 x 3/4 in.), flat washers, and locknuts
(Fig. 3).
Figure 3
15
2. Latch bracket
5. Adjust latch bracket, until aligned with switch latch,
then tighten capscrews.
BASKET BASKET
GUIDE BRACKET
6. Rotate latch to locked and unlocked position with key.
Remove key and store in memorable place.
BASKET
GUIDE
L.H.
FRONT
7. Close hood.
Replacing the Panel Fasteners
BASKET
GUIDE
L.H.
REAR
1. Remove fasteners securing left front corner of floor
panel and left end of access panel to frame (Fig. 4).
R.H.
FRONT
CENTER
BASKET
BRACKET
BASKET
GUIDE
BASKET
BRACKET
BASKET
BRACKET
R.H.
REAR
Figure 5
2
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.
1
1
2
Figure 4
1. Floor panel
2. Access panel
Figure 6
2. Replace floor panel fastener with flange head capscrew
(5/16 x 5/8 in.) supplied in loose parts (Fig. 4).
1. Carrier frame
3. Replace access panel fastener with flange head
capscrew (5/16 x 3/4 in.) supplied in loose parts
(Fig. 4).
4. Install a roll pin (Fig. 7) into hole in appropriate side of
each cutting unit carrier frame (Fig. 5).
2. Basket guide
3
1
Checking the Tire Pressure
The tires are over-inflated for shipping. Therefore, release
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
4
1. Remove cutting units from cartons. Assemble and
adjust per the Operator’s Manual for the cutting unit.
2
Figure 7
1. Carrier frame
2. Roll pin
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.
16
3. Basket bracket
4. Basket collar
5. Align the mounting shaft of the cutting unit with the
pivot tube on the carrier frame. Insert the shaft into the
tube (Fig. 8).
2
3
4
9. Detach chain from lift arm and secure it to cross tube on
each rear cutting unit with a capscrew, flat washer, and
locknut (Fig. 10).
5
1
6
1
Figure 10
1. Lock-up chain
Figure 8
1. Cutting unit mounting
shaft
2. Carrier frame pivot tube
3. Thrust washer
Important Make sure that all hydraulic hoses are
routed away from cutting unit so when cutting unit pivots
excessive rubbing does not occur.
4. Flat washer
5. Lock washer
6. Capscrew
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
fully raised.
6. Secure shaft in pivot tube with a thrust washer, flat
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.
1
2
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.
2
1
Figure 9
1. Reel drive motor
2. Mounting nuts
17
Adjusting the Turf
Compensation Spring
Lifted Height of Outer Front
Cutting Units (Enable Position)
Note: This adjustment is needed for Cutting Unit Models
03527 and 03528 only.
The turnaround height of the front outer cutting units (#4 &
#5) may be increased to provide additional ground
clearance on contoured fairways. Contact your distributor
for assistance.
The turf compensation spring (Fig. 12), connecting carrier
frame to cutting unit, controls the amount of fore-aft
rotation available.
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.
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.)
To increase the turn around height of the front cutting units
proceed as follows:
Important Make spring adjustments with cutting unit
mounted to traction unit and lowered to shop floor.
• Position machine on a level surface, lower the cutting
units and stop the machine.
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).
• Loosen the carriage bolt nut securing the lift arm switch
bracket to the No. 4 lift arm (left front) (Fig. 13).
• Move the lift switch bracket inward in the slot until the
desired position is attained.
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).
• Set the distance between the lift arm switch and the flag
on the lift arm to approximately .062 inches.
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.
• Tighten the carriage bolt nut.
Note: As gap (C) between spring bracket and washer
increases, carrier frame/cutting unit rotation angle (B)
increases.
“B”
“C”
“A”
3
2
Figure 13
1. Lift arm switch
2. Carriage bolt nut
Figure 12
18
3. Lift arm flag
1
Installing the Rear Weight
The Reelmaster 5200-D & 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 lb. of calcium chloride ballast is added to rear wheels.
Use chart below to determine combinations of weight required. Order parts from your local Authorized Toro Distributor.
Rear Weight
Required
Weight Part
Number
Weight Description
Qty.
2wd Traction Unit with ROPS
w/o baskets
291 lb.
75-6690
Rear Weight Kit
3
2wd Traction Unit with ROPS
with baskets
358 lb.
75-6690
Rear Weight Kit
4
2wd Traction Unit w/o ROPS
w/o baskets
157 lb.
75-6690
Rear Weight Kit
1
2wd Traction Unit w/o ROPS
with baskets
224 lb.
75-6690
Rear Weight Kit
2
4wd Traction Unit with ROPS
w/o baskets
157 lb.
75-6690
Rear Weight Kit
1
4wd Traction Unit with ROPS
with baskets
249 lb.
75-6690
Rear Weight Kit
2
98-9780
Rear Weight Kit—25 lb.
1
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 turf, immediately soak affected area with water.
19
Before Operating
2
Caution
1
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.
