Toro 03540 Operator's Manual

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Operator's manual (24 pages)

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Page 1 FORM NO. 3321-307 Rev A MODEL NO. 03540 - 80001 & UP MODEL NO. 03541 - OPERATOR’S 80001 & UP MODEL NO. 03543 - 80001 & UP MANUAL MODEL NO. 03544 - 80001 & UP ® ® REELMASTER 5200-D/5400-D To understand this product, and for safety and It means CAUTION, WARNING or DANGER—...
Page 2: Table Of Contents
The model and serial number for the cutting unit is on a plate that is mounted on the top front of the center cutting unit. Use model and serial number in all correspondence and when ordering parts. To order replacement parts from an authorized TORO Distributor, supply the following information: Model and serial numbers of the machine.
Page 3: Safety
Safety Training WARNING—Petrol is highly flammable. • Store fuel in containers specifically Read the instructions carefully. Be familiar with designed for this purpose. the controls and the proper use of the equipment. • Refuel outdoors only and do not smoke Never allow children or people unfamiliar with while refueling.
Page 4 Safety • machine speeds should be kept low on 13. Disengage the drive to attachments when slopes and during tight turns; transporting or not in use. • stay alert for bumps and hollows and other 14. Stop the engine and disengage the drive to the hidden hazards;...
Page 5 Safety 8. Be careful during adjustment of the machine to Sound & Vibration Levels prevent entrapment of the fingers between moving blades and fixed parts of the machine. Sound Levels 9. On multi-bladed machines, take care as rotating This unit has a continuous A-weighted sound one blade can cause other blades to rotate.
Page 6 Symbol Glossary Caustic liquids, Poisonous Electrical shock, High pressure High pressure High pressure Crushing of Crushing of chemical burns to fumes or toxic electrocution fluid, injection spray, erosion of spray, erosion of fingers or hand, toes or foot, force fingers or hand gases, asphyxiation into body flesh...
Page 7 Safety Eye protection Head protection Hearing Caution, toxic First aid Flush with water Engine Transmission must be worn must be worn protection must risk be worn Hydraulic Brake system Fire, open light Coolant (water) Intake air Exhaust gas Pressure system &...
Page 8 Safety Engine coolant Engine coolant f Engine Engine intake/ Engine intake/ Engine intake/ Engine start Engine stop pressure ilter lubricating oil combustion air combustion air air filter pressure pressure n/min Engine failure/ Engine rotational Choke Primer (start aid) Electrical preheat Transmission oil Transmission oil Transmission oil malfunction...
Page 9: Specifications
Specifications Engine: Kubota three-cylinder, 4-cycle, liquid- system. 12-volt, maintenance free battery with 530 cooled diesel. 18.6 kW (25 hp) @ governed to 3200 cold cranking Amps @ –18°C (0° F) and 85 minute rpm; 1123 cc displacement. Heavy-duty, 3-stage, reserve capacity @ 29° C (85° F). 40-amp alternator remote-mounted air cleaner.
Page 10 Specifications Rear Weight Kit, Part No. 75-6690 Rear Roller Scraper Kit, Model No. 03512 Front Roller Scraper Kit, Model No. 83-5400 High Height-of-Cut Kit, Model No. 83-5300 Scraper/Comb Kit, Model No. 03518 Armrest Kit, Model No. 30707 Front Scraper, HHOC Kit P/N 82-6920 Thatcher Unit, Model No.
Page 11: Before Operating
Before Operating CHECK THE ENGINE OIL Park the machine on a level surface, stop the engine and remove the key from the ignition switch. Open the hood. Remove the dipstick, wipe it clean, then reinstall it. Remove it again and check the oil level on the dipstick;...
Page 12 Before Operating than .6 cm (1/4 inch) above the groove. DANGER Screw the dipstick filler cap finger-tight onto Because diesel fuel is flammable, use caution the filler neck. It is not necessary to tighten the when storing or handling it. Do not smoke while cap with a wrench.
Page 13 Note: Oils within this group are inter- sufficient for 15–22 l of hydraulic oil. Order Part changeable. No. 44-2500 from your Authorized Toro Distributor IMPORTANT: Two groups of hydraulic oil are Position the machine on a level surface, lower specified to allow optimal operation of the the cutting units and stop the engine.
