Toro 5400d Fairway Mower Manual
. 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. IntroductionCAUTION, WARNING, or DANGER—“personalsafety instruction.” Failure to comply with theinstruction may result in personal injury or death.Read this manual carefully to learn how to operate andmaintain your product properly. The information in thismanual can help you and others avoid injury and productdamage. Although Toro designs and produces safeproducts, you are responsible for operating the productproperly and safely. Preparation– stay alert for humps and hollows and other hiddenhazards;.
While mowing, always wear substantial footwear, longtrousers, hard hat, safety glasses, and ear protection.Long hair, loose clothing, or jewelry may get tangled inmoving parts. Do not operate the equipment whenbarefoot or wearing open sandals.– never mow across the face of the slope, unless themower is designed for this purpose. Stay alert for holes in the terrain and other hiddenhazards.
Carefully release pressure from components with storedenergy. Reduce the throttle setting during engine run-out and, ifthe engine is provided with a shut-off valve, turn thefuel off at the conclusion of mowing.
Disconnect battery and remove spark plug wire beforemaking any repairs. Disconnect the negative terminalfirst and the positive last. Reconnect positive first andnegative last. Keep hands and feet away from the cutting units. To ensure safety and accuracy, have an Authorized ToroDistributor check the maximum engine speed with atachometer.
Maximum governed engine speed should be2900 RPM.– Do not drive close to sand traps, ditches, creeks, orother hazards.– Reduce speed when making sharp turns. Avoidsudden stops and starts. If major repairs are ever needed or if assistance isdesired, contact an Authorized Toro Distributor.– When near or crossing roads, always yield theright-of-way.
Safety and Instruction DecalsSafety decals and instructions are easily visible to the operator and are located near any areaof potential danger. Replace any decal that is damaged or lost.107-8104-20521. Hazard to hands–pinch points2. Stop reels before touching1.
Reels raised & off4. Reels lowered and on whenenabled—forward andbacklap5. Reels disabled—lift only7. Reels disabled—lift andlower8. Headlights (optional)9. Read operator’s manual104-92981.
Read operator’s manual94-61. Read operator’s manual2.
Engine start3. Headlights (Optional)1.2.3.4.5.6. Traction speed106-92241. Warning—read the Operator’s Manual.2. Cutting hazard of hand and foot—stop the reels beforetouching.93-66911.
Read operator’s manual–eccentric bolt93-6697(Model 03544 only)1. Read operator’s manual2. Lubrication point3.
Time interval93-66921. Read operator’s manual2. Do not prime engine3. Do not use starting fluid98-93351. Cutting dismemberment hazard–stay away from moving parts93-66861.
Hydraulic oil level2. Danger—no riders1. Diesel fuelBattery SymbolsSome or all of these symbols are on your battery.1. Explosion hazard2.
No fire, open flames, orsmoking.3. Caustic liquid/chemicalburn hazard4. Wear eye protection5. Read the Operator’sManual.6.
Keep bystanders a safedistance from the battery.105-75061. Read the Operator’sManual2. Read operator’s manual2. Read the Operator’s Manual.2. Do not tow the machine.3. Warning—read theOperator’s Manual.4.
Cutting hazard of hand orfoot—stay away frommoving parts.5. Warning—keep bystandersa safe distance from themachine.6. Warning—lock the parkingbrake, stop the engine, andremove the ignition keybefore leaving the machine.7. Warning—use a roll overprotection system and wearthe seat belt.8. Tipping hazard—lower thecutting unit when drivingdown slopes. SpecificationsGeneral SpecificationsEngineKubota three cylinder, 4 cycle liquid cooled diesel engine. 25 hp @ 3000 rpm forReelmaster 5200 and 31.5 hp @ 3000 rpm for Reelmaster 5400.
Both governed to3200 rpm. (1123 cc) displacement. Heavy duty, 3-stage, remotemounted air cleaner. High water temperature shutdown switch.Cooling SystemRadiator capacity is approximately 7-1/2 qt. Of 50/50 mixture of ethylene glycolanti-freeze.
