Toro 03540 Operator's Manual
Two-wheel and four-wheel drive traction units
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Summary of Contents for Toro 03540
- Page 1 Form No. 3326-748 Reelmaster 5200-D/5400-D Two-Wheel and Four-Wheel Drive Traction Units 03540—220000001 and Up 03541—220000001 and Up 03543—220000001 and Up 03544—220000001 and Up Operator’s Manual English (EN)
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Page 2: Table Of Contents
Checking the Hydraulic Fluid ....The Toro General Commercial Products Warranty Checking the Rear Axle Lubricant ... . -
Page 3: Introduction
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service The following instructions are from ANSI standard Dealer or Toro Customer Service and have the model and B71.4—1999. serial numbers of your product ready. The model and serial... -
Page 4: Toro Mower Safety
Look behind and down before backing up to be sure of The following list contains safety information specific to a clear path. Toro products or other safety information that you must know that is not included in the ANSI standards. Never carry passengers and keep pets and bystanders away. -
Page 5: Sound Pressure Level
Do not settings. To ensure safety and accuracy, have an attempt to free a blocked cutting unit by reversing reel Authorized Toro Distributor check the maximum engine direction or damage to the reel may result. speed. -
Page 6: Sound Power Level
Sound Power Level Vibration Level This unit has a guaranteed sound power level of: 105 This unit does not exceed a vibration level of 2.5 m/s dBA/1 pW, based on measurements of identical machines the hands based on measurements of identical machines per per Directive 2000/14/EC and amendments. - Page 7 104-9296 1. Throttle—slow 4. Reels lowered and on when 6. Reels disabled—lift only 9. Headlights—on enabled—forward and 2. Throttle—fast 7. Reels disabled—lift and 10. Headlights—off backlap lower 3. Reels raised & off 11. Read operator’s manual 5. Reels—enabled 8. Headlights (optional) 104-9298 1.
- Page 8 93-6699 1. Slow 2. Fast 3. Traction speed 93-8060 1. Danger 2. Read operator’s manual 3. Height–of–cut 4. Move throttle to slow 93-6691 5. Hazard to feet 1. Read operator’s manual–eccentric bolt 6. Hazard to hands 7. Stop reels before touching 93-6697 (Model 03541 &...
- Page 9 93-6686 1. Hydraulic oil level 2. Read operator’s manual 105-7506 1. Read the Operator’s 3. On Manual 4. Engine—preheat 2. Engine—stop 5. Engine—start 76-8730 1. See operator’s manual 2. Wheel torque specifications 93-1263 104-9294 1. Read operator’s manual 1. Danger To engage parking brake–connect pedals with locking pin, push down on both pedals and pull parking brake latch out.
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Page 10: Specifications
Specifications General Specifications Kubota three cylinder, 4 cycle liquid cooled diesel engine. 25 hp @ 3000 rpm for Reelmaster 5200 and 31.5 hp @ 3000 rpm for Reelmaster 5400. Both governed to Engine 3200 rpm. 68.5 cu. in. (1123 cc) displacement. Heavy duty, 3-stage, remote mounted air cleaner. -
Page 11: Measurements
1/4–5/8 in. Thatching Reel Model No. 03516 Weight 4 Wheel Drive Kit (for use with Model No. 03538 models 03540 and 03543 only) Models 03540 & 03543 2320 lb.* TurfDefender Electronic Leak Model No. 03521 Models 03541 & 03544 2675 lb.*... -
Page 12: Setup
Operator’s Manual (Traction Unit) Read before operating the machine. Engine Manual Registration card Fill out and return to Toro. Connecting the Battery 1. Open hood. 2. Ensure battery is securely fastened in place and check battery charge with a hydrometer. If battery needs... -
Page 13: Mounting The Hood Latch
5. Coat both battery connections with Grafo 112X (skin Warning over) grease, Toro Part No. 505–47, petroleum jelly or light grease to prevent corrosion and slide rubber boot over positive terminal. Charging the battery produces gasses that can explode. -
Page 14: Replacing The Panel Fasteners
2. Replace floor panel fastener with flange head capscrew (5/16 x 5/8 in.) supplied in loose parts (Fig. 4). 3. Replace access panel fastener with flange head capscrew (5/16 x 3/4 in.) supplied in loose parts (Fig. 4). Checking the Tire Pressure The tires are over-inflated for shipping. - Page 15 Figure 6 1. Carrier frame 2. Basket guide Figure 8 5. Install a roll pin (Fig. 7) into hole in appropriate side of 1. Basket bracket 2. Torsion spring each cutting unit carrier frame (Fig. 5). 7. Align the mounting shaft of the cutting unit with the pivot tube on the carrier frame.