Page 14 Before Operating Remove the dipstick from the filler neck and wipe it with a clean cloth. Insert it into the filler neck; then remove it and check the fluid level. It should be within 6 mm (1/4 inch) of the mark on the dipstick. If the level is low, add fluid to raise the level to the full mark.
Page 15: Controls
Controls Seat (Fig. 8)—The seat adjusting lever allows 10 cm the tank. (4 inches) fore and aft adjustment. The seat adjusting knob adjusts the seat for operators’ weight. To adjust the seat fore and aft, pull lever on the left side of the seat assembly outward.
Page 16 Controls Charge Indicator (Fig. 10)—Illuminates when system charging circuit malfunctions. Key Switch (Fig. 10)—Three positions: OFF, ON/Preheat and START. Throttle Control (Fig. 10)—Move the control forward to increase engine speed, rearward to decrease speed. Enable/Disable Switch (Fig.10)—Used in with the lower mow/raise control lever to operate reels.
Page 17: Starting And Stopping
Figure 14 1. Brake Pedals 2. Parking Brake Latch 3. Locking Pin Operation position. An automatic timer will control CAUTION preheat for six seconds. After preheat, turn the key to START. CRANK THE ENGINE FOR Before servicing or making adjustments to the NO LONGER THAN 15 SECONDS.
Page 18 Operation Pump the lever on the fuel pump (Fig. 16) until a solid stream of fuel flows out around the screw on the fuel injection pump. Tighten the air bleed screw. Note: Normally the engine should start after the above bleeding procedures. However, if the engine does not start, air may be trapped between the injection pump and the injectors;...
Page 19 Operation ignition switch. 19.0 17.5 15.9 Remove the floor plate in front of the seat and 14.3 open the hood to gain access to all (5) springs. 12.7 11.1 CAUTION 5-BLADE REEL Springs are under tension, use caution when MOWING SPEED (KMH) 19.0 adjusting.
Page 20 Operation shaft as shown in Figure 21. (The splines are 20). Remove the drive shaft. designed to allow assembly only when the two Important: If the drive shaft is not removed halves of the shaft are properly oriented.) before towing, severe damage to the transmission may occur.
Page 21 Operation Check electrical connections, input fuses and the Open the control panel cover. Locate the wire diagnostic light bulb to find the malfunction. Make harness and connectors near the controller. sure the connector is secured to the wire harness Carefully unplug the connector from harness. connector.
Page 22 ECU outputs. problem. If this occurs, contact your Toro Distributor for assistance. The “output displayed” LED on the lower right column of Diagnostic ACE should be IMPORTANT: The Diagnostic ACE display must illuminated.
Page 23 Operation machine's every day use. When finished using the CHECKING LEAK DETECTOR Diagnostic ACE, disconnect it from the machine and OPERATION reconnect the connector to the harness connector. Machine will not operate without the connector The operation of the TurfDefender™ should be installed on the harness.
Page 24 • Self-diagnostic (LED Blinking): Internal circuit failure in TurfDefender™. Consult Toggle “outputs displayed” on the Diagnostic your Authorized Toro Distributor for ACE display (Fig. 28). assistance. • Alarm open circuit (LED blinking): • Data Line (LED Blinking): Indicates a Check/replace the TurfDefender™...
Page 25 Operation Diagnostic ACE Display Functions Overlay decal (English shown) “Inputs Displayed” LED (Red) “Outputs Displayed” LED (Green) Toggle button Figure 26 Using “Inputs Displayed” (Red Text) LED lit if oil level is too high LED lit if oil level is OK LED lit if oil level is too low LED lit if oil is too hot LED lit if system air leak has been detected...
Page 26: Operating
Once the ignition key is turned to CHARACTERISTICS OFF, the TurfDefender™ will reset. CAUTION Your Authorized Toro Distributor has equipment to analyze system problems. When operating the machine, always use the seat belt and roll-over protection system together.
Page 27 Operation The cutting units should be lowered when going downhill for steering control. Selecting Clip Rate (Reel Speed)—The automatic clip control programmed into the machine controller requires that it be told at what height of cut the machine is being operated and whether the machine is equipped with 5- or 8-blade reels.