Remote mounted 1 qt. Expansion tank. MeasurementsOptional EquipmentRear Roller Scraper95 in.Overall WidthTransportWithout grass basketsModel No. 03533Front H.O.C. Adjusting Kit103-1/2 in.With grass basketsModel No.
03528Rear Roller Brush KitOverall LengthModel No. 035278 Blade Cutting Unit52-1/2 in.Part No. 82-66805 Blade Cutting Unit87 in.Outside of rear tiresPart No. 104–3385Solid Front Roller87 in.Outside of front tiresPart No. 104–3395Comb KitWidth of CutPart No. SetupNote: Determine the left and right sides of the machine from the normal operating position.Loose PartsNote: 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.DescriptionQty.UseLocking hood switch1Lock washer1Nut1Key2Hood latch bracket1Capscrew, 1/4 x 3/4 in.2Flat washer, 1/4 in.2Locknut, 1/4 in.2Flange head capscrew, 5/16 x 5/8 in. Slide the black, negative battery cable onto the negativebattery post and tighten nut securely.5. Coat both battery connections with Grafo 112X (skinover) grease, Toro Part No. 505–47, petroleum jelly orlight grease to prevent corrosion and slide rubber bootover positive terminal.26.
Close hood.1Mounting the Hood Latch1. Remove plug from hole in left front corner of hood(Fig. Open hood.Figure 11.
Positive battery cable12. Adjust latch bracket, until aligned with switch latch,then tighten capscrews.BASKET BASKETGUIDE BRACKET6. Rotate latch to locked and unlocked position with key.Remove key and store in memorable place.BASKETGUIDEL.H.FRONT7. Close hood.Replacing the Panel FastenersBASKETGUIDEL.H.REAR1. Remove fasteners securing left front corner of floorpanel and left end of access panel to frame (Fig.
Align the mounting shaft of the cutting unit with thepivot tube on the carrier frame. Insert the shaft into thetube (Fig. Detach chain from lift arm and secure it to cross tube oneach rear cutting unit with a capscrew, flat washer, andlocknut (Fig.
10).5161Figure 101. Lock-up chainFigure 81. Cutting unit mountingshaft2. Carrier frame pivot tube3. Adjusting the TurfCompensation SpringLifted Height of Outer FrontCutting Units (Enable Position)Note: This adjustment is needed for Cutting Unit Models03527 and 03528 only.The turnaround height of the front outer cutting units (#4 ) may be increased to provide additional groundclearance on contoured fairways. Contact your distributorfor assistance.The turf compensation spring (Fig.
12), connecting carrierframe to cutting unit, controls the amount of fore-aftrotation available. Installing the Rear WeightThe Reelmaster 5200-D & 5400-D Traction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, andANSI 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 WeightRequiredWeight PartNumberWeight DescriptionQty.2wd Traction Unit with ROPSw/o baskets291 lb. Before Operating2Caution1If you leave the key in the ignition switch, someonecould accidently start the engine and seriouslyinjure you or other bystanders.Remove the key from the ignition switch and lowerthe cutting units to the ground before servicing ormaking adjustments to the machine.Figure 151. DipstickChecking the Engine Oil2. Oil fill cap3. If oil is below FULL mark, remove fill cap and add oiluntil level reaches FULL mark on dipstick. Do notoverfill. 11Figure 171.
Fuel tank capChecking the TransmissionFluidFigure 161. Expansion tankThe front axle housing acts as the reservoir for the system.The transmission and axle housing are shipped from thefactory with approximately 5 quarts of Mobil 424 hydraulicfluid. However, check level of transmission oil beforeengine is first started and daily thereafter.2. If coolant level is low, remove expansion tank cap andreplenish the system.
