Form No. 3432-531 Rev B Reelmaster® 3555, 3575, and 3550 Traction Unit Model No. 03820—Serial No. 403446001 and Up Model No. 03821—Serial No. 403446001 and Up Model No. 03910—Serial No. 403446001 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. Visit www.Toro.com for more information, including safety tips, training materials, accessory information, help finding a dealer, or to register your product.
Contents Inspecting the Fuel Lines and Connections.................................................. 42 Draining the Water Separator ........................... 43 Changing the Fuel Filter Canister...................... 43 Bleeding Air from the Injectors .......................... 43 Electrical System Maintenance ........................... 44 Electrical System Safety ................................... 44 Servicing the Battery......................................... 44 Checking the Fuses ................
Safety This machine has been designed in accordance with EN ISO 5395 (when you complete the setup procedures) and ANSI B71.4-2017. 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. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.
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. decal133-8062 decal110-9642 133-8062 110-9642 1. Stored energy hazard—read the Operator's Manual. 2. Move the cotter pin to the hole closest to the rod bracket and then remove the lift arm and pivot yoke. decal93-7276 93-7276 1. Explosion hazard—wear eye protection. 2.
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.
decal120-2105 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.
decal133-4901 133-4901 1. 8-blade reel adjustment 3. Read the Operator’s Manual for information on adjusting the reel. 2.
Model 03910 decal121-7928 121-7928 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.
Models 03820 and 03821 Affix over Part No. 120-1683 for CE decal138-1186 138-1186 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.
Model 03910 decal138-6980 138-6980 1. Read the Operator’s Manual. Models 03820 and 03821 decal138-6981 138-6981 1. Read the Operator’s Manual.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away 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 1 2 3 4 5 6 Use Qty. Right hose guide Left hose guide 1 1 Install the cutting units. No parts required – Adjust the turf compensation spring.
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 Right hose guide 1 Left hose guide 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.
8. Lower all the lift arms completely. 9. Remove the snapper pin and the cap from the lift-arm pivot yoke (Figure 9). 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 g003975 Figure 9 1. Snapper pin 10. 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 10). g015160 Figure 7 1.
Important: Make sure that the reel motor hoses are not twisted, kinked, or at risk of being pinched. g003979 Figure 11 1. Lift-arm shaft lynch pin and washer B. Insert the lift-arm yoke onto the carrier frame shaft (Figure 10). C. Insert the lift-arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 11). 12. Insert the cap over the carrier frame shaft and lift-arm yoke. 13. Secure the cap and the carrier frame shaft to the lift-arm yoke with the snapper pin.
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) g020164 Figure 14 1. Turf compensation spring 3. Spring rod 2. Hairpin cotter 4. Hex nuts 2. Procedure Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring (Figure 14) is 12.7 cm (5 inches) for 5-inch cutting units and 15.8 cm (6-1/4 inches) for 7-inch cutting units. 1.
g012631 Figure 18 g012629 1. Bolt 2. Nut Figure 16 1. CE lock bracket 3. Arm of hood-lock bracket 2. Bolt and nut 4. Align the washers with the holes on the inside of the hood. 5. Rivet the brackets and the washers to the hood (Figure 16). 6. Hook the latch onto the hood-latch bracket (Figure 17). 5 Reducing the Tire Pressure No Parts Required Procedure The tires are overinflated at the factory for shipping purposes.
Product Overview g216864 Figure 21 g020158 Figure 19 1. Engine hood 5. Seat adjustment lever 2. Seat 6. Front cutting units 3. Control arm 7. Rear cutting units 4. Steering wheel 1. Cutting-unit kickstand Secure the kickstand to the chain bracket with the snapper pin (Figure 20). Controls g020079 Figure 22 1. Forward traction pedal 3. Mow/transport slide 2. Reverse traction pedal 4. Tilt-steering lever g004144 Figure 20 1. Chain bracket Traction Pedals 3. Cutting-unit kickstand 2.
Mow/Transport Slide Using your heel, move the mow/transport slide (Figure 22) to the left to transport and to the right to mow. The cutting units will only operate in the MOW position and not lower in the TRANSPORT position. Important: The mow speed is set at the factory to 9.7 km/h (6 mph). It can be increased or decreased by adjusting the speed stop screw (Figure 23). g019980 Figure 24 1. Parking brake 7. Oil-pressure light 2. Ignition switch 8. Temperature light 3. Enable/Disable switch 9.
Diagnostic Light Engine Coolant Temperature Warning Light The diagnostic light (Figure 24) will illuminate if the system recognizes a system fault. The temperature warning light (Figure 24) glows if the engine coolant temperature is high. At this temperature, the cutting units are disabled. If the coolant temperature rises another 5.5° C (10° F), the engine shuts off to prevent further damage. Fuel Gauge The fuel gauge (Figure 25) indicates the amount of fuel in the tank.
