Toro 5200-D - Manual

5 • Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Slow down and use cauti...

6 – Do not drive close to sand traps, ditches, creeks, or other hazards. – Reduce speed when making sharp turns. Avoid sudden stops and starts. – When near or crossing roads, always yield the right-of-way. – Apply the service brakes when going downhill to keep forward speed slow and to maintain cont...

7 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 1. Hazard to hands–pinch points2. Stop reels before touching 104-2052 1. See operator’s man...

12 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...

14 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 ...

15 2 1 Figure 1 1. Positive battery cable 2. Negative battery cable Charging the battery produces gasses that canexplode.Never smoke near the battery and keep sparks andflames away from the battery. Warning Battery terminals or metal tools could shortagainst metal tractor components, causing sparks....

16 5. Adjust latch bracket, until aligned with switch latch, then tighten capscrews. 6. Rotate latch to locked and unlocked position with key. Remove key and store in memorable place. 7. Close hood. Replacing the Panel Fasteners 1. Remove fasteners securing left front corner of floor panel and left ...

18 Adjusting the Turf Compensation Spring Note: This adjustment is needed for Cutting Unit Models 03527 and 03528 only. The turf compensation spring (Fig. 12), connecting carrier frame to cutting unit, controls the amount of fore-aft rotation available. The Turf Compensation Spring also transfers we...

19 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 comb...

20 Before Operating If 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. Caution Checkin...

21 1 Figure 16 1. Expansion tank 2. If coolant level is low, remove expansion tank cap and replenish the system. Do not overfill . 3. Install expansion tank cap. Filling the Fuel Tank 1. Remove fuel tank cap (Fig. 17). 2. Fill tank to about one inch below top tank, not filler neck with No. 2 diesel ...

22 Checking the Hydraulic Fluid The machines reservoir is filled at the factory with approximately 8 gallons of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is: Toro Premium Transmissio...

24 Operation Note: Determine the left and right sides of the machine from the normal operating position. If you leave the key in the ignition switch, someonecould accidently start the engine and seriouslyinjure you or other bystanders.Remove the key from the ignition switch and lowerthe cutting unit...

26 Reel Speed Controls The reel speed controls (Fig. 27) control the RPM of front and rear cutting units. #1 position is for backlapping. Remaining settings are for mowing operations. See section in manual for operating instructions. 1 Figure 27 1. Reel speed controls Hour Meter The hour meter (Fig....

27 Danger Under 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, in an open area, when the engine is off and is cold. Wipe up any fuel ...

28 Adjusting the Lift Arm Down Pressure The down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf conditions. Increased down pressure will help keep the cutting units on the ground when mowing at higher speeds and helps maintain a uniform height-of-cut i...

29 3. Attach the other end of the towing device to a vehicle that is capable of towing the machine safely and at speeds below 3 mph. 4. An operator must be on the machine to steer it and keep the traction pedal fully depressed in the forward position while towing. 5. When towing is completed, reinst...

30 1 Figure 36 1. Wire harness and connectors 3. Connect the Diagnostic ACE display connector to the harness connector (Fig. 37). Make sure correct overlay decal is positioned on Diagnostic ACE display. 4. Turn the key switch to the ON position, but do not start machine. 1 Figure 37 1. Diagnostic AC...

31 If the output LED’s are on as specified, but the machine does not function properly, this indicates a non–electrical problem. Repair as necessary. Note: Due to electrical system constraints, the output LED’s for “START”, “PREHEAT” and “ETR/ALT” may not blink even though an electrical problem may ...

32 Logic Chart Raise (T o turn around front & Raise (T o turn around front & A=OUTPUT ON IF REELS WERE PREVIOUSL Y RUNNING 2) Start 0) Controller OK 1) Preheat 3) Run (No operator) 4) Lower (T o turn around) Lower (All units when disabled) Lower / Mow–Front 5) Mow 6) Raise (transport) Raise ...

33 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 After first 10 hours ...

34 Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check safety interlock operation.Check brake operation.Check engine oil and fuel level.Drain the water/fuel separator.Check the air filter restriction ind...

35 Service Interval Chart If 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. Caution G...

38 Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1. Remove drain plug (Fig. 48) and let oil flow into drain pan. When oil stops, install drain plug. 1 Figure 48 1. Engine oil drain plug 2. Remove oil fil...

39 3. Loosen the hose clamps at both ends of the filter and pull fuel lines off filter. 1 2 2 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 inj...

40 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. 2 1 3 Figure 54 1. Reel oil cooler2. Radiator 3. Transmission oil cooler 4. Install screen and close hood. Servicing t...

41 1 Figure 57 1. Injection pump lever arm Changing the Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when co...

42 Checking the Hydraulic Lines and Hoses Daily, check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating. Hydraulic fluid escaping under pressure canpenetrate...

43 Adjusting the Cutting Unit Lift Rate The cutting unit lift circuit is equipped with (3) adjustable valves used to ensure the cutting units do not raise too quickly and bang against lift stops. Adjust cutting units as follows: Center Cutting Unit 1. Locate valve behind access panel above operator’...

44 Checking and Adjusting the Traction Linkage Due to normal wear in the control linkage and hydrostatic transmission, an increased amount of force may be required to return the transmissions to neutral. Periodically check the machine. 1. Park machine on a level surface, lower cutting units to the f...

45 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. 1 2 Figure 67 1. Transmission suction ...

46 1 Figure 69 1. Tie rods 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. 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 bal...

47 posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. Fuses There are 4 fuses in the machines electrical system. They are located below control panel (Fig. 71 and 72). 1 Figure 71 1. Fuses Figure 72 Optional Lighting Importan...

49 Electrical Schematic ST AR T RELA Y 2A RUN (ETR) SOLENOID OUTPUTS INPUTS B A I Y X RUN ST AR T S 3C 2B 3M ENGINE WATER TEMP SENSOR STA RT – KEY SWITCH ST AR TER 1S 1B 2S 3S 4S 1E 5S 6S 7S 1F 1H NEUTRAL SENSOR SEA T SENSOR 2C 2E 3G 1N 1G AL TERNA TO R KE Y SWITCH PULL (B ) HOLD (A) FIELD (R) OUTPU...

50 Hydraulic Schematic C2 FD1 C1 P P3 P1 P2 TEST POR T FOR FRONT UNITS (3) STEERING CYLINDER FOR W ARD SIDE OF CLOSED LOOP SUNSTRAND M25 1.5 IN3 /REV ”A” ”A” SYSTEM RELIEF 3625 PSI OUTPUT SHAFT TO DIFFERENTIAL INPUT SHAFT 3200 RPM MAX OIL COOLER DIFFERENTIAL HOUSING T FOR REAR[R]UNITS 1250 PSI 3 AUX...

51 Preparation for Seasonal Storage Traction Unit 1. Thoroughly clean the traction unit, cutting units and the engine. 2. Check the tire pressure. Inflate all traction unit tires to 15–20 psi. 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot ...

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...