Do not overfill.3. Install expansion tank cap.1. Checking the Hydraulic Fluid3. Remove dipstick from filler neck and wipe it with aclean rag. Insert dipstick into filler neck; then remove itand check level of fluid. Fluid level should be within1/4 inch of mark on dipstick.The machines reservoir is filled at the factory withapproximately 8 gallons of high quality hydraulic fluid.Check the level of the hydraulic fluid before the engineis first started and daily thereafter.
Toro 5400d Parts
The recommendedreplacement fluid is:4. Remove each end check plug and add enough lubricantto bring the level up to the bottom of each check plughole.5. Install all plugs.Checking Reel to BedknifeContactEach 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 reeland bedknife (refer to Adjusting Reel to Bedknife inCutting Unit Operator’s Manual). OperationTo stop, reduce foot pressure on traction pedal and allow itto return to center position.Note: Determine the left and right sides of the machinefrom the normal operating position.CautionIf you leave the key in the ignition switch, someonecould accidently start the engine and seriouslyinjure you or other bystanders.1Figure 23Remove the key from the ignition switch and lowerthe cutting units to the ground before servicing ormaking adjustments to the machine.1.
Fuel Gauge3The fuel gauge (Fig. 25) shows amount of fuel in tank.14Lower Mow/Raise Control Lever2The lever (Fig. 25) raises and lowers the cutting units andalso starts and stops the reels.5Glow Plug Indicator Light76When lit (Fig. 25), indicates a control system problem.Light blinks when glow plugs are preheating.Figure 241.2.3.4.Traction speed limiterReel control lightSpeedometerBrake pedals5. Parking brake latch6.
Locking pin7. Reel Speed Controls1.
Sit on the seat, keep foot off traction pedal. Ensure thatthe parking brake is engaged, traction pedal is inNEUTRAL, throttle is in FAST position and theENABLE/DISABLE switch is in the DISABLEposition.The reel speed controls (Fig.
27) control the RPM of frontand rear cutting units. #1 position is for backlapping.Remaining settings are for mowing operations. See sectionin manual for operating instructions.2. Turn ignition switch to ON/Preheat position. DangerUnder certain conditions, diesel fuel and fuelvapors are highly flammable and explosive.
A fireor explosion from fuel can burn you and othersand can cause property damage. Use a funnel and fill the fuel tank outdoors, inan 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 fuelto the fuel tank until the level is 1/4 to 1/2 in. (6to 13 mm) below the bottom of the filler neck. Adjusting the Lift Arm DownPressureTowing the Traction UnitIf it becomes necessary to tow the machine, tow it forwardonly, for a short distance and at a speed no greater than 3mph.The down pressure spring on each cutting unit lift arm canbe adjusted to compensate for different turf conditions.Increased down pressure will help keep the cutting units onthe ground when mowing at higher speeds and helpsmaintain a uniform height-of-cut in rough conditions or inareas of thatch build up.
Toro 5400d Fairway Mower Manual Manual
Attach the other end of the towing device to a vehiclethat is capable of towing the machine safely and atspeeds below 3 mph. Fuses are blown.4. An operator must be on the machine to steer it and keepthe traction pedal fully depressed in the forwardposition while towing.Check electrical connections, input fuses and diagnosticlight bulb to determine malfunction.
Make sure loopbackconnector is secured to wire harness connector. Not functioning correctly.5.
Toro 5410 Fairway Mower
blink on and off when corresponding switch is closed.Repeat on each switch that is it possible to be changedby hand.7. If switch is closed and appropriate LED does not turnon, check all wiring and connections to switch and/orcheck switches with an ohm meter. Replace anydefective switches and repair any defective wiring.The Diagnostic ACE also has the ability to detect whichoutput solenoids or relays are turned on. This is a quickway to determine if a machine malfunction is electrical orhydraulic. If the output LED’s are on as specified, but the machinedoes not function properly, this indicates a non–electricalproblem. Repair as necessary.Operating CharacteristicsNote: Due to electrical system constraints, the outputLED’s for “START”, “PREHEAT” and “ETR/ALT” maynot blink even though an electrical problem may exist forthose functions.