Form No. 3412-511 Rev D Reelmaster® 3555 and 3575 Traction Unit Model No. 03820—Serial No. 400000000 and Up Model No. 03821—Serial No. 400000000 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Changing the Engine Oil and Filter.................... 40 Fuel System Maintenance ................................... 41 Servicing the Fuel Tank..................................... 41 Inspecting the Fuel Lines and Connections.................................................. 41 Draining the Water Separator ........................... 41 Changing the Fuel Filter Canister...................... 42 Bleeding Air from the Injectors .......................... 42 Electrical System Maintenance ...........
Safety This machine has been designed in accordance with EN ISO 5395:2013 (when appropriate decals are applied) and ANSI B71.4-2012. Important: For CE required regulatory data, refer to the Declaration of Conformity supplied with the machine. General Safety This product is capable of amputating hands and feet and of throwing objects. • Read and understand the contents of this Operator’s Manual before starting the engine. • Use your full attention while operating the machine.
Safety and Instructional 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 missing. decal93-6688 decal117-2718 93–6688 117-2718 1. Warning—read the Operator’s Manual before performing maintenance. 2. Cutting hazard of hand or foot—shut off the engine and wait for all moving parts to stop. decal117-3270 117-3270 decal106-6755 1. Warning—do not touch the hot surface. 106-6755 2.
99-3444 decal99-3444 99–3444 1. Transport speed 2. Mow speed decal133-4900c 133-4900 1. Read the Operator's Manual.
decal120-1683 120-1683 4. Warning—do not park the machine on slopes; engage the parking brake, lower the cutting units, shut off the engine, and remove the key before leaving the machine. 1. Warning—read the Operator's Manual; all operators should be trained before operating the machine. 5. Thrown object hazard—keep bystanders away. 2. Warning—read the Operator's Manual before towing the machine. 3. Tipping hazard—drive slowly when turning; do not turn sharply 6.
decal120-1686 120-1686 (Affix over Part No. 120-1683 for CE) Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
decal121-7884 121-7884 1. 8-blade reel adjustment 3. Read the Operator’s Manual for information on adjusting the reel. 2. 11-blade reel adjustment decal133-4901 133-4901 1. 8-blade reel adjustment 3. Read the Operator’s Manual for information on adjusting the reel. 2.
decal120-2105 120-2105 1. Lower the cutting units 5. Read the Operator’s Manual for information on starting the engine—1) Sit in the operator’s position; 2) Turn the key to the engine—preheat position; 3) Wait until the electrical preheat light turns off; 4) Turn the key to the engine—start position; 5) Disengage the parking brake. 2. Raise the cutting units 10. Lights 6.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. Hose guide (right) Hose guide (left) 1 1 Install the cutting units. No parts required – Adjust the turf compensation spring. Warning decal (120-1686) 1 Install the CE decal, if required. 4 Lock bracket Rivet Washer Screw (1/4 x 2 inches) Locknut (1/4 inch) 1 2 1 1 1 Install the hood latch (CE only). 5 Cutting-unit kickstand 1 Use the cutting-unit kickstand.
compensation spring is mounted to the same side of the cutting unit as the reel drive motor. Position the turf compensation as follows: 1 A. Installing the Cutting Units Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting unit tabs (Figure 4). Parts needed for this procedure: 1 Hose guide (right) 1 Hose guide (left) Procedure 1. g003949 Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key from the ignition switch. 2.
g031275 Figure 6 1. Cutting unit 1 5. Cutting unit 5 2. Cutting unit 2 6. Reel motor 3. Cutting unit 3 7. Weight 4. Cutting unit 4 g015160 Figure 7 1. Hose guide (left side shown) 3. Nuts 2. Rod bracket g019602 Figure 8 1. Hose guides (each must lean toward the center cutting unit) 8. Lower all the lift arms completely. 9. Remove the snapper pin and the cap from the lift-arm pivot yoke (Figure 9). g003975 Figure 9 1. Snapper pin 13 2.
10. Note: Use the slot if a steering cutting unit is For the front cutting units, slide a cutting unit under the lift arm while inserting the carrier frame shaft up into the lift-arm pivot yoke (Figure 10). desired or use the hole if the cutting unit is to be locked in position (Figure 9). 14. Secure the lift-arm chain to the chain bracket with the snapper pin (Figure 12). Note: Use the number of chain links specified in the cutting unit Operator's Manual. g003948 Figure 12 g020321 Figure 10 1.