Page 28: Maintenance
Maintenance Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check battery fluid level Every Every Every Every Every Check battery cable connections 800 hours Lubricate all grease fittings hours hours hours hours Change engine oil Instpect air filter, dust cap and baffle ‡...
Page 29 Maintenance CHECK/SERVICE (DAILY) 1. Oil level, engine 7. Radiator screen 2. Oil level, transmission 8. Brake function 3. Oil level, hydraulic tank 9. Tire pressure 4. Coolant level, radiator 10. Battery 5. Fuel/Water separator 11. Belts (Fan, alt) 6. Precleaner—air cleaner...
Page 30 Maintenance GREASING BEARINGS AND BUSHINGS The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 25 hours of operation. Figure 32 Figure 29 Figure 33...
Page 31: Air Cleaner Maintenance
Maintenance and thumb screw. Note: When operating the machine in extremely dusty conditions, an optional extension tube (Toro Part No. 43-3810), which raises the precleaner bowl above the hood, is available from your local authorized Toro Distributor. Figure 36 CAUTION...
Page 32: Engine Oil And Filter
Maintenance center of the filter. Reinstall the cover and secure the latches. Reset the indicator if it is showing red. ENGINE OIL AND FILTER (Fig. 39 & 40) CAUTION Figure 38 1. Filter element Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch.
Page 33: Fuel Tank
Maintenance Figure 40 Figure 41 1. Engine oil filter 1. Fuel filter/water separator 2. Drain plug FUEL SYSTEM (Fig. 42) Replace the filter canister after every 400 hours of operation. Fuel Tank Clean the area where the filter canister mounts. Drain and clean the fuel tank every two years.
Page 34: Engine Cooling System
Maintenance ENGINE COOLING SYSTEM (Fig. 44 & 45) Removing Debris—Remove debris from the screen, oil coolers and radiator daily, clean more often in dirty conditions. A. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris.
Page 35 Maintenance and the bolt securing the alternator to the brace. Insert a pry bar between the alternator and engine and pry out on the alternator. When proper tension is achieved, tighten the alternator and brace bolts to secure adjustment. Cooling Fan Belt (Fig. 47) Loosen the lock nut on the belt tensioner lever.
Page 36 If fluid becomes contaminated, contact your local TORO distributor Use the Toro replacement filter (Part No. 75-1310). because the system must be flushed. Contaminated fluid looks milky or black when compared to clean IMPORTANT: Use of any other filter may void oil.
Page 37 Figure 50 1. Traction adjustment cam The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro Start the engine and rotate the cam hex in either distributor for assistance. direction until the wheel ceases rotation.
Page 38 Maintenance Loosen the setscrew on the valve and rotate the valve approximately 1/2 turn clockwise. Verify the lift rate adjustment by raising and lowering cutting unit several times. Readjust as required. After desired lift rate is attained, tighten the setscrew to lock adjustment. Figure 52 1.
Page 39 Maintenance threaded end of the brake cable. Then tighten the rear nut to move the cable backward until the brake pedals have 1.25 cm to 2.5 cm of free travel. Tighten front nuts after brakes are adjusted correctly. CHANGING TRANSMISSION FLUID (Fig.
Page 40 Figure 55 of operation and every 800 hours thereafter. Only the 1. Drain Plugs (3) Toro replacement filter (Part No.75-1330) can be used in the hydraulic system. Remove the plugs allowing oil to drain into the IMPORTANT. Use of any other filter may void drain pans.
Page 41: Battery Care
Maintenance tie rod. Rotate tie rod(s) to move the front of the tire inward or outward. Tighten the tie rod clamps when adjustment is correct. BATTERY CARE 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.
Page 42 1 or the desired speed. c. Coat the cable terminals and battery posts 10. To make an adjustment to the cutting units with Grafo 112X skin-over grease (Toro Part while backlapping, turn reels OFF by moving No. 50547) or petroleum jelly to prevent the Lower Mow/Raise lever rearward;...
Page 43 Use model and serial number in all correspondence and when ordering parts. To order replacement parts from an authorized TORO Distributor, supply the following information: Model and serial numbers of the machine. Part number, description and quantity of parts desired.

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Toro 03540 Operator's Manual

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