Toro 03540, 03541, 03543, 03544, REELMASTER 5200-D Operator's Manual

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.

It means CAUTION, WARNING or DANGER—
personal safety instruction. Failure to comply with
the instruction may result in personal injury.

®

©The TORO COMPANY—1998

MODEL NO. 03540-80001 & UP
MODEL NO. 03541­MODEL NO. 03543­MODEL NO. 03544-

80001 & UP
80001 & UP
80001 & UP

REELMASTER

FORM NO. 3321-307 Rev A

OPERATOR’S

MANUAL

®

5200-D/5400-D

2

Table of Contents

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.

Page
Safety 3
Specifications 9
Before Operating 10
Controls 13
First-Time Operation 16
Operating 20

Maintenance 22

3

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

responsible 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;
– 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.

• 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.

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;

Safety

4

• machine speeds should be kept low on
slopes and during tight turns;

• stay alert for bumps and hollows and other
hidden hazards;

• 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

roadways.

8. Stop the blades rotating before crossing

surfaces other than grass.

9. When using any attachments, never direct

discharge 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.

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

transporting 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
operator’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 run-

out 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.

6. Replace worn or damaged parts for safety.

7. If the fuel tank has to be drained, this should

be done outdoors.

5

Safety

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 a continuous A-weighted sound
pressure level of 88 dB(A), based on measurements
of identical machines per Directive 91/386/EEC and
amendments.

This unit has a sound power level of 101 LWA,
based on measurements of identical machines per
Directive 84/538/EEC and amendments

Vibration Levels

This unit has a vibration level of 1.3 m/s2at the
hands, based on measurements of identical machines
per ISO 5349 procedures.

This unit does not exceed a vibration level of 0.5
m/s

2

at the posterior, based on measurements of

identical machines per ISO 2631 procedures.

6

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 entangle­ment, chain drive

Hand & arm
entanglement,
belt drive

Explosion Fire or open

Shut off engine
& remove key before
performing mainten­ance or repair work

Thrown or fly­ing objects, whole
body exposure

flame

Riding on this
machine is allowed
only on a passen­ger 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/back­over, (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

7

Safety

Eye protection
must be worn

Fire, open light
& smoking
prohibited

Level
indicator

Head protection
must be worn

Hydraulic
system

Liquid level Filter Temperature Failure/

Hearing
protection must
be worn

Brake system

Caution, toxic
risk

Oil Coolant (water) Intake air Exhaust gas Pressure

First aid

Malfunction

Flush with water Engine Transmission

Start switch/
mechanism

On/start Off/stop

Engage Disengage

Horn Battery charging

Machine travel
direction,
forward/rearward

Jack or
support point

condition

Control lever
operating
direction, dual
direction

Draining/
emptying

Attachment
lower

Hourmeter/elapsed
operating hours

Engine lubricat­ing oil

Attachment
raise

Fast Slow Continuous

Control lever
operating
direction, multiple
direction

Clockwise
rotation

Engine lubricating
oil pressure

Spacing distance Snow thrower,

Counter-clock­wise rotation

Engine lubricating
oil level

collector auger

variable, linear

Grease
lubrication
point

Engine lubricating
oil filter

Plus/increase/
positive polarity

Volume empty Volume full

Oil lubrication
point

Engine
lubricating oil
temperature

Minus/decrease/
negative polarity

Lift point

Engine coolant

8

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 t em perature
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

Engine: Kubota three-cylinder, 4-cycle, liquid­cooled diesel. 18.6 kW (25 hp) @ governed to 3200
rpm; 1123 cc 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. 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 03541—
Mechanical rear axle is coupled to the front axle by
a drive shaft and overrunning clutch.

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, 4­ply 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.

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 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.)

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
Grass Basket Kit, Model No. 03513

9

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. 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

Specifications

CHECK THE ENGINE OIL

1. Park the machine on a level surface, stop the

engine and remove the key from the ignition
switch. 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.

Figure 1

1. Dipstick

2. Oil fill

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.

4. Install the oil fill cap and close the hood.

CHECK THE COOLING
SYSTEM

Clean debris from the screen, oil cooler and the front
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 9.1 l.

Figure 2

1. Expansion Tank

1. Check the level of coolant in the expansion

tank. It should be between the marks on the
side of the 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.

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

If the engine has been running, pressurized hot
coolant can escape when the radiator cap is
removed and cause burns.

CAUTION

Before Operating

➀

2

1

1

Figure 3

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 hydraulic fluid. 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
groove mark. DO NOT OVERFILL by more

than .6 cm (1/4 inch) above the groove.