Figure 15
1. Dipstick
Checking the Engine Oil
2. Oil fill cap
3. If oil is below FULL mark, remove fill cap and add oil
until level reaches FULL mark on dipstick. Do not
overfill.
The engine is shipped with oil in the crankcase; however,
the oil level must be checked before and after the engine is
first started.
4. Install oil fill cap and close hood.
Crankcase capacity is approximately 4 qt. (2.8 l) with the
filter.
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.
Use high-quality engine oil that meets the following
specifications:
API Classification Level Required: CH–4, CI–4 or
higher.
Checking the Cooling System
Preferred oil: SAE 15W–40 (above 0_ F)
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.
Alternate oil: SAE 10W–30 or 5W–30
(all temperatures)
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.
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.
Caution
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).
If the engine has been running, the pressurized,
hot coolant can escape and cause burns.
• Do not open the radiator cap when the engine is
running.
• Use a rag when opening the radiator cap, and
open the cap slowly to allow steam to escape.
2
1
1. Check level of coolant in expansion tank (Fig. 16).
Coolant level should be between the marks on side of
tank.
Figure 14
1. Dipstick
2. Oil fill cap
20
1
1
Figure 17
1. Fuel tank cap
Checking the Transmission
Fluid
Figure 16
1. Expansion tank
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.
2. If coolant level is low, remove expansion tank cap and
replenish the system. Do not overfill.
3. Install expansion tank cap.
1. Position machine on a level surface, lower the cutting
units and stop the engine.
Filling the Fuel Tank
2. Remove floor panel.
1. Remove fuel tank cap (Fig. 17).
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 above groove.
2. Fill tank to about one inch below top tank, not filler
neck with No. 2 diesel fuel. Then install cap.
Danger
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.
1
• 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.
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.
21
Checking the Hydraulic Fluid
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.
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:
4. If level is low, add appropriate fluid to raise level to full
mark.
5. Install dipstick and cap onto filler neck.
Toro Premium Transmission/Hydraulic Tractor
Fluid
(Available in 5 gallon pails or 55 gallon drums. See
parts catalog or Toro distributor for part numbers.)
Checking the Rear Axle
Lubricant
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: This procedure is for Model 03544 only.
The rear axle has three separate reservoirs which use SAE
80W-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.
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.
2. Remove the 3 check plugs from axle (Fig. 20 and 21)
and make sure lubricant is up to bottom of each hole.
Material Properties:
Viscosity, ASTM D445 cSt @ 40_ C 55 to 62
cSt @ 100_ C 9.1 to 9.8
2
Viscosity Index ASTM D2270 140 – 152
Pour Point, ASTM D97
–35_ F to –46_ F
Industry Specifications:
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.
1
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
Figure 20
1. Check plug
2. Fill plug
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.
1
1
Figure 21
1. Left check plug (rear of axle)
Figure 19
1. Hydraulic tank cap
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 if 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
Warning
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
To stop, reduce foot pressure on traction pedal and allow it
to return to center position.
Note: Determine the left and right sides of the machine
from the normal operating position.
Caution
If you leave the key in the ignition switch, someone
could accidently start the engine and seriously
injure you or other bystanders.
1
Figure 23
Remove the key from the ignition switch and lower
the cutting units to the ground before servicing or
making adjustments to the machine.
1. Traction pedal
Traction Speed Limiter
Controls
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.
Seat
The seat adjusting lever (Fig. 22) allows 4 inch fore and aft
adjustment. Seat 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.
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 transport.
2
1
Parking Brake Latch
Figure 22
1. Seat adjusting lever
2. Seat adjusting knob
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.
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.
Key Switch
The key switch (Fig. 24) has three positions: OFF,
ON/Preheat, and START.
24
Fuel Gauge
3
The fuel gauge (Fig. 25) shows amount of fuel in tank.
1
4
Lower Mow/Raise Control Lever
2
The lever (Fig. 25) raises and lowers the cutting units and
also starts and stops the reels.
5
Glow Plug Indicator Light
7
6
When lit (Fig. 25), indicates a control system problem.
Light blinks when glow plugs are preheating.
Figure 24
1.
2.
3.
4.
Traction speed limiter
Reel control light
Speedometer
Brake pedals
5. Parking brake latch
6. Locking pin
7. Key switch
Engine Oil Pressure Warning Light
This light (Fig. 25) indicates dangerously low engine oil
pressure.
Charge Indicator
Engine Coolant Temperature Warning
Light
The charge indicator (Fig. 25) illuminates when system
charging circuit malfunctions.
The light (Fig. 25) illuminates and engine shuts down when
coolant reaches a dangerously high temperature.
Throttle Control
Enable/Disable Switch
Move control (Fig. 25) forward to increase engine speed,
rearward to decrease speed.
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.
4
2
5
3
Backlap Switch
1
7
The backlap switch (Fig. 26) is used in conjunction with
lower mow / raise control lever for backlapping operation.
