FORM NO. 3326 296 MODEL NO. 03550 - 210000401 & UP MODEL NO. 03551 - 210000401 & UP OPERATOR'S MANUAL REELMASTER® 5500-D 2 & 4 WHEEL DRIVE TRACTION UNITS 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.
FOREWORD This operator's manual has instructions on safety, proper set-up and operation, adjustments and maintenance. Therefore, anyone involved with the product, including the operator, should read and understand this manual. Major sections are: - Safety Instructions - Know Your Controls - Specifications - Operating Instructions - Set-up Instructions - Maintenance - Before Operating - Schematics This manual emphasizes safety, mechanical and general product information.
TABLE OF CONTENTS Page SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY INSTRUCTIONS & DECALS . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . LOOSE PARTS CHART . . . . . . . . . . . . . . . . . . . . . . . SET UP INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . Connect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . Mount Hood Latch . . . . . . . . . . . . . . . . . . . . . . . . Replace Floor Panel Fastener . . . . . . . . . . .
SAFETY INSTRUCTIONS The REELMASTER 5500-D was tested and certified by TORO for compliance with the B71.4 1999 specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
SAFETY INSTRUCTIONS 18. DON'T TAKE AN INJURY RISK! When a person or pet appears unexpectedly in or near the mowing area, STOP MOWING. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until area is cleared. 27. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor. 19.
SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. Part No. 104–0081 1. See the operator’s manual Part No. 104–9296 1. Throttle–slow 2. Throttle–fast 3. Reels raised & off 6 4. Reels lowered and on when enabled –forward and backlap 5. Reels –enabled 6. Reels disabled–lift only 7. Reels disabled–lift and lower 8.
Part No. 93-6689 1. Danger—no riders Part No. 104–2052 1. See operator’s manual Part No. 104–9298 1. Read operator’s manual Part No. 104–0082 1. 2. 3. 4. 5. 6. Height–of–cut Mow and backlap Read operator’s manual Traction unit speed Rear reels circuit controls Front reels circuit controls Part No. 94–6767 Part No. 93–6693 1. Hazard to hands–pinch points 2. Stop reels before touching 1. Read operator’s manual 2. Engine start 3.
Part No. 93–6699 1. Slow 2. Fast 3. Traction speed Part No. 93–8060 1. 2. 3. 4. 5. 6. 7. Danger Read operator’s manual Height–of–cut Move throttle to slow Hazard to feet Hazard to hands Stop reels before touching Part No. 93–8050 (Model 03551 only) Part No. 93–6691 1. 2. 3. 4. Danger Read operator’s manual Tipping hazard Wear seat belts 1. Read operator’s manual–eccentric bolt Part No. 93–6692 Part No. 93–6697 (Model 03551 only) 1. Read operator’s manual 2. Do not prime engine 3.
Part No. 98–7976 1. Danger 2. Read operator’s manual Part No. 93–6687 1. Do not step Part No. 104–9294 1. 2. 3. 4. 5. 6. 7. Danger Read operator’s manual Thrown objects–keep bystanders away Cutting hazard to hands and feet Do not tow Cutting hazard to hands–keep away from moving parts Danger–set the parking brake, stop the engine, and remove the key before leaving the operator’s position 8. Tipping hazard–always fasten seat belts Part No. 93–6686 1. Hydraulic oil level 2.
SPECIFICATIONS Engine: Kubota three cylinder, 4 cycle, liquid cooled, turbo diesel engine. 35 hp @ 3000 rpm. Governed to 3200 rpm. 68.5 cu. in. (1123 cc) displacement. Heavy duty, 3 stage, remote mounted air cleaner. High water temperature shutdown switch. Main Frame: All welded formed steel frame, includes three tie-down loops. Cooling System: Radiator capacity is approximately 7-1/2 qts. (7 l) of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted 1 qt. (.9 l) expansion tank.
SPECIFICATIONS Diagnostic ACE Tool Weight Kit Part No. 85 4750 Part No. 104-1478 High Torque Reel Motor Part No. 98 9998 Wiehle Roller Scraper Part No. 100 9908 Basket Tipper Kit Part No. 100 9945 Rear Roller Scraper Kit Low Height of Cut Bedknife* Part No. 93 9774 Gauge Bar Assembly Part No. 98 1852 Angle Indicator Part No. 99 3503 Backlapping Brush Assembly Part No. TOR299100 Part No. 100 9920 Bedknife Screw Tool Part No. TOR510880 Shoulder Wiehle Roller Part No.