3. Screw the dipstick filler cap finger-tight onto

the filler neck. It is not necessary to tighten the
cap with a wrench.

Figure 4

1. Transmission dipstick cap

CHECK THE HYDRAULIC
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):

12

Before Operating

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.

DANGER

➀

Figure 5

1. Hydraulic tank cap

➀

1

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
Phillips HG Fluid

Note: Oils within this group are

interchangeable.

Group 2 Hydraulic Oil—Recommended for
ambient temperatures consistently above 21° C
(70° F):

ISO type 68 anti-wear hydraulic fluid

Mobil DTE 26 or DTE 16
Shell Tellus 68
Amoco Rykon Oil 68
Arco Duro AW S-315
Boron Industron 53
BP Oil Energol HLP68
Castrol Hyspin AWS68
Chevron Chevron EP68
Citgo Citgo A/W68
Conoco Super Hydraulic Oil 31
Exxon Nuto H68
Gulf 68AW
Pennzoil AW Hyd Oil 68
Phillips Magnus A315
Standard Industron 53
Texaco Rando HD68
Union Unax AW 315

Note: Oils within this group are inter-

changeable.

IMPORTANT: Two groups of hydraulic oil are
specified to allow optimal operation of the
machine in a wide range of temperatures
encountered. The group 1 oils are a multi­viscosity hydraulic oil that allow operation at
lower temperatures without the increased
viscosity associated with straight viscosity oils.

Using the Mobil 424-type oils in the higher ambient
temperatures may result in decreased efficiency in
some hydraulic components compared to using the
Mobil DTE 26 type oils.

The Mobil DTE 26 type oils are straight viscosity
oils which remain slightly more viscous at higher
temperatures than the multi-viscosity oils.

Using the Mobil DTE 26 type oils in the lower
ambient temperatures may result in harder starting,
increased engine laboring while cold, sluggish or
non-operating valve spools while cold and increased
filter back pressure due to the higher oil viscosity.

Select the set of conditions (either ambient
temperatures above 21° C or below 38° C, and use
that type of oil throughout the year, rather than
changing oil types several times per year.

Group 3 Hydraulic Fluid (Biodegradable):

ISO VG 32/46 anti-wear Hydraulic fluid

Mobil EAL 224H

Note: This biodegradable hydraulic fluid in this
group is not compatible with the fluides in group 1
or 2.

Note: When changing from one type of hydraulic
oil to the other, remove all the old oil from the
system, because some brands of one type are not
completely compatible with some brands of the
other type of hydraulic oil.

IMPORTANT: Use only the types of hydraulic
oils specified. Other fluids could cause system
damage.

Note: A red dye additive for the hydraulic system

oil is available in 20 ml bottles. One bottle is
sufficient for 15–22 l of hydraulic oil. Order Part
No. 44-2500 from your Authorized Toro Distributor

1. Position the machine on a level surface, lower

the cutting units and stop the engine.

2. Clean the area around the filler neck and cap of

the hydraulic tank. Remove the cap from the
filler neck.

13

Before Operating

3. 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.

4. If the level is low, add fluid to raise the level to

the full mark.

5. Install the dipstick and cap onto the filler neck.

CHECK REAR AXLE
LUBRICANT (Model 03541 only)

The rear axle has three separate reservoirs which use
SAE 80W-90 weight gear lube. Although the axle is
shipped with lubricant from the factory, check the
level before operating the machine.

1. Position the machine on a level surface.

2. Remove a check plug from each end of axle

and make sure the lubricant is up to bottom of
the hole. If the level is low, remove a mounting
bolt above each end plug and add enough
lubricant to bring the level up to the bottom of
the hole (Fig. 7).

Figure 6

1. Check Plugs (2)

2. Mounting Bolts

3. Remove the plug in the center of the axle and

check the level. If the level is low, add enough
lubricant to bring it up to the bottom of the hole
(Fig. 8).

Figure 7

1. Check/Fill Plug

CHECK REEL-TO-BEDKNIFE
CONTACT

Each day before operating, check the reel-to­bedknife contact, regardless of whether the quality
of cut has been acceptable. There must be light
contact across the full length of the reel and
bedknife.

CHECK WHEEL NUT TORQUE

14

WARNING

Tighten the wheel nuts to 61-75 Nm after 1–4
hours of operation and again after 10 hours of
operation and every 250 hours thereafter. Failure
to maintain correct torque could result in failure or
loss of a wheel, which may result in personal
injury.

➀

➁

➀

Before Operating