Form No. 3350–414 Reelmaster 5500–D 2 and 4 Wheel Drive Traction Units Model No. 03550—230000001 and Up Model No.
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . Setting the Reel Speed . . . . . . . . . . . . . . . . . . . . . . Adjusting the Rear Lift Arm Counterbalance . . . . Towing the Traction Unit . . . . . . . . . . . . . . . . . . . . Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic ACE Display . . . . . . . . . . . . . . . . . . . . Checking the Interlock Switches . . . . . . . . . . . . . . Hydraulic Valve Solenoid Functions . . . . . . . . . . .
Introduction Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention.
• being driven too fast; • inadequate braking; • Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. • the type of machine is unsuitable for its task; • Do not use on slopes of more than • lack of awareness of the effect of ground conditions, especially slopes; – 5° when mowing on side hills; – 10° when mowing uphill; • incorrect hitching and load distribution. – 15° when mowing downhill.
• Keep all parts in good working condition and all hardware and hydraulic fittings tightened. Replace all worn or damaged parts and decals. – change into neutral and set the parking brake; – stop the engine and remove the key. • Disengage drive to attachments when transporting or not in use. • If the fuel tank has to be drained, do this outdoors. • Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine.
• 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 the area is cleared. Warning Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. Do not run engine indoors or in an enclosed area.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-6680 93-6699 93-6689 1. Machine speed 2. Slow 1. Warning—do not carry passengers. 3. Continuous variable setting 4. Fast 93-6696 1. Stored energy hazard—read the Operator’s Manual. 104-2052 93-6686 2. Read the Operator’s Manual. 1. Hydraulic oil 105-7506 93-6687 1. Read the Operator’s Manual 2.
104-9296 1. Read the Operator’s Manual. 2. Lower and engage the reels. 3. Raise and disengage the reels. 4. Fast 5. Slow 6. Enable the reels 7. Disable and raise the reels 8. Disable the reels 9. On 10. Off 11. Headlights 104-9294 1. Read the Operator’s Manual. 2. Do not tow the machine. 3. Warning—read the Operator’s Manual. 4. Cutting hazard of hand or foot—stay away from moving parts. 7. Warning—use a roll over protection system and wear the seat belt. 5.
105-7515 1. Read the Operator’s Manual 93-6692 1. Read the Operator’s Manual—do not prime or use starting fluid. 105-7527 93-6691 1. Read the Operator’s Manual. 93-8050 (Model 03551 only) 1. Warning—read the Operator’s Manual. 9 2. Tipping hazard—wear the seatbelt.
93-6693 1. Crushing hazard of hand—wait for moving parts to stop. 93-8060 98-7976 3. For backlapping, set the parking brake and move the throttle lever to Slow (do not change the engine speed while the reels are running). 1. Warning—read the Operator’s Manual. 2. Cutting hazard of and or foot—wait for moving parts to stop. 1. Warning—read the Operator’s Manual. 76-8730 1. Torque the lug nuts to 6–7.5 Kg-m (45–55 ft-lb); read the Operator’s Manual. 104-9298 1. Read the Operator’s Manual. 94-6767 1.
98-9335 1. Cutting/dismemberment hazard, fan—stay away from moving parts. 104-0082 1. Reel—height of cut 2. Reel—mow and backlap 3. Read the Operator’s Manual. 4. Machine speed 5. Rear reels circuit controls 6.
General Specifications Engine Main frame Cooling system Fuel system Traction system Ground speed Kubota three cylinder, 4 cycle, liquid cooled, turbo diesel engine. 35 hp @ 3000 rpm. Governed to 3200 rpm. 68-1/2 cubic inch (1123 cc) displacement. Heavy duty, 3 stage, remote mounted air cleaner. High water temperature shutdown switch. All welded formed steel frame, includes tie-down loops Radiator capacity is approximately 240 ounces (9.4 l) of 50/50 mixture of ethylene glycol anti–freeze.