2 3 Adjusting the Turf Compensation Spring Installing the CE Decal Parts needed for this procedure: 1 No Parts Required Warning decal (120-1686) Procedure Procedure The turf compensation spring (Figure 14) transfers weight from the front to the rear roller. This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing. If this machine will be used for CE, affix the warning decal (120-1686) over the English warning decal (120-1683).
g012630 Figure 17 1. Hood latch g012628 Figure 15 1. Hood-latch bracket 3. 2. Rivets 7. Screw the bolt into the other arm of the hood-lock bracket to lock the latch in position (Figure 18). While aligning the mounting holes, position the CE lock bracket and the hood-latch bracket onto the hood. Note: Tighten the bolt securely but do not tighten the nut. Note: The lock bracket must be against the hood (Figure 16). Do not remove the bolt and nut assembly from the lock-bracket arm.
Product Overview Controls g020079 Figure 21 g020158 Figure 19 1. Forward traction pedal 3. Mow/transport slide 2. Reverse traction pedal 4. Tilt-steering lever 1. Cutting-unit kickstand Traction Pedals Secure the kickstand to the chain bracket with the snapper pin (Figure 20). Press the forward traction pedal (Figure 21) to move forward. Press the reverse traction pedal (Figure 21) to move backward or to assist in stopping when moving forward.
Tilt-Steering Lever Hour Meter Pull the tilt-steering lever (Figure 21) back to tilt the steering wheel to the desired position. Then push the lever forward to secure the position. The hour meter (Figure 23) indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is in the ON position.
Fuel Gauge The fuel gauge (Figure 24) registers the amount of fuel in the tank. g019982 Figure 24 1. Fuel gauge g020248 Figure 26 Power Point 1. Backlap lever The power point, located on the outside of the control panel, is a 12-volt power supply for electronic devices (Figure 25). 2. Reel speed control knob Backlap Lever Use the backlap lever in conjunction with the lower mow/raise control lever for the reels (Figure 26). g019983 Figure 25 1.
Specifications Note: Specifications and design are subject to change without notice.
Performing Daily Maintenance 3. Remove the fuel-tank cap. 4. Fill the tank to the bottom of the filler neck. Do not overfill the tank. Service Interval: Before each use or daily 5. Install the cap. Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 35). 6. To prevent a fire hazard, wipe up any fuel that may have spilled.
Note: Toro Premium Engine oil is available from your distributor in either 15W-40 or 10W-30 viscosity. Refer to the parts catalog for part numbers. Checking the Cooling System Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking.
3. 4. If the coolant level is low, remove the expansion-tank cap and replenish the system. Do not overfill the tank. Viscosity index, ASTM D2270 Pour point, ASTM D97 Install the expansion-tank cap. 140 or higher (high viscosity index indicates a multiweight fluid) -36.
DANGER Low tire pressure decreases machine side hill stability. This could cause a rollover, which may result in personal injury or death. Do not underinflate the tires. Torquing the Wheel Nuts Service Interval: After the first hour After the first 10 hours Every 200 hours g008886 Figure 32 Torque the wheel nuts to 103 to 127 N∙m (76 to 94 ft-lb). 1. Hydraulic-tank cap 3. Remove the cap. 4. Remove the dipstick from the filler neck and wipe it with a clean rag.
Note: If the machine moves forward with the parking brake engaged: service the parking brakes, check left and right brake linkage for damage, and check the brake lever pivot for damage; refer to Servicing the Parking Brakes (page 45). 5. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s seat. Positioning the Seat Changing the Seat Position The seat can move forward and backward.
Slope Safety • Before you start the engine, ensure that all drives • • • • • • • • • • • • are in neutral, the parking brake is engaged, and you are in the operating position. Do not carry passengers on the machine and keep bystanders and children out of the operating area. Operate the machine only in good visibility to avoid holes or hidden hazards. Avoid mowing on wet grass. Reduced traction could cause the machine to slide. Keep your hands and feet away from the cutting units.
Setting the Reel Speed • The engine has ceased running due to lack of fuel. • Maintenance has been performed upon the fuel To achieve a consistent, high quality of cut and a uniform after-cut appearance, it is important that you set the reel speed controls (located under the seat) correctly. Adjust the reel speed controls as follows: system components. Starting the Engine 1. 2. Ensure that the parking brake is engaged and the cutting unit drive switch is in the DISENGAGE position.
decal121-7884 Figure 35 Model 03820 1. 8-blade reel adjustment 3. Read the Operator’s Manual for information on adjusting the reel. 2. 11-blade reel adjustment decal133-4901 Figure 36 Model 03821 1. 8-blade reel adjustment 3. Read the Operator’s Manual for information on adjusting the reel. 2. 11-blade reel adjustment 4. To set the reel speed, rotate the knob (Figure 37) until the indicator arrow is in line with the number designating the desired setting.
g034346 Figure 38 1. Spring 3. Additional hole locations 2. Spring actuator g020259 Figure 37 4. Move the spring actuator to the desired hole location and secure it with the bolt and the locknut. 5. Repeat the procedure on the remaining spring. 1. Reel speed control knob Note: The reel speed can be increased or decreased to compensate for turf conditions. When using baskets, increase the reel speed to improve collection performance.
the engine does not start, air may be trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors (page 42). 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 damage property. • 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.
