Toro 03530, 03531, reelmaster 5300-d Operator's Manual
FORM NO. 3318-590 GB Rev A
MODEL NO. 03530—60001 & UP
MODEL NO. 03531—
®
To understand this product, and for safety and
optimum performance, read this manual before
starting the engine. Pay special attention to
SAFETY INSTRUCTIONS highlighted by this
symbol.
OPERATOR'S
60001 & UP
®
REELMASTER
5300-D
It means CAUTION, WARNING or DANGER—personal safety instruction. Failure to
comply with the instruction may result in personal injury.
MANUAL
©The TORO COMPANY—1995
This operator's manual has instructions on safety, operation, and maintenance.
This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and
CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, understand the safety message that follows. “IMPORTANT” highlights special mechanical information and “NOTE” emphasizes
general product information worthy of special attention.
IDENTIFICATION AND ORDERING
MODEL AND SERIAL NUMBER
The model and serial number for the traction unit is on a plate that is mounted on the left front frame member.
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:
1. Model and serial numbers of the machine.
2. Part number, description and quantity of parts desired.
NOTE: Do not order by reference number if a parts catalog is being used; use the part number.
Table of Contents
Safety 3
Specifications 9
Before Operating 11
Controls 13
Operating 17
Maintenance 28
Page
2
Safety
Training
1. Read the instructions carefully. Be familiar with
the controls and the proper use of the equipment.
2. Never allow children or people unfamiliar with
these instructions to use the lawn mower. Local
regulations may restrict the age of the operator.
3. Never mow while people, especially children, or
pets are nearby.
4. Keep in mind that the operator or user is respon-
sible for accidents or hazards occurring to other
people or their property.
5. Do not carry passengers.
6. All drivers should seek and obtain professional
and practical instruction. Such instruction should
emphasize:
• 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:
– insufficient wheel grip;
– being driven too fast;
• Store fuel in containers specifically
designed for this purpose.
• Refuel outdoors only and do not smoke
while refueling.
• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add petrol
while the engine is running or when the
engine is hot.
• If petrol is spilled, do not attempt to start the
engine but move the machine away from the
are of spillage and avoid creating any source
of ignition until petrol vapors have dissipated.
• Replace all fuel tanks and container caps
securely.
4. Replace faulty silencers.
Operation
1. Do not operate the engine in a confined space
where dangerous carbon monoxide fumes can
collect.
2. Mow only in daylight or in good artificial light.
3. Before attempting to start the engine, disengage
all blade attachment clutches and shift into neutral.
– inadequate braking;
– the type of machine is unsuitable for its
task;
– lack of awareness of the effects of
ground conditions, especially slopes;
– incorrect hitching and load distribution.
Preparation
1. While mowing, always wear substantial footwear
and long trousers. Do not operate the equipment
when barefoot or wearing open sandals.
2. Thoroughly inspect the area where the equipment
is to be used and remove all objects which may
be thrown by the machine.
3. WARNING—Petrol is highly flammable.
4. Do not use on slopes of more than:
• Never mow side hills over 5°
• Never mow uphill over 10°
• Never mow downhill over 15°
5. Remember there is no such thing as a “safe”
slope. Travel on grass slopes requires particular
care. To guard against overturning:
• do not stop or start suddenly when going up
or downhill;
• engage the clutch slowly, and always keep
the machine in gear, especially when travailing downhill;
• machine speeds should be kept low on
slopes and during tight turns;
• stay alert for bumps and hollows and other
hidden hazards;
3
Safety
• never mow across the face of the slope,
unless the lawn mower is designed for this
purpose.
6. Use care when pulling loads or using heavy
equipment.
• Use only approved drawbar hitch points.
• Limit loads to those you can safely control.
• Do not turn sharply. Use care when reversing.
• Use counterweight(s) or wheel weights
when suggested in the instruction handbook.
7. Watch out for traffic when crossing or near road-
ways.
8. Stop the blades rotating before crossing surfaces
other than grass.
9. When using any attachments, never direct dis-
charge of material toward bystanders nor allow
anyone near the machine while in operation .
10. Never operate the lawn mower with defective
guards, shields or without safety protective
devices in place.
11. Do not change the engine governor settings or
overspeed the engine. Operating the engine at
excessive speeds may increase the hazard of personal injury.
tor’s position.
• before clearing blockages;
• before checking, cleaning or working on
the lawnmower;
• after striking a foreign object. Inspect the
lawnmower for damage and make repairs
before restarting and operating the equipment.
15. Reduce the throttle setting during engine runout
and, if the engine is provided with a shutoff
valve, turn the fuel off at the conclusion of
mowing.
Maintenance and Storage
1. Keep all nuts, bolts and screws tight to be sure
the equipment is in safe working condition.