Reel Speed Control Knob The reel speed control controls the speed of the cutting units (Figure 27). The reel speed increases as you turn the knob counterclockwise. Refer to the reel speed chart decal (Figure 31), to determine the proper reel speed. g020248 Figure 27 1. Backlap lever 2. Reel speed control knob Backlap Lever Use the backlap lever in conjunction with the lower mow/raise control lever for the reels (Figure 27).
Specifications Note: Specifications and design are subject to change without notice.
Filling the Fuel Tank Performing Daily Maintenance Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra-low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness. Service Interval: Before each use or daily Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 35). The fuel tank capacity is approximately 42 L (11 US gallons).
g008884 Figure 29 1. Fuel-tank cap Adjusting the Seat 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. 1. Move the lever sideways to unlock the seat (Figure 30). 2. Slide the seat to the desired position and release the lever to lock it in position. g010515 Figure 30 Changing the Seat Suspension You can adjust the seat to provide a smooth and comfortable ride.
During Operation • During Operation Safety Rollover Protection System (ROPS) Safety General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • – Wait for all movement to stop. Operate the machine only in good visibility and appropriate weather conditions. Do not operate the machine when there is the risk of lightning. for accidents that may cause personal injury or property damage.
embankments, water hazards, or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge caves in. Establish a safety area between the machine and any hazard. CAUTION Contact with moving parts could result in injury. Shut off the engine and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions. – Identify hazards at the base of the slope. If there are hazards, mow the slope with a pedestrian-controlled machine.
decal121-7884 Figure 31 Model 03820 and 03910 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 32 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 33) until the indicator arrow is in line with the number designating the desired setting.
g034346 Figure 34 1. Spring 3. Additional hole locations 2. Spring actuator g020259 Figure 33 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.
6. • Fuses are blown. • It is not functioning correctly. Tighten the screw and turn the ignition key to OFF. Note: Normally the engine should start after the above bleeding procedures are followed. However, if the engine does not start, air may be trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors (page 43). Check the electrical connections, input fuses, and diagnostic light bulb to determine the malfunction.
2. Remove the cover from the control panel. 3. Locate the wire harness and loop-back connector (Figure 37). Diagnostic ACE, to change LED to “inputs displayed.” The Diagnostic ACE illuminates the LED associated with each of the inputs when that input switch is closed. 8. Individually, change each of the switches from open to closed (i.e., sit on the seat, engage the traction pedal, etc.), and note that the appropriate LED on the Diagnostic ACE blinks on and off when the corresponding switch is closed.
Operating Tips back and forth, press the toggle button once. This may be done as often as required. Do not hold the button. 8. Becoming Familiar with the Machine Sit on the seat and attempt to operate the desired function of the machine. The appropriate output LEDs should illuminate to indicate that the ECM is turning on that function. Before mowing grass, practice operating the machine in an open area. Start and shut off the engine. Operate in forward and reverse.
After Operation • • • • After Operation Safety Toro Part No. 354-79, diagnostic-fitting cap Toro Part No. 95-8843, hydraulic hose Toro Part No. 95-0985, coupler fitting (2) Toro Part No. 340-77, hydraulic fitting (2) 1. General Safety • Shut off the engine, remove the key, and wait • • • • for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
3. forward slowly without damaging the transmission. Note the position of the valve when opening and closing it. Rotate the bypass valve 90° (1/4 turn) in either direction to open it and allow fluid to bypass internally (Figure 41). Note: Because the fluid bypasses the transmission, you can move the machine slowly without damaging the transmission. Note the position of the valve when opening and closing it. 3. Rotate the bypass valve 90° (1/4 turn) back before starting the engine.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Important: Refer to your engine owner’s manual and cutting unit Operator's Manual for additional maintenance procedures. Maintenance Safety • Support the machine with jack stands whenever you work under the machine.
Maintenance Service Interval Maintenance Procedure Every 400 hours • Check the fuel lines and connections. • Replace the fuel filter canister. • Service the parking brakes. Every 800 hours • If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, change the hydraulic fluid. • If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, replace the hydraulic filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Mon. Maintenance Check Item Tues. Wed. Thurs. Fri. Sat. 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 for debris. Check for unusual operating noises. Check the hydraulic system fluid level.
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 43). g034350 Figure 44 1. Battery cover g008908 Figure 43 1. Hairpin cotter 3. Slide the hood to the right side, lift the other side, and pull it out of the brackets. Note: Reverse the procedure to install the hood. Removing the Battery Cover Loosen the knobs and remove the battery cover (Figure 44).