Measurements Optional Equipment Width-of-cut 100 inch (254 cm) Overall width 5 Blade Cutting Unit (7 inch) Model No. 03860 7 Blade Cutting Unit (7 inch) Model No. 03861 Transport 88 inch (224 cm) 11 Blade Cutting Unit (7 inch) Model No. 03862 Outside of front tires 87 inch (221 cm) Dethatching Cutting Unit Model No. 03871 Grass Basket Kit Model No. 03882 Arm Rest Kit Model No. 30707 4 Wheel Drive Kit (For use with model 03550 only) Turf Defender Electronic Leak Detector Model No.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts, total set-up cannot be completed. Some parts may have already been assembled at the factory. Description Qty.
Connecting the Battery Warning CALIFORNIA Proposition 65 Warning 2 1 Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Figure 2 Warning 1. Positive battery cable Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 2.
Mounting the Hood Latch Replacing the Floor Panel Fastener (Required for CE) 1. Remove plug from hole in left front corner of hood (Fig. 3). 1. Remove fastener securing left front corner of floor panel to frame (Fig. 5). 2. Open the hood. 2. Replace with a flange head capscrew (5/16 x 5/8 inch) supplied in loose parts (Fig. 5). 1 Figure 3 1. Hood plug 1 3. Mount locking latch to hood with lock washer and nut. Position switch with latch toward front of machine (Fig. 4). 4.
Motor Weight #4 Weight Motor Weight #1 Motor Weight Motor 5 #5 Weight #2 Motor #3 Figure 6 3 Note: Counter weight mounting capscrews are shipped installed on the right bearing housing of the cutting units. The capscrews on left bearing housing are to be used for securing the hydraulic motor. 1. Remove cutting units from cartons. Assemble and adjust per Cutting Unit Operator’s Manual. 2 4 1 2. Remove protective plugs from each end of cutting unit. Figure 8 3.
Important Make spring adjustments with cutting unit is mounted to traction unit and lowered to shop floor. Refer to Traction Unit Operator’s Manual for mounting instructions. 1 3 2 1. Tighten lock nut on rear of spring rod until the gap C between rear of spring bracket and front of washer is 1 inch (26 mm) (Fig. 11). 2. Tighten hex nuts on front end of spring rod until the compressed length A of spring is 8 inches (203 mm) (Fig. 11).
• Loosen the carriage bolt nut securing the lift arm switch bracket to the #4 lift arm (left front) (Fig. 12). Note: Additional holes are provided to further adjust, if required. Rear Ballast 3 1 Model 03550 (2 Wheel Drive) complies with the CEN standard EN 836:1997, ISO standard 5395:1990 and the ANSI B71.4–1999 Standard when 100 lbs. (45 kg) of calcium chloride ballast is added to rear wheels and rear weight kit (Part No. 104–1478) is installed.
Before Operating Checking the Cooling System Note: Determine the left and right sides of the machine from the normal operating position. Clean debris off screen, oil cooler and front of radiator daily, more often if conditions are extremely dusty and dirty. Refer to Servicing the Engine Cooling System, page 38. Warning The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti–freeze.
Filling the Fuel Tank 1 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. Figure 17 1. Transmission dipstick cap • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1 in.
2. Clean area around filler neck and cap of hydraulic tank. Remove cap from filler neck (Fig. 18). 2 1 1 1 Figure 18 1. Hydraulic tank cap Figure 19 1. Check plug 2. Fill plug 3. Remove dipstick from filler neck and wipe it with a clean rag. Insert dipstick into filler neck; then remove it and check level of fluid. Fluid level should be within 1/4 inch (6 mm) of mark on dipstick. 4. If level is low, add appropriate fluid to raise level to full mark. 5. Install dipstick and cap onto filler neck.
Warning Failure to maintain proper torque of the wheel nuts could result in personal injury. Torque the front wheel nuts and rear wheel bolts to 45-55 ft-lb after 1–4 hours of operation and again after 10 hours of operation. Torque every 250 hours thereafter. 1 Figure 22 1. Traction pedal Operation Brake Pedals Note: Determine the left and right sides of the machine from the normal operating position.