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Page 16: Adjusting The Turf Compensation Spring
10. 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. -
Page 17: Lifted Height Of Outer Front Cutting Units (Enable Position)
The Reelmaster 5200-D & 5400-D Traction Units comply with 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... -
Page 18: Before Operating
Before Operating 3. If oil is below FULL mark, remove fill cap and add SAE 10W-30 CD, CE, CF, CF-4, or CG-4 classification oil until level reaches FULL mark on dipstick. Do not overfill. Crankcase capacity is 4.0 qt. with filter. Caution 4. -
Page 19: Filling The Fuel Tank
Hydraulic fluids produced by other manufacturers may be used if they can cross reference to find an equivalent to the products listed. Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation. -
Page 20: Checking The Rear Axle Lubricant
2. Clean area around filler neck and cap of hydraulic tank (Fig. 19). Remove cap from filler neck. Figure 19 Figure 21 1. Hydraulic tank cap 1. Left check plug (rear of axle) 3. Remove dipstick from filler neck and wipe it with a 3. -
Page 21: Operation
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. -
Page 22: Fuel Gauge
Fuel Gauge The fuel gauge (Fig. 25) shows amount of fuel in tank. Lower Mow/Raise Control Lever The lever (Fig. 25) raises and lowers the cutting units and also starts and stops the reels. Glow Plug Indicator Light When lit (Fig. 25), indicates a control system problem. Figure 24 Light blinks when glow plugs are preheating. -
Page 23: Starting And Stopping
Reel Speed Controls Refer to Bleeding the Fuel System, page 23. 1. Sit on the seat, keep foot off traction pedal. Ensure that The reel speed controls (Fig. 27) control the RPM of front the parking brake is engaged, traction pedal is in and rear cutting units. -
Page 24: Setting The Reel Speed
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. -
Page 25: Adjusting The Lift Arm Down Pressure
Adjusting the Lift Arm Down Towing the Traction Unit Pressure If it becomes necessary to tow the machine, tow it forward only, for a short distance and at a speed no greater than 3 The down pressure spring on each cutting unit lift arm can mph. -
Page 26: Diagnostic Light
3. Attach the other end of the towing device to a vehicle Fuses are blown. that is capable of towing the machine safely and at Not functioning correctly. speeds below 3 mph. Check electrical connections, input fuses and diagnostic 4. An operator must be on the machine to steer it and keep light bulb to determine malfunction. - Page 27 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.
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Page 28: Hydraulic Valve Solenoid Functions
ECU problem. If this traction. For example, in some slope conditions, the uphill occurs, contact your Toro Distributor for assistance. wheel slips and loses traction. If this situation occurs, depress uphill turn pedal gradually and intermittently until... -
Page 30: Maintenance
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important Refer to your engine operator’s manual for additional maintenance procedures. Recommended Maintenance Schedule Maintenance Service Maintenance Procedure Interval Check the fan and alternator belt tension. Torque the wheel lug nuts. -
Page 31: Daily Maintenance Checklist
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Maintenance Check Item Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Drain the water/fuel separator. Check the air filter restriction indicator. -
Page 32: Service Interval Chart
Service Interval Chart Drive shaft support bearing (1), Rear axle drive shaft (3) Caution (Fig. 42); Brake pedal (1) (Fig. 43); Lift cylinders (5) (Fig. 44) and Fan shaft (Fig. 45). If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. - Page 33 Figure 42 Figure 39 Figure 43 Figure 40 Figure 44 Figure 41...
