Form No. 3402-732 Rev B Reelmaster® 3555 and 3575 Traction Unit Model No. 03820—Serial No. 316000001 and Up Model No. 03821—Serial No. 316000001 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 Electrical System Maintenance ........................... 42 Servicing the Battery......................................... 42 Checking the Fuses .......................................... 43 Drive System Maintenance .................................. 43 Adjusting the Traction Drive for Neutral ............. 43 Cooling System Maintenance .............................. 44 Cleaning the Engine Cooling System ................ 44 Brake Maintenance .............................................
Safety ◊ Incorrect hitching and load distribution Preparation This machine has been designed in accordance with EN ISO 5395:2013 (when appropriate decals are applied) and ANSI B71.4-2012. • Wear appropriate clothing, including eye protection; substantial, slip-resistant footwear; and hearing protection. Tie back long hair. Do not wear jewelry. Improperly using or maintaining the machine can result in injury.
• When using any attachments, never direct • Lightning can cause severe injury or death. If you discharge of material toward bystanders nor allow anyone near the machine while in operation. see lightning or hear thunder in the area, do not operate the machine; seek shelter. • Never operate the machine with damaged guards, • Turn on flashing warning lights, if provided, shields, or without safety protective devices in place.
• • • • Hauling refuel such equipment with a portable container rather than from a fuel dispenser nozzle. Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device. If fuel is spilled on clothing, change clothing immediately. Never overfill the fuel tank. Install the fuel cap and tighten it securely.
Maintenance and Storage • Keep hands, feet, and clothing away from moving parts and the mower discharge area. • Before servicing or making adjustments, shut off • Fill the fuel tank until the level is 12 mm (1/2 inch) the engine, and remove the ignition key. below the bottom of the filler neck. Do not overfill. • Ensure that the entire machine is properly • Check the safety interlock switches daily for proper maintained and in good operating condition.
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 lost. 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.
9-3444 decal99-3444 99–3444 1. Transport speed 2. Mow speed decal133-4900 133-4900 1. Read the Operator's Manual. decal120-1683 120–1683 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 4. Warning—do not park the machine on slopes; engage the parking brake, lower the cutting units, shut off the engine, and remove the ignition key before leaving the machine. 2. Warning—read the Operator's Manual before towing the machine. 3.
decal120-1686 120–1686 (Affix over part 120-1683 for CE) 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 4. Warning—do not park the machine on slopes; engage the parking brake, lower the cutting units, shut off the engine, and remove the ignition key before leaving the machine. 2. Warning—read the Operator's Manual before towing the machine. 3.
decal133-4901 133-4901 1. 8-blade reel adjustment 3. Read the Operator’s Manual for information on adjusting the reel. 2. 11-blade reel adjustment decal120-2105 120–2105 9. Engine—start 1. Lower the reels 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.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5. Read the Operator's Manual. 10.
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.
A. 1 Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting unit tabs (Figure 4). Installing the Cutting Units Parts needed for this procedure: 1 Hose guide (right) 1 Hose guide (left) g003949 Figure 4 1. Turf compensation spring Procedure 1. Remove the reel motors from the shipping brackets. 2. Remove and discard the shipping brackets. 3. Remove the cutting units from the cartons. Assemble and adjust them as described in the cutting unit Operator's Manual. 4. 3.
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) 7. Lower all the lift arms completely. 8. Remove the snapper pin and the cap from the lift-arm pivot yoke (Figure 9). g003975 Figure 9 1. Snapper pin 15 2.
9. 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). 13. 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.
3. 4. • Use B5 (biodiesel content of 5%) or lesser blends Push the dipstick down into the dipstick tube and make sure that it is seated fully. Pull the dipstick out and check the oil level. in cold weather. • Monitor seals, hoses, and gaskets in contact with If the oil level is low, remove the oil-fill cap (Figure 28) and gradually add small quantities of oil, checking the level frequently, until the level reaches the Full mark on the dipstick. fuel as they may degrade over time.
Checking the Cooling System 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 damage property. Service Interval: Before each use or daily Clean debris off of the radiator/oil cooler daily (Figure 30). Clean the radiator/oil cooler hourly if conditions are extremely dusty and dirty; refer to Cleaning the Engine Cooling System (page 44).
Industry Specifications: Vickers I-286-S, Vickers M-2950-S, Denison HF-0, Vickers 35 VQ 25 (Eaton ATS373-C) The proper hydraulic fluids must be specified for mobile machinery (as opposed to industrial plant usage), multiweight-type, with ZnDTP or ZDDP anti-wear additive package (not an ashless-type fluid). Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system fluid is available in 20 ml (2/3 fl oz) bottles.