SET UP INSTRUCTIONS CONNECT BATTERY (Fig. 1) WARNING Connecting cables to the wrong post could result in personal injury and/or damage to the electrical system. 5. Coat both battery connections with Grafo 112X (skin over) grease, Toro Part No. 505 47, petroleum jelly or light grease to prevent corrosion and slide rubber boot over positive terminal. 6. Close hood. MOUNT HOOD LATCH (Fig. 2 & 3) 1. Remove plug from hole in left front corner of hood (Fig. 2). 2. Open hood. 1. Open hood. 2.
SET UP INSTRUCTIONS REPLACE FLOOR PANEL FASTENER (Required for CE) (Fig. 4) cutting units. The capscrews on left bearing housing are to be used for securing the hydraulic motor. 1. Remove fastener securing left front corner of floor panel to frame (Fig. 4). 1. Remove cutting units from cartons. Assemble and adjust per Cutting Unit Operator's Manual. 2. Remove protective plugs from each end of cutting unit. 3.
SET UP INSTRUCTIONS 7. Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame (Fig. 7). 8. Secure pivot knuckle to carrier frame with a thrust washer, flat washer and a flange head capscrew (Fig. 7). 9. Insert a thrust washer onto vertical shaft of pivot knuckle (Fig. 7). ALTERNATE ADJUSTMENTS Traction units are setup at the factory appropriately for most fairway mowing applications.
SET UP INSTRUCTIONS Lifted Height of Outer Front Cutting Units (Enable Position) The turnaround height of the front outer cutting units (#4 & #5) may be increased to provide additional ground clearance on contoured fairways. Contact your distributor for assistance. CUTTING UNIT STABILIZER The stabilizer for the front center cutting unit can be adjusted up or down to stabilize the cutting unit when in the fully raised position. 1. Raise all cutting units to the transport position and shut off the engine.
BEFORE OPERATING CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Lower cutting units to the ground. 1. Check level of coolant in expansion tank. Coolant level should be between the marks on side of tank. 1 CHECK ENGINE OIL (Fig. 12) 1. Park machine on a level surface, stop engine and remove key from ignition switch. Open hood. 2. Remove dipstick, wipe clean and reinstall dipstick.
BEFORE OPERATING CHECK TRANSMISSION FLUID (Fig. 15) The front axle housing acts as the reservoir for the system. The transmission and axle housing are shipped from the factory with approximately 5 quarts (4.7 l) of Mobil 424 hydraulic fluid. However, check level of transmission oil before engine is first started and daily thereafter. 1. Position machine on a level surface, lower the cutting units and stop the engine. 2. Remove access panel behind foot rest. 3. Remove floor panel. 4.
BEFORE OPERATING It is recommended that you select which set of conditions (either ambient temperatures above 70° F. or below 100° F.), and use that type of fluid throughout the year, rather than changing fluid types several times per year. 4. Remove each end check plug and add enough lubricant to bring the level up to the bottom of each check plug hole. 5. Install all plugs.
KNOW YOUR CONTROLS Seat (Fig. 19) - Seat adjusting lever allows 4 inch fore and aft adjustment. Seat adjusting knob adjusts seat for operators weight. To adjust seat fore and aft, pull lever on left side of seat assembly outward. After moving seat to desired location, release lever to lock seat into position. To adjust for operators weight, turn spring tension knob; clockwise to increase tension, counterclockwise to decrease spring tension.
KNOW YOUR CONTROLS Engine Oil Pressure Warning Light (Fig. 22) Indicates dangerously low engine oil pressure. Engine Coolant Temperature Warning Light (Fig. 22) - The light illuminates and engine shuts down when coolant reaches a dangerously high temperature. 1 2 1 2 Glow Plug Indicator Light (Fig. 22) - When lit, indicates glow plugs are on. Charge Indicator (Fig. 22) - Illuminates when system charging circuit malfunctions. Throttle Control (Fig.
OPERATING INSTRUCTIONS CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Lower cutting units to the ground. 1 STARTING AND STOPPING IMPORTANT: The fuel system must be bled if any of the following situations have occurred. Figure 25 1. Air bleed screw A. Initial start up of a new machine. B. Engine has ceased running due to lack of fuel. 3. Pump lever on fuel pump (Fig. 26) until a solid stream of fuel flows out around screw.
OPERATING INSTRUCTIONS 5. Pump lever on fuel pump (Fig. 26) until a solid stream of fuel flows out around screw on fuel injection pump. Tighten air bleed screw. Note: Normally, engine should start after above bleeding procedures are followed. However, if engine does not start, air may be trapped between injection pump and injectors; refer to Bleeding Air From Injectors. 4. To set reel speed, rotate knobs (Fig. 29) until indicator arrows are in line with the number designating desired setting.