Refer to Cutting Unit Maintenance, Backlapping.
6
8
9
1
Figure 25
1. Lower mow/raise control
lever
2. Fuel gauge
3. Engine coolant
temperature gauge
4. Engine oil pressure
warning light
5. Engine coolant
temperature warning light
6. Glow plug indicator light
7. Charge indicator
8. Throttle control
9. Enable/disable switch
Figure 26
1. Backlap switch
25
Reel Speed Controls
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/DISABLE switch is in the DISABLE
position.
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.
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.
1
Note: Move throttle to FAST position when restarting a
warm engine.
1. Reel speed controls
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.
Hour Meter
Important 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.
The hour meter (Fig. 28) shows total hours that machine
has been operated.
Bleeding the Fuel System
Figure 27
1. Park the machine on a level surface. Make sure fuel
tank is at least half full.
2. Raise hood over engine.
1
3. Open the air bleed screw on the fuel injection pump
(Fig. 29) with a 12 mm wrench.
Figure 28
1. Hour meter
1
Starting and Stopping
Important The fuel system must be bled if any of the
following situations have occurred:
Figure 29
A. Initial start up of a new machine.
1. Fuel injection pump bleed screw
B. Engine has ceased running due to lack of fuel.
C. Maintenance has been performed upon fuel system
components; i.e., filter replaced, separator serviced,
etc.
4. Turn key in ignition switch to the ON position. Electric
fuel pump will begin operation, thereby forcing air out
around air bleed screw. Leave key in ON position until
solid stream of fuel flows out around screw. Tighten
screw and turn key to OFF.
Refer to Bleeding the Fuel System, page 26.
26
Danger
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.
• 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 39.
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.
Figure 30
Adjust the reel speed controls as follows:
4. To set reel speed, rotate knobs (Fig. 31) until indicator
arrows are in line with the number designating desired
setting.
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 appropriate graph (Fig. 30) for 5 blade or 8
blade cutting units, determine the proper reel speed
setting.
1
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
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.
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.
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.
Each down pressure spring may be adjusted to one of four
settings. Each increment increases or decreases down
pressure on cutting unit by 8 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.
1
2. Remove floor plate in front of seat and open the hood to
gain access to all 5 springs.
Caution
Springs are under tension.
Use caution when adjusting.
3. Place an open end wrench on the hex shaft of the spring
bracket (Fig. 32).
Figure 33
1. Drive shaft
4. Remove the capscrew and locknut securing retaining
bracket (Fig. 32), while rotating hex shaft to relieve
spring tension.
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).
2
1
Figure 32
1. Spring bracket hex shaft
2. Retaining bracket
1
5. Move spring bracket to desired location and install
capscrew and locknut, while rotating hex shaft to
relieve spring tension.
Figure 34
1. Center of front frame member
Note: Lock both brake pedals together before towing.
28
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.
• Fuses are blown.
4. An operator must be on the machine to steer it and keep
the traction pedal fully depressed in the forward
position while towing.
Check electrical connections, input fuses and diagnostic
light bulb to determine malfunction. Make sure loopback
connector is secured to wire harness connector.
• Not functioning correctly.
5. When towing is completed, reinstall driveshaft as
shown in Figure 33. The splines are designed to allow
assembly only when the two halves of the shaft are
properly oriented.
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.
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.
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.
1
Caution
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
Figure 35
1. Electronic controller light
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
• Replace switches every two years regardless of
whether they are operating properly or not.
When the controller diagnostic light blinks, one of the
following problems has been detected by the controller:
• One of the outputs has been shorted.
• One of the outputs is open circuited.
Using the diagnostic display, determine which output is
malfunctioning; refer to Checking the Interlock Switches,
page 29.
Verifying Interlock Switch Function
1. Park machine on a level surface, lower the cutting units,
stop the engine and engage the parking brake.
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:
2. Open control panel cover. Locate wire harness and
connectors near controller (Fig. 36). Carefully unplug
loop back connector from harness connector.
• Loopback is not connected.
• The light is burned out.
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.
1
Figure 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
decal is positioned on Diagnostic ACE display.
2. Open control panel cover. Locate wire harness and
connectors near controller. Carefully unplug loopback
connector from harness connector.
4. Turn the key switch to the ON position, but do not start
machine.
3. Connect the Diagnostic ACE connector to the harness
connector. Make sure correct overlay decal is positioned
on Diagnostic ACE.
1
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
button once. This may be done as often as required. Do not
hold the button.
Figure 37
1. Diagnostic ACE
6. Sit on the seat and attempt to operate the desired
function of the machine. (If you need help verifying the
correct input settings for each function, refer to the
Logic Chart on page 32) The appropriate output LED’s
should illuminate to indicate that the ECU is turning on
that function. (Refer to the list on page 31, or the logic
chart to be certain of the specified output LED’s.
Note: The red text on the overlay decal refers to input
switches and the green text refers to outputs.