Check the electrical connections, input fuses, and diagnostic light bulb to determine the malfunction. Ensure that the loop-back connector is secured to the wire harness connector. Understanding the Diagnostic ACE Display The machine is equipped with an electronic controller which controls most machine functions. The controller determines what function is required for various input switches (i.e. seat switch, key switch, etc.
8. The Diagnostic ACE illuminates the LED associated with each of the inputs when that input switch is closed. 8. 9. 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 the Diagnostic ACE blinks on and off when the corresponding switch is closed. Repeat this for all switches that you can change by hand. Sit on the seat and attempt to operate the desired function of the machine.
Understanding the Warning System Identifying the Tie-Down Points If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if you operate the machine with a malfunction. Mowing Grass Start the engine and move the throttle to the FAST position.
2. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn). Important: Do not start the engine when the valve is open.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel nuts. After the first 10 hours • Torque the wheel nuts. • Check the condition and tension of all belts. • Change the hydraulic filter. After the first 50 hours • Change the oil and oil filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check the brake operation. Check the engine-oil level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter, dust cup, and burp valve. Check for unusual engine noises.1 Check the radiator/oil cooler for debris. Check for unusual operating noises. Check the hydraulic-fluid level.
Service Interval Chart decal133-4900 Figure 45 Pre-Maintenance Procedures Removing the Hood 1. Unlatch and raise the hood. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 46). Pre-Maintenance Safety • Before adjusting, cleaning, repairing, or leaving the machine, do the following: – Park the machine on a level surface. – Move the throttle switch to the low-idle position. – Disengage the cutting units. – Lower the cutting units.
Lubrication Removing the Battery Cover Greasing the Bearings and Bushings Loosen the knobs and remove the battery cover (Figure 47). Note: Refer to Servicing the Battery (page 43) for Service Interval: Every 50 hours (daily when conditions are dusty and dirty). more information. The machine has grease fittings that must be lubricated regularly with No. 2 lithium grease. Lubricate the bearings and bushings daily when operating conditions are extremely dusty and dirty.
• Neutral adjust mechanism (Figure 52) g008901 Figure 52 g034347 Figure 49 • Mow/transport slide (Figure 53) • Rear lift-arm pivots and lift cylinders (4 each); refer to Figure 50. g008902 Figure 53 • Belt tension pivot (Figure 54) g200803 Figure 50 • Cutting unit pivots (2 each); refer to Figure 51.
Engine Maintenance Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine. Servicing the Air Cleaner Service Interval: Every 200 hours (more frequently in extremely dusty or dirty conditions). g002401 • Check the air-cleaner body for damage which Figure 55 could cause an air leak. Replace it if it is damaged. Check the whole intake system for leaks, damage, or loose hose clamps. 1. Air-cleaner cover 6.
Fuel System Maintenance Servicing the Fuel Tank Service Interval: Every 2 years—Drain and clean the fuel tank. g020086 Figure 56 Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. 1. Engine-oil drain plugs 3. Drain and clean the tank if the fuel system becomes contaminated or if the machine will be stored for an extended period of time. Use clean fuel to flush out the tank. Remove the oil filter (Figure 57).
g008913 Figure 59 1. Fuel injectors g009880 Figure 58 1. Water separator/filter canister 2. Vent plug 4. 3. Drain valve 3. Move the throttle to the FAST position. 4. Turn the key in the key switch to the START position and watch the fuel flow around the connector. Turn the key to the OFF position when there is a continuous flow. 5. Tighten the pipe connector securely. 6. Repeat the procedure on the remaining nozzles. Tighten the valve after draining.
Electrical System Maintenance DANGER Battery electrolyte contains sulfuric acid which is fatal if consumed and causes severe burns. Electrical System Safety • Do not drink electrolyte and avoid contact with skin, eyes, or clothing. Wear eye protection to shield your eyes and rubber gloves to protect your hands. • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
Drive System Maintenance WARNING The engine must be running so that you can make a final adjustment of the traction adjustment cam. Contact with hot or moving parts can result in personal injury. Adjusting the Traction Drive for Neutral Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and rotating parts. If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam. 1. 2.