OPERATING INSTRUCTIONS 2 3 1 1 Figure 30 1. Counterbalance Spring 2. Spring Bolt 3. Adjustment Locations 2. Remove the capscrew and locknut while relieving spring tension. 3.. Move spring bolt to desired location and install capscrew and locknut, while relieving spring tension. TOWING TRACTION UNIT (Fig. 31 & 32) If it becomes necessary to tow the machine, tow it forward only, for a short distance and at a speed no greater than 3 mph.
OPERATING INSTRUCTIONS Using the Diagnostic Display, determine which output is malfunctioning, refer to Checking Interlock Switches. If the diagnostic light is not illuminated when the key switch is in the ON position, this indicates that the electronic controller is not operating. Possible causes are: 1. Loopback is not connected. 2. The light is burned out. 3. Fuses are blown. 4. No battery power. To verify interlock switch function: 1.
OPERATING INSTRUCTIONS 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. Replace any defective switches and repair any defective wiring. The Diagnostic Display also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic. To verify output function: 1.
OPERATING INSTRUCTIONS Warning System - If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if the machine is operated with a malfunction. Mowing -Start engine and move throttle to FAST so engine is running at maximum speed. Move the ENABLE / DISABLE switch to ENABLE and use the LOWER MOW / RAISE lever to control the cutting units (front cutting units are timed to lower before the rear 26 cutting units).
LUBRICATION CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Lower cutting units to the ground. GREASING BEARINGS AND BUSHINGS (Fig. 34 - 41) The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation.
LUBRICATION Figure 40 Figure 42 Figure 41 SERVICE INTERVAL CHART 28
DAILY MAINTENANCE CHART AND CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance Check Item MON Safety Interlock Operation Brake Operation Engine Oil & Fuel Level Cooling System Fluid Level TUES WED THURS FRI SAT SUN Drain Water/Fuel Separator Air Filter Restriction Indicator Radiator and Screen for Debris Unusual Engine Noise
AIR CLEANER MAINTENANCE 2. Gently slide filter element out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Lower cutting units to the ground. GENERAL AIR CLEANER MAINTENANCE 1. Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. 1 2.
ENGINE MAINTENANCE CAUTION Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Lower cutting units to the ground. ENGINE OIL AND FILTER (Fig. 45 & 46) Change oil and filter initially after the first 50 hours of operation, thereafter change oil every 50 hours and filter every 100 hours. 1. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug.
ENGINE MAINTENANCE 1 3 4 2 ENGINE COOLING SYSTEM (Fig. 50 & 51) 1. Removing Debris - Remove debris from screen, oil coolers and radiator daily, clean more frequently in dirty conditions. A. Turn engine off and raise hood. Clean engine area thoroughly of all debris. B. Loosen clamps and pull up on screen to slide it out of mounting tracks. Clean screen thoroughly with water or compressed air. Figure 48 1. Fuel filter mounting head 2. Filter bowl 3. Filter 4. O-ring 2.
ENGINE MAINTENANCE SERVICING ENGINE BELTS Check condition and tension of all belts after first day of operation and every 100 operating hours thereafter. 2 Alternator Belt (Fig. 52) To Check Tension: 1. Open hood. 1 2. Check tension by depressing belt midway between alternator and crankshaft pulleys with 22 lb. of force. Belt should deflect 7/16 in. If deflection is incorrect, proceed to step 3. If correct, continue operation. Figure 53 1. Cooling Fan Belt 2.
HYDRAULIC MAINTENANCE CAUTION 2. Clean area around filter mounting area. Place drain pan under filter and remove filter. Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Lower cutting units to the ground. CHANGING HYDRAULIC FLUID (Fig. 55) Change hydraulic fluid after every 2 years or 1600 operating hours, in normal conditions. If fluid becomes contaminated, contact your local Toro distributor because the system must be flushed.
HYDRAULIC MAINTENANCE WARNING 2 1 Engine must be running so final adjustment of the traction adjustment cam can be per formed. To guard against possible personal injury, keep hands, feet, face and other parts of the body away from the muffler, other hot parts of the engine, and other rotating parts. Figure 57 4. Start engine and rotate cam hex in either direction until wheel ceases rotation. 2. Test Port #2 is used to assist in trouble shooting the hydraulic circuit for the rear cutting units. 6.
HYDRAULIC MAINTENANCE ADJUSTING TRACTION LINKAGE (Fig. 62) Due to normal wear in hydrostatic transmission, force may be required to neutral. Periodically check 1 the control linkage and an increased amount of return the transmission to the machine. To Adjust Traction Linkage 1. Park machine on a level surface, lower cutting units to the floor and shut engine off. 2. Connect brake pedals together with locking pin, push both pedals down and pull parking brake latch out. 3.