5. The “inputs displayed” LED, on lower right column of
the Diagnostic ACE, should be illuminated. If “outputs
displayed” LED is illuminated, press the toggle button,
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
defective electrical parts immediately. To reset a blinking
LED, turn the key switch “OFF”, then back “ON”.
6. The Diagnostic ACE will illuminate the LED associated
with each of the inputs when that input switch is closed.
Individually, change each of the switches from open to
closed (i.e., sit on seat, engage traction pedal, etc.), and
note that the appropriate LED on Diagnostic ACE will
If no output LED’s are blinking, but the correct output
LED’s do not illuminate, verify that the required input
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.
Operating Characteristics
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.
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.
Familiarization
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 maintain
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.
If each output switch is in the correct position and
functioning correctly, but the output LED’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.
Warning
When operating the machine, always use the seat
belt and ROPS together.
Hydraulic Valve Solenoid
Functions
Warning System
If a warning light comes on during operation, stop the
machine immediately and correct the problem before
continuing operation. Serious damage could occur if the
machine is operated with a malfunction.
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.
Solenoid
Function
S1
Front reel circuit
Mowing
S2
Rear reel circuit
S3
Lift/lower front wing cutting units
S4
Lift/lower center cutting unit
S5
Lift/lower rear cutting unit
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.
S6
Lower any cutting units
S7
Lift any cutting units
Transport
Backlap any cutting units
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.
S8, S9
Important 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.
31
0
1
2 Key Run
INPUTS
32
8) Backlap Rear
Raise (To turn around front &
rear)
Raise (To turn around front &
rear)
7) Backlap Front
Raise (To turn around front)
6) Raise (transport)
5) Mow
Lower / Mow–Front & Rear
Lower / Mow–Front
Lower (All units when enabled)
Lower (All units when disabled)
4) Lower (To turn around)
Run (with operator)
8 Enable Reels
7 Raise
OO
OO
O X
O X
O X
O X
X O
MX
X X
X X
O X
O X
O X
O X
O O
9 Front Units Down
X
X
O
X
X
X
X
O
X
O
X
X
X
11 Backlap Rear
10 Backlap Front
O O
O O
O O
O O
O O
O O
O O
O O
O O
O O
X O
X O
O X
O X
12 Lower / Mow
AO Start Key
T3
T1
T2
T6
T2
13
M
17
T5
T2
X
A1
O
O
O
M
X
X
X
M
X
M
O
O
/
3) Run (No operator)
1) Preheat
X
X X
O
X O X O
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X X
X X
XX
3 Traction Neutral
2) Start
4 Seat Switch
X
X
5 High Coolant Temp
0) Controller OK
ACTIONS
14
RM 5200–D
RM 5400–D
15
TIMERS
T1= .5 sec
T2= 5.0 sec
T3= .9 sec
T4= .1 sec
T5= .9 sec
T6= 6 sec
16
LOGIC
GRID
T Timer Involved
6
X=CLOSED, O=OPEN, P=OUTPUT ON,
KEY: M=MOMENTARILY CLOSED,
A=OUTPUT ON IF REELS WERE PREVIOUSLY RUNNING
0 Diagnostic Light
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
3 S3
2 S2
6 S6
5 S5
1 S8,S9
P
P
P P P P P P
P P
P
P
P P
P
P
P P P
P
P
P
P
P P P
4 S4
P
P
P
P
P P
P
P
P
P
P P
P
P
A P
P
7 ETR Hold / Alt
P
P
10 S1
P
P
P
P
P
11 S7
P
P
P
P
13 Preheat
12 Start
P
P P
Logic Chart
OUTPUTS
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
Interval
Maintenance Procedure
Check the fan and alternator belt tension.
Torque the wheel lug nuts.
Change the transmission fluid.
Replace the transmission filter.
After first 10 hours
•
•
•
•
After first 50 hours
• Replace the engine oil and filter.
• Check the engine RPM (idle and full throttle).
Check the battery fluid level.
Check the battery cable connections.
Lubricate all grease fittings.
Inspect the air filter, dust cup, and baffle.
Every 50 hours
•
•
•
•
Every 100 hours
• Check the fan and alternator belt tension.
• Inspect the cooling system hoses.
Every 150 hours
• Replace the engine oil and filter.
Every 200 hours
•
•
•
•
•
Torque the wheel lug nuts.
Drain moisture from the hydraulic tank.
Drain moisture from the fuel tank.
Check the reel bearing preload.
Lubricate the front axle bearings.
Every 400 hours
•
•
•
•
•
Service the air cleaner (when the indicator shows red).
Replace the fuel/water separator filter.
Replace the fuel filter.
Inspect the traction linkage movement.
Check the engine RPM (idle and full throttle).
Every 800 hours
•
•
•
•
•
•
•
Change the hydraulic filter.
Change the transmission fluid.
Replace the transmission filter.
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).
Every 1600 hours or 2
years, whichever occurs
first
•
•
•
•
•
Replace all moving hoses.