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Page 34: Servicing The Air Cleaner
3. Assemble and install precleaner bowl, cover, and thumb screw. Figure 47 Note: When operating machine in extremely dusty conditions, an optional extension tube (Toro Part No. 1. Filter element 43-3810), which raises precleaner bowl above hood, thus, lengthening the time between precleaner bowl servicing, is 3. -
Page 35: Engine Oil And Filter
4. Washing Method A. Prepare a solution of filter cleaner and water and soak filter element about 15 minutes. Refer to directions on filter cleaner carton for complete information. B. After soaking filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the filter element. -
Page 36: Bleeding Air From The Injectors
Fuel Filter/Water Separator 3. Loosen the hose clamps at both ends of the filter and pull fuel lines off filter. Drain water or other contaminants from fuel filter / water 4. Slide hose clamps onto ends of fuel lines. Push fuel separator (Fig. -
Page 37: Servicing The Engine Cooling System
1. Loosen the pipe connection to the No. 1 nozzle and holder assembly (Fig. 52). Figure 53 1. Screen 3. Slightly raise oil coolers and pivot forward (Fig. 54). Clean both sides of oil coolers and radiator area Figure 52 thoroughly with compressed air. -
Page 38: Servicing The Engine Belts
Servicing the Engine Belts Check condition and tension of all belts after first day of operation and every 100 operating hours thereafter. Alternator Belt To Check Tension: 1. Open hood. 2. Check tension by depressing belt (Fig. 55) midway between alternator and crankshaft pulleys with 22 lb. of force. -
Page 39: Changing The Hydraulic Fluid
If fluid becomes contaminated, contact interval indicator. With the engine running, view the your local Toro distributor because the system must be indicator, it should be in the GREEN zone. When the flushed. Contaminated fluid looks milky or black when indicator is in the RED zone, the filter element should be compared to clean oil. -
Page 40: Checking The Hydraulic Lines And Hoses
The test ports are used to test pressure in the hydraulic removed. circuits. Contact your local Toro distributor for assistance. 3. Under right side of machine, loosen locknut on traction Test Port #1 (Fig. 60) is used to assist in trouble shooting adjustment cam (Fig. -
Page 41: Adjusting The Cutting Unit Lift Rate
Outside Front Cutting Units Warning 1. Locate valve on flow divider (under foot rest) (Fig. 63). The engine must be running so the final 2. Loosen setscrew on valve. Rotate valve 1/2 turn clockwise. adjustment of the traction adjustment cam can be performed. -
Page 42: Checking And Adjusting The Traction Linkage
4. After desired lift rate is attained, tighten setscrew to Adjusting the Service Brakes lock adjustment. Adjust the service brakes when there is more than 1 inch of “free travel” of the brake pedal, or when the brakes do not Checking and Adjusting the work effectively. -
Page 43: Replacing The Transmission Filter
Figure 68 Change the transmission filter after the first 10 hours of 1. Drain plugs operation and every 800 hours thereafter. 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 The rear wheels should have 0 to 1/8 in. -
Page 44: Servicing The Battery
Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) 6. Install the ball joint in the axle case support and tighten grease (Toro Part No. 505-47) or petroleum jelly to prevent the slotted hex nut finger tight. corrosion. -
Page 45: Fuses
Fuses Optional Lighting There are 4 fuses in the machines electrical system. They Important If optional lighting is be added to the are located below control panel (Fig. 71 and 72). traction unit, use the following schematic and part numbers to prevent damage to the traction units electrical system. - Page 46 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.
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Page 47: Electrical Schematic
Electrical Schematic... -
Page 48: Hydraulic Schematic
Hydraulic Schematic... -
Page 49: Preparation For Seasonal Storage
B. Clean the battery, terminals, and posts with a wire brush and baking soda solution. 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. -
Page 52: The Toro General Commercial Products Warranty
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.