LH RH P1 V1 P3 R3 100MESH SUCTION STRAINER P2 OUT IN G1 P1 FC1 MOW1 LC1 R1 T MSV1MSV2 BACKLAP OR1 .025 DIA MD1 M5 R9 BKLP1 3000 PSI M1 M4 AUX MOW R9 R9 rR10 R2 LC2 P2 2000 PSI MD2 MOW2 OR2 .025 DIA MOW M2 R9 FC2 BKLP2 M3 R9 C.U.
BRAKE MAINTENANCE CAUTION cable. Then tighten rear nut to move cable backward until brake pedals have 1/2 to 1 inch of free travel. Tighten front nuts after brakes are adjusted correctly. Before servicing or making adjustments to the machine, stop engine and remove key from the switch. Lower cutting units to the ground. ADJUSTING SERVICE BRAKES (Fig. 63) Adjust the service brakes when there is more than 1 inch of free travel" of the brake pedal, or when the brakes do not work effectively.
AXLE MAINTENANCE 3. Remove line from transmission allowing fluid to drain into drain pan. 4. Reinstall suction line to transmission. 5. Fill with oil; refer to Check Transmission Fluid. 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. REPLACING TRANSMISSION 1 Figure 65 1. Drain Plugs FILTER (Fig.
AXLE MAINTENANCE REAR WHEEL TOE IN ADJUSTMENT (Fig. 67) (Model 03551 only) The rear wheels should have 0 to 1/8 of an inch toe in when they are pointed straight ahead. To check toe in, measure the center to center distance, at axle height, in front and rear of steering tires. If toe in is not within specifications, an adjustment is required. 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.
ELECTRICAL MAINTENANCE 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. CAUTION Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated so gases produced while charging can dissipate.
SP10 FUSIBLE LINK G S RED BATTERY 12 VOLTS - RED WATER TEMP SENSOR + ORANGE/RED STARTER FUSIBLE LINKS 5 6 4 3 BLACK START RELAY SPEEDOMETER WARNING LIGHTS 1 2 B FUEL GAGE GREEN/BLUE BLACK OIL PRESS SWITCH BLACK BLUE/GREEN BLACK GRAY BLACK BLUE/WHITE TEMP GAGE ALTERNATOR OPTIONAL LIGHT GREEN/BLACK 2 1 4 5 LIGHT SWITCH RED BLACK ORANGE ORANGE BLACK ORANGE ORANGE BLACK ORANGE BLACK G S I BLACK RED SP9 BLACK RED DIAGNOSTIC INDICATOR B HOUR METER A RED/BLUE
CUTTING UNIT MAINTENANCE BACKLAPPING 5. Start engine and run at idle speed. POTENTIAL HAZARD Changing engine speed while backlapping may cause reels to stall. POTENTIAL HAZARD Reels may stall when backlapping. WHAT CAN HAPPEN Reels may restart. Contact with rotating reels will cause serious injury. HOW TO AVOID THE HAZARD Do not attempt to restart reels by hand or touch reels while backlapping. Stop engine and turn height-of-cut knob one position toward “1.
CUTTING UNIT MAINTENANCE 12. When the cutting unit is adequately sharpened, a burr will form on the front edge of the knife. Using a file, carefully remove the burr without dulling the cutting edge (Fig. 71 ). 13. Repeat procedure for all cutting units to be backlapped. When backlap operation has been completed, return the backlap knobs to the forward flow position, lower seat and wash all lapping compound off cutting units. Adjust cutting unit reel to bedknife as needed.
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Check Battery Fluid Level Check Battery Cable Connections Lubricate All Grease Fittings Change Engine Oil Maintenance Interval & Service Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs Inspect Air Filter, Dust Cup, & Baffle Check Fan and Alternator Belt Tension ‡ Replace Engine Oil Filter Inspect Cooling System Hoses Drain Moisture from Hydraulic Tank Drain Moisture from Fuel Tank Check Reel Bearin
PREPARATION FOR SEASONAL STORAGE Traction Unit Engine 1. Thoroughly clean the traction unit, cutting units and the engine. 1. Drain the engine oil from the oil pan and replace the drain plug. 2. Check the tire pressure. Inflate all traction unit tires to 15-20 psi. 2. Remove and discard the oil filter. Install a new oil filter. 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. 5.
IDENTIFICATION AND ORDERING MODEL AND SERIAL NUMBER 1. Model and serial numbers of the machine. The model and serial number is on a plate that is mounted on the left side of frame above footrest. Use model and serial number in all correspondence and when ordering parts. 2. Part number, description and quantity of parts desired.
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 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