Replace the interlock safety switches.
Flush/replace the cooling system fluid.
Drain/flush the fuel tank.
Drain/flush the hydraulic tank.
33
Daily Maintenance Checklist
Duplicate this page for routine use.
For the week of:
Maintenance Check Item
Mon.
Tues.
Wed.
Check safety interlock operation.
Check brake operation.
Check engine oil and fuel level.
Drain the water/fuel separator.
Check the air filter restriction indicator.
Check the radiator and screen for
debris.
Check unusual engine noises.1
Check unusual operating noises.
Check the transmission oil level.
Check the hydraulic system oil level.
Check the hydraulic filter indicator.2
Check hydraulic hoses for damage.
Check for fluid leaks.
Check the tire pressure.
Check instrument operations.
Check the reel-to-bedknife adjustment.
Check the height-of-cut adjustment.
Check the cutting units shear pin.
Lubricate all grease fittings.3
Touch up damaged paint.
1Check
the glow plugs and injector nozzles if excess smoke or rough running is noted.
with the engine running and the oil at operating temperature.
3Grease immediately after every washing, regardless of the interval listed.
2Check
Notation for Areas of Concern
Inspection performed by:
Item
Date
Information
1
2
3
4
5
6
7
8
34
Thurs.
Fri.
Sat.
Sun.
Service Interval Chart
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.
Figure 38
Greasing the Bearing and
Bushings
The machine has grease fittings that must be lubricated
regularly with No. 2 General Purpose Lithium Base Grease.
If machine 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
Figure 40
Figure 43
Figure 41
Figure 44
Figure 42
Figure 45
36
General Air Cleaner
Maintenance
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.
• Check the air cleaner body for damage which could
cause an air leak. Replace if damaged. Check the whole
intake system for leaks, damage or loose hose clamps.
• Service the air cleaner filter only when the service
indicator requires it. Changing the air filter before it is
necessary only increases the chance of dirt entering the
engine when the filter is removed
• 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 up above level marks on
precleaner bowl.
1
1. Remove thumb screw and separate cover from
precleaner bowl (Fig. 46).
2
1
3
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 to seat it in the canister. Do
not apply pressure to the flexible center of the filter.
Figure 46
1. Air cleaner indicator
2. Precleaner bowl
3. Dust cup
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.
2. Empty precleaner bowl and wipe clean.
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.
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.
5. Secure the cover latches.
6. Reset indicator (Fig. 46) if showing red.
37
Engine Oil and Filter
Fuel Lines and Connections
Change oil and filter initially after the first 50 hours of
operation, thereafter change oil and filter every 150 hours.
Check lines and connections every 400 hours or yearly,
whichever comes first. Inspect for deterioration, damage, or
loose connections.
1. Remove drain plug (Fig. 48) and let oil flow into drain
pan. When oil stops, install drain plug.
Fuel Filter/Water Separator
Drain 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.
1
2. Loosen drain plug on bottom of filter canister. Tighten
plug after draining.
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.
1
2
Figure 50
1. Fuel filter/water separator
1
2. Drain plug
Replace filter canister after every 400 hours of operation.
Figure 49
1. Clean area where filter canister mounts.
1. Engine oil filter
2. Remove filter canister and clean mounting surface.
3. Lubricate gasket on filter canister with clean oil.
3. Add oil to crankcase; refer to Checking the Engine Oil,
page 20.
4. Install filter canister by hand until gasket contacts
mounting surface, then rotate an additional 1/2 turn.
Servicing the Fuel System
Replacing the Fuel Pre Filter
Fuel Tank
Replace the fuel pre filter after every 400 operating hours
or yearly, whichever occurs first.
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.
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.
38
4. Tighten pipe connector securely.
3. Loosen the hose clamps at both ends of the filter and
pull fuel lines off filter.
5. Repeat steps on remaining nozzles.
2
2
1
1
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.
Figure 52
1. Fuel injectors (3)
Danger
Servicing the Engine Cooling
System
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.
Removing Debris
• 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.
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 it out of
mounting tracks (Fig. 53). Clean screen thoroughly with
compressed air.
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
1. Loosen the pipe connection to the No. 1 nozzle and
holder assembly (Fig. 52).
Figure 53
1. Screen
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
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.
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.
2
Cooling Fan Belt
1
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
3. Tighten locknut to secure adjustment.
Figure 54
1. Reel oil cooler
2. Radiator
3. Transmission oil cooler
4. Install screen and close hood.
2
Servicing the Engine Belts
1
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.
Figure 56
2. Check tension by depressing belt (Fig. 55) midway
between alternator and crankshaft pulleys with 22 lb. of
force. Belt should deflect 7/16 in. If deflection is
incorrect, proceed to step 3. If correct, continue
operation.
1
1. Cooling fan belt
2. Tensioner lever
Adjusting the Throttle
1. Position throttle lever forward so it stops against seat
base slot.