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours (daily when conditions are dusty and dirty). 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. g034347 Figure 46 Lubricate the grease fittings regularly with No. 2 lithium grease. Lubricate the bearings and bushings daily when operating conditions are extremely dusty and dirty.
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. g008901 Figure 49 Checking the Engine-Oil Level • Mow/transport slide (Figure 50) 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.
1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. 2. Release the latches securing the air-cleaner cover to the air-cleaner body (Figure 54). 3. Remove the cover from the air-cleaner body (Figure 54). 4. Before removing the filter, use low-pressure air (276 kPa [40 psi], clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister.
10. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5 o’clock to 7 o’clock when viewed from the end. 11. Secure the cover latches. Fuel System Maintenance Servicing the Fuel Tank Changing the Engine Oil and Filter Service Interval: Every 2 years—Drain and clean the fuel tank. Service Interval: After the first 50 hours Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.
Draining the Water Separator Bleeding Air from the Injectors Service Interval: Before each use or daily Note: Use this procedure only if the fuel system has been purged of air through normal priming procedures and the engine does not start; refer to Bleeding the Fuel System (page 29). 1. 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. 2. Place a clean container under the fuel filter. 3.
Electrical System Maintenance 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. Electrical System Safety • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • 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 If the machine is not supported adequately, it may accidentally fall, injuring anyone under the machine. Checking the Tire Pressure A front wheel and a rear wheel must be raised off the ground; otherwise, the machine will move during adjustment. Service Interval: Before each use or daily The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the tires is 83 kPa (12 psi). 3.
Cooling System Maintenance CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. Cooling System Safety • Do not open the radiator cap when the engine is running. • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
Brake Maintenance Cleaning the Engine Cooling System Adjusting the Parking Brake Service Interval: Before each use or daily Remove debris from the radiator daily. Clean it more frequently in dirty conditions. 1. Service Interval: Every 200 hours—Check the adjustment of the parking brake. 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. 2. Raise the hood. 3.
Removing the Front Wheels 1. Remove the 4 lug nuts that secure the front wheel to the hub, and remove the wheel (Figure 64). g332520 Figure 66 Machines with the Optional Grass Shield 1. Locknut 2. Hub and brake drum g332518 Figure 64 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 68) , and when installed, the optional grass shield of any grass, dirt, and dust. g332545 Figure 70 Machines with the Optional Grass Shield g332543 Figure 68 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 72) 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 73 1. Woodruff key 3. g332541 2.
g332520 Figure 75 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 74 or Figure 75), 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. • Seek immediate medical attention if fluid is injected 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. 2. Position the throttle lever rearward so that it stops against the control panel slot. 3. Loosen the throttle cable connector on the injection pump lever arm (Figure 79). into skin.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C (104°F) 44 to 48 140 or higher Viscosity Index ASTM D2270 Pour Point, ASTM D97 -37°C to -45°C (-34°F to -49°F) Industry Specifications: Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S) g008886 Figure 80 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.
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 oil. 1. 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. 2. Disconnect the large hydraulic hose (Figure 81) from the reservoir and let the hydraulic fluid flow into a drain pan. g008886 Figure 82 1. Hydraulic fill cap 5. 6. 7.
Cutting Unit System Maintenance Blade Safety A worn or damaged blade or bedknife can break, and a piece could be thrown toward you or bystanders, resulting in serious personal injury or death. • Inspect the blades and bedknives periodically for excessive wear or damage. • Use care when checking the blades. Wear gloves and use caution when servicing them. Only replace or backlap the blades and bedknives; never straighten or weld them.
Using the Optional Gauge Bar 4. Start the engine and allow it to run at low idle speed. DANGER Use the gauge bar (Figure 84) to adjust the cutting unit. Refer to the cutting unit Operator's Manual for the adjustment procedure. Changing the engine speed while backlapping may cause the cutting units to stall. • Never change the engine speed while backlapping • Backlap only at idle engine speed. 5. Set the reel speed control to position 1 (Figure 85). g004552 Figure 84 1. Gauge bar 4.
9. 10. Cleaning If the cutting units 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. Washing the Machine To make an adjustment to the cutting units while backlapping, turn the cutting units off by moving the Lower Mow/Raise lever rearward; the Enable/Disable switch to the DISABLE position, and shut off the engine. After completing the adjustments, repeat steps 5 through 9. 11.
Preparing the Engine Storage Storage Safety • Shut off the engine, remove the key, and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. 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 specified motor oil. 4. Start the engine and run it at idle speed for approximately 2 minutes. 5.
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The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts 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 2 years or 1,500 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).