2. Never store the equipment with petrol in the
tank inside a building where fumes may reach
an open flame or spark.
3. Allow the engine to cool before storing in any
enclosure.
4. To reduce the fire hazard, keep the engine,
silencer, battery compartment and petrol storage
area free of grass, leaves, or excessive grease.
5. Check the grass catcher frequently for wear or
deterioration.
12. Before leaving the operator’s position:
• disengage the power take-off and lower the
attachments;
• change into neutral and set the parking
brake;
• stop the engine and remove the key.
13. Disengage the drive to attachments when trans-
porting or not in use.
14. Stop the engine and disengage the drive to the
attachment
• before refueling;
• before removing the grass catcher;
• before making height adjustments unless
the adjustment can be made from the opera-
4
6. Replace worn or damaged parts for safety.
7. If the fuel tank has to be drained, this should be
done outdoors.
8. Be careful during adjustment of the machine to
prevent entrapment of the fingers between moving blades and fixed parts of the machine.
9. On multi-bladed machines, take care as rotating
one blade can cause other blades to rotate.
10. When the machine is to be parked, stored or left
unattended, lower the cutting means unless a
positive mechanical lock is used.
Sound & Vibration Levels
Sound Levels
This unit has an equivalent continuous A-weighted
sound pressure at the operator ear of: 89.5 dB(A),
based on measurements of identical machines per
84/538/EEC.
This unit has a sound power level of 103.5
dB(A)/1pW, based on measurements of identical
machines per procedures outlined in Directive
79/113/EEC and amendments.
Vibration Levels
This unit has a vibration level of 2.5 m/s2at the posterior, based on measurements of identical machines
per ISO 2631 procedures.
Safety
This unit does not exceed a vibration level of 0.5
2
at the posterior based on measurements of iden-
m/s
tical machines per ISO 2631 procedures.
5
Symbol Glossary
Caustic liquids,
chemical burns to
fingers or hand
Crushing of
whole body,
applied from
above
Cutting or
entanglement of
foot, rotating auger
Poisonous
fumes or toxic
gases, asphyxiation
Crushing of
torso, force
applied from side
Severing of
foot, rotating
knives
Electrical shock,
electrocution
Crushing of fingers
or hand/, force
applied from side
Severing of
fingers or hand,
impeller blade
High pressure
fluid, injection
into body
force applied
from side
Wait until all
machine
components have
completely stopped
before touching them
High pressure
spray, erosion of
flesh
Crushing of
whole body
Severing of
fingers or hand,
engine fan
High pressure
spray, erosion of
flesh
Crushing of
head, torso and
arms
Whole body entanglement,
implement input drive line
Crushing of
fingers
or hand,
force
applied from
above
Cutting of
fingers or hand
Crushing of
toes or foot, force
applied from above
Cutting of footCrushing of leg,
Fingers or
hand entangle-
ment, chain drive
Hand & arm
entanglement,
belt drive
Explosion Fire or open
Shut off engine
& remove key before
performing mainten-
ance or repair work
Thrown or fly-
ing objects, whole
body exposure
flame
Riding on this
machine is allowed
only on a passen-
ger seat & only if the
driver’s view is not
hindered
Thrown or
flying objects,
face exposure
Secure lifting
cylinder with locking
device before getting
in hazardous area
Consult
technical manual
for proper service
procedures
Runover/back-
over, (relevant
machine to appear
in dashed box)
Stay a safe
distance from
the machine
Fasten seat belts Safety alert
Machine tipping,
riding mower
Stay clear of
articulation area
while engine is
running
Machine rollover,
ROPS (relevant
machine to appear
in dashed box)
Stored energy
hazard, kickback
or upward motion
Do not open
or remove safety
shields while
engine is
running
triangle
Do not step on
loading platform if
PTO is connected to tractor
& engine is running
outline safety
alert symbol
Hot surfaces,
burns to fingers
or hands
Do not step
Read operator’s
manual
6
Safety
Eye protection
must be worn
Fire, open light
& smoking
prohibited
Level
indicator
Engage Disengage
Head protection
must be worn
Hydraulic
system
Liquid level Filter Temperature Failure/
Hearing
protection must
be worn
Brake system
Attachment
lower
Caution, toxic
risk
First aid
Oil Coolant (water) Intake air Exhaust gas Pressure
Malfunction
Attachment
raise
Spacing distance Snow thrower,
Flush with water Engine Transmission
Start switch/
mechanism
collector auger
On/start Off/stop
Plus/increase/
positive polarity
Minus/decrease/
negative polarity
Horn Battery charging
Machine travel
direction,
forward/rearward
Jack or
support point
condition
Control lever
operating
direction, dual
direction
Draining/
emptying
Hourmeter/elapsed
operating hours
Control lever
operating
direction, multiple
direction
Engine lubricating oil
Fast Slow Continuous
Clockwise
rotation
Engine lubricating
oil pressure
Counter-clockwise rotation
Engine lubricating
oil level
variable, linear
Grease
lubrication
point
Engine lubricating
oil filter
Volume empty Volume full
Oil lubrication
point
Engine
lubricating oil
temperature
Lift point
Engine coolant
7
Safety
Engine coolant
pressure
Engine coolant f
ilter
n/min
Engine failure/
malfunction
Transmission
failure/malfunction
Engine rotational
speed/frequency
Clutch Neutral High Low Forward Reverse Park
231
First gear Second gear
Engine
lubricating oil
pressure
Choke Primer (start aid) Electrical preheat
Engine intake/
combustion air
Engine intake/
combustion air
pressure
(low temperature
start aid)
Engine intake/
air filter
Transmission oil Transmission oil
Engine start Engine stop
pressure
Transmission oil
temperature
NHLFRP
Third gear (other #'s
may be used until
the maximum # of forward gears is reached.)