2
2. Loosen the throttle cable connector on the lever arm at
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 lb.
Figure 55
1. Alternator belt
2. Brace
40
Replacing the Hydraulic Filter
1
The hydraulic 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).
Figure 57
Important Use of any other filter may void the
warranty on some components.
1. Injection pump lever arm
1. Position machine on a level surface, lower the cutting
units, stop the engine, engage the parking brakes, and
remove key from ignition switch.
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.
2. Clean area around filter mounting area (Fig. 59). Place
drain pan under filter and remove filter.
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.
1
1
Figure 59
1. Hydraulic filter
3. Lubricate new filter gasket and fill the filter with
hydraulic fluid.
4. Ensure that the filter mounting area is clean. Screw
filter on until gasket contacts mounting plate. Then
tighten filter one half turn.
Figure 58
5. Start engine and let run for about two minutes to purge
air from the system. Stop the engine and check for
leaks.
1. Hydraulic reservoir
3. Fill reservoir with approximately 8.5 gallons of
hydraulic fluid; refer to Checking the Hydraulic Fluid,
page 22.
Important 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.
41
Checking the Hydraulic Lines
and Hoses
Adjusting the Traction Drive for
Neutral
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.
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.
Warning
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.
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
Note: On 4 wheel drive models, left rear tire must also be
off the shop floor or 4 wheel drive driveshaft must be
removed.
• Make sure all hydraulic fluid hoses and lines are
in good condition and all hydraulic connections
and fittings are tight before 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.
3. Under right side of machine, loosen locknut on traction
adjustment cam (Fig. 61).
1
Hydraulic System Test Ports
The test ports are used to test pressure in the hydraulic
circuits. Contact your local Toro distributor for assistance.
Figure 61
1. Traction adjustment cam
Test Port #1 (Fig. 60) is used to assist in trouble shooting
the hydraulic circuit for the front cutting units and lift
cylinders.
Warning
Test Port #2 (Fig. 60) is used to assist in trouble shooting
the hydraulic circuit for the rear cutting units.
The engine must be running so the final
adjustment of the traction adjustment cam can be
performed. This could cause personal injury.
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.
Keep hands, feet, face, and other body parts away
from the muffler, other hot parts of the engine, and
any rotating parts.
2
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.
1
Figure 60
1. Test port #1
2. Test port #2
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:
1
Center Cutting Unit
1. Locate valve behind access panel above operator’s
platform (Fig. 62).
2. Loosen setscrew on valve and rotate valve
approximately 1/2 turn clockwise.
Figure 63
1. Outside front cutting units adjustment valve
3. Verify lift rate adjustment by raising and lowering
cutting unit several times. Readjust as required.
4. After desired lift rate is attained, tighten setscrew to
lock adjustment.
Rear Cutting Units
1. Raise hood and locate valve on left rear side of machine
(Fig. 64).
1
Figure 62
1
1. Center cutting unit adjustment valve
Figure 64
Outside Front Cutting Units
1. Rear cutting units adjustment valve
1. Locate valve on flow divider (under foot rest) (Fig. 63).
2. Loosen setscrew on valve and rotate valve
approximately 1/2 turn clockwise.
2. Loosen setscrew on valve. Rotate valve 1/2 turn
clockwise.
3. Verify lift rate adjustment by raising and lowering
cutting units several times. Readjust as required.
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.
4. After desired lift rate is attained, tighten set screw to
lock adjustment.
43
Checking and Adjusting the
Traction Linkage
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.
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. Disengage locking pin from brake pedals so both pedals
work independently of each other.
1. Park machine on a level surface, lower cutting units to
the floor and shut engine off.
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.
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).
2
3
1
1
5
4
Figure 65
1.
2.
3.
4.
Spring anchor plate
Eye bolt
Inner locknut
Outer locknut
Figure 66
5. Shorten distance to
decrease time required to
stop machine.
1. Brake cables
Changing the Transmission
Fluid
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.
Change the transmission fluid after every 800 hours of
operation, in normal conditions.
5. Operate the machine and check stopping distance.
Repeat procedure if required.
1. Position machine on a level surface, lower the cutting
units, stop the engine, engage the parking brakes, and
remove key from ignition switch.
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.
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
Changing the Rear Axle
Lubricant
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.
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.
2
5. Fill axle with lubricant; refer to Checking the Rear Axle
Lubricant, page 22.
1
Figure 67
1. Transmission suction line
2. Transmission oil filter
1
Replacing the Transmission
Filter
1
Figure 68
Change the transmission filter after the first 10 hours of
operation and every 800 hours thereafter.
1. Drain plugs
Only the Toro replacement filter (Part No.75-1330) can be
used in the hydraulic system.
Adjusting Rear Wheel Toe-In
Important Use of any other filter may void the
warranty on some components.
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.
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.
Models 03540 and 03543
3. Lubricate new filter gasket with hydraulic oil.
1. Rotate the steering wheel so the rear wheels are straight
ahead.
