Form No. 3412-549 Rev B Reelmaster® 3550 Traction Unit Model No. 03910—Serial No. 400000000 and Up Register at www.Toro.com.
WARNING Model No. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Serial No. This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Introduction g000502 Figure 2 1.
Contents Inspecting the Fuel Lines and Connections.................................................. 39 Draining the Water Separator ........................... 39 Changing the Fuel Filter Canister...................... 39 Bleeding Air from the Injectors .......................... 39 Electrical System Maintenance ........................... 40 Electrical System Safety ................................... 40 Servicing the Battery......................................... 40 Checking the Fuses ................
Safety • Keep clear of any discharge opening. Keep This machine has been designed in accordance with EN ISO 5395:2013 (when appropriate decals are applied) and ANSI B71.4-2012. • Keep children out of the operating area. Never bystanders and pets a safe distance away from the machine. allow children to operate the machine. • Stop the machine and shut off the engine before servicing, fueling, or unclogging the machine. General Safety Improperly using or maintaining this machine can result in injury.
decal93-6688 93–6688 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. decal120-2102 120–2102 1. Read the Operator’s Manual decal106-6755 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—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.
decal120-2105 120-2105 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. Raise the reels. 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.
A. 1 Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting unit tabs (Figure 4). Installing the Cutting Units No Parts Required Procedure 1. g003949 2. Remove the reel motors from the shipping brackets. 3. Remove and discard the shipping brackets. 4. Remove the cutting units from the cartons. Assemble and adjust as described in the cutting unit Operator's Manual. 5.
g003979 Figure 8 1. Lift-arm shaft lynch pin and washer g003975 Figure 6 1. Snapper pin 9. 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). 11. Insert the cap over the carrier frame shaft and lift-arm yoke. 12.
2 Adjusting the Turf Compensation Spring No Parts Required g003948 Figure 10 1. Lift-arm chain Procedure 3. Snapper pin The turf compensation spring (Figure 12) 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. 2. Chain bracket 14. Coat the spline shaft of the reel motor with clean grease. 15. Oil the reel-motor O-ring and install it onto the motor flange. 16.
3 Installing the CE Decal Parts needed for this procedure: 1 Warning decal (120-1686) Procedure g012628 Figure 13 If this machine will be used for CE, affix the warning decal 120-1686 over English warning decal 120-1683. 1. Hood-latch bracket 4 3. Installing the Hood Latch (CE Only) 2. Rivets While aligning the mounting holes, position the CE lock bracket and the hood-latch bracket onto the hood. Note: The lock bracket must be against the hood (Figure 14).
g012630 Figure 15 1. Hood latch 7. Screw the bolt into the other arm of the hood-lock bracket to lock the latch in position (Figure 16). Note: Tighten the bolt securely but do not tighten the nut. g020158 Figure 17 1. Cutting unit kickstand Secure the kickstand to the chain bracket with the snapper pin (Figure 18). g012631 Figure 16 1. Bolt 2. Nut 3. Arm of hood-lock bracket 5 Using the Cutting Unit Kickstand Parts needed for this procedure: 1 g004144 Figure 18 Cutting unit kickstand 1.
Tilt-Steering Lever Product Overview Pull the tilt-steering lever (Figure 19) 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 21), used to start, shut off, and preheat the engine, has 3 positions: OFF, ON/PREHEAT , and START .
Hour Meter Fuel Gauge The hour meter (Figure 21) indicates the total hours of machine operation. It starts to function whenever the key switch is on. The fuel gauge (Figure 22) indicates the amount of fuel in the tank. Lower Mow/Raise Control Lever This lever (Figure 21) raises and lowers the cutting units and also starts and stops the reels when the reels are enabled in the mow mode. You cannot lower the cutting units when the mow/transport lever is in the TRANSPORT position.
delivers replacement parts designed to the exact engineering specification of our equipment. For peace of mind, insist on Toro genuine parts. g020248 Figure 24 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 24). Specifications Note: Specifications and design are subject to change without notice.
Operation The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Note: Determine the left and right sides of the machine from the normal operating position. Crankcase capacity is approximately 3.8 L (4 US qt) with the filter.
• Expect plugging of the fuel filter for a time after converting to biodiesel blends. • Contact your authorized Toro distributor for more information on biodiesel. 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. Clean the area around the fuel-tank cap (Figure 27). 3. Remove the fuel-tank cap. 1. Oil-fill cap 4. Fill the tank to the bottom of the filler neck. Do not overfill the tank. Install the cap. 5. 5.
Checking the Cooling System 3. If the coolant level is low, remove the expansion-tank cap and replenish the system. Do not overfill the tank. Service Interval: Before each use or daily 4. Install the expansion-tank cap. Clean debris off the radiator daily (Figure 28). Clean the radiator hourly if conditions are extremely dusty and dirty; refer to Cleaning the Engine Cooling System (page 42). g008885 Figure 29 1.
Viscosity, ASTM D445 Viscosity index, ASTM D2270 Pour point, ASTM D97 cSt @ 40°C (104°F) 44 to 48 cSt @ 100°C (212°F) 7.9 to 9.1 140 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.
• Before you start the engine, ensure that all drives • • • • • • • • g010515 Figure 32 1. Backrest knob 3. Seat-suspension knob 2. Seat-position adjustment lever 4. Armrest-adjusting knob • • • During Operation Safety General Safety • The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage. • Wear appropriate clothing, including eye • protection; slip-resistant, substantial foot protection; and hearing protection.