Brake Maintenance Cooling System Maintenance Adjusting the Parking Brake Cooling System Safety • Swallowing engine coolant can cause Service Interval: Every 200 hours—Check the adjustment of the parking brake. poisoning; keep out of reach from children and pets. Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. – Always allow the engine to cool at least 15 minutes before removing the radiator cap.
Removing the Front Wheels 1. Remove the 4 lug nuts that secure the front wheel to the hub, and remove the wheel (Figure 63). g332520 Figure 65 Machines with the Optional Grass Shield 1. Locknut 2. Hub and brake drum g332518 Figure 63 1. Lug nut 3. Hub 2. Wheel 2. 3. Wheel-motor shaft Repeat step 1 at the other side of the machine. Removing the Wheel Hub and Brake Drum 2. Repeat step 1 at the other side of the machine. 3. Release the parking brake. 4.
Cleaning the Brake Drum and Shoes At both sides of the machine, clean inside the brake drums, the brake shoes, backing plate (Figure 67) , and when installed, the optional grass shield of any grass, dirt, and dust. g332545 Figure 69 Machines with the Optional Grass Shield g332543 Figure 67 1. Backing plate Inspecting and Lubricating the Brake Cam Shaft 1. 2.
3. Repeat steps 1 and 2 at the other side of the machine. 4. Move the parking brake lever down (the disengaged position). Inspecting the Brake Linkage 1. Inspect the left and right brake-rod assemblies (Figure 71) for damage and wear. Note: If the brake rod parts are damaged and worn, replace them; refer to the Service Manual for your machine. g332521 Figure 72 1. Woodruff key 3. g332541 2.
g332520 Figure 74 Machines with the Optional Grass Shield 1. Locknut 2. Hub and brake drum 4. 3. Wheel-motor shaft Secure the wheel hub to the shaft with the locknut (Figure 73 or Figure 74), and tighten by hand. Note: The brake shoes and backing plate must concentrically align with the brake drum. If the shoes, plate, and drum are misaligned, refer to the Service Manual for your machine. 5. Repeat steps 1 through 4 at the other side of the machine. Installing the Wheel 1.
Belt Maintenance the engine, and remove the key from the ignition switch. 2. Servicing the Engine Belts Service Interval: After the first 10 hours—Check the condition and tension of all belts. Insert a nut driver or small piece of tubing onto the end of the belt tensioning spring. WARNING The spring is under a heavy load and could cause personal injury Every 100 hours—Check the condition and tension of all belts. Use caution when de-tensioning the spring. Tensioning the Alternator/Fan Belt 1.
Controls System Maintenance Hydraulic System Maintenance Adjusting the Throttle Hydraulic System Safety 1. 2. 3. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key from the ignition switch. • Ensure that all hydraulic-fluid hoses and Position the throttle lever rearward so that it stops against the control panel slot.
g020253 Figure 80 g034351 Figure 79 1. Hydraulic hose 1. Hydraulic filter 3. Lubricate the new filter gasket and fill the filter with hydraulic fluid. 4. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate; then tighten the filter 1/2 turn. 5. Start the engine and let it run for about 2 minutes to purge air from the system. Shut off the engine and check for leaks. 3. Install the hydraulic hose when hydraulic fluid stops draining. 4.
Checking the Hydraulic Lines and Hoses Cutting Unit System Maintenance Service Interval: Before each use or daily Cutting Unit Safety Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key from the ignition switch. A worn or damaged cutting unit can break, and a piece of a reel or bedknife could be thrown at you or bystanders, resulting in serious personal injury or death.
Backlapping the Cutting Units WARNING Contact with the cutting units or other moving parts can result in personal injury. • Keep your fingers, hands, and clothing away from the cutting units and other moving parts. • Never attempt to turn the cutting units by hand or foot while the engine is running. Note: When backlapping, all the cutting units operate together. g020248 1.
contact as needed. Move the cutting unit reel speed control to the desired mowing position. Storage Important: If the backlap switch is not returned to the F (MOW) position after backlapping, the cutting units will not raise or function properly. Storing the Battery If the machine will be stored more than 30 days, remove the battery and charge it fully. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery.
F. Preparing the Engine Either store the battery on the shelf or on the machine in a cool area. Leave the cables disconnected if the battery is stored on the machine. 56 1. Drain the engine oil from the oil pan and replace the drain plug. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with approximately 3.8 L (4 US qt) of SAE 15W-40 motor oil. 4. Start the engine and run it at idle speed for approximately 2 minutes. 5. Shut off the engine. 6.
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The Toro 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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