Key Switch Glow Plug Indicator Light Three positions: Off, On/Preheat and Start (Fig. 23). When lit, indicates glow plugs are on (Fig. 24). Speedometer Charge Indicator Indicates ground speed at which machine is traveling (Fig. 23). Illuminates when system charging circuit malfunctions (Fig. 24). Lower Mow/Raise Control Lever Throttle Control The lever raises and lowers the cutting units and also starts and stops the reels (Fig. 24).
Hour Meter (Located under control panel) shows total hours that machine has been operated. Warning 1 Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. Lower the cutting units to the ground. Figure 26 1. Fuel injection pump bleed screw Starting and Stopping 3. Turn key in ignition switch to the on position. Electric fuel pump will begin operation, thereby forcing air out around air bleed screw.
3. Using the appropriate graph (See figure 27) for 5, 7 or 11 blade cutting units, determine the proper reel speed setting. 2 1 1 2 Figure 28 1. Backlap knobs 2. Reel speed control 5. Operate the machine for several days, then examine the cut to ensure satisfaction with the quality of cut.
2 3 1 1 Figure 31 Figure 29 1. Counterbalance spring 2. Spring bolt 1. Center of front frame member 3. Adjustment locations Note: Lock both brake pedals together before towing. 2. Remove the capscrew and locknut while relieving spring tension (Fig. 29). 3. Attach the other end of the towing device to a vehicle that is capable of towing the machine safely and at speeds below 3 mph. 3. Move spring bolt to desired location and install capscrew and locknut, while relieving spring tension (Fig. 29). 4.
Verifying the Interlock Switch Function B. One of the outputs is open circuited. Using the diagnostic display, determine which output is malfunctioning; refer to Checking Interlock Switches, page 28. 1. Park machine on a level surface, lower the cutting units, stop the engine and engage the parking brake. 2. Open control panel cover. Locate wire harness and connectors near controller. Carefully unplug loop back connector from harness connector.
6. The Diagnostic ACE will illuminate the LED associated with each of the inputs when that input switch is closed. Individually, change each of the switches from open to closed (i.e., sit on seat, engage traction pedal, etc.), and note that the appropriate LED on Diagnostic ACE will blink on and off when corresponding switch is closed. Repeat on each switch that is it possible to be changed by hand.
Running the Mower Operating Characteristics 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 cutting units). To move forward and cut grass, press traction pedal forward. Becoming Familiar with the Machine Before mowing grass, practice operating machine in an open area. Start and stop the engine.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • • • • After first 50 hours • Change the engine oil and filter. • Check the engine RPM (idle and full throttle). • Torque the head and adjust valves. After first 200 hours • Change the planetary gear oil Check the fan and alternator belt tension. Torque the wheel lug nuts.
Important Refer to your engine operator’s manual for additional maintenance procedures. Lubricating the Mower Warning Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. Lower the cutting units to the ground. Greasing the Bearing and Bushings Figure 35 The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Figure 38 Figure 41 Figure 39 Figure 42 Figure 40 Figure 43 33
Service Interval Chart Figure 44 34
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun.
2 4. Blow compressed air from inside to the outside of dry filter element. Do not exceed 40 psi to prevent damage to the element. 1 3 5. Keep air hose nozzle at least 2 inches (52 mm) from filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light. 6. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter. 7. Insert new filter properly into air cleaner body.
1 1 Figure 48 2 1. Engine oil filter Figure 49 3. Add oil to crankcase; refer to Checking the Engine Oil, page 20. 1. Fuel Filter/ Water Separator 2. Drain plug Servicing the Fuel System Replace filter canister after every 400 hours of operation. Changing the Fuel Tank 1. Clean area where filter canister mounts. Drain and clean fuel tank every 2 years. Also, drain and clean tank if fuel system becomes contaminated or if machine is to be stored for an extended period.
3. Turn key in key switch to start position and watch fuel flow around connector. Engine will crank. Turn key to off position when solid flow is observed. 2 4. Tighten pipe connector securely. 2 5. Repeat steps on remaining nozzles. Servicing the Engine Cooling System 1 Figure 50 1. Fuel filter Removing Debris 2. Hose clamp Remove debris from screen, oil coolers and radiator daily, clean more frequently in dirty conditions. Bleeding Air from the Injectors 1. Turn engine off and raise hood.