5. 6. level. The fluid level should be within 6 mm (1/4 inch) of the mark on the dipstick. If the level is low, add the appropriate fluid to raise the level to the full mark. Install the dipstick and cap onto the filler neck. Checking the Reel-to-Bedknife Contact Each day before operating, check the reel-to-bedknife contact, regardless of whether the quality of cut had previously been acceptable.
Changing the Back Position Starting and Shutting Off the Engine The back of the seat can be adjusted to provide a comfortable ride. Position the back of the seat where it is most comfortable. You may need to bleed the fuel system if any of the following situations have occurred; refer to Bleeding the Fuel System (page 30): To adjust it, turn the knob, under the right-side armrest, in either direction to provide the best comfort (Figure 34).
Shutting Off the Engine set the reel speed controls (located under the seat) correctly. Adjust the reel speed controls as follows: Move the throttle control to the IDLE position, move the cutting unit drive switch to DISENGAGE, and rotate the starter key to the OFF position. Remove the key from the switch to prevent accidental starting. Setting the Reel Speed To achieve a consistent, high quality of cut and a uniform after-cut appearance, it is important that you 1.
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. Adjusting the Lift-Arm Counterbalance To set the reel speed, rotate the knob (Figure 37) until the indicator arrow is in line with the number designating the desired setting.
3. While relieving the spring tension, remove the bolt and locknut securing the spring actuator to the bracket (Figure 38). 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. the engine does not start, air may be trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors (page 42). Understanding the Diagnostic Light The machine is equipped with a diagnostic light that indicates if the electronic controller senses an electronic malfunction.
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.) and turns on the outputs to actuate solenoids or relays for the requested machine function. For the electronic controller to control the machine as desired, each of the input switches, output solenoids, and relays must be connected and functioning properly.
8. 9. output LEDs should illuminate to indicate that the ECM is turning on that function. The Diagnostic ACE illuminates 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 the Diagnostic ACE blinks on and off when the corresponding switch is closed. Repeat this for all switches that you can change by hand.
Towing the Machine Mowing Grass In case of an emergency, you can tow the machine for a short distance; however, Toro does not recommend this as a standard procedure. Start the engine and move the throttle to the FAST position. Move the Enable/Disable switch to the ENABLE position and use the Lower Mow/Raise lever to control the cutting units (the front cutting units are timed to lower before the rear cutting units). To move the machine forward and cut grass, press the traction pedal forward.
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. Before each use or daily • • • • • • • • • Check the level of the engine oil.
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 Battery Cover Loosen the knobs and remove the battery cover (Figure 47). Removing the Hood Note: Refer to Servicing the Battery (page 42) for 1. Unlatch and raise the hood. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 46). more information. g008908 Figure 46 1. Hairpin cotter g034350 3.
Lubrication • Rear lift-arm pivots and lift cylinders (4 each); refer to Figure 50. Greasing the Bearings and Bushings Service Interval: Every 50 hours (daily when conditions are dusty and dirty). 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.
• Mow/transport slide (Figure 53) g008901 g008902 Figure 52 Figure 53 • Belt tension pivot (Figure 54) g008903 Figure 54 39
Engine Maintenance 5. Servicing the Air Cleaner Important: Do not use a damaged element. Service Interval: Every 200 hours (more frequently in extremely dusty or dirty conditions). • Check the air-cleaner body for damage which could cause an air leak. Replace it if it is damaged. Check the whole intake system for leaks, damage, or loose hose clamps. • Service the air cleaner at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions.
Fuel System Maintenance Servicing the Fuel Tank Service Interval: Every 2 years—Drain and clean the fuel tank. 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. g022147 Figure 57 1. Engine oil filter 3. 4. Inspecting the Fuel Lines and Connections Apply a light coat of clean oil to the new filter seal, and install the filter. Important: Do not overtighten the filter.
Changing the Fuel Filter Canister Electrical System Maintenance Service Interval: Every 400 hours 1. Clean the area where the filter canister mounts (Figure 58). 2. Remove the filter canister and clean the mounting surface. 3. Lubricate the gasket on the filter canister with clean oil. 4. Servicing the Battery Service Interval: Every 25 hours—Check the electrolyte level of the battery (if the machine is in storage, check every 30 days).
Drive System Maintenance and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly. WARNING Adjusting the Traction Drive for Neutral CALIFORNIA Proposition 65 Warning 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.
4. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span. 5. Tighten the locknut securing the adjustment. 6. Shut off the engine. 7. Remove the support blocks and lower the machine to the shop floor. Test drive the machine to make sure that it does not move when the traction pedal is in neutral.
Brake Maintenance Removing the Front Wheels 1. Adjusting the Parking Brake Remove the 4 lug nuts that secure the front wheel to the hub, and remove the wheel (Figure 63). Service Interval: Every 200 hours—Check the adjustment of the parking brake. 1. Loosen the setscrew securing the knob to the parking-brake lever (Figure 62). g332518 Figure 63 1. Lug nut 3. Hub 2. Wheel 2. Repeat step 1 at the other side of the machine. g008923 Figure 62 1.
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. g332520 Figure 65 Machines with the Optional Grass Shield 1. Locknut 2. Hub and brake drum 3. Wheel-motor shaft 2. Repeat step 1 at the other side of the machine. 3. Release the parking brake. 4.
g332545 Figure 69 Machines with the Optional Grass Shield 1. Backing plate 2. g332560 2. Brake cam shaft Figure 70 1. Brake-cam lever Move the parking brake lever up and down to check that the lever for the brake-cam lever moves freely (Figure 70). 3. Note: If the brake cam binds, repair or replace the brake cam; refer to the Service Manual for your machine. 4. Repeat steps 1 and 2 at the other side of the machine. Move the parking brake lever down (the disengaged position).
If the pivot shaft is damaged and worn, replace them; refer to the Service Manual for your machine. Installing the Wheel Hub and Brake Drum 1. Thoroughly clean the wheel hub and hydraulic motor shaft. 2. Insert the woodruff key into the groove of the wheel-motor shaft (Figure 72). 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.
5. Torque the locknut is to 339 to 372 N∙m (250 to 275 ft-lb). Belt Maintenance 6. Check parking brake and adjust it if necessary; refer to Checking the Parking Brake (page 26). Servicing the Engine Belts Service Interval: After the first 10 hours—Check the condition and tension of all belts. Every 100 hours—Check the condition and tension of all belts. Tensioning the Alternator/Fan Belt 1. 2. Open the hood.
2. Controls System Maintenance Push down and forward on the spring end (Figure 77) to unhook it from the bracket and release tension on the spring. Adjusting the Throttle 1. Position the throttle lever rearward so it stops against the control-panel slot. 2. Loosen the throttle-cable connector on the injection-pump lever arm (Figure 78). g008917 Figure 77 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4. Reverse the procedure to tension the spring. g020336 Figure 78 1.
Changing the Hydraulic Fluid Hydraulic System Maintenance Service Interval: Every 400 hours Changing the Hydraulic Filter If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean fluid. Service Interval: After the first 10 hours Every 200 hours/Yearly (whichever comes first) 1.
Checking the Hydraulic Lines and Hoses Service Interval: Before each use or daily Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. g008886 Figure 81 1. Hydraulic fill cap 5. Install the reservoir cap.
Cutting Unit System Maintenance 3. Make the initial reel-to-bedknife adjustments appropriate for backlapping; refer to the cutting unit Operator's Manual. 4. Start the engine and allow it to run at low idle speed. Using the Optional Gauge Bar DANGER Changing the engine speed while backlapping may cause the reels to stall. • Never change the engine speed while backlapping • Backlap only at low idle engine speed. Use the gauge bar (Figure 82) to adjust the cutting unit.
9. Storage If the reels stall or become erratic while backlapping, select a higher reel speed setting until the speed stabilizes, then return the reel speed to setting 1 or to your desired speed. 10. To make an adjustment to the cutting units while backlapping, turn the reels off by moving the Lower Mow/Raise lever rearward; the Enable/Disable switch to the DISABLE position, and shut off the engine. After completing adjustments, repeat steps 5 through 9. 11.
Preparing the Engine 1. Drain the engine oil from the oil pan and install the drain plug. 2. Remove and discard the oil filter. Install a new oil filter. 3. Fill the engine with approximately 3.8 L (4 US qt) of SAE 15W-40 engine oil. 4. Start the engine and run it at idle speed for approximately 2 minutes. 5. Shut off the engine. 6. Thoroughly drain all fuel from the fuel tank, fuel lines, fuel filter, and water-separator assembly. 7. Flush the fuel tank with fresh, clean diesel fuel. 8.
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International Distributor List Distributor: Agrolanc Kft Asian American Industrial (AAI) B-Ray Corporation Brisa Goods LLC Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Fat Dragon Femco S.A. FIVEMANS New-Tech Co., Ltd ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd.
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).
