Form No. 3389-654 Rev B Reelmaster® 3550 Traction Unit Model No. 03910—Serial No. 315000001 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. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws.
Contents Draining the Water Separator ........................... 40 Changing the Fuel Filter Canister...................... 41 Bleeding Air from the Injectors .......................... 41 Electrical System Maintenance ........................... 41 Servicing for the Battery.................................... 41 Checking the Fuses .......................................... 42 Drive System Maintenance .................................. 42 Adjusting the Traction Drive for Neutral .............
Preparation Safety • While mowing, always wear substantial, slip-resistant footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. This machine has been designed in accordance with EN ISO 5395:2013 (when appropriate decals are applied) and ANSI B71.4-2012. Improperly using or maintaining the machine can result in injury.
• Lightning can cause severe injury or death. If • When using any attachments, never direct • • • • • • • • • • • • lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter. discharge of material toward bystanders nor allow anyone near the machine while in operation. Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.
• Never store the machine or fuel container where positive last. Reconnect positive first and negative last. there is an open flame, spark, or pilot light such as on a water heater or on other appliances. • Keep hands and feet away from moving parts. If • Never fill containers inside a vehicle or on a truck possible, do not make adjustments with the engine running. or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.
Training • Raise the cutting units when driving from one work The operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause the vehicle to tip or roll, possibly resulting in personal injury or death. • • Operation • Know how to stop the machine and engine quickly. • Do not operate the machine while wearing tennis • • • • • • • • • • • • • • shoes or sneakers.
Sound Power Level This unit has a guaranteed sound power level of 101 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound power level was determined according to the procedures outlined in ISO 11094. Sound Pressure Level This unit has a sound pressure level at the operator’s ear of 85 dBA, which includes an Uncertainty Value (K) of 1 dBA. Sound pressure level was determined according to the procedures outlined in EN ISO 5395:2013.
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—stop 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 decal120-2102 120–2102 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, stop 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, stop the engine and remove the ignition key before leaving the machine. 2. Warning—read the Operator's Manual before towing the machine. 3.
decal120-2105 120-2105 1. Lower the cutting units. 5. Read the Operator’s Manual for 9. Engine—Start information on starting the engine—sit in the operator’s position, turn the key to the engine preheat position, wait until the engine preheat light turns off, turn the key to the engine start position, and 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 1 2 3 Description Use Qty. No parts required – 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.
1 Installing the Cutting Units g003949 No Parts Required Figure 4 1. Turf compensation spring Procedure 1. 3. Spring tube 2. Rod bracket Remove the reel motors from the shipping brackets. 2. Remove the shipping brackets and discard. 3. Remove the cutting units from the cartons. Assemble and adjust as described in the cutting unit Operator's Manual. 4. Make sure that the counterweight (Figure 3) is installed to the proper end of the cutting unit as described in the cutting unit Operator's Manual.
g003979 Figure 8 1. Lift-arm shaft lynch pin and washer g003975 Figure 6 1. Snapper pin 8. 2. Cap 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 7). B. Insert the lift-arm yoke onto the carrier frame shaft (Figure 7). C. Insert the lift-arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 8). 10. Insert the cap over the carrier frame shaft and lift-arm yoke. 11.
Important: Make sure that the reel motor hoses are not twisted, kinked, or at risk of being pinched. g020164 Figure 11 g020322 Figure 10 1. Reel-drive motor 2. Mounting nuts 1. Turf compensation spring 3. Spring rod 2. Hairpin cotter 4. Hex nuts 2. Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring (Figure 11) is 12.7 cm (5 inches). 2 Note: When operating on rough terrain, decrease the spring length by 2.5 cm (1/2 inch).