2 1 2 1 Figure 54 3 1. Alternator belt 2. Brace 3. Loosen bolt securing brace to engine and bolt securing alternator to brace. 4. Insert pry bar between alternator and engine and pry out on alternator. 5. When proper tension is achieved, tighten alternator and brace bolts to secure adjustment. Figure 53 1. Reel oil cooler 2. Radiator 3. Transmission oil cooler Servicing the Cooling Fan Belt 1. Loosen lock nut on belt tensioner lever. Servicing the Engine Belts 2. Apply 5–10 lb.
Adjusting the Throttle 1 1. Position throttle lever forward so it stops against seat base slot. 2. Loosen the throttle cable connector on the lever arm at the injection pump. 3. Hold the injection pump lever arm against the high idle stop and tighten the cable connector. Note: When tightened, the cable connector must be free to swivel. 4.
Using the Hydraulic System Test Ports The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. 1 1. Test Port #1 is used to assist in trouble shooting the hydraulic circuit for the front cutting units and lift cylinders. Figure 58 2 1. Hydraulic filter 1 3. Lubricate new filter gasket and fill the filter with hydraulic fluid. 4. Assure filter mounting area is clean. Screw filter on until gasket contacts mounting plate.
3. Verify drop rate adjustment by raising and lowering cutting unit several times. Readjust as required. 4. After desired drop rate is attained, tighten setscrew to lock adjustment. 1 Figure 60 1 1. Traction adjustment cam Figure 61 1. Center cutting unit adjustment valve Warning Engine must be running so final adjustment of the traction adjustment cam can be performed. Adjusting the Outside Front Cutting Units 1. Locate valve on right side of lift block (Fig. 62).
Adjusting the Rear Cutting Units Adjusting the Traction Linkage 1. Raise hood and locate valve in center of machine behind engine (Fig. 63). 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. Loosen outer hex nut securing eye bolt to spring anchor plate. 1 2 3 1 Figure 63 1. Rear cutting unit adjustment valve 5 2.
Hydraulic Schematic 44
Warning Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. Lower the cutting units to the ground. 2 Adjusting the Service Brakes Adjust the service brakes when there is more than 1 inch (26 mm) of free travel of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1 1. Disengage locking pin from brake pedals so both pedals work independently of each other.
5. Start engine and let run for about two minutes to purge air from the system. Stop the engine and check for leaks. Check fluid level and replenish if necessary. Changing Rear Axle Lubricant (Model 03551 Only) After every 800 hours of operation the oil in the rear axle must be changed. 1 1. Position machine on a level surface. Figure 68 2. Clean area around the drain plugs. 1. Tie rod 3. Remove plug allowing oil to drain into drain pans. 4.
Adjusting the Parking Brake Switch Warning Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. The parking brake uses a proximity sensor located under the cover of the steering tower. This sensor is adjusted so the sensor locates a flag on the latch rod when the parking brake is released. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Wiring Diagram 48
Backlapping Note: Backlapping speed may be increased by moving the reel speed selector knob toward “13.” Each position will increase speed approximately 100 rpm. After changing selector, wait 30 seconds for the system to stabilize at the new speed. Danger The reels may stall while backlapping and could restart suddenly. Contact with the reels during backlapping will cause personal injury. 4.
10. To make an adjustment to the cutting units while backlapping, turn reels off by moving the Lower Mow/Raise lever rearward; move the Enable/Disable switch to disable and turn the engine off. After adjustments have been completed, repeat steps 5–9. 2. 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.
Engine Storage 1. Drain the engine oil from the oil pan and replace the drain plug. Traction Unit 2. Remove and discard the oil filter. Install a new oil filter. 1. Thoroughly clean the traction unit, cutting units and the engine. 3. Refill oil pan with 128 ounces of SAE10W-30 motor oil. 2. Check the tire pressure. Inflate all traction unit tires to 10–15 psi. 4. Start the engine and run at idle speed for approximately two minutes. 3. Check all fasteners for looseness; tighten as necessary. 5.
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 Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