4. Ensure that the filter mounting area is clean. Screw
filter on until gasket contacts mounting plate. Then
tighten filter 1/2 turn.
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.
5. Start engine 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.
45
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
Warning
1
CALIFORNIA
Figure 69
Proposition 65 Warning
1. Tie rods
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.
3. When toe-in is correct, tighten jam nuts against tie rods.
Models 03544 only
1. Rotate the steering wheel so the rear wheels are straight
ahead.
Important Before welding on the machine, disconnect
both cables from the battery, disconnect both wire harness
plugs from the electronic control unit and the terminal
connector from the alternator to prevent damage to the
electrical system.
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).
Danger
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• 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.
1
Figure 70
Warning
1. Tie rod
Charging the battery produces gasses that can
explode.
4. Rotate the detached ball joint inward or outward one (1)
complete revolution. Tighten the clamp at the loose end
of the tie rod.
Never smoke near the battery and keep sparks and
flames away from battery.
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.
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
6. Install the ball joint in the axle case support and tighten
the slotted hex nut finger tight.
46
Optional Lighting
posts and cable connectors with Grafo 112X (skin-over)
grease (Toro Part No. 505-47) or petroleum jelly to prevent
corrosion.
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.
Fuses
There are 4 fuses in the machines electrical system. They
are located below control panel (Fig. 71 and 72).
SCHEMATIC FOR OPTIONAL LIGHTING
To Lights w/external ground
Black
30
Red
1
To Lights
30
Orange
85
2
3
Switch
86
Relay
Figure 71
1. Fuses
Switch*
Relay
Toro Part No. 75–1010
Honeywell Part No. 1TL1–2
Toro Part No. 70–1480
Bosch Part No. 0–332–204
Black, red and orange wires are located in control console.
Add 10 Amp fuse to fuse block at location shown
* Punch out in control panel provided for switch installation
Note: Make sure a good ground is achieved to prevent
damage to traction unit.
Backlapping the Cutting Units
Warning
Contact with the reels or other moving parts can
result in personal injury.
• Keep fingers, hands, and clothing away from the
reels or other moving parts.
• Never attempt to turn the reels by hand or foot
while the engine is running.
Figure 72
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.
47
Danger
Changing the engine speed while backlapping may
cause the reels to stall.
• Never change the engine speed while
backlapping.
• 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
to backlap.
Danger
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
RELAY
5
4
1
2
LIGHT
SWITCH
FUEL
GAGE
G
S
I
BLACK
BLACK
G
BLACK
OIL PRESS
SWITCH
L
S
B
6
4
2
RED
–
BLACK
BATTERY
12 VOLTS
+
RED
WATER
TEMP
SENSOR
FUSIBLE
LINK
HARNESS
5
3
1
WARNING LIGHTS
SPEEDOMETER
G
S
I
ORANGE/RED
STARTER
START
RELAY
GREEN/BLUE
ALTERNATOR
ORANGE
BLACK
BLACK
GRAY
BLACK
BLUE/GREEN
ORANGE
BLUE/WHITE
ORANGE
TEMP
GAGE
FUSIBLE
LINK
OPTIONAL
LIGHT
ORANGE
G
S
I
ORANGE
ORANGE
RED
GREEN/BLACK
ORANGE
BLACK
BLACK
ORANGE
L
BLACK
BLACK
RED
DIAGNOSTIC
INDICATOR
HOUR
METER
B
A
GLOW PLUGS
RED
RED
#2A
ORANGE
B
#2B
A
I
#3A
GREEN/RED
#3B
PINK/BLACK
10A
L
#1B
YELLOW
7.5A
RED/BLACK
3B
3A
ORANGE
ALTERNATOR
2J
2P
3N
HOLD (A)
FIELD (R)
SPEED SENSOR
1H
RUN (ETR)
SOLENOID
(C)
PULL (B)
BLACK
3M
BATTERY
POWER
START – KEY SWITCH
GLOW PLUG
RELAY
ORANGE
OUTPUT (B)
#1A
1M
1L
1K
1J
1A
RUN
START
FAULT
INDICATOR
LIGHT
VCC
Y
X
WRNG LIGHTS (L)
#4A
10A
RED/BLUE
KEY SWITCH
20A
RED
10A
PARKING BRAKE
L
GREEN/BLACK
1N
GREEN
2B
SEAT SENSOR
1G
ENGINE WATER TEMP SENSOR
2C
3E
2G
1P
1S
OUTPUTS
1B
FUEL
PUMP
1R
85–4400
SOLID STATE CONTROLLER
INPUTS
3C
TAN
PINK/BLUE
4A
BLUE/WHITE
10A
GREEN/WHITE
PINK/BLUE
BRN
VIOLET/RED
BROWN
BROWN/WHITE
VIOLET/RED
PINK/WHITE
START
REEL DISABLE SWITCH
2S
GRAY
BROWN/RED