4 Installing the Hood Latch (CE only) Parts needed for this procedure: 1 Lock bracket 2 Rivet 1 Washer 1 Screw, 1/4 x 2 inches 1 Locknut, 1/4 inch g012629 Figure 13 1. CE lock bracket Procedure 1. 2. Unhook the hood latch from the hood-latch bracket. 2. Bolt and nut assembly 4. Align the washers with the holes on the inside of the hood. 5. Rivet the brackets and the washers to the hood (Figure 13). 6. Hook the latch onto the hood-latch bracket (Figure 14).
g012631 Figure 15 1. Bolt 2. Nut 3. Arm of hood-lock bracket 5 Using the Cutting Unit Kickstand g020158 Figure 16 1. Cutting unit kickstand Parts needed for this procedure: 1 Secure the kickstand to the chain bracket with the snapper pin (Figure 17).
Tilt-Steering Lever Product Overview Pull the tilt-steering lever (Figure 18) back to tilt the steering wheel to the desired position. Then push the lever forward to secure the position. Controls Ignition Switch The ignition switch (Figure 20), used to start, stop, and preheat the engine, has 3 positions: Off, On/Preheat, and Start.
Hour Meter Fuel Gauge The hour meter (Figure 20) indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is On. The fuel gauge (Figure 21) registers the amount of fuel in the tank. Lower Mow/Raise Control Lever This lever (Figure 20) raises and lowers the cutting units and also starts and stops the cutterheads when the cutterheads are enabled in the mow mode. The cutting units cannot be lowered when the mow/transport lever is in the transport position.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Checking the Engine-Oil Level Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Crankcase capacity is approximately 3.8 L (4 US qt) with the filter. Use high-quality engine oil that meets the following specifications: • API Classification Level Required: CH-4, CI-4 or higher.
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, gaskets in contact with fuel as they may be degraded over time. Fuel filter plugging may be expected for a time after converting to biodiesel blends.
Checking the Cooling System Service Interval: Before each use or daily Clean debris off of the radiator/oil cooler daily (Figure 27). Clean the radiator/oil cooler hourly if conditions are extremely dusty and dirty; refer to Cleaning the Engine Cooling System (page 43). g008885 Figure 28 1. Expansion tank Checking the Hydraulic System Service Interval: Before each use or daily—Check the hydraulic-fluid level. The reservoir is filled at the factory with approximately 13.2 liters (3.
Viscosity index, ASTM D2270 Pour point, ASTM D97 140 or higher (high viscosity index indicates a multiweight fluid) -36.
Torquing the Wheel Nuts Positioning the Seat Service Interval: After the first hour After the first 10 hours Every 200 hours Changing the Seat Position The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable Torque the wheel nuts to 61 to 88 N-m (45 to 65 ft-lb). WARNING Failure to maintain proper torque of the wheel nuts could result in personal injury. Maintain proper torque of the wheel nuts. 1.
4. Insert the key into the switch and rotate it to the On/Preheat position until the glow-plug indicator light goes out (approximately 7 seconds); then rotate the key to the Start position to engage the starter motor. Note: Release the key when the engine starts. The key will move automatically to the On/Run position. Important: To prevent overheating of the starter motor, do not engage the starter longer than 15 seconds.
Setting the Reel Speed 1. Select the height of cut at which the cutting units are set. 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: 2. Choose the desired ground speed best suited for conditions. 3. Use the graph on the reel speed chart decal (Figure 32), to determine the proper reel speed setting. decal121-7884 Figure 32 1.
2. Insert a tube or similar object onto the long spring end to relieve the spring tension during the adjustment (Figure 34). 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. • 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.
Ensure that the loop-back connector is secured to the wire harness connector. the injection pump and injectors; refer to Bleeding Air from the Injectors (page 41). Understanding the Diagnostic Light Understanding the Diagnostic ACE Display The machine is equipped with a diagnostic light which indicates if the electronic controller senses an electronic malfunction. The diagnostic light is located on the control panel (Figure 36).
Checking the Interlock Switches Note: Make sure correct overlay decal is positioned on Diagnostic ACE display. Service Interval: Before each use or daily The purpose of the interlock switches is to prevent the engine from cranking or starting unless the traction pedal is in the Neutral position, the Enable/Disable switch is in the Disable position, and the Lower Mow/Raise control is in the Neutral position.