• Initial startup of a new engine • Keep the ROPS in safe operating condition by • thoroughly inspecting it periodically for damage and keeping all the mounting fasteners tight. Replace a damaged ROPS. Do not repair or alter it. • The engine has ceased running due to lack of fuel. • Maintenance has been performed upon the fuel system components; i.e. filter replaced, etc. Starting the Engine Machines with a Fixed Roll Bar • The ROPS is an integral safety device. • Always wear your seat belt.
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 33), to determine the proper reel speed setting. decal121-7884 Figure 33 1.
2. Insert a tube or similar object onto the long spring end to relieve the spring tension during the adjustment (Figure 35). DANGER Under certain conditions, 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. CAUTION The springs are under tension and could cause personal injury. Do not fill the fuel tank completely full.
Understanding the Diagnostic Light Understanding the Diagnostic ACE Display The machine comes with a diagnostic light that indicates if the electronic controller senses an electronic malfunction. The diagnostic light is located on the control panel (Figure 37). When the electronic controller is functioning correctly and the key switch is moved to the ON position, the controller diagnostic light will turn on for 3 seconds and turn off to indicate that the light is working properly.
Checking the Interlock Switches Note: Ensure that the correct overlay decal is positioned on the 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 of the everyday use of the machine. When you are finished using the Diagnostic ACE, disconnect it from the machine and connect the loop-back connector to the harness connector. The machine does not operate without the loop-back connector installed on the harness. Store the Diagnostic ACE in a dry, secure location in the shop, not on the machine. 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.
Hauling the Machine DANGER Operating the machine without using the seat belt could result in serious personal injury or death. • Use full-width ramps for loading the machine onto a trailer or truck. • Tie the machine down securely. Always use the seat belt. Towing the Machine Understanding the Warning System In case of an emergency, you can tow the machine for a short distance; however, Toro does not recommend this as a standard procedure.
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.1 Check the radiator for debris. Check for unusual operating noises. Check the hydraulic system fluid level.
Service Interval Chart decal120-2102 Figure 42 Pre-Maintenance Procedures Removing the Hood The hood may be easily removed to ease maintenance procedures in the engine area of the machine. Pre-Maintenance Safety 1. Unlatch and raise the hood. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 43). • Before adjusting, cleaning, repairing, or leaving the machine, do the following: – Park the machine on a level surface.
Removing the Battery Cover Loosen the knobs and remove the battery cover (Figure 44). Note: Refer to Servicing the Battery (page 40) for more information. g008874 Figure 44 1.
Lubrication • Rear lift-arm pivots and lift cylinders (3 each side); refer to Figure 47. 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. Lubricate the grease fittings regularly with No. 2 lithium grease.
Engine Maintenance • Mow/transport slide (Figure 50) 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. g008902 Figure 50 Servicing the Air Cleaner Service Interval: Every 200 hours (more frequently in extremely dusty or dirty conditions). • Belt tension pivot (Figure 51) • Check the air-cleaner body for damage which could cause an air leak. Replace it if it is damaged.
g020086 Figure 53 1. Engine-oil drain plugs 3. Remove the oil filter (Figure 54). g002401 Figure 52 1. Air-cleaner cover 6. 2. Filter Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Important: Do not use a damaged element. 7. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Important: Do not apply pressure to the g022147 Figure 54 flexible center of the filter. 8.
Fuel System Maintenance Servicing the Fuel Tank Service Interval: Every 2 years—Drain and clean the fuel tank. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key. g009880 Figure 55 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. 1. Water separator/filter canister 2. Vent plug 4.
Electrical System Maintenance Electrical System Safety • 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. g008913 Figure 56 1. Fuel injectors 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.
Drive System Maintenance DANGER Battery electrolyte contains sulfuric acid which is fatal if consumed and causes severe burns. Adjusting the Traction Drive for Neutral • 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. If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam. • Fill the battery where clean water is always available for flushing the skin.
Cooling 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. Cooling System Safety • Swallowing engine coolant can cause Keep your hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and rotating parts. 4. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span. 5.
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 60). Service Interval: Every 200 hours—Check the adjustment of the parking brake. 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. Loosen the setscrew securing the knob to the parking-brake lever (Figure 59).
Cleaning the Brake Drum and Shoes At both sides of the machine, clean inside the brake drums, the brake shoes, backing plate (Figure 64) , and when installed, the optional grass shield of any grass, dirt, and dust. g332520 Figure 62 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 66 Machines with the Optional Grass Shield 1. Backing plate 2. g332560 2. Brake cam shaft Figure 67 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 67). 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 69). g332520 Figure 71 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 70 or Figure 71), 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 23). 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. Controls System Maintenance 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 Adjusting the Throttle Use caution when de-tensioning the spring. 3. Push down and forward on the spring end (Figure 74) to unhook it from the bracket and release tension on the spring. 1.
Hydraulic System Maintenance Hydraulic System Safety • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system.
Cutting Unit System Maintenance Cutting Unit Safety 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. • Inspect the cutting units periodically for wear or g008886 damage. Figure 78 • Use care when checking the cutting units. Wrap 1. Hydraulic fill cap 5. Install the reservoir cap. Start the engine and use all of the hydraulic controls to distribute the hydraulic fluid throughout the system.
Backlapping the Cutting Units WARNING Contact with the reels or other moving parts can result in personal injury. • Keep your fingers, hands, and clothing away from the reels and other moving parts. • Never attempt to turn the reels 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. 53 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).