ORANGE
BLACK
2D
VIOLET
ORANGE/BLUE
1C
A
2E
BLACK/WHITE
1D
3G
1E
BLACK
2H
C
1F
D
RED/WHITE
YELLOW
LEAK DETECTOR
B
YELLOW/BLACK
S
RED/WHITE
PREHEAT
RAISE SWITCH (JOYSTICK)
FD1
FRONT REELS DOWN SENSOR
3S
LOWER/MOW SWITCH (JOYSTICK)
4S
IGNITION
SWITCH
ORANGE/RED
PINK
YELLOW/WHITE
GEAR
TOOTH
SENSOR
5S
BLACK
3H
YELLOW/BLUE
2S
BACKLAP
SWITCH
2F
”M”
2A
GROUND
3F
WHITE
DECAL – ECU
I.D. #1
BROWN/WHITE
C
A
B
6S
BLACK
BLUE
BLACK/RED
BACKLAP FRONT SWITCH
7S
BACKLAP REAR SWITCH
8S
FUEL
SENDER
BLACK/WHITE
9S
B
BLACK
BLACK
CAN (–)
CAN (+)
E
E
A
A
B
C
C
ECU COMMUNICATION PORT
AND LOOPBACK
CONNECTOR
3S
3R
3P
2L
2K
3K
3J
3L
ORANGE/BLUE
RS232 (RX)
NEUTRAL SENSOR
RED/WHITE
BLACK
RED/BLUE
RUN \ ALTERNATOR
RED/BLUE
GREEN/PINK
RS232 (TX)
REEL ENABLE SWITCH
1S
RED/BLUE
49
GRAY
BLACK
RS232 (GND)
TEMP
SENDER
Electrical Schematic
50
P1
P3
STEERING
CYLINDER
TANK BREATHER
40 MICRON
P2
LH
RH
100MESH
TEST PORT
FOR FRONT
UNITS
INPUT SHAFT
3200 RPM MAX
DIFFERENTIAL
HOUSING
STRAINER IN TANK
100 MESH
INPUT SHAFT
TO TRANSMISSION
CCW ROTATION
R
F
R
F
”A” SYSTEM RELIEF 3625 PSI
”B” CHARGE PRESSURE 150 PSI
”C” COOLER BY–PASS 70 PSI
”D” FILTER BY–PASS 70 PSI
”E” SYSTEM RELIEF 3625 PSI
”C”
”A”
FORWARD SIDE
OF CLOSED LOOP
”D”
”B”
SUNSTRAND M25
1.5 IN3 /REV
”E”
M4
S4A
S3A
OUT
IN
TRW HGF 16
STEERING CONTROL VALVE
6.6 IN3
1250 PSI
D1
M5
G1
P2
T M3 G2 M2
D2
S5A
P1
AUX
TEST PORT
FOR REAR[R]UNITS
SYSTEM PRESSURE GAGE PORT ”E”
SYSTEM PRESSURE GAGE PORT ”A”
(3)
R
F
R
F
R
F
OIL COOLER
P
OUTPUT SHAFT
TO DIFFERENTIAL
FD1
CHARGE PRESSURE GAGE PORT ”B”
C2
C1
Hydraulic Schematic
Preparation for Seasonal
Storage
Engine
1. Drain the engine oil from the oil pan and replace the
drain plug.
Traction Unit
2. Remove and discard the oil filter. Install a new oil filter.
1. Thoroughly clean the traction unit, cutting units and the
engine.
3. Refill oil pan with 4 quarts of motor oil.
2. Check the tire pressure. Inflate all traction unit tires to
15–20 psi.
4. Start the engine and run at idle speed for approximately
two minutes.
3. Check all fasteners for looseness; tighten as necessary.
5. Stop the engine.
4. Grease or oil all grease fittings and pivot points. Wipe
up any excess lubricant.
6. Thoroughly drain all fuel from the fuel tank, lines and
the fuel filter/water separator assembly.
5. Lightly sand and use touch-up paint on painted areas
that are scratched, chipped, or rusted. Repair any dents
in the metal body.
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.
6. Service the battery and cables as follows:
A. Remove the battery terminals from the battery posts.
10. Seal the air cleaner inlet and the exhaust outlet with
weatherproof tape.
B. Clean the battery, terminals, and posts with a wire
brush and baking soda solution.
11. Check anti-freeze protection and add as needed for
expected minimum temperature in your area.
C. Coat the cable terminals and battery 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.
51
The Toro General Commercial Products Warranty
A Two-Year Limited Warranty
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 original 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: [email protected]
Owner Responsibilities
As the Product owner, you are responsible for required maintenance 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:
• Product failures which result from the use of non-Toro
replacement parts, or from installation and use of add-on,
modified, or unapproved accessories
• Product failures which result from failure to perform required
maintenance and/or adjustments
• Product failures which result from operating the Product in an
abusive, negligent or reckless manner
• 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.
•
•
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.
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
liable 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 substitute 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 contained 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 Canada 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

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