Verifying Output Function 1. Park the machine on a level surface, lower the cutting units, stop the engine, and engage the parking brake. 2. Remove the access panel from the side of the control arm. 3. Locate the wire harness and connectors near the controller. 4. Carefully unplug the loop-back connector from the harness connector. 5. Connect the Diagnostic ACE connector to the harness connector. of the everyday use of the machine.
Transporting the Machine wide enough to extend beyond the front tires of the machine is recommended instead of individual ramps for each tire (Figure 40). If it is not possible to use one full-width ramp, use enough individual ramps to simulate a full-width continuous ramp. Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions.
Operating Tips General Tips Becoming Familiar with the Machine Before mowing grass, practice operating the machine in an open area. Start and stop the engine. Operate in forward and reverse. Lower and raise the cutting units and engage and disengage the reels. When you feel familiar with the machine, practice operating up and down slopes at different speeds. DANGER When operating the machine, always use the seat belt and ROPS together. Do not use a seat belt without a ROPS. g000951 Figure 40 1.
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 engine-oil level.
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.2 Check the radiator/oil cooler for debris Check for unusual operating noises. Check the hydraulic system oil level.
Service Interval Chart decal120-2102 Figure 42 Pre-Maintenance Procedures Removing the Battery Cover Loosen the knobs and remove the battery cover (Figure 44). Removing the Hood Note: Refer to Servicing for the Battery (page 41) for more information. The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 43). g008874 Figure 44 1.
Lubrication • Rear lift-arm pivots and lift cylinders (3 each); refer to Figure 47. 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 #2 general-purpose lithium-based grease. Lubricate the bearings and bushings daily when operating conditions are extremely dusty and dirty.
• Mow/transport slide (Figure 50) Note: If desired, an additional grease fitting may be installed in the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 53).
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 56 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 57). 2. Remove the filter canister and clean the mounting surface. 3. Lubricate the gasket on the filter canister with clean oil. 4. Install the filter canister by hand until the gasket contacts the mounting surface; then rotate an additional 1/2 turn. Servicing for the Battery Service Interval: Every 25 hours—Check the electrolyte level.
Drive System Maintenance and terminals separately. Reconnect 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. Stop 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. Cooling System Maintenance Cleaning the Engine Cooling System Service Interval: Before each use or daily Remove debris from the radiator/oil cooler daily.
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 62). 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 61). g332518 Figure 62 1. Lug nut 3. Hub 2. Wheel 2. Repeat step 1 at the other side of the machine. g008923 Figure 61 1.
Cleaning the Brake Drum and Shoes At both sides of the machine, clean inside the brake drums, the brake shoes, backing plate (Figure 66) , and when installed, the optional grass shield of any grass, dirt, and dust. g332520 Figure 64 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 68 Machines with the Optional Grass Shield 1. Backing plate 2. g332560 2. Brake cam shaft Figure 69 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 69). 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 71). g332520 Figure 73 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 72 or Figure 73), 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 25). 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 76) 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 77). g008917 Figure 76 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4. Reverse the procedure to tension the spring. g020336 Figure 77 1.
Hydraulic System Maintenance 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and remove the key from the ignition switch. Changing the Hydraulic Filter 2. Disconnect the large hydraulic hose (Figure 79) from the reservoir and let the hydraulic fluid flow into a drain pan. Service Interval: After the first 10 hours Every 200 hours/Yearly (whichever comes first) Use a genuine Toro replacement filter, Part 86-3010.
5. Install the reservoir cap. Start the engine and use all of the hydraulic controls to distribute the hydraulic fluid throughout the system. Checking the Hydraulic Lines and Hoses 6. Check for leaks; then stop the engine. Service Interval: Before each use or daily 7. Check the fluid level and add enough to raise the level to Full mark on the dipstick.
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. Use the gauge bar (Figure 81) to adjust the cutting unit. Refer to the Cutting Unit Operator's Manual for the adjustment procedures.
8. Apply lapping compound with a long handle brush. Never use a short handled brush. Storage 9. 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. Storing the Battery 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 stop the engine.
Preparing the Engine 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 liters (4 US qt) of SAE 15W-40 motor oil. 4. Start the engine and run it at idle speed for approximately 2 minutes. 5. Stop 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.
Toro General Commercial Product 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).