Hydraulic oil Hydraulic oil
Hydraulic oil
pressure
Hydraulic oil level Hydraulic oil filter
temperature
Hydraulic oil
failure/malfunction
Headlights Lock Unlock Differential lock 4-Wheel drive Power Take-Off Power Take-Off,
Reel cutting
element, height
adjustment
Parking brake Fuel Fuel level Fuel filter Fuel system
Traction Above working
temperature range
Drilling Manual metal arc
0430 weight Do not dispose
welding
in the garbage
failure/malfunction
Manual 0356 Water pump
CE logo
Diesel fuel Unleaded fuel
rotational speed
Reel cutting
element
0626 Keep dry
8
Specifications
Engine: Mitsubishi three-cylinder, liquid-cooled
diesel. 20.9 kW (28 hp) @ governed maximum rpm
of 3200; 1,318 cc (80.4 cu. in.) displacement
Heavy-duty, 3-stage, remote-mounted air cleaner.
High water temperature shutdown switch.
Cooling System: Radiator capacity is 7.1 l (7.5 qt.)
of 50/50 mixture of ethylene glycol anti-freeze.
Remote mounted .9 l (1 qt.) expansion tank. A twospeed fan drive controls air flow.
Fuel System: Fuel tank capacity is 37.9 l (10 gal.)
of #2 diesel fuel. 12-volt, electric fuel pump with
replaceable fuel filter. Equipped with a fuel
filter/water separator to capture water in the fuel.
Traction System: Foot pedal controls forward/
reverse ground speed. Ground speed: 0–16.1 kmh
(0–10 m.p.h.) forward and 0–6.4 kmh (0-4 mph)
reverse. Hydrostatic transmission mounted directly
on a 20.9:1 ratio front axle. Axle/reservoir capacity
is 4.7 l (5 qts). Replaceable filter mounted directly
on transmission housing. Model 03531 only:
Mechanical rear axle is coupled to the front axle by a
drive shaft and overrunning clutch.
Electrical System: Automotive type electrical system. 12-volt, maintenance free battery with 530 cold
cranking Amps @ –18°C (0° F) and 85 minute
reserve capacity @ 29° C (85° 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.
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 the operator seat.
Gauges: Hour meter, speedometer, fuel gauge, temperature gauge. 4 warning lamps: oil pressure, water
temperature, amps and glow plug.
General Specifications (approx.):
Width-of-Cut : 241 cm (95 in.)
Overall Width:
Transport 220 cm (87 in.)
Outside of tires 208 cm (82 in.)
Cutting Unit Drive System: Hydraulic reel motors
feature quick disconnects to ease removal/installation on cutting units. Hydraulic fluid reservoir
capacity is 32.2 l (8.5 gal.). System protected by a
filter assembly with service indicator.
Seat: Deluxe high-back seat with adjustable fore
and aft travel, weight and height. Tool box at the left
side of the seat.
Steering System: Power steering with dedicated
power source.
Tires: Two rear tires: 19 x 8.50-8, tubeless, 4-ply rating. Two front tires: 26 x 12.00-12 tubeless, 4-ply
rating. Recommended tire pressure for the front and
rear tires is 69–103 kPa (10–15 psi).
Brakes: Individual drum-type wheel brakes on the
front traction wheels. Brakes controlled by individual pedals operated by the left foot. Hydrostatic
braking through traction drive.
Overall Length:
Without grass baskets: 263 cm (103.5 in.)
With grass baskets: 294 cm (116 in.)
Height:
With Rollover protector: 214 cm (84.5 in.)
Without 142 cm (56 in.)
Recommended Height-of-Cut:
5-Blade Cutting Unit: 1–1.9cm (1/2–3/4 in.)
8-Blade Cutting Unit: 0.4–1.6 cm (1/4–5/8 in.)
Weight: Model 03502 821 kg (2,200 lbs.)*
Model 03504 952 kg (2,550 lbs.)*
Model 03530 868 kg (2,325 lbs.)*
Model 03531 998 kg (2,675 lbs.)*
*With 8-Blade Cutting Units, baskets & full
fluid levels
Optional Equipment
5-Blade Cutting Unit, Model No. 03505
8-Blade Cutting Unit, Model No. 03508
9
Specifications
Grass Basket Kit, Model No. 03513
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. 03516
Precleaner Bowl Extension Tube, Part No. 43-3810
(Clamp, Part No. 20-4840 required to install extension tube)
4-Wheel Drive Kit, Model No. 03517 (For use with
models 03502, 03530 only)
10
Before Operating
CHECK THE ENGINE OIL
1. Park the machine on a level surface. Open the
hood.
2. Remove the dipstick, wipe it clean, then reinstall
it. Remove it again and check the oil level on
the dipstick; The oil level should be up to the
FULL mark.
➀
of the radiator daily, more often if conditions are
extremely dusty and dirty.
The cooling system is filled with a 50/50 solution of
water and permanent ethylene glycol anti-freeze.
Check the level of coolant in the expansion tank each
day before starting the engine. Cooling system
capacity is 9.6 l.
1. Check the level of coolant in the expansion tank.
It should be between the marks on the side of
the tank.
CAUTION
If the engine has been running, pressurized hot
coolant can escape when the radiator cap is
removed and cause burns.
Figure 1
1. Dipstick
3. If the oil is below the FULL mark, remove the
fill cap and add SAE 10W-30 CD classification
oil until the level reaches the FULL mark on the
dipstick. DO NOT OVERFILL. Crankcase
capacity is 3.8 l with filter.
➀
Figure 2
1. Oil Fill Cap
4. Install the oil fill cap and close the hood.
➀
Figure 3
1. Expansion Tank
2. If coolant level is low, remove the expansion
tank cap and replenish the system. DO NOT
OVERFILL.
3. Install the expansion tank cap.
FILL THE FUEL TANK
1. Remove the fuel tank cap.
CHECK THE COOLING SYSTEM
Clean debris from the screen, oil cooler and the front
2. Fill the tank to about 2.5 cm (one inch) below
the top of the tank, not the filler neck, with No.
2 diesel fuel. Then install the cap.
11
Before Operating
DANGER
Because diesel fuel is flammable, use caution when
storing or handling it. Do not smoke while filling
the fuel tank. Do not fill the fuel tank while the
engine is running, hot, or when the machine is in an
enclosed area. Always fill the fuel tank outside and
wipe up any spilled diesel fuel before starting the
engine. Store the fuel in a clean, safety-approved
container and keep the cap in place. Use Diesel fuel
for the engine only; not for any other purpose.
groove mark. DO NOT OVERFILL by more
than .6 cm (1/4 inch) above the groove.
➀
Figure 5
1. Transmission Dipstick Cap
➀
Figure 4
1. Fuel Tank Cap
CHECK THE TRANSMISSION
FLUID
The front axle housing acts as the reservoir for the
system. The transmission and axle housing are
shipped from the factory with 4.7 l (5 quarts) of
Mobil 424 engine oil. However, check the level of
transmission oil before first starting the engine and
daily thereafter.
1. Position the machine on a level surface, lower
the cutting units and stop the engine.
2. Remove the access panel behind the foot rest.
3. Unscrew the dipstick cap from the transmission
filler neck and wipe it with a clean cloth. Screw
the dipstick into the filler neck. Remove the
dipstick and check the oil level. If the level is
not within 1.2 cm (1/2 inch) from the groove in
the dipstick, add enough oil to raise it to the
4. Screw the dipstick filler cap finger-tight onto
the filler neck. It is not necessary to tighten the
cap with a wrench.
CHECK THE HYDRA ULIC FLUID
The hydraulic system driving the reels is designed to
operate on anti-wear hydraulic fluid. The machine’s
reservoir is filled at the factory with 32.2 l (8.5 gallons) of Mobil 424 hydraulic fluid. Check the level
of hydraulic fluid before the first starting the engine
and daily thereafter.
Group 1 Hydraulic Oil (Recommended for ambient temperatures consistently below 38° C (100°
F):
ISO type 46/68 anti-wear hydraulic fluid
Mobil Mobil Fluid 424
Amoco Amoco 1000
International Harvester Hy-Tran
Texaco TDH
Shell Donax TD
Union Oil Hydraulic/Tractor Fluid
Chevron Tractor Hydraulic Fluid
BP Oil BP HYD TF
Boron Oil Eldoran UTH
Exxon Torque Fluid
Conoco Power-Tran 3
Kendall Hyken 052
